CataLyst Express User Guide

CRS CataLyst Express
User Guide
UMI-CAT5-400
Arm power beacon

Microplate servo gripper
Robotic arm
Removable random-access
microplate hotel
Removable microplate
feeder hotel
Base
Rear
panel
Guarding
Parking bracket E-stop control
Re-grip station
Front panel
Rev. Revision History Date
001 First release 03-2002
Copyright © May 2004 Thermo CRS, Ltd.
CataLyst, ActiveRobot, POLARA, and RAPL are trademarks of Thermo CRS, Ltd. and may be used to
describe only Thermo CRS products.
All brand names and product names used in this guide are trademarks, registered trademarks, or trade
names of their respective holders.
The information in this document is subject to change without notice.
Thermo CRS, Ltd. makes no warranty of any kind with regard to this material, including, but not limited to,
the implied warranties of merchantability and fitness for a particular purpose. Thermo CRS, Ltd. assumes
no responsibility for any errors that may appear in this document. Thermo CRS, Ltd. makes no commitment
to update nor to keep current the information contained in this document.
Thermo CRS, Ltd. software products shall remain the property of Thermo CRS, Ltd.
Additional copies of this guide, or other Thermo CRS literature, may be obtained from the Sales Department
or from your distributor.
ii
PREFACE
About This Guide
This user guide accompanies the Thermo Electron CRS CataLyst Express™
articulated robot instrument loader. It contains installation instructions,
specifications, and operating procedures for the CataLyst Express.
Who Uses This Guide

This guide is intended for scientists, technicians, and other users of
laboratory equipment. It assumes the reader has basic electrical and
mechanical skills, and knows how to operate a personal computer running
Microsoft Windows.
How to Use This Guide

Throughout this manual warnings are marked by a “!” symbol in the left
margin. Failure to comply with these warnings can result in system errors,
memory loss, damage to the robot and its surroundings, or injury to personnel.
This manual is task-based and uses navigational aids to help you quickly find
the topics and information you need. If a technical term is not familiar to you,
refer to the Glossary.
Before following instructions in a section, read the entire section first.
This guide consists of the following chapters:
• Chapter 1, Introducing the CataLyst Express introduces the major
features of the CataLyst Express.
• Chapter 2, Safe Use of the CataLyst Express discusses safety
considerations.
• Chapter 3, Installing the CataLyst Express provides instructions for
installing the robot in a work cell.
• Chapter 4, Using the CataLyst Express describes how to use the
CataLyst Express hardware.
• Chapter 5, CataLyst Express Ports includes detailed pinouts and
configuration information to help you attach other devices to the
CataLyst Express.
• Chapter 6, Maintenance Procedures describes how to establish a
service schedule, replace fuses, and perform other basic maintenance
activities.
• Chapter 7, Troubleshooting helps you to resolve problems that you may
encounter.
CataLyst Express User Guide: Preface iii

Preface: Contacts
• Appendix A, Technical Specifications contains physical and electrical

specifications, including guidelines for nominal use.
• Appendix B, GPIO Termination Block Option provides installation and
mounting instructions for the optional GPIO termination block.
• Appendix C, Installing New Firmware describes how to re-install or
install a new version of the CataLyst Express operating system firmware.
• Glossary provides definitions of the terminology used in this guide.
• Index provides a list of subjects used in this guide and their page
numbers.
Contacts
You can contact Thermo Electron at the following addresses:
Surface Mail/Shipping
Thermo Electron Corporation
Laboratory Automation and Integration
5344 John Lucas Drive
Burlington, Ontario L7L 6A6
Canada
Telephone
1-905-332-2000 (voice)
1-800-365-7587 (voice: toll free in Canada and United States)
1-905-332-1114 (facsimile)
E-Mail
Sales: sales.labautomation@thermo.com
Customer Support and Training: services.labautomation@thermo.com
General: info.labautomation@thermo.com
World Wide Web
www.thermo.com
iv CataLyst Express User Guide: Preface

Preface: Contents
Contents
Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

What is the CataLyst Express? . . . . . . . . . . . . . . . . . 1-2
Benefits of the CataLyst Express . . . . . . . . . . . . . 1-2
CataLyst Express Features . . . . . . . . . . . . . . . . . . . . 1-3
CataLyst Express Software . . . . . . . . . . . . . . . . . . . . 1-6
CataLyst Express Options . . . . . . . . . . . . . . . . . . . . . 1-7
Chapter 2: Safe Use of the CataLyst Express . . . . . . . . . . . . . . . 2-1

Safety Conformance . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Designated Use . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Built-in Safety Features . . . . . . . . . . . . . . . . . . . . . . 2-3
Triggering the E-Stop . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CataLyst Express Hazards . . . . . . . . . . . . . . . . . . . . 2-5
Establishing a Safeguarded Perimeter . . . . . . . . . . . . 2-6
Preventing Accidents . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Ensuring Operator Safety . . . . . . . . . . . . . . . . . . 2-7
Locking Out the CataLyst Express . . . . . . . . . . . . 2-8
Chapter 3: Installing the CataLyst Express . . . . . . . . . . . . . . . . . 3-1

Preparing the Bench . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Unpacking the CataLyst Express . . . . . . . . . . . . . . . . 3-4
Setting up the CataLyst Express . . . . . . . . . . . . . . . . 3-5
Unpacking the Computer . . . . . . . . . . . . . . . . . . . . . 3-7
Installing the Computer . . . . . . . . . . . . . . . . . . . . . . 3-8
Connecting the Cables . . . . . . . . . . . . . . . . . . . . . 3-8
Testing the CataLyst Express . . . . . . . . . . . . . . . . . . 3-9
Re-teaching Paths to a Hotel or Re-grip Station . 3-10
Connecting Instruments . . . . . . . . . . . . . . . . . . . . . 3-11
Chapter 4: Using the CataLyst Express . . . . . . . . . . . . . . . . . . . . 4-1

Using the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Using the E-Stop Control . . . . . . . . . . . . . . . . . . . . . 4-3
Using the E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Understanding the Arm Status Indicators . . . . . . 4-4
Using the Brake Release . . . . . . . . . . . . . . . . . . . 4-4
Using the Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pre-power Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Starting the CataLyst Express . . . . . . . . . . . . . . . . . . 4-8
Shutting Down the CataLyst Express . . . . . . . . . . . 4-10
Parking the Arm . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Performing a Controlled Shutdown . . . . . . . . . . 4-10
Powering Off the CataLyst Express . . . . . . . . . . 4-11
CataLyst Express User Guide: Preface v

Preface: Contents
Chapter 5: CataLyst Express Ports . . . . . . . . . . . . . . . . . . . . . . . 5-1

The Wrist/OPTIONS Ports . . . . . . . . . . . . . . . .. . . . . 5-2
Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-3
P.C. Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-4
General Purpose Input/Output (GPIO) Port . . .. . . . . 5-5
Pinouts for the GPIO Port . . . . . . . . . . . . .. . . . . 5-5
Connecting Inputs and Outputs . . . . . . . .. . . . . 5-9
Using the Relays . . . . . . . . . . . . . . . . . . . .. . . . . 5-9
Using GPIO Devices in Your Application . .. . . . . 5-9
The E-Stop Port (Front Panel) . . . . . . . . . . . . .. . . . 5-10
The E-Stop Port (Rear Panel) . . . . . . . . . . . . . .. . . . 5-12
Adding E-Stops . . . . . . . . . . . . . . . . . . . . .. . . . 5-12
The Guarding Port . . . . . . . . . . . . . . . . . . . . .. . . . 5-14
Chapter 6: Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . 6-1

Backing up Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Routine Inspections . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Checking Front Panel Fuses and Circuit Breakers . . . 6-5
Inspecting AC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . 6-8
Chapter 7: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

The LCD Display Remains Blank . . . . . . . . . . . . . . . . 7-2
Arm Power Cannot Be Turned On . . . . . . . . . . . . . . . 7-3
Contacting the Customer Support Group . . . . . . . . . 7-4
Chapter A: Technical Specifications . . . . . . . . . . . . . . . . . . . . . . A-1

Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . A-2
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . A-3
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . A-3
Chapter B: GPIO Termination Block Option . . . . . . . . . . . . . . . . B-1
Chapter C: Installing New Firmware . . . . . . . . . . . . . . . . . . . . . . C-1

Backing up Files from the CataLyst Express . . . . . . . C-2
Downloading the CataLyst Express Firmware . . . . . . C-4
Configuring the Robot Controller . . . . . . . . . . . . . . . . C-6
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
vi CataLyst Express User Guide: Preface

Preface: Figures
List of Figures
Figure 1-1: CataLyst Express workstation . . . . . . . . . . . . . . . . . . . . . . 1-2

Figure 1-2: Main hardware features of the CataLyst Express . . . . . . . . 1-3
Figure 1-3: CataLyst Express with front- and rear-side guarding . . . . 1-5
Figure 2-1: Removing the fuse drawer . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Figure 3-1: Positioning of the CataLyst Express . . . . . . . . . . . . . . . . . . 3-2
Figure 3-2: Dimensions of the CataLyst Express in in.[mm] . . . . . . . . . 3-2
Figure 3-3: Location of guarding frame components. . . . . . . . . . . . . . . 3-5
Figure 3-4: Push the storage unit base down onto the mount. . . . . . . . 3-6
Figure 3-5: Reach of the CataLyst Express in in.[mm] . . . . . . . . . . . . 3-11
Figure 3-6: Location of instrument mounting plate holes . . . . . . . . . . 3-12
Figure 4-1: Front panel of CataLyst Express . . . . . . . . . . . . . . . . . . . . 4-2
Figure 4-2: The E-Stop control cuts power. . . . . . . . . . . . . . . . . . . . . . 4-3
Figure 4-3: The Easy Teach Setup main screen . . . . . . . . . . . . . . . . . . 4-9
Figure 5-1: Pin numbering for the wrist/OPTIONS ports . . . . . . . . . . . 5-2
Figure 5-2: SERIAL port pin numbering. . . . . . . . . . . . . . . . . . . . . . . . 5-3
Figure 5-3: P.C. port pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Figure 5-4: Pin numbering scheme used by the GPIO connector . . . . . 5-5
Figure 5-5: Wiring schematic for the GPIO connector . . . . . . . . . . . . . . 5-8
Figure 5-6: Pin numbering scheme for the E-Stop port (front panel) . . 5-10
Figure 5-7: Wiring schematic for the E-Stop port . . . . . . . . . . . . . . . . 5-11
Figure 5-8: Pin numbering scheme for the E-Stop port (rear panel) . . 5-12
Figure 5-9: Pin numbering for the GUARDING port . . . . . . . . . . . . . . 5-14
Figure 6-1: Location of front panel fuses and circuit breakers . . . . . . . 6-5
Figure B-1: The GPIO termination block. . . . . . . . . . . . . . . . . . . . . . . . B-1
Figure C-1: The ActiveRobot Explorer window . . . . . . . . . . . . . . . . . . . C-2
CataLyst Express User Guide: Preface vii

