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Investigate OT-2/App updates behind custom-labware height errors#2
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[WIP] Investigate update changes relevant to custom labware errors
Investigate OT-2/App updates behind custom-labware height errors
Jun 5, 2026
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Investigates why the wireless color-sensor custom labware (byu-vcl#33) fails OT-2 tip-length calibration with a "too tall" error (Opentrons/ot2#10), and determines which Opentrons OT-2 / App versions changed to cause it.
Finding
The error is a fixed OT-2 hardware geometry limit, not a software regression. The labware declares
zDimension: 100mm, but the pipette can only be raised to ≈96.3 mm above the deck, so the legacy motion planner raisesLabwareHeightError.homePosition − Z_RETRACT_DISTANCE(2mm) + critical_point_z— all pipette/hardware constants, independent of the app/robot release._build_safe_height/LabwareHeightErrorcheck has existed since the 2020 motion-planning refactors, present in every v4→v9 build. This explains why downgrading to v8.8.1 behaved identically to v9 — no version omits the limit, so no downgrade can fix it.Adaptation
Reduce the loaded labware
zDimensionto ≤ ~95 mm and/or adopt the shorter replaceable-nozzle-on-fixed-body design; the tall 100 mm part cannot clear the gantry on any software version.Changes
docs/custom-labware-height-error-investigation.md— report with the exact error, root-cause trace (code citations intoplanning.py,pipette_handler.py,calibration/util.py,defaults_ot2.py), version history, the secondary mechanical (worn press-fit) issue, and four adaptation options.README.md— links the report under a new "Investigations" section.Documentation-only; no hardware or code files modified.