Getinge GEV TS 121650 AR-2 User manual

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GEV TS 121650 AR-2
PFIZER ROBOTIC SYSTEMS
0011393179-010
USER MANUAL

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TABLE OF CONTENTS
PREFACE................................................................................................................................................... 5
INTRODUCTION ....................................................................................................................................... 6
SAFETY ..................................................................................................................................................... 7
Attention symbols............................................................................................................................ 7
Warnings.......................................................................................................................................... 7
Advice .............................................................................................................................................. 7
Symbols on the unit ......................................................................................................................... 8
Electrical hazards ............................................................................................................................. 8
Other hazards .................................................................................................................................. 8
Machine Identification..................................................................................................................... 9
General .......................................................................................................................................... 10
Emergency stop ............................................................................................................................. 12
Machine stop ................................................................................................................................. 12
Emergency stop placement ........................................................................................................... 13
Protection zones ............................................................................................................................ 14
Working methods in case of problems or breakdown .................................................................. 15
Removal of personnel.................................................................................................................... 15
Restrictions .................................................................................................................................... 16
THE PROCESS ......................................................................................................................................... 17
General function ............................................................................................................................ 17
Tub, nest, and rack handling.......................................................................................................... 17
OPERATION INSTRUCTIONS................................................................................................................... 19
General .......................................................................................................................................... 19
Before start..................................................................................................................................... 19
Start................................................................................................................................................ 19
Auto mode ..................................................................................................................................... 20
Activate operation mode Auto....................................................................................................... 20
Deactivate operation mode Auto ................................................................................................... 20
Semi-auto for a zone...................................................................................................................... 20
Manual mode................................................................................................................................. 21
Activate operation mode Manual................................................................................................... 21
Deactivate operation mode Manual ............................................................................................... 21
Interlock manual functions ............................................................................................................ 21
Jogging function ............................................................................................................................ 21

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General functions .......................................................................................................................... 22
Sluicing of empty racks ................................................................................................................. 22
Emptying of system....................................................................................................................... 22
Hold time monitoring..................................................................................................................... 22
Separation of autoclave cycles....................................................................................................... 23
Request access, Haake locks on gates ........................................................................................... 24
Haake boxes................................................................................................................................... 24
Entering the facility area................................................................................................................ 25
Exit area......................................................................................................................................... 25
Restart after stop........................................................................................................................... 26
Restart after an emergency stop..................................................................................................... 26
Restart after safety stop.................................................................................................................. 26
Restart after an error ...................................................................................................................... 26
Restart after PLC-stop ................................................................................................................... 26
Alarms............................................................................................................................................ 27
Manual operations......................................................................................................................... 28
Manual rack handling .................................................................................................................... 28
Loading side –manual loading...................................................................................................... 29
Unloading side –manual loading .................................................................................................. 29
Autoclave cycle, pharma-alarm handling ...................................................................................... 30
Unloading robot logic.................................................................................................................... 31
ERROR HANDLING ................................................................................................................................. 32
General errors................................................................................................................................ 32
Robot grippers ............................................................................................................................... 32
Lost product (Sleeve) during transportation.................................................................................. 37
ZONE 1 ........................................................................................................................................... 38
ZONE 2 ........................................................................................................................................... 38
ZONE 3 ........................................................................................................................................... 38
Control Panel ......................................................................................................................................... 44
Cabinet........................................................................................................................................... 44
AK1................................................................................................................................................. 44
Light tower, Pfizer standard........................................................................................................... 45
Robot cabinets ............................................................................................................................... 45
Robots, basic functions.......................................................................................................................... 46
ABB-menu ...................................................................................................................................... 46
Robot pendant ............................................................................................................................... 49

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Manual/Auto mode........................................................................................................................ 49
Starting program execution............................................................................................................ 50
Manual operation of robot. (Jog window or Quick selection)....................................................... 51
Home position................................................................................................................................ 53
Picture illustrates robot in home position ...................................................................................... 53
Move the robot to home position................................................................................................... 55
Gripper........................................................................................................................................... 57
Open/close manually...................................................................................................................... 57
Speed ............................................................................................................................................. 59
Change speed................................................................................................................................. 59