Preface: Figures
viii CataLyst Express User Guide: Preface

Preface: Tables
List of Tables
Table 3-1: Instrument Names of factory-taught paths . . . . . . . . . . . 3-10

Table 5-1: Pinouts for the wrist/OPTIONS connector . . . . . . . . . . . . . 5-2
Table 5-2: SERIAL port pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Table 5-3: P.C. port pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Table 5-4: Pinouts for the GPIO connector . . . . . . . . . . . . . . . . . . . . . 5-6
Table 5-5: Pinouts for the E-Stop port (front panel) . . . . . . . . . . . . . 5-10
Table 5-6: Pinouts for the E-Stop port (rear panel) . . . . . . . . . . . . . . 5-12
Table 5-7: Pinouts for the GUARDING port . . . . . . . . . . . . . . . . . . . 5-14
Table 6-1: Front panel fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Table 6-2: AC fuses required for the CataLyst Express . . . . . . . . . . . 6-7
Table A-1: Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Table A-2: Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Table A-3: Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
CataLyst Express User Guide: Preface ix

Preface: Tables
x CataLyst Express User Guide: Preface

CHAPTER 1
Introducing the CataLyst Express
The CRS CataLyst Express from Thermo Electron Corporation enables

scientists to automate the transfer of microplates between instruments and
storage units. For a detailed introduction to the CataLyst Express, see the
following topics:
• “What is the CataLyst Express?” on page 1-2
• “CataLyst Express Features” on page 1-3
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• “CataLyst Express Software” on page 1-6
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• “CataLyst Express Options” on page 1-7
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CataLyst Express User Guide: Introducing the CataLyst Express 1–1

Introducing the CataLyst Express: What is the CataLyst Express?
What is the CataLyst Express?
The CRS CataLyst Express enables scientists to automate the transfer of

microtiter plates between instruments and storage units. The
CataLyst Express provides the reliability, precision, and dexterity of Thermo’s
CRS CataLyst robot in an integrated package that makes it easy for
researchers to automate the loading and unloading of several, microtiter
plate-based instruments.
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Figure 1-1: CataLyst Express integrated with two Thermo CRS random-access Microplate
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Hotels, a Thermo CRS Platefeeder Hotel, and a Thermo Labsystems MicroDrop

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Benefits of the CataLyst Express

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Users of the CataLyst Express enjoy the following benefits:
• Continuous, error-free operation
• Precise, repeatable motion
• The ability to handle a wide range of containers
• The ability to automate loading and unloading of instruments, such as

microscopes, that no other laboratory plate mover has the dexterity to
handle
• Safety features that meet OSHA requirements
• Easy to use, yet powerful method development and scheduling
1–2 CataLyst Express User Guide: Introducing the CataLyst Express

Introducing the CataLyst Express: CataLyst Express Features
CataLyst Express Features

The CataLyst Express has the following main features:
Arm power beacon

Microplate servo gripper
Robotic arm
Removable random-access
microplate hotel
Removable microplate
feeder hotel
Base
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Rear
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Parking bracket E-stop control
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Re-grip station
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Front panel
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Figure 1-2: Main hardware features of the CataLyst Express

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• The robotic arm gets microplates from receptacles, or nests, and puts
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microplates into nests.

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• The base supports the arm and microplate storage devices, and houses
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the electronics that power and control the system.

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• The removable storage units provide the following types of storage:
• Random-access microplate hotels provide 15 nests, each of which

can be accessed by the arm at any time. They are available in both
portrait and landscape orientations.
• Microplate feeder hotels provide storage for up to 40, stacked

microplates. The arm accesses microplates at the top of the stack.
The base can support up to three random-access hotels or three

microplate feeder hotels.
• The re-grip station provides a nest for the CataLyst Express to

temporarily put a microplate, so that it can change the way it grips the
microplate: from portrait orientation to landscape orientation, for
example.

• The microplate servo gripper holds the microplates as the arm moves
them. Its features enable the CataLyst Express to control the strength of
the grip and the distance between the fingers, allowing the
CataLyst Express to apply the optimum gripping force for each type of
microplate and to confirm that it has a microplate in its grasp.
Thermo CRS offers two types of fingers with the microplate servo gripper:
offset fingers, which are the standard type of fingers provided with the
CataLyst Express, and straight, which are required for use only with the
random-access, portrait-orientation hotel.
• The parking bracket provides a parking location for the arm, a known
physical position that enables the CataLyst Express to establish an origin
in space, or home, for the arm.
Note: The arm must be homed before it can move microplates.
• The E-Stop control provides an emergency stop button that, when
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pressed, immediately cuts power to the arm. The control also provides
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arm status indicators, and a brake release that enables operators to
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manually move the arm into its parking bracket. For details, see “Using
the E-Stop Control” on page 4-3.
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• The arm power beacon glows yellow when the arm is powered, providing
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a clear signal to operators that the arm is capable of moving.
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The front panel provides a system status display, controls, input/output
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ports, and fuses and circuit breakers. For details, see “Using the Front
Panel” on page 4-2.
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• The rear panel provides the main AC power input, the AC fuses, and
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three electrical ports: an E-Stop port, the guarding port, and an options
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port that provides access to the end-of-arm user port.

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• The teaching jig (not shown) is used for testing and teaching paths to
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instruments.
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• The guarding protects operators from the arm while it is moving. When
opened, it immediately cuts power to the arm. Rear-side guarding is
available as an option. For details, see “Setting up the CataLyst Express”
on page 3-5.
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Figure 1-3: CataLyst Express with front- and rear-side guarding attached and open
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Introducing the CataLyst Express: CataLyst Express Software
CataLyst Express Software

The CataLyst Express package also includes a Dell computer with pre-
installed and configured software, and two serial cables to connect it to the
CataLyst Express.
The CataLyst Express software includes the following software for Microsoft
Windows computers:
• POLARA 2.1, a version of Thermo’s advanced laboratory automation
software created specifically for the CataLyst Express, which includes
Easy Teach for simple point-and-click teaching and control.
• CataLyst Express Self Test, software that ensures the factory-taught
paths are accurate.
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Introducing the CataLyst Express: CataLyst Express Options
CataLyst Express Options

Thermo Electron LAI offers the following options for the CataLyst Express:
• Rear-side guarding, which protects operators from the arm of the
CataLyst Express
• Removable storage units:
• CRS Microplate Hotels provide 15 nests, each of which can be
accessed by the arm at any time. They are available in both portrait
and landscape orientations.
• CRS Platefeeder Hotels provide storage for up to 40, stacked
microplates. The arm accesses microplates from the top of the stack.
The base can support up to three storage units. The CataLyst Express can
access a combination of random-access, landscape-orientation hotels and
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microplate feeder hotels, but it cannot access these types of hotel in
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combination with random-access, portrait orientation hotels.
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• Gripper fingers:
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• CRS Offset Microplate Fingers, which are the standard type of
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fingers provided with the CataLyst Express
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CRS Straight Microplate Fingers, which are required for use only
with the portrait-orientation Microplate Hotel.
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• The GPIO Termination Block, which extends the GPIO port to a

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termination block for easier access

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• Mounting kits that simplify instrument connections to the

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CataLyst Express
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• POLARA instrument interfaces for popular lab instruments

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• CataLyst Express DLL, an easy to use ActiveX component that enables

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Windows applications to load and unload instruments with the

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CataLyst Express
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• ActiveRobot, a set of ActiveX components that provide extensive control

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of every feature of the CataLyst Express, including its integrated

input/output capabilities
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For more information, contact Thermo LAI sales at

sales.labautomation@thermo.com.

Introducing the CataLyst Express: CataLyst Express Options
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CHAPTER 2
Safe Use of the CataLyst Express
Before installing or using the CRS CataLyst Express, ensure that you are
familiar with the safety directives in this chapter.
Caution! It is your responsibility to ensure that the robot system is safely
installed and operated.
For details, see the following topics:

• “Safety Conformance” on page 2-2
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• “Built-in Safety Features” on page 2-3
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• “Triggering the E-Stop” on page 2-4
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• “CataLyst Express Hazards” on page 2-5
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• “Establishing a Safeguarded Perimeter” on page 2-6
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• “Preventing Accidents” on page 2-7
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CataLyst Express User Guide: Safe Use of the CataLyst Express 2–1
Safe Use of the CataLyst Express: Safety Conformance
Safety Conformance
The CataLyst Express has been designed and built in accordance with the
following safety standards:
• UL 1740:1998 Robots and Robotic Equipment
• ANSI/RIA15.06-1992 Industrial Robots and Robot Systems - Safety
Requirements
• CAN/CSA-C22.2 No. Z434-94 Industrial Robots and Robot Systems --
General Safety Requirements
• EN60204-1:1992, EN292:1991, EN954:1997 Category-1, and the
Essential Health and Safety Requirements of the EC Machinery Directive
• ISO10218:1992 Manipulating industrial Robots -- Safety
Ensure that your CataLyst Express application complies with all additional
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safety regulations and standards in effect at the site where the system is
installed.
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Designated Use
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The CataLyst Express should not be operated in the following conditions:
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• In explosive environments
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• In radioactive or biohazardous environments, except as part of a system

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that has been specifically designed for such use

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• Directly on humans (e.g. surgery)

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If you are unsure whether your robot application falls within the designated
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use for the CataLyst Express system, contact the Thermo LAI Customer
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Support Group, as described in “Contacting the Customer Support Group” on

page 7-4.
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2–2 CataLyst Express User Guide: Safe Use of the CataLyst Express
Safe Use of the CataLyst Express: Built-in Safety Features
Built-in Safety Features

The CataLyst Express robot system includes the following basic safety
features:
• An E-Stop button enables you to cut power to the arm at any time.
• Guarding connected to the E-Stop circuit protects operators while the
arm is moving and cuts arm power when the guarding is opened.
• The CataLyst Express automatically cuts arm power when it detects
collisions or robot runaway.
• Fail-safe brakes built into all joints engage automatically when arm power
is cut, preventing the arm from motion due to gravity.
• Arm speed is restricted to 10% until the arm is homed and while
teaching.
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• The CataLyst Express enforces single point of control, preventing more
than one person or process from controlling the arm at any time.
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Safe Use of the CataLyst Express: Triggering the E-Stop
Triggering the E-Stop

In case of emergency, operators can quickly halt all arm motion by triggering
an emergency stop.
To stop the arm in case of emergency

• Press the E-Stop button on the E-Stop control, or any other E-Stop that
has been integrated into the CataLyst Express’s E-Stop circuit.
To recover from an E-Stop

1 Remove all dangers from the workcell and verify that it is safe to power
the arm.
2 Twist the E-Stop button to reset it or, if other devices have been
connected to the E-Stop chain, close the E-Stop device that triggered the
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stop.
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3 Press the Arm Power button to restore power to the arm.
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4 If arm power cannot be restored, see “Arm Power Cannot Be Turned On”
on page 7-3 for the relevant troubleshooting procedure.
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Safe Use of the CataLyst Express: CataLyst Express Hazards
CataLyst Express Hazards

Warning! All users of the CataLyst Express must be made aware of the following
potential hazards:
• A fire hazard may be exposed if the arm comes in contact with a

piece of equipment that is at a different electrical potential. If a
charged piece of equipment is in contact with the arm for an extended
period of time, the wiring in the CataLyst Express could overheat and
catch fire.
• The space between moving links presents a crushing/pinching
hazard. Do not touch or lean against the arm when arm power is on and
the arm is capable of motion.
• The brakes in the arm do not instantaneously halt arm motion when
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arm power is removed. It takes about 0.2 seconds for the arm to stop
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moving.
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• Water or other liquids may cause a short circuit, which could cause
robot runaway. Water or other electrically conductive liquids must not be
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allowed to enter the arm or base.
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• The servo gripper will drop its payload if power to the CataLyst
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Express is cut. Do not use the CataLyst Express if a dropped payload
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presents a severe hazard. The servo gripper will continue to grasp the
payload if arm power is removed by triggering the E-Stop or opening the
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guarding.
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• The fingers on the servo gripper pose a severe injury hazard. You
must install the guarding to protect users against inadvertent contact
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with the fingers, and users must wear safety goggles while in the
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immediate vicinity of the arm.

