Alert Alphabot User manual

Alphabot
User Manual
1000004-MN-01 - Rev C
Manual Template PN: 1000020-FM-01 Rev A

© 2021. ALL RIGHTS RESERVED.
REPRODUCTION OF ANY PART OF THIS MANUAL IN ANY MEDIUM WITHOUT THE EXPRESS WRITTEN
PERMISSION OF ALERT INNOVATION, INC. IS PROHIBITED.
This manual must always be placed in an operator accessible location near the Alphabot® System.
This manual is intended to provide generic information related to all models of Alphabot® System. Due to
specific design changes, contents of this manual may not entirely apply to the purchased model of the system.
Alert Innovation, Inc. will not take responsibility for any malfunction resulting from improper operation of the
Alphabot® System.
Alert Innovation, Inc. makes no representations or warranties with respect to the contents hereof. In addition,
information contained herein is subject to change without notice. Every precaution has been taken in
preparation of this manual. Nevertheless, Alert Innovation, Inc. assumes no responsibility for errors or omissions
or any damages resulting from the use of the information contained in this publication.
Alphabot® and the Alert Innovation logo are registered U.S. trademarks of Alert Innovation, Inc.
Alphatote™ and the Alert Innovation logo are trademarks of Alert Innovation, Inc.
This technology is subject to United States export Administration Regulations and authorized to the destination
only. Diversion contrary to U.S. law is prohibited.
For any queries related to this manual, please contact our office at the address given below:
101 Billerica Avenue, Building 3
North Billerica, MA 01862
[phone]
Visit us Online: www.alertinnovation.com
Alphabot User Manual
Page 2 of 771000004-MN-01 - Rev C

Table of Contents Alphabot User Manual
Page 3 of 771000004-MN-01 - Rev C
Introduction 61.
Purpose & Scope of the Manual ......................................................................................... 61.1
Reference Documents ......................................................................................................... 71.2
Product Overview ................................................................................................................ 81.3
Supporting Products ............................................................................................................ 91.4
Totes and Sub-Totes .......................................................................................................... 101.5
Transit Planes .................................................................................................................... 111.6
Express Planes ................................................................................................................... 111.7
Static Workstation ............................................................................................................. 121.8
Dynamic Workstation / Picking Workstation .................................................................. 131.9
Master Control System (MCS) ........................................................................................... 141.10
Safety 152.
Personnel Safety ................................................................................................................ 162.1
2.1.1 Hazard Description ..................................................................................................... 16
2.1.2 Personal Protective Equipment (PPE) ........................................................................ 17
2.1.3 Environmental Safety ................................................................................................. 18
2.1.4 Inherent Safety Hazards of the Alphabot ................................................................. 19
2.1.5 Persons with Pacemakers ........................................................................................... 22
2.1.6 Fire Safety ................................................................................................................... 22
2.1.7 Seismic ........................................................................................................................ 22
2.1.8 Ergonomics ................................................................................................................. 23
2.1.9 RF Safety ..................................................................................................................... 23
2.1.10 Safety Equipment Rules ............................................................................................. 24
2.1.11 Corrective Action Records .......................................................................................... 25
Product Safety .................................................................................................................... 262.2
2.2.1 Bot Safety Features .................................................................................................... 26
2.2.1.1 Lockout/Tagout Standards ................................................................................................................. 26
2.2.1.2 Local E-Stop Button & Function ......................................................................................................... 28
2.2.1.3 Bot Lockout/Tagout Procedure .......................................................................................................... 28
2.2.1.4 Discharge Bot ....................................................................................................................................... 29
2.2.1.5 Safety Controller .................................................................................................................................. 29
2.2.1.6 Motion drives ....................................................................................................................................... 29
2.2.1.7 E-stop Command or System E-Stop .................................................................................................. 29
2.2.1.8 Mechanical Brakes ............................................................................................................................... 29
2.2.1.9 Bot Switch and Connector .................................................................................................................. 30
2.2.1.10 Mode Switch ........................................................................................................................................ 31
2.2.1.11 Manual Brake Release ......................................................................................................................... 32
2.2.2 Description and Location of Safety Labels ................................................................ 33