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PREFACE
ThisUSERMANUAL,containsalltheinformationyouneedin order to safely
operate your Evomatic AB equipment.
Please read and follow the entire manual carefully, and please pay special
attention to the framed warnings and caution remarks. See “Attention
symbols” under SAFETY
In the event of an accident or incident you are obliged to report this.
Evomatic AB shall not be liable for any damages, directly or indirectly, due
to actions, which are not in accordance with this manual.
Should any unforeseen problems occur, you are of course welcome to contact
us.
The machines included in the equipment are described in detail in separate
manuals. Spare parts lists, electrical drawings, maintenance, troubleshooting
etc.
See accompanying documents.
Manufacturer address:
Evomatic AB
Södra Stillerydsvägen 17A,
SE-374 31 Karlshamn, Sweden

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INTRODUCTION
This system is designed to receive tubs with syringe nests, load and unload a sterilizer. Put
back the syringe nest in its tub and proceed down the line to inspection and packing.
Depending on process, the system also store empty tubs in a separate buffer zone until the
last sterilized nest comes to unloading side at the end of a batch from filling line.
System can buffer 16 fully loaded racks on loading side before the sterilizer and buffer
8pcs on the unloading side after the sterilizer.

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SAFETY
Attention symbols
Some of the warnings, instructions and advice in this manual are so
important that we use the following special symbols to draw attention
to them. The designs and symbols used are:
Warnings
Instructions
Advice
This symbol indicates a warning in the manual. It’s a
warning of a hazard that may lead to more or less severe
injury and in certain cases mortal danger.
The symbol is also used to highlight safety components,
etc. See “Overview of safety devices” in the Introduction
chapter in the USER MANUAL.
This symbol appears in instructions that should be
followed to avoid damage to both the unit and the load.
This symbol indicates important advice and hints that
make it easier to work with the unit.

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Symbols on the unit
Electrical hazards
This symbol is a warning for electrical hazards.
Other hazards
This warning symbol alerts the user
to other hazards that may occur.

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Machine Identification
The Robotic system Type Plate
The unique identification information for the Robotic system is found
on the Robotic system type plate, attached to the machine.
When contacting Evomatic concerning the Robotic system,
information included in the type plate is required.
The CE mark ensures that the Robotic system complies with all relevant
European directives of the European Economic Area (EEA) / the
European Economic Community (EEC).
1. Location of type plate
2. Reference
3. Frequency (Hz) and Connection voltage (V)
4. Nominal current (A)
5. Short-circuit current cap (kA)
6. Fuse (A)
7. Control voltage (V)
8. Year of manufacture
2
3
4
5
6
7
8
1

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General
All machines can be dangerous in case of improper operation. It is therefore of the utmost
importance that all users of the machine read through, understand and observe the
following security measures and warnings. Read through the instruction regularly.
All safety precautions have been taken as far as possible when designing the machine.
However, it is not possible to completely exclude all risks without reducing the machine's
capacity.
ALL equipment has been tested by personnel from Evomatic AB, if the machine is
installed according to our regulations, it will work correctly.
In the event of improper operation, please call our service department, before you try to fix
the problem yourself. Basic safety precautions should always be followed to reduce the
risk of fire, electric shock and personal injury.
Warning!
Observe and follow local safety precautions.
Unauthorized persons should never use the equipment.
Never leave the machine in operation without supervision. Make sure that all users of the
machine have read and understood the information in this manual.
Personal Protective equipment.
Hearing protection should be used by the personnel when exposed to noisy
environments.
We recommend use of hearing protection when working with and around the production
cell, as handling materials and surrounding processes can cause high noise levels.
The sound pressure level of equipment delivered by Evomatic AB amounts to a maximum
of 75 dB (A).
However, adjoining equipment may cause the sound pressure level at the workplace to be
higher.
Padlock.
Locks from Haake replace padlock functionality to prevent automatic restart in this
equipment without the approval of personnel.

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Equipment in raised position, moving parts.
Equipment in the raised position, shall be blocked or otherwise adequately secured in its
raised position before intervention/maintenance. In this raised position, application racks
drop down 40mm when air pressure disappears. Depressurizing takes place when zone is
unlocked.
Robot breaks can be released manually, use precaution and support the robot arm.
General interventions.
Intervention in the cell may only take place via the facility's supervised gates, entry into
the cell through any other way is strictly prohibited.
When in the danger zone, operation of the robots must only be carried out using the
(pendant) three-mode actuators. See manual “Operating manual - IRC5 with
FlexPendant.pdf”, for detailed instructions.
Disconnection or tampering with the safety functions of the facility is strictly prohibited.
The machine must not be put into service if protective devices are not working as intended.