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Safe Use of the CataLyst Express: Establishing a Safeguarded Perimeter
Establishing a Safeguarded Perimeter

Use the guarding supplied with the CataLyst Express to protect operators and
other personnel from the arm while it is powered.
The guarding connects to the E-Stop circuit via the GUARDING port on the
rear of the base. Opening the guarding opens the circuit, cutting power to the
arm. When the arm is not powered, the brakes on its joints engage, preventing
gravity from moving it.
Perform a risk assessment before installing the CataLyst Express. If a wall or
an instrument blocks operator access to the arm’s workspace on that side, it
might not be necessary to install the guarding on that side.
For more information, see the following topics:
• “Preparing the Bench” on page 3-2
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• “Setting up the CataLyst Express” on page 3-5
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Safe Use of the CataLyst Express: Preventing Accidents
Preventing Accidents
Warning! If incorrectly installed or programmed, the arm may perform
unexpected movements at high speeds.
In order to minimize risks to personnel and equipment near the

CataLyst Express, obey the following safety rules:
• Wear safety goggles and have the E-Stop control within reach whenever
you are using or in the vicinity of the CataLyst Express.
• Test your installation of the CataLyst Express after initial setup and after
any changes.
• Alert all operators to the potential hazards presented by the
CataLyst Express.
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• Make all persons entering the safeguarded area aware of potential
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hazards and of the need to wear safety goggles and have an E-Stop button
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in reach at all times.
• Schedule routine inspections of all safety devices to ensure that they are
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functioning normally.
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• If the system is under repairs or acting abnormally, lock-out the
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CataLyst Express to prevent the system from being used. See “Locking
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Out the CataLyst Express” on page 2-8.
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Ensuring Operator Safety

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Ensure that all personnel who program, operate, or maintain the

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CataLyst Express are adequately trained to perform their jobs safely. You
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should attend a Thermo CRS training course before programming a custom

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application for the CataLyst Express.

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Ensure that all operators:

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• Have a clear definition of their duties.

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• Receive adequate training.

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• Are fully aware of the potential hazards of the CataLyst Express.

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• Know the location and use of all safety devices.
Safe Use of the CataLyst Express: Preventing Accidents
Locking Out the CataLyst Express

If the CataLyst Express is awaiting or undergoing service, you must lock it out
to ensure it can’t be used.
Note: OSHA safety procedure 1910-147 recommends locking out the AC
power outlet at the main panel. If you prefer to implement the OSHA-
recommended procedure, refer to OSHA 1910-147 Control of
Hazardous Energy (Lockout/Tagout) for further information.
To lock out the CataLyst Express

1 Unplug the AC power cord from the AC input module in the rear of the
base.
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Figure 2-1: Removing the fuse drawer
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2 Insert a flat head screwdriver below the fuse drawer clip and remove the
fuse drawer from the AC input module. See Figure 2-1 for the location of
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the fuse drawer and clip.

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3 Create a tag labeled “DO NOT POWER THE ROBOT” and hang it on the
front of the CataLyst Express. The tag must be conspicuous and easy to
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read.
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CHAPTER 3
Installing the CataLyst Express
The CataLyst Express has been designed to be easy to install. For details, see
the following topics:
• “Preparing the Bench” on page 3-2
• “Unpacking the CataLyst Express” on page 3-4
• “Setting up the CataLyst Express” on page 3-5
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• “Unpacking the Computer” on page 3-7
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• “Installing the Computer” on page 3-8
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• “Testing the CataLyst Express” on page 3-9
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• “Connecting Instruments” on page 3-11
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CataLyst Express User Guide: Installing the CataLyst Express 3–1

Installing the CataLyst Express: Preparing the Bench
Preparing the Bench

The bench on which you place the CataLyst Express should conform to the
layout shown in Figure 3-1.
Wall
Bench
Instrument
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Front-side guarding
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Figure 3-1: Positioning of the CataLyst Express, an instrument, and the bench
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Follow these guidelines:
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Select a bench wide enough to provide at least 1 m clearance between the
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side of the CataLyst Express and the side edge of the bench. For the
dimensions of the CataLyst Express, see Figure 3-2.
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Figure 3-2: Dimensions of the CataLyst Express in in.[mm]
• Place the bench against a wall to restrict access to the rear side of the
CataLyst Express.
Note: You can provide access to the CataLyst Express from the rear if
you install the optional rear-side guarding.
3–2 CataLyst Express User Guide: Installing the CataLyst Express

Installing the CataLyst Express: Preparing the Bench
• Make sure the bench is level, fixed in place, and clean.
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Installing the CataLyst Express: Unpacking the CataLyst Express
Unpacking the CataLyst Express

The CataLyst Express ships in a wooden crate. The following procedures
describe how to unpack the CataLyst Express and its components from the
crate.
Caution! The CataLyst Express weighs 76 kg [167 lb]. Use at least two
people to lift it out of the crate.
To unpack the CataLyst Express

1 Remove the top of the crate, using the supplied screwdriver.
2 Remove the sides of the crate.
3 Using at least two people, lift the unit out of the box and place it on the
bench.
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To unpack the microtiter plate storage units
• Cut the ribbons fastening the storage units to the side of the crate.
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The remaining components of the CataLyst Express, including cables,
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teaching jig, and software CD, are stored in the box attached to the inside of
the crate.
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To unpack the guarding

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• Lift the front guarding door up and off the hook holding it on the side of
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the crate.
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• Remove protective wrapping.

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Installing the CataLyst Express: Setting up the CataLyst Express
Setting up the CataLyst Express

To setup the CataLyst Express hardware, you attach the guarding, install the
storage units, connect the E-Stop control, and connect the AC power supply.
Door hinges Guarding frame
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Frame mounting pins

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Mounting screws
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Figure 3-3: Location of guarding frame components

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To install the front guarding

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1 Peel off the protective covering from the guarding doors.

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2 Drop the front door onto the hinges on the frame. See Figure 3-3 for the
location of the door hinges.
3 Slide the guarding as far as possible under the base of the

CataLyst Express.
4 Adjust the set screws on the side door hinges with a 2 mm hex key to set
the position for each side door.
5 Remove the dummy plug from the GUARDING port on the rear panel and
plug in the guarding cable.
To install each microplate storage unit

1 Grasp the storage unit by the base and by the handle at the top, so that
the Thermo CRS label is facing you.

Installing the CataLyst Express: Setting up the CataLyst Express
2 Position the storage unit over the mounting bracket, with the number
matching the one on the storage unit, and push it down until it snaps into
place. See Figure 3-4 for guidance.
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Figure 3-4: Push the storage unit base down onto the mount until it snaps in place.
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Caution! Ensure that the number on the storage unit matches the
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number of the mounting bracket. Paths are factory-taught with the hotels
positioned as shown by the numbers.
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To connect the E-Stop control
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• Plug the E-Stop control into the E-STOP port on the front panel.
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Note: To connect other E-Stops into the E-Stop circuit of the

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CataLyst Express, remove the dummy plug from the E-STOP port on
the rear panel and connect the E-Stops between pins 8 and 9 on the
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port. For details, see “Adding E-Stops” on page 5-12.

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Adjust the guarding

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• Adjust the position of the guarding frame under the base of the
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CataLyst Express so that the closed guarding door does not touch the
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storage units.
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To connect AC power
1 Move the POWER switch on the front panel of the CataLyst Express to the
‘0’ position.
2 Plug the female end of the power supply cord into the socket labelled “AC”
on the rear of the CataLyst Express.
3 Plug the male end of the power supply cord into the main AC power
supply plug.

Installing the CataLyst Express: Unpacking the Computer
Unpacking the Computer

Follow the manufacturer’s instructions for unpacking the computer.
You do not install any CataLyst Express software; it is already installed.
The software CD contains configuration, calibration, and instrument files
unique to your CataLyst Express. Create a backup copy of the software CD
and store it in a secure location.
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Installing the CataLyst Express: Installing the Computer
Installing the Computer

Place the computer out of reach of the CataLyst Express arm, but close
enough to allow cable connections.
Place the monitor and keyboard so that you can see the movement of the
CataLyst Express at all times. Do not operate the CataLyst Express remotely.
Connecting the Cables

The two serial cables must be connected between ports on the personal
computer and the CataLyst Express. The cables are labelled with yellow and
green ties, and the computer ports are labelled with yellow and green stickers.
Warning! Ensure power is off for both the PC and the CataLyst Express
before connecting cables.
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To connect the cables
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• Plug the female end of the yellow serial cable into the serial port labelled
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yellow on the computer.
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• Plug the female end of the green serial cable into the serial port labelled
green on the computer. al
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• Plug the male end of the yellow serial cable into the port labelled P.C. on
the front panel of the CataLyst Express.
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• Plug the female end of the green serial cable into the port labelled
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SERIAL 0 on the front panel of the CataLyst Express.

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Installing the CataLyst Express: Testing the CataLyst Express
Testing the CataLyst Express

Before putting the CataLyst Express into regular use, test it with the supplied
CataLyst Express Self Test program. If necessary, re-teach the paths, as
described in “Re-teaching Paths to a Hotel or Re-grip Station” on page 3-10.
To test the CataLyst Express

1 Set the POWER switch on the front panel of the CataLyst Express to the
‘1’ position. The CataLyst Express powers up.
2 Remove all containers from the hotels mounted on the CataLyst Express.
Warning! A collision will occur if any containers are still in the hotels
when the test starts! Make sure all containers are removed.
Place the teaching jig into the regrip station.
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4 Run the CataLyst Express Self Test program by selecting
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Start > Programs > CRS Robotics > CataLyst Express > Self Test.
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To halt the tests at any time, click Abort.

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Warning! If a collision occurs during the test, click Abort immediately,

and contact Thermo CRS Customer Support.
The Self Test program proceeds through the tests listed on the left side of
the program screen, highlighting each in yellow as it performs the test,
and placing a check mark beside each when it completes the test.
Note: The unparking and homing test takes several minutes to complete,
since arm speed is limited before it has been homed.
5 During the motion test part of the setup test, carefully monitor the arm’s
movements, and confirm the following conditions:
• When the arm grips the jig, the jig does not slip or twist.
• When the arm places the jig in a hotel or in the regrip station, the
plate does not drop or lie tilted.