Table of Contents Alphabot User Manual
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2.2.3 Repair and Maintenance of Safety-Relevant Modules ............................................ 37
2.2.4 Decommissioning of Equipment ................................................................................ 37
2.2.5 Radiation Exposure Statement .................................................................................. 37
2.2.6 Description of the Alphabot System E-Stop Circuitry .............................................. 38
2.2.6.1 Bot: Emergency Stop and Safe Torque Off (STO) ............................................................................. 40
Hardware 413.
General Description ........................................................................................................... 413.1
Alphabot Components ...................................................................................................... 413.2
Bot LEDs ............................................................................................................................. 443.3
Master Safety PLC Operation ............................................................................................ 453.4
Safety Controller Safe States and User Interaction ......................................................... 463.5
Alphabot Architecture ....................................................................................................... 473.6
Alphabot Hardware Overview .......................................................................................... 483.7
Physical Specifications ....................................................................................................... 583.8
Power Requirements ......................................................................................................... 593.9
Technical Specifications, Capacity, Velocity ..................................................................... 593.10
Environmental Specifications ............................................................................................ 613.11
Lifecycle .............................................................................................................................. 613.12
Operation 624.
Overview ............................................................................................................................ 624.1
Theory of Operation .......................................................................................................... 634.2
Unpacking an Alphabot ..................................................................................................... 644.3
System Start ....................................................................................................................... 654.4
System Shutdown .............................................................................................................. 664.5
Bot Removal ....................................................................................................................... 664.6
Bot Induction ..................................................................................................................... 664.7
Alphabot Interactions with Workstations ....................................................................... 674.8
4.8.1 Picking ......................................................................................................................... 67
4.8.2 Load Product ............................................................................................................... 67
4.8.3 Pull Empty Tote .......................................................................................................... 67
4.8.4 Pull Product ................................................................................................................ 67
4.8.5 Load Order Tote ......................................................................................................... 67
4.8.6 Load Empty Tote ........................................................................................................ 67
4.8.7 Pull Order .................................................................................................................... 68
Troubleshooting 695.

Table of Contents Alphabot User Manual
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Scope of Troubleshooting ................................................................................................. 695.1
Regulatory Compliance Information 706.
Standards Compliance ....................................................................................................... 706.1
FCC Compliance ................................................................................................................. 726.2
ISED Regulatory Information ............................................................................................. 746.3
Revision History 767.

Alphabot User Manual
Introduction
1000004-MN-01 - Rev C Page 6 of 77
1. Introduction
1.1 Purpose & Scope of the Manual
This manual is intended to provide all necessary information for safe interaction with the
Alphabot.
This user manual details the safety information relating specifically to the Alphabot,
instructions to be followed by the user, steps involved in the operation of the bot, and
basic diagnostic procedures.
Note: The term Alphabot is interchangeable with "Bot". This manual uses both terms to
refer to the Alphabot.

Alphabot User Manual
Introduction
1000004-MN-01 - Rev C Page 7 of 77
1.2 Reference Documents
Document Part Number / Link
Alert Academy https://academy.alertinnovation.com/
Alphabot System
Reference Guide
1010755-01
Alphabot Pre and
Post Procedures
1000067-SR-01
Alphabot APSD
System LOTO
Manual
1000035-SF-01
Acronyms and
Alert-Specific Terms
1000030-OP-01
Alphabot system
Master Control
System (MCS) User
Manual
1000016-MN-01

Alphabot User Manual
Introduction
1000004-MN-01 - Rev C Page 8 of 77
1.3 Product Overview
The Alert Innovation, Inc. Alphabot is a compact, motorized, remote-controlled, semi-
autonomous vehicle with vertical and horizontal movement capabilities. Alphabots
handle all tote picking, transportation, and distribution within the larger “Alphabot
System.”
The Alphabot System includes storage modules, totes & sub-totes, tower modules, transit
planes, dynamic workstations, static workstations, and a Master Control System (MCS)
software. Alphabots are at the heart of this system, moving product from station to
station, and ultimately presenting the completed order to customers.
Alphabots have their own vertical-drive mechanism, which engages with vertical tracks in
the Alphabot System structure to allow each bot to move from one elevation to another.
A wheel retraction/extension mechanism enables the Alphabot to transition between
vertical and horizontal modes at any point, and travel horizontally to any storage or
workstation level. It is in this way that the Alphabot can transfer totes between its
payload bay, and storage-rack locations, using a simple single-motor mechanism.

Alphabot User Manual
Introduction
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1.4 Supporting Products
The Alphabot is one part of the larger Alphabot System, working in concert with a
number of other Alert products to fulfill customer orders.
Individual Alphabots are inducted into the Alphabot System and commanded by the
Master Control System to arrive at workstations upon command. At the workstation, tote
containers are loaded with product and handed off to the Alphabot, which will carry
product throughout the system using structures, transit planes, and express planes.

Alphabot User Manual
Introduction
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1.5 Totes and Sub-Totes
The Alphabot interacts with two kinds of totes, distinguished by their purpose: Product
Totes and Order Totes.
Product Totes are stored in racks within the Structure’s storage module aisles.
These totes contain “eaches” (individual items) that are made available to Pickers
as stock to fulfill orders for sale.
Order Totes contain all the picked product for any specific order.
Totes can be further divided into sub-totes, which are smaller compartments that can be
slotted into a tote. Each sub-tote contains its own product, or type of product. This
allows for higher tote density when storing small items.