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Emergency stop
Two types of emergency stop circuits are located near the equipment and they have
different functions, see Emergency stop for more details.
The emergency stop stops all functions and releases pressure in the pneumatic parts of the
equipment in cases where pneumatic movements are a risk.
Central reset of the safety circuit (emergency stop) is a requirement for restart, see Restart
after an emergency stop.
Machine stop
In the event of a machine stop, the machine functions within the selected safety zone are
quickly stopped. The power supply is interrupted. Electricity and pneumatics are
stopped in cases where it is considered that continued movements are a risk.
The pneumatic parts of the robot grippers are an exception and will continue to have
pressure even in the event of a machine stop.
Machine stop is used when entering the robot cell to make sure that all electric and
pneumatic parts are stopped by the machine safety stop circuit.
Central reset of the machine safety circuit requirements for restart, centralized reset
through the Haake locking system, see section Restart after safety stop.

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Emergency stop placement
The map below shows the placement of the emergency stop devices
for the sterilizer and the robot zone with its robots.
There are two kinds of emergency stop labels are used depending on
the purpose of emergency stop. The T42205a are used for the
sterilizer and the T42205b are used for the robot cells.

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Protection zones
The machine is divided into different protection zones (which are also operating zones).
When the gate and light protection is turned off in the zone, pneumatics and electricity are
turned off to the equipment where it is considered that movements pose a risk. One
exception, as mentioned above, is the of pneumatics to robotic gripper.
Local restart at each stopped security circuit is required for restart.
Gate-andlightbarriers
No.
Name
Designation
Reset
Description
1
Zon1 Gate 1
1F7SG1
Haake key back in
original place
Gate used for access robot cell
2
Zon1 Gate 2
1F7SG2
Haake key back in
original place
Gate used for access robot cell
3
Zon1 Gate 3
1F7SG3
Haake key back in
original place
Gate used for rack (un)loading
4
Zon2 Gate 1
2F7SG1
Haake key back in
original place
Gate used for access robot cell
5
Zon2 Gate 2
2F7SG2
Haake key back in
original place
Gate used for access robot cell
6
Zon2 Gate 3
2F7SG3
Haake key back in
original place
Gate used for rack (un)loading
7
Zon3 Gate 1
3F7SG1
Haake key back in
original place
Gate used for access robot cell
1
Zone 1
4
5
Zone 2
Zone 3
2
3
7
8
9
6

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Zones
Zone
Description
1
Loading: Stopped by emergency stop and safety stop. Stops all
pneumatic equipment except for the robot gripper.
2
Unloading: Stopped by emergency stop and safety stop. Stops all
pneumatic equipment except for the robot gripper.
3
Buffer: Stopped by emergency stop and safety stop. Stops all
pneumatic equipment except for the robot gripper.
Working methods in case of problems or breakdown
Interventions in case of problems and rectification, troubleshooting.
Contact your local maintenance, otherwise contact Evomatic AB.
Removal of personnel
See security information from robot supplier (ABB), will be included in the supplied
documentation from Evomatic.
Look for Section Safety information
Chapter- Emergency safety information –Operating manual ESI.
See chapter 1.4 Releasing a person trapped by the robot arm.
8
Zon3 Gate 2
3F7SG2
Haake key back in
original place
Gate used for access robot cell
9
Light barrier
100SG1
Outside, other zone
1A2S2, 2AS2
Protection between Zone 1 and 2.
Only active when 1 of the zones is
turned off

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Restrictions
Risk area and personnel requirements.
The production cell is surrounded by protective fences and monitored gates.
Access to the cell is described in section Protection zones.
Repair and replacement of spare parts.
During the warranty period, Pfizer must contact Evomatic if anything breaks. If anything is
changed, original manufactured parts must be used.
After the warranty period has expired, Pfizer can purchase replacement parts from other
suppliers. However, Evomatic cannot take responsibility for functionality if Pfizer do not
replace broken parts with the intended parts from the original manufacturer.
If anything is to be replaced yourselves, remember to follow each manufacturer's /
supplier's instructions for each machine / appliance.
Personnel requirements.
Staff shall be aware of the risks involved of