Installing the CataLyst Express: Testing the CataLyst Express
• If the arm is moving the jig in and out of a Platefeeder Hotel, the jig
moves freely up and down the hotel without binding with the sides.
If any of the conditions are not met during the test, you must re-teach the
paths to the re-grip station or to the hotel where the problem occurs.
Re-teaching Paths to a Hotel or Re-grip Station

The paths to the re-grip station and to hotels on your CataLyst Express are
pre-taught at the factory. These instruments have standard names, as listed
in Table 3-1. The instrument names for the hotels vary by the type of hotel and
its mounting position (1, 2, or 3) on the CataLyst Express.
Table 3-1: Instrument Names of factory-taught paths
Storage Unit Instrument Names of Factory-taught Paths
Thermo CRS Microplate Hotel StdShelf1, StdShelf2, StdShelf3
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Thermo CRS Portrait Hotel PortShelf1, PortShelf2, PortShelf13
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Thermo CRS Platefeeder Hotel StdFeeder1, StdFeeder2, StdFeeder3
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Re-grip station regrip
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To re-teach the paths to a hotel or to the re-grip station, you use the Easy
Teach program and re-teach the locations that define the paths. For details
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about the Easy Teach program, see Chapter 5: Defining Motion in your
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POLARA 2.cx User Guide.
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Warning! Do not edit the Park.v3 and robot.v3 files in the V3_Files directory!
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Doing so will cause the CataLyst Express to behave unpredictably! These

files are created at the factory and are unique to each CataLyst Express.
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Installing the CataLyst Express: Connecting Instruments
Connecting Instruments
You can connect any instrument whose nests fall within the reach of the
CataLyst Express. For details on the reach, see Figure 3-5.
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Figure 3-5: Reach of the CataLyst Express in in.[mm]

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Tip: You might have to raise and/or rotate the instrument to enable the
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CataLyst Express to reach it.

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Once the instrument’s nests are within the reach of the CataLyst Express,
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both must be prevented from moving, relative to each other. You can fix them
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in position in the following ways:

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• Stick the supplied corner stops to the bench, around the feet of the
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instrument and the CataLyst Express.

Installing the CataLyst Express: Connecting Instruments
• Before connecting the instrument, fix it to a mounting plate that has

dowel pins that can slip into the matching holes on the base of the
CataLyst Express. (See Figure 3-6 for the location of the holes.)
Side instrument
mounting holes
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Rear instrument
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mounting holes
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Side instrument
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mounting holes
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Figure 3-6: Location of instrument mounting plate holes on bottom surface

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Note: Thermo CRS supplies mounting kits for many instruments. Contact
Thermo CRS sales for more information, as described in “Contacting
the Customer Support Group” on page 7-4.

CHAPTER 4
Using the CataLyst Express
This chapter describes how to operate the CataLyst Express. For details, see
the following topics:
• “Using the Front Panel” on page 4-2
• “Using the E-Stop Control” on page 4-3
• “Pre-power Checklist” on page 4-7
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• “Starting the CataLyst Express” on page 4-8
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• “Shutting Down the CataLyst Express” on page 4-10
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CataLyst Express User Guide: Using the CataLyst Express 4–1

Using the CataLyst Express: Using the Front Panel
Using the Front Panel

The front panel provides basic hardware controls and connectors for the
CataLyst Express.
Figure 4-1: Front panel of CataLyst Express
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The front panel has the following features:
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• The MAIN POWER switch controls power to the CataLyst Express.
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• The LCD panel displays status messages and prompts.
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• The fuse panel contains fuses and circuit breakers. For details about the
fuse panel, see “Checking Front Panel Fuses and Circuit Breakers” on
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page 6-5.
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• The ARM POWER button controls power to the arm. When its LED glows,
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the arm is powered. If the LED does not glow, pressing the ARM POWER
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button turns on power to the arm.
• When the HOME button’s LED glows, the arm is homed. If the LED does
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not glow, pressing the HOME button when the arm is powered homes the
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arm.
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• The PAUSE/CONTINUE button’s LED flashes when the CataLyst Express

needs confirmation of a request to take control of the arm. To confirm the
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request, the operator must press the PAUSE/CONTINUE button. For

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more information, see “Understanding the Arm Status Indicators” on

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page 4-4.
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• ActiveRobot applications can use the F1 and F2 buttons to get input from
the operator.
• The E-Stop control plugs into the E-STOP port. For more information
about the E-Stop control, see “Using the E-Stop Control” on page 4-3. For
details about the connector, see “The E-Stop Port (Front Panel)” on
page 5-10.
• The GPIO port provides access to the input/output features of the

CataLyst Express. For details, see “General Purpose Input/Output (GPIO)
Port” on page 5-5.
• The personal computer used to teach and control the CataLyst Express
plugs into the P.C. port. For details, see “P.C. Port” on page 5-4.
• The SERIAL port enables other devices that to communicate with the
CataLyst Express. For details, see “Serial Port” on page 5-3.
4–2 CataLyst Express User Guide: Using the CataLyst Express

Using the CataLyst Express: Using the E-Stop Control
Using the E-Stop Control

The E-Stop control enables you to cut power immediately to the arm. The E-
Stop control also displays arm status, and provides a brake release that
enables you to move the arm manually.
E-Stop button
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Arm status indicators
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Brake release
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Figure 4-2: The E-Stop control cuts power to the arm, displays its status, and provides a
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brake release.
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Note: The CataLyst Express cannot apply power to the arm unless the E-
Stop is plugged into the E-STOP port on the front panel.
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Note: To connect other E-Stops into the E-Stop circuit of the

CataLyst Express, remove the dummy plug from the E-STOP port on
the rear panel and connect the E-Stops between pins 8 and 9 on the
port. For details, see “Adding E-Stops” on page 5-12.
Using the E-Stop

Use the E-Stop to immediately cut power to the arm.
To trigger the E-Stop

• Press the E-Stop button. The CataLyst Express cuts power to the arm
and engages the brakes. The arm power beacon turns off, as do the arm
power indicators on the front panel and the E-Stop control.

To reset the E-Stop

1 Remove all hazards from the CataLyst Express and the instruments, and
confirm that it is safe to power the arm.
2 Twist the E-Stop button clockwise until it pops up.
Understanding the Arm Status Indicators

The arm power status indicator glows when arm power is on.
To turn on arm power

• Press the ARM POWER button on the front panel of the CataLyst Express.
The ARM POWER indicators on the front panel and the E-Stop control
light.
Note: If you cannot turn on arm power, see “Arm Power Cannot Be Turned
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On” on page 7-3.
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The pause/continue status indicator flashes when the CataLyst Express
needs you to manually confirm that you want control of the arm. For example,
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suppose another Windows application had gained control of the arm and then
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crashed, leaving it unable to release control. If Easy Teach then requests
control of the arm, the CataLyst Express, for safety reasons, requires you to
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manually confirm that request by pressing the PAUSE/CONTINUE button on
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the front panel.
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To confirm a request for control of the arm

1 Determine whether it is safe to confirm the request. In particular, ensure
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that the work space is free of obstructions and that all personnel are
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outside the safeguarded area.

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2 If it is safe to confirm the request for control, press the flashing

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PAUSE/CONTINUE button on the front panel.

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Note: You may also need to press the ARM POWER button to restore
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power to the arm.

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Using the Brake Release

Use the brake release when you need to manually move the arm: for example,
when you need to return the arm to its parking bracket.
To manually move the arm

1 Trigger the E-Stop or open the guarding. The CataLyst Express cuts
power to the arm.
2 With one hand, support the arm.
3 With the other hand, press and hold the brake release button on the E-
Stop control. The arm sags.
4 Manually rotate the arm’s joints to the desired position.
5 Release the brake release button. The arm’s brakes engage.

6 Reset the E-Stop and close the guarding.
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Using the CataLyst Express: Using the Guarding
Using the Guarding

The guarding consists of a Lexan barrier with a safety interlock
To open the guarding

1 Ensure the CataLyst Express is not moving.
2 Pull the handle on the front door. The arm power indicators go dark and
the arm’s brakes engage.
To close the guarding

1 Close the front door so that the door key is in the key interlock on the
guarding frame. The door and frame magnets align and meet to hold the
door closed.
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2 Turn on arm power by pressing the ARM POWER button on the front
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panel of the CataLyst Express.
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Using the CataLyst Express: Pre-power Checklist
Pre-power Checklist
Before turning on the power to the CataLyst Express, confirm the following
conditions:
• The arm is not carrying anything.
• There are no people or unusual objects within the reach of the arm.
• The E-Stop circuit is closed:
• The E-Stop button is reset.
• The guarding is closed.
• The computer is connected to the P.C. port on the front of the
CataLyst Express.
• The CataLyst Express is connected to main AC power.
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Using the CataLyst Express: Starting the CataLyst Express
Starting the CataLyst Express

Before you can use the CataLyst Express for moving microplates or teaching
paths, you must power it up, test the E-Stop and guarding, and unpark and
home it.
Note: If you are starting the CataLyst Express for the first time, perform the
self-test after startup, as described in “Testing the CataLyst Express”
on page 3-9.
To power up the CataLyst Express

• Switch the MAIN POWER button to the ‘1’ position. The CataLyst Express
turns on. When it has finished its boot sequence, the LCD panel displays
the following ready message:
C500C CROS
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Note: If you do not see the ready message on the front panel display or if
you encounter any errors, do not use the CataLyst Express. To
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correct boot-up problems, refer to Chapter 7, Troubleshooting.
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To turn on arm power
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1 Confirm that the guarding is closed and connected, and that the E-Stop
button is reset and within reach.
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2 Press the ARM POWER button on the front panel of the CataLyst Express.
The arm power beacon, the ARM POWER LED on the front panel, and the
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Arm Power indicator on the E-Stop control glow, indicating that the arm
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Note: If you cannot turn on arm power, see “Arm Power Cannot Be
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Turned On” on page 7-3.

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To test the E-Stop and guarding

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1 Press the E-Stop. The arm power indicators go dark and the arm’s brakes
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engage.
Caution! If the arm power LED remains lit when the E-Stop button has
been pressed, do not start the CataLyst Express! Inform all users that the
CataLyst Express is unavailable and contact Thermo CRS Customer Support
immediately.
2 Reset the E-Stop.
3 Turn on arm power. The arm power indicators glow and the arm’s brakes
release.
4 Open the guarding. The arm power indicators go dark and the arm’s
brakes engage.
Caution! If the arm power LED remains lit when the guarding is open, do
not start the CataLyst Express! Inform all users that the CataLyst Express
is unavailable and contact Thermo CRS Customer Support immediately.
5 Close the guarding.

Using the CataLyst Express: Starting the CataLyst Express
6 Turn on arm power. The arm power indicators glow and the arm’s brakes
release.
Note: If you cannot turn on arm power, see “Arm Power Cannot Be
Turned On” on page 7-3.
To unpark and home the arm

1 Turn on the computer and its display, and wait until Windows has
started.
2 Log in to Windows and take the following step to start the Easy
Teach Setup program:
• In the Windows Start menu, choose
Programs > CRS Robotics > CataLyst Express > Easy Teach.
The Easy Teach Setup program opens.
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Figure 4-3: The Easy Teach Setup main screen

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3 Click Unpark and Home. The CataLyst Express moves the arm out of the
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homing bracket, homes the arm, and puts it into the Ready position.
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Tip: To halt the unpark and home operation, click Abort. To issue arm
commands again, click Clear Abort.
4 Click Park to park the arm before starting a POLARA run.

Using the CataLyst Express: Shutting Down the CataLyst Express
Shutting Down the CataLyst Express

To shut down the CataLyst Express, you park the arm, perform a controlled
shutdown, and power it off.
Warning! Turning off power to the CataLyst Express without first performing
a controlled shutdown may corrupt its memory and damage its internal
files!
• “Parking the Arm” on page 4-10
• “Performing a Controlled Shutdown” on page 4-10
• “Powering Off the CataLyst Express” on page 4-11
Note: POLARA always parks the arm after a successful run.
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Parking the Arm
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You can park the arm from Easy Teach Setup or manually.
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To park the arm from Easy Teach Setup
• In the Windows Start menu, choose
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• Click Park. The CataLyst Express moves the arm into the parking
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bracket.
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Tip: To halt the park operation, click Abort. To issue arm commands
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again, click Clear Abort.

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To park the arm manually

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1 Open the guarding. The CataLyst Express cuts power to the arm.
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2 With one hand, support the arm.

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3 With the other hand, press and hold the brake release button on the E-
Stop control. The arm sags.
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4 Manually rotate the arm’s joints into the parking bracket until the
parking LED glows.
5 Release the brake release button. The arm’s brakes engage.
6 Close the guarding.
Performing a Controlled Shutdown

You can perform a controlled shutdown either from Easy Teach Setup or from
the front panel.
To shut down the CataLyst Express from Easy Teach Setup

1 In the Windows Start menu, choose

2 Click Shutdown.
3 Wait until the CataLyst Express LCD screen displays the message:
C500C CROS
System Halted
To shut down the CataLyst Express from the front panel

1 While holding down the HOME button on the front panel, press and
release the PAUSE/CONTINUE button.
2 Release the HOME button. The CataLyst Express will begin shutting
down.
Note: You must complete steps 1 and 2 within a second or two. If nothing
happens, simply try again a little faster or a little slower.
3 Wait until the CataLyst Express LCD screen displays the message:
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C500C CROS
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System Halted
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Powering Off the CataLyst Express
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Once you performed a controlled shutdown of the CataLyst Express, you can
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power it off.
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To power off the CataLyst Express

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• Switch the CataLyst Express MAIN POWER to the ‘0’ position.

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CHAPTER 5
CataLyst Express Ports
This chapter describes the pin layout and use of the ports provided with
CataLyst Express.
Never connect devices while the CataLyst Express is powered. Doing so
may damage the CataLyst Express or the device or both.
Warning! Incorrect wiring can seriously damage sensitive

CataLyst Express components. Verify that you have correctly matched the
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pin numbering scheme and that all connections are properly wired before
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using the connector.
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• “The Wrist/OPTIONS Ports” on page 5-2
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• “Serial Port” on page 5-3
• “P.C. Port” on page 5-4
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• “General Purpose Input/Output (GPIO) Port” on page 5-5
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• “The E-Stop Port (Front Panel)” on page 5-10

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• “The E-Stop Port (Rear Panel)” on page 5-12

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• “The Guarding Port” on page 5-14

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CataLyst Express User Guide: CataLyst Express Ports 5–1

CataLyst Express Ports: The Wrist/OPTIONS Ports
The Wrist/OPTIONS Ports

The Wrist and OPTIONS ports together provide a set of circuits between the
wrist and the base of the CataLyst Express. This enables you to electrically
control such end-of-arm devices as bar code readers.
8 7 6 5 4 3 2 1 5 4 3 2 1
9 8 7 6
15 14 13 12 11 10 9
OPTIONS port Wrist port

(DB-15, rear of CataLyst Express base) (wrist DB-9)
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Figure 5-1: Pin numbering for the wrist/OPTIONS ports
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The wiring for the port on the wrist is routed through the inside of the arm and
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emerges at pins 1-8 of the OPTIONS port on the rear panel.
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Table 5-1: Pinouts for the wrist/OPTIONS connector
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OPTIONS port pin Wrist port pin Function
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1 1 User 1
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2 2 User 2
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3 3 User 3
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4 4 User 4
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5 5 User 5
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6 6 User 6
7 7 User 7
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8 8 User 8
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9 9 Shield chassis GND

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10-15 Not Connected

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Note: To integrate end-of-arm devices into an application under program

control, you must connect them to the GPIO port. See “General
Purpose Input/Output (GPIO) Port” on page 5-5.
5–2 CataLyst Express User Guide: CataLyst Express Ports

CataLyst Express Ports: Serial Port
Serial Port
The SERIAL port uses a standard DB9 connector.
Note: The SERIAL port is configured as standard DTE port.
5 4 3 2 1
9 8 7 6
Figure 5-2: SERIAL port pin numbering
Table 5-2: SERIAL port pinout
Pin # Signal Name Signature Description
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1 DCD Input / RS232 Data Carrier Detect
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2 RXD Input / RS232 / ±10 V Receive Data
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3 TXD Output / RS232 / ±10 V Transmit Data
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4 DTR Output / RS232 Data Terminal Ready
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5 GND GND Signal Ground
6 DSR Input / RS232

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7 RTS Output / RS232 Request To Send
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8 CTS Output / RS232 Clear To Send

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9 RI Input / RS232 Ring Indicator

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CataLyst Express Ports: P.C. Port
P.C. Port
The P.C. port uses a standard DB-9 connector and is used to connect a
computer to the CataLyst Express.
Note: The P.C. port is configured as a standard DCE port. However, only pins
2, 3, and 5 are used.
5 4 3 2 1
9 8 7 6
Figure 5-3: P.C. port pin numbering
Table 5-3: P.C. port pinout
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Pin # Signal Name Signature Description
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2 TXD Output / RS232 / ±10 V Transmit Data
3 RXD Input / RS232 / ±10 V Receive Data
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5 GND GND Signal Ground
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CataLyst Express Ports: General Purpose Input/Output (GPIO) Port
General Purpose Input/Output (GPIO) Port

Connect devices to the GPIO port to monitor and control external events.
Note: Add the CRS C500 PLC (using GPIO) component class to your
POLARA workspace. For details, see “PLC Instance Settings” in chapter
4 of your POLARA 2.cx Administrator Guide.
The general purpose input/output (GPIO) port provides a total of 15 digital

inputs, 12 digital outputs, and 4 relay outputs for connecting external
hardware devices to the CataLyst Express. With the exception of the analog
input, GPIO inputs and outputs are electrically isolated from the
CataLyst Express’s power and logic circuits.
GPIO outputs include low current, optically isolated relay drivers with 50 mA
capacity, and 1 A relay contact outputs with normally closed (NC) and
normally open (NO) contacts. All relays are connected to a common line,
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RLYCOM, which is fused on the front panel.
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Warning! Using an external power supply for the input/output devices can
damage the circuits of the CataLyst Express. Power the devices from the
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supply provided by the CataLyst Express, as shown in Figure 5-5.
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Connect devices to the GPIO port through a standard DD-50 connector. To
connect devices more easily, you can extend the port with the optional GPIO
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termination block (part number SEC-23-501) available from CRS.
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Note: For installation instructions for the GPIO termination block, see
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Appendix B, GPIO Termination Block Option.

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Warning! Do not use the numbers embossed on the plastic inside the
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connector. Refer to the pin numbers shown in Figure 5-4. Incorrectly matched
pins in your GPIO connection can severely damage the CataLyst Express.
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Pinouts for the GPIO Port

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The GPIO port uses the numbering convention for a ribbon-type connector
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instead of standard DD-50 numbering.

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Note: Refer to the numbering scheme shown in Figure 5-4.

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Figure 5-4: Pin numbering scheme used by the GPIO connector

Table 5-4: Pinouts for the GPIO connector
Pin Function Signature Description
1 +24 V 24 VDC internal + 24 VDC
5 GPI0 Opto General Purpose input #1
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16 GPI11 Opto
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General Purpose input #12
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20 GPI15 Opto Not connected
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21 GPO0 Opto General Purpose output #1

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33 Shield
34 N/C
35 GPO13NC Relay General Purpose output #13, Normally closed contact
36 GPO13NO Relay General Purpose output #13, Normally open contact



43 RLYCOM Relay common All relays attached here, and to front panel fuse
44 RLYCOM Relay common All relays attached here, and to front panel fuse
45 Analogln1 Analog Provides an analog input
46 Analogln2 Not supported
47 Gnd Digital Internal ground return for 24 VDC
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Note: Opto = optocoupler (optically coupled). N/C = not connected. ISORET=
isolated return.
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Note: All opto-outputs are NPN, all opto-inputs require NPN devices.
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Inside Controller Outside Controller

+24V_Internal
ISO_SUPPLY INTERNAL_24V_SUPPLY
1
2
+24 VDC
3
10 to 40 VDC, max.
+ISO_SUPPLY
4
Input_01
5
Input_02 6
Input_03 7
Input_04 8
Input_05 9
Sample Internal Input Stage Input_06 10
ISO_GROUND
Input_07 11
Input_08 12
Input_09 13
Input_10
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14
Input_11
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15
Input_12 16
ISO_SUPPLY
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Input_13 17
Input_14 18
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Input_15 19
NC 20 +24 VDC (pins 1-4)
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21
LOAD
Output_02
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22
Output_03
23
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Output_04
24
Output_05
25
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10 to 40 VDC, max.
50 mA per output Output_06
26
Output_07
27
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Output_08
28
Output_09
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Sample Internal Output Stage Output_10
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30
Output_11 +24 VDC
31
Output_12 (internal or external)
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32
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Relay_Common 43
FP_F2 or F10
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Output_13_RELAY_NC 35
Output_13_RELAY_NO
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36
2 A, 30 VDC
LOAD
Output_14_RELAY_NO 38
Output_15_RELAY_NO GND
40
(internal or external)
Output_16_RELAY_NO 5V (external)
42
AnalogIn_1 45
Not supported
46
47
ISO_RETURN
48
49
INTERNAL_GROUND
50
Figure 5-5: Wiring schematic for the GPIO connector

Connecting Inputs and Outputs

Connect inputs and outputs to the GPIO circuit as shown in Figure 5-5.
Note: An open input is off.
• Connect input devices as switches between the desired INPUT line (pins 5
through 19) and the ground on pin 50.
• Connect output devices between the desired OUTPUT line (pins 21
through 32) and the +24 VDC supply on pins 1, 2, 3, or 4. The output
device must not draw more than 50 mA.
Using the Relays

Relays behave like switches between the output pairs and the shared
Relay_Common line. Each relay output terminal consists of a normally open
(NO) and a normally closed (NC) contact pair.
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If an external power supply is connected to the relay contacts, take care not to
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exceed the 2 A, 30 VDC rating for the circuit.
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Warning! The relay circuit may be damaged by AC power. The
CataLyst Express relays are not rated for AC use.
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Relay contacts are fused through front panel fuse F10.
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Using GPIO Devices in Your Application

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To integrate GPIO devices into your application with ActiveRobot, refer to the
following commands in the ActiveRobot User Guide: AnalogInput, CTPath,
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CTPathGo, Input, Inputs, Motor, Output, and Outputs.

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CataLyst Express Ports: The E-Stop Port (Front Panel)
The E-Stop Port (Front Panel)

The E-Stop port provides access to the E-Stop circuit, enabling you to connect
other passive devices into the E-Stop chain.
25 23 21 19 17 15 13 11 9 7 5 3 1
24 22 20 18 16 14 12 10 8 6 4 2
Figure 5-6: Pin numbering scheme for the E-Stop port (front panel)
Table 5-5: Pinouts for the E-Stop port (front panel)
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1 +24 VDC Power Internal supply
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5 RPS Opto-input Pause/Continue

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6 ERA Opto-output unused
7 HMS Opto-input Home Request
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8 R0A Opto-output Pause/Continue Ack

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9 PRS Opto-input F2
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10 R1A Opto-output unused

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11 CSS Opto-input F1
12 HMA Opto-output Home Ack

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13 JigIns Opto-input unused

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14 PRA Opto-output F2 button Ack

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15 APA Opto-output Arm Power Ack
16 CSA Opto-output F1 button Ack

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17 REMONSW+ Contact-input
18 REMONSW- Contact-input
19 REMESTOP+ Contact-input remote E-Stop
20 REMESTOP- Contact-input remote E-Stop
21 N/C unused
22 Shield Ground shield
23 Gnd Digital Internal return for 24 VDC
Note: Opto = optocoupler (optically coupled). N/C = not connected, ISORET=

isolated return, Ack = acknowledged.

CataLyst Express Ports: The E-Stop Port (Front Panel)
Note: All opto-outputs are NPN, all opto-inputs require NPN devices.
Inside Controller Outside Controller

+24V_Internal
ISO_SUPPLY INTERNAL_24V_SUPPLY
1
2
+24 VDC
10 to 40 VDC, max. 3
+ISO_SUPPLY
4
Pause/Cont_Input_Sw. 5
Home_Input_Sw. 7
F2_Input_Sw. 9
F1_Input_Sw. 11
Sample Internal Input Stage
ISO_GROUND
+Arm_On_Mom_Contact_Inp** 17 Remote Arm Power

-Arm_On_Mom_Contact_Inp** 18 Control Input
(Momentary Contact Only)
ISO_SUPPLY
+E-Stop_Input_Sw. (contact only)
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19
Emergency
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-E-Stop_Input_Sw. (contact only) 20 Stop INPUT
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+24 VDC (pins 1-4)
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LOAD
Pause/Cont_Ouput_Sig 8
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Home_Ouput_Sig 12
F2_Output_Sig 14
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Arm_Power_Output_Sig 15
F1_Output_Sig 16
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10 to 40 VDC, max.
50 mA per output
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23
ISO_RETURN 24
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Sample Internal Output Stage INTERNAL_GROUND 25
GND
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Figure 5-7: Wiring schematic for the E-Stop port

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CataLyst Express Ports: The E-Stop Port (Rear Panel)
The E-Stop Port (Rear Panel)

The E-Stop port on the rear panel provides connections into the E-Stop
circuit. It also provides arm power and guarding status.
5 4 3 2 1
10 9 8 7 6
15 14 13 12 11
E-STOP port
(high density DB15)
Figure 5-8: Pin numbering scheme for the E-Stop port (rear panel)
Table 5-6: Pinouts for the E-Stop port (rear panel)
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Pin Description
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1 Guarding door interlock status
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2 Guarding door interlock status
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3 Not used
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4 Arm power status
5 +24 VDC
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6 Not used
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7 Not used
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8 12 VDC internal E-Stop chain

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10 GND
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11 Not used
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12 Not used
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14 Not used
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15 Arm power status

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Adding E-Stops
You can connect additional E-Stop safety devices through the E-Stop contact
terminals on the rear panel E-Stop port.
• An E-Stop button must be a large, palm-cap, red button that has been
third-party approved for use as an E-Stop. Once triggered, the E-Stop
button must require a manual reset.
• In addition to buttons that halt robot motion, E-Stop devices can include
passive triggers such as door latching mechanisms or pressure sensors.
Note: All mechanisms used as E-Stop devices must be safety-rated.
• Devices connected into the E-Stop circuit must be dry contact or jumpers.

CataLyst Express Ports: The E-Stop Port (Rear Panel)
• Connect all E-Stop devices in series to ensure that power is removed

when any device in the circuit is disconnected or disrupted.
To connect external devices to the E-Stop circuit

• Connect all E-Stop devices in series between pins 8 and 9 on the rear
panel E-STOP port.
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CataLyst Express Ports: The Guarding Port
The Guarding Port

The GUARDING port provides the following connections:
• Connections to the guarding interlock
• Arm power status to the guarding beacon
• Connections to the E-Stop circuit
5 4 3 2 1
10 9 8 7 6
15 14 13 12 11
GUARDING port
(high density DB15)
Figure 5-9: Pin numbering for the GUARDING port
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Table 5-7: Pinouts for the GUARDING port
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Pin Description
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1 Guarding door interlock
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2 Guarding door interlock al
3 Not used
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4 Arm power status

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5 +24 VDC
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7 Not used
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10 GND
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12 Not used
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13 Not used
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14 Not used
15 Arm power status

CHAPTER 6
Maintenance Procedures
In order to protect your application and to prolong the life of the

CataLyst Express, schedule and perform the maintenance procedures
described in this chapter. For details, see the following topics:
• “Backing up Files” on page 6-2
• “Cleaning” on page 6-3
• “Routine Inspections” on page 6-4
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• “Checking Front Panel Fuses and Circuit Breakers” on page 6-5
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• “Inspecting AC Fuses” on page 6-7
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• “Scheduled Maintenance” on page 6-8
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CataLyst Express User Guide: Maintenance Procedures 6–1

Maintenance Procedures: Backing up Files
Backing up Files
On a regular basis, backup the following files:
• The .v3 files in the install directory’s V3_Files sub-directory (by default,
C:\Program Files\CRS Robotics\CataLyst Express\V3_Files).
• POLARA workspace files which are, by default, in the
C:\Program Files\CRS Robotics\POLARA directory, but can be in other
directories. Workspace files have file extension .mdr.
To backup files
• Use Windows Explorer to copy .v3 and .mdr files to secure storage.
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6–2 CataLyst Express User Guide: Maintenance Procedures

Maintenance Procedures: Cleaning
Cleaning
Clean exterior surfaces with mild cleaning products only. Some solvents and
degreasers may damage printed surfaces.
Warning! Electric Shock Hazard. Do not immerse any part of the robot system
in liquid.
When cleaning, do not allow liquids to seep inside the base or enter the arm
casing. Be particularly careful to avoid connectors when cleaning the wrist
area on the arm.
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Maintenance Procedures: Routine Inspections
Routine Inspections
Inspect the exterior and function of the CataLyst Express at regular intervals.
To perform the monthly Inspection

• Unscrew the finger screw holding the fan filter cover in place at the rear of
the base and remove the filter. Inspect the filter for accumulated dirt and,
if necessary, rinse it under water. Return it to the same location and
fasten the fan filter cover back in place with the finger screw.
• If the arm is dirty, wipe the exterior clean with a damp cloth.
• Inspect the arm and cables for signs of damage or wear.
• Inspect all E-Stops and safety devices to ensure that they are functioning
normally.
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• Inspect the flex covers for creases, splits, or cracks. Replacement flex
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covers are available from CRS.
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To perform the annual inspection
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• Check for wear along the inside of the parking bracket notch or binding
when the arm enters or leaves the parking bracket. Wear or binding can
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indicate a loss of positional accuracy.
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• Check arm covers for wear and cracks.

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Maintenance Procedures: Checking Front Panel Fuses and Circuit Breakers
Checking Front Panel Fuses and Circuit Breakers

Fuses and circuit breakers located on the front panel protect
CataLyst Express circuits from overload.
fuses and circuit breakers
Figure 6-1: Location of front panel fuses and circuit breakers
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Under normal operating conditions, the front panel fuses should not need to
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be replaced. A blown fuse or tripped circuit breaker may indicate a more
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serious problem. If you replace fuses or reset circuit breakers often within a
short period of time and cannot identify the cause of the failure, contact the
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Thermo CRS Customer Support Group for assistance.
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Tip: A collision can sometimes blow a fuse or trip a circuit breaker. Correct
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the condition that caused the collision, and then replace the fuse or
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reset the circuit breaker.
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Table 6-1: Front panel fuses

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Fuse Signal Name Fuse Rating Function

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F1 Axis 1 250 V, 2 A, circuit breaker • axis 1 motor

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F8 Gripper 250 V, 0.38 A, slow blow • servo gripper

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F9 24VDC 250 V, 2 A, slow blow • 24V power supply

• main CataLyst Express board circuits
• internal 24 V power supply
F10 RLYCOM 250 V, 2 A, slow blow • GPIO relay common
Note: All fuses are standard 1/4 in. x 1 1/4 in.
To inspect and reset a circuit breaker

1 With the CataLyst Express shut down and powered off, examine the
circuit breakers. A tripped circuit breaker will have sprung outward from
its casing, revealing a white band.
2 To reset a tripped circuit breaker, push the breaker in until it clicks back
into its casing. The white band should no longer be showing.

Maintenance Procedures: Checking Front Panel Fuses and Circuit Breakers
To inspect and replace a fuse

1 With the CataLyst Express shut down and powered off, unscrew the fuse
clip and remove the affected fuse.
2 Measure the resistance across the fuse. If the resistance is larger than 2
Ohms, the fuse has blown and must be replaced.
Note: Test fuses with an Ohm-meter. Visual inspection can be deceptive.
3 Insert a new fuse of the same rating in the fuse clip. Ratings for the
CataLyst Express front panel fuses are given in Table 6-1.
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Maintenance Procedures: Inspecting AC Fuses
Inspecting AC Fuses
The AC fuses are located inside the fuse drawer at the back of the base.
Warning! High Voltage. Always shut down and unplug the CataLyst Express
before inspecting the AC fuses.
Table 6-2: AC fuses required for the CataLyst Express
Mains Voltage Required Fuses
100 VAC 8 A, 250 V, 6.3 mm x 32 mm [¼ in. x 1¼ in.], slow blow

To inspect the AC Fuses
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1 Shut down and turn off the
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CataLyst Express.
Unplug the power cord from the power
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2
connector at the back of the
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CataLyst Express.
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Insert a screwdriver below the clip to release
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the fuse drawer.
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4 Make sure that the voltage is properly

selected for your local mains power.
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5 Remove the two AC fuses from the fuse drawer and measure the
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resistance across each fuse. If the resistance is larger than 2 Ohms, the
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fuse has blown and must be replaced.

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Note: Test fuses with an Ohm-meter. Visual inspection can be deceptive.

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If necessary, replace blown fuses with the appropriate fuses for your local
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mains power. Determine the required fuse rating from Table 6-2.
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7 Replace the fuse drawer into the power module and push until you hear
the drawer click into place.
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Maintenance Procedures: Scheduled Maintenance
Scheduled Maintenance
To keep the arm in good working order, schedule the following maintenance
procedures according to the duty cycle for your application.
Maintenance Task Normal Duty Cycle Light Duty Cycle
Lubricate chains every 2,000 hours every 4,000 hours
Adjust chain tension every 2,000 hours every 4,000 hours
Adjust wrist gear mesh every 2,000 hours every 4,000 hours
Check inner wiring harness every 5,000 hours every 10,000 hours
Check motor brush wear every 5,000 hours every 10,000 hours
Hysteresis check and every 5,000 hours every 10,000 hours

inspect grease distribution
Inspect and clean every 12,000 hours every 24,000 hours
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Note: Scheduled maintenance procedures should only be carried out by
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Thermo CRS-authorized service technicians.
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Example Duty Cycle Determination al
A CataLyst Express is used in a laboratory application to move a light
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payload. The environment is controlled, the payload is less than rated, and
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default accelerations are used. In addition, the arm is only in motion 50% of
the time during a pick-and-place operation.
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Based on this information, the robot in this example has a light duty cycle.
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CHAPTER 7
Troubleshooting
This chapter contains diagnostic procedures to help you correct problems

with your robot system. If a problem cannot be resolved easily, see
“Contacting the Customer Support Group” on page 7-4.
Warning! Do not open the CataLyst Express case or remove arm covers unless
instructed by CRS-authorized personnel. Service procedures should only be
carried out by qualified service technicians.
For more information, see the following topics:
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• “The LCD Display Remains Blank” on page 7-2.
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• “Arm Power Cannot Be Turned On” on page 7-3
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CataLyst Express User Guide: Troubleshooting 7–1

Troubleshooting: The LCD Display Remains Blank
The LCD Display Remains Blank

If the LCD display remains blank after the system is powered on, there may be
a problem with the power supply. Switch the CataLyst Express off and try the
following troubleshooting steps:
• Make sure that the CataLyst Express is plugged into a live power outlet.
• Verify that the power plug is securely connected in the power connector at
the back of the CataLyst Express.
• Verify that the voltage indicator is correctly selected for your local power.
• Unplug the CataLyst Express and check the AC fuses. See “Inspecting AC
Fuses” on page 6-7.
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7–2 CataLyst Express User Guide: Troubleshooting

Troubleshooting: Arm Power Cannot Be Turned On
Arm Power Cannot Be Turned On

If arm power does not come on when the ARM POWER button is pressed, try
the following troubleshooting steps:
• Make sure that the E-Stop circuit is closed.
• Verify that all E-Stop buttons and devices have been reset. You cannot
turn on arm power while an E-Stop is triggered.
• Verify that the guarding is closed.
• Verify that the guarding is connected to the GUARDING port at the
back of the CataLyst Express.
• Check the fuses and circuit breakers.
• Shut down and restart the CataLyst Express.
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CataLyst Express User Guide: Troubleshooting 7–3

Troubleshooting: Contacting the Customer Support Group
Contacting the Customer Support Group

Before contacting Thermo LAI, make sure that you can provide a clear
description of the problem. The following information will help the Customer
Support Group diagnose and resolve the problem efficiently:
• Serial numbers for the CataLyst Express (located on the rear)
• Whether the arm is part of a POLARA laboratory system.
• A brief description of the operating environment and the type of
application
• Any errors or warning messages observed
• Steps necessary to reproduce the problem and the circumstances
surrounding the failure.
Once you have gathered all of the relevant information, contact the Customer
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Support Group by telephone, fax, or e-mail.
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Telephone
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1-905-332-2000 (voice)
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1-800-365-7587 (voice: toll free in Canada and United States)
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Fax
1-905-332-1114 (facsimile)
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E-Mail
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Technical Services: services.labautomation@thermo.com

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7–4 CataLyst Express User Guide: Troubleshooting

APPENDIX A
Technical Specifications
For specifications on the CataLyst Express, see the following topics:

• “Physical Characteristics” on page A-2
• “Electrical Specifications” on page A-3
• “Operating Environment” on page A-3
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CataLyst Express User Guide: Technical Specifications A–1

Technical Specifications: Physical Characteristics
Physical Characteristics
Table A-1 lists the physical characteristics of the CataLyst Express.
Table A-1: Physical Characteristics
Number of axes 5
Weight 76 kg [167 lb]
Nominal payload 0.1 kg [0.2 lb]
Repeatability ± 0.05 mm [0.002 in.]
Drive system Electromechanical motors

Incremental encoders in each joint
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Transmission Harmonic drives
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Brakes Brakes on all joints
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Memory 4 MB RAM user memory
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512KB NVRAM for application storage
1 MB flash memory for system firmware
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User I/O 15 digital inputs
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12 digital outputs
1 analog input
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4 relay outputs
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Front Panel interface 16x2 character, back-lit LCD display

User programmable buttons and LED lights
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System connections 2 E-Stop control ports

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1 personal computer serial port

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1 serial port
1 guarding port
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1 option port
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A–2 CataLyst Express User Guide: Technical Specifications

Technical Specifications: Electrical Specifications
Electrical Specifications
Table A-2 lists the electrical specifications of the CataLyst Express.
Table A-2: Electrical Specifications
AC Input voltage 100/115/230 VAC ± 10%
Line frequency 50-60 Hz
Power consumption (max) 350 VA
Operating Environment
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Table A-3 specifies the operating environment for the CataLyst Express.
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The CataLyst Express is rated for indoor use only.
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Table A-3: Operating Environment
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Temperature 10° to 40° C [50 to 104 F]
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Humidity Keep below 80% humidity,

Non-condensing environment only
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Vibration Not rated for excessive vibration or shock

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Electromagnetic Interference Do not expose to excessive electrical noise

or plasma
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CataLyst Express User Guide: Technical Specifications A–3

Technical Specifications: Operating Environment
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A–4 CataLyst Express User Guide: Technical Specifications

APPENDIX B
GPIO Termination Block Option
A GPIO termination block is available as an optional component. It provides

easier access to GPIO connections by extending the pins in the GPIO port to
external screw terminals.
The mounting rail bracket on the underside of the GPIO block fits all standard
DIN EN rails.
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insert
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ribbon cable
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here
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insert
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DIN rail
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terminals
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Figure B-1: The GPIO termination block

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Installing the GPIO block

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1 Mount a DIN rail outside the arm’s work space, near the back of the
CataLyst Express.
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Note: The ribbon cable is 152 cm [5 ft.] in length. Mount the rail close
enough to the CataLyst Express to ensure that the cable is strain-
relieved.
2 Snap the GPIO termination block onto the rail.
3 With the CataLyst Express shut down and powered off, connect the
ribbon cable between the CataLyst Express and the GPIO block:
a Connect the male DD-50 ribbon connector to the GPIO port.
b Connect the box header end of the ribbon cable to the connector on
the GPIO termination block.
4 Referring to “Pinouts for the GPIO Port” on page 5-5, connect your devices
to the GPIO block terminals.
CataLyst Express User Guide: GPIO Termination Block Option B–1

GPIO Termination Block Option:
Note: The screw terminal numbers printed on the GPIO terminal block
correspond to the GPIO pin numbers shown in “General Purpose
Input/Output (GPIO) Port” on page 5-5. Do not use the pin
numbering embossed on the plastic inside the GPIO connector
on the CataLyst Express.
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B–2 CataLyst Express User Guide: GPIO Termination Block Option

APPENDIX C
Installing New Firmware
During troubleshooting or maintenance, you may need to re-install or install

a new version of the CataLyst Express’s operating system firmware.
Caution! Files on the CataLyst Express may be destroyed by the firmware
installation process. Always back up CataLyst Express calibration and
configuration files before updating firmware.
This appendix covers the following topics:
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• “Backing up Files from the CataLyst Express” on page C-2
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• “Downloading the CataLyst Express Firmware” on page C-4
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• “Configuring the Robot Controller” on page C-6
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CataLyst Express User Guide: Installing New Firmware C–1

Installing New Firmware: Backing up Files from the CataLyst Express
Backing up Files from the CataLyst Express
When you install new firmware, all files on the CataLyst Express are erased.
Before installing the new firmware, use ActiveRobot Explorer to back up the
CataLyst Express’s configuration files to a safe location on the PC.
To back up files from the CataLyst Express

1 Choose Start > Programs > CRS ActiveRobot > ActiveRobot Explorer
to start ActiveRobot Explorer. ActiveRobot Explorer opens a tree-view
window into the root directory of the CataLyst Express’s operating
system:
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Figure C-1: The ActiveRobot Explorer window displays the CataLyst Express’s directory
structure in the left pane and the contents of the selected directory in the
right pane.
2 Open Windows Explorer to the backup directory on the PC.
3 In ActiveRobot Explorer, select the files /conf/robot.cal, /conf/robot.cfg,

/conf/rc, /conf/simsockd.cfg, and /conf/startup.sh.
4 While pressing the left mouse button, drag the selected files to the backup
directory in Windows Explorer.
5 Watch the copy progress in the ActiveRobot Explorer status bar.
6 When the copy operation has completed (i.e. the copy progress field in the
status bar is blank), release the left mouse button.
C–2 CataLyst Express User Guide: Installing New Firmware

Installing New Firmware: Backing up Files from the CataLyst Express
Note: If you release the left mouse button before the ActiveRobot Explorer’s
status bar indicates that a file copy operation has completed, the file
will not be copied.
Tip: You can copy controller files to the host computer’s desktop simply by
dragging them there; you don’t have to go through Windows Explorer
in this case.
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Installing New Firmware: Downloading the CataLyst Express Firmware
Downloading the CataLyst Express Firmware

You use the Firmware Download Utility to download the operating system
firmware to the CataLyst Express.
To download firmware to the CataLyst Express

1 On the PC’s Start menu, choose
Programs > CRS Robotics > CROS-500C > Firmware Download Utility.
The download utility opens the following configuration screen:
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Use the following values for each setting:
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Setting Required Value

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CommPort The number of the PC’s COM port that is connected to the robot
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system.
Baud Rate The baud rate of the CataLyst Express SERIAL port. The factory
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default setting is 57600 bps.

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Path of Flash File The name and location of the file flash.img on the PC. You can press
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the “...” button to search for the file yourself.

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Path of MCE File The name and location of the file mcecat5.img on the PC. You can
press the “...” button to search for the file yourself.
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Path of Remote The name and location of the file remote.exe on the PC. You can
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press the “...” button to search for the file yourself.

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When the settings are correct, click Download. The download utility
prompts you to restart the CataLyst Express in diagnostic mode.
3 Restart the controller in diagnostic mode:
a Shut down the CataLyst Express, as described in “Shutting Down the
CataLyst Express” on page 4-10.
b Switch off controller power.
c While holding down the F1, F2, and Pause/Continue buttons, switch
on power to the CataLyst Express. Continue holding the buttons for
10 seconds. The CataLyst Express boots into diagnostic mode.
d Verify that the message
Diagnostic Mode
is displayed on the controller LCD screen.

Installing New Firmware: Downloading the CataLyst Express Firmware
4 On the PC, click OK in the Firmware Download Utility to start the

download.
5 When the download is complete, switch off power to the
CataLyst Express.
6 While holding down the F2 and Home buttons, switch on power to the
CataLyst Express. The front panel display shows the message
Loading new MFS from Flash
while the file system in the CataLyst Express is being rebuilt. When the
process is complete, the CataLyst Express continues with its normal
bootup sequence.
7 Open ActiveRobot Explorer to the /conf directory on the
CataLyst Express.
8 In Windows Explorer, select your backup files robot.cal, robot.cfg, rc,
simsockd.cfg, and startup.sh.
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9 Pressing the left mouse button, drag the selected files to the
CataLyst Express /conf directory in ActiveRobot Explorer.
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10 Shut down the CataLyst Express and re-start it.
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Installing New Firmware: Configuring the Robot Controller
Configuring the Robot Controller

You must configure CROS on the robot’s controller to work with POLARA.
To configure the robot controller to work with POLARA

1 Install on the controller the version of CROS for C500C that you installed
on the PC from the POLARA CD. For details on installing CROS, see
“Downloading the CataLyst Express Firmware” on page C-4.
2 Reconfigure the controller to launch the simsockd program on startup:
a In ActiveRobot Terminal, set the /conf directory to the current
directory. For details on using ActiveRobot, see the ActiveRobot User
Guide. For details on using the system shell, see the CROS and
System Shell user guide.
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b Rename the rc file:
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ren rc rc.nosimsockd
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c Copy the file rc.simsockd to rc:
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cp rc.simsockd rc
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3 Shut down and re-boot the controller.
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At the CROS command prompt, use the ps command to check that the
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simsockd program is running.
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Glossary
ActiveRobot
The ActiveX component for creating robot applications under Microsoft
Windows.
See: ActiveRobot User Guide on the documentation CD.
arm
An articulated, mechanical manipulator
articulated robot
Robotic arm consisting of rigid links connected by rotary joints. This type of
robot most closely resembles a human arm.
beacon
Awareness signal that indicates a condition or hazard. The beacon on the
guarding flashes amber when the arm is powered.
collision
Unscheduled physical contact between the arm and an object
diagnostic mode
CataLyst Express mode for low-level diagnostic operations
emergency stop (E-Stop)

Switch connected to the CataLyst Express E-Stop port that removes arm
power and halts robot motion when triggered. Once triggered, it must be
manually reset.
General Purpose Input Output (GPIO)

The GPIO port on the CataLyst Express provides inputs and outputs for
connecting external hardware devices.
guarding
Physical barrier that blocks access to the arm’s workspace. When opened, it
cuts arm power.
hardstop
Hardware safety device fastened at a fixed position that determines the
absolute ends of movement of a joint or track. A hardstop restricts the
workspace and provides some safety in the case of robot runaway.
homing
Procedure by which the motion control engine exactly locates the position of
each of the arm’s axes.
CataLyst Express User Guide: Glossary G-1

Glossary: I/O
I/O
Input/output.
interlock
In robot systems, a device that automatically prevents robot use under
dangerous conditions. For example, a door contact switch can be interlocked
with the arm power circuit to prevent robot use when the door is open.
joint
Location where two links join, usually consisting of a motor and drive.
See: link.
link
Rigid part of a robot arm between two neighboring joints
nest
The receptacle that holds a microplate
nominal payload
The amount of weight carried by the robot at maximum speed while
maintaining rated precision. This rating is highly dependent on the size and
shape of the payload.
operator
Person who uses the CataLyst Express to perform work. This can include
loading the workcell, running the robot, monitoring the running, and
responding to any problems, but does not include designing the workcell or
programming the robot.
parking led
An LED at the bottom of the parking bracket that indicates when the arm is
correctly parked.
payload
Amount of weight carried by the arm and/or the amount of force the arm
can exert on an object.
range of motion
Extent of travel of a link or of an arm. This is dependent on the limits of
rotational motion of the joints and the lengths of the links.
reach
Maximum distance to which the arm can extend the gripper. Reach defines
the work space of the arm.
repeatability
Ability of the robot to repeat the same motion or position a tool at the same
position when presented with the same control signals (over repeated cycles).
Also, the cycle-to-cycle error of the robot system when trying to perform a
specific task.
robot calibration file (robot.cal)

File that contains calibration information for the arm.
G-2 CataLyst Express User Guide: Glossary

Glossary: robot configuration file (robot.cfg)
robot configuration file (robot.cfg)

File which contains the configuration information for your robot system.
safeguard
Barrier, device, or procedure designed to protect persons from a hazardous
point or area.
tool transform
Offset value applied to the tool frame of reference. By default, the origin of
the tool frame of reference is located at the centre of the surface of the tool
flange. By applying a tool transform, you center the tool frame of reference at
another point such as the center of a microplate.
work space
Volume of space that can be swept by all robot parts plus the space that can
be swept by the gripper and the payload.
workstation
A station composed of the CataLyst Express integrated with instruments
CataLyst Express User Guide: Glossary G-3

Glossary: workstation
G-4 CataLyst Express User Guide: Glossary

Index
A E
AC input voltage A-3 electrical noise A-3
accident prevention 2-7 electromagnetic interference A-3
analog input 5-5 E-Stop 2-3, 6-4, 7-3
application design 2-2, 6-8
arm power
stays off 7-3
arm power beacon 2-3
F
fan filter 6-4
fault detection 2-3
fingers 2-5
B firmware download utility C-1
backing up files 6-2, C-2 flex covers 6-4
brakes 2-3, 2-5 front panel
display blank 7-2
pushbutton sequences C-4
shutting down from 4-10
C fuses 6-5, 7-3
cables 6-4 AC 6-7
CataLyst Express
lockout 2-8
parking 4-10
powering off 4-11 G
shutdown 4-10 GPIO
technical specifications A-1 Termination Block B-1
unparking 4-9 GPIO port
using 4-1 pinouts 5-5
chain tension 6-8 wiring 5-5
circuit breakers 6-5 GPIO Termination Block 1-7
cleaning 6-3 guarding 1-7
controlled shutdown 4-10
controller
backing up files C-2
firmware upgrade C-1 H
CROS C-1 hazards 2-5
customer support 7-4 humidity A-3
D I
designated use 2-2 input/output devices 5-5, B-1
development computer C-4 inspections
diagnostic mode C-4 routine 6-4
duty cycle 6-8 installation 3-1
instrument mounting kits 1-7
isolated circuits 5-5
CataLyst Express User Guide: Index I-1

Index: L
L U
life expectancy 6-8 unparking 4-9
lockout procedure 2-8 using the CataLyst Express 4-1
lubrication 6-8
V
M vibration A-3
maintenance 6-1, 6-8
backing up files 6-2
W
wrist port 5-2
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operating environment A-3
options 1-7
GPIO Termination Block 1-7
guarding 1-7
instrument mounting kits 1-7
P
parking 4-10
parking LED 4-10
pinch points 2-5
pinouts 5-1, 5-2
point of control 2-3
ports 5-1
power 4-7, A-3
powering off 4-11
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relays 5-9
S
safety 2-1
system features 2-3
servo gripper 2-5
shutting down 4-10
specifications A-1
start up 4-8
support 7-4
T
temperature A-3
troubleshooting 7-1, 7-4
I-2 CataLyst Express User Guide: Index

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CRS CataLyst Express

Arm power beacon

Parking bracket E-stop control

Copyright © May 2004 Thermo CRS, Ltd.

The information in this document is subject to change without notice.

About This Guide

Who Uses This Guide

How to Use This Guide

CataLyst Express User Guide: Preface iii

• Appendix A, Technical Specifications contains physical and electrical

iv CataLyst Express User Guide: Preface

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter 2: Safe Use of the CataLyst Express . . . . . . . . . . . . . . . 2-1

Chapter 3: Installing the CataLyst Express . . . . . . . . . . . . . . . . . 3-1

Chapter 4: Using the CataLyst Express . . . . . . . . . . . . . . . . . . . . 4-1

CataLyst Express User Guide: Preface v

Chapter 5: CataLyst Express Ports . . . . . . . . . . . . . . . . . . . . . . . 5-1

Chapter 6: Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . 6-1

Chapter 7: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Chapter A: Technical Specifications . . . . . . . . . . . . . . . . . . . . . . A-1

Chapter B: GPIO Termination Block Option . . . . . . . . . . . . . . . . B-1

Chapter C: Installing New Firmware . . . . . . . . . . . . . . . . . . . . . . C-1

vi CataLyst Express User Guide: Preface

Figure 1-1: CataLyst Express workstation . . . . . . . . . . . . . . . . . . . . . . 1-2

CataLyst Express User Guide: Preface vii

viii CataLyst Express User Guide: Preface

Table 3-1: Instrument Names of factory-taught paths . . . . . . . . . . . 3-10

CataLyst Express User Guide: Preface ix

x CataLyst Express User Guide: Preface

Introducing the CataLyst Express

The CRS CataLyst Express from Thermo Electron Corporation enables

CataLyst Express User Guide: Introducing the CataLyst Express 1–1

What is the CataLyst Express?

The CRS CataLyst Express enables scientists to automate the transfer of

Hotels, a Thermo CRS Platefeeder Hotel, and a Thermo Labsystems MicroDrop

Benefits of the CataLyst Express

Users of the CataLyst Express enjoy the following benefits:

• Continuous, error-free operation

• Precise, repeatable motion

• The ability to handle a wide range of containers

• The ability to automate loading and unloading of instruments, such as

• Safety features that meet OSHA requirements

• Easy to use, yet powerful method development and scheduling

1–2 CataLyst Express User Guide: Introducing the CataLyst Express

CataLyst Express Features

Arm power beacon

Figure 1-2: Main hardware features of the CataLyst Express

microplates into nests.

the electronics that power and control the system.

• The removable storage units provide the following types of storage:

• Random-access microplate hotels provide 15 nests, each of which

• Microplate feeder hotels provide storage for up to 40, stacked

The base can support up to three random-access hotels or three

• The re-grip station provides a nest for the CataLyst Express to

CataLyst Express User Guide: Introducing the CataLyst Express 1–3

• The E-Stop control provides an emergency stop button that, when

port that provides access to the end-of-arm user port.

1–4 CataLyst Express User Guide: Introducing the CataLyst Express

CataLyst Express User Guide: Introducing the CataLyst Express 1–5

CataLyst Express Software

1–6 CataLyst Express User Guide: Introducing the CataLyst Express

CataLyst Express Options

• The GPIO Termination Block, which extends the GPIO port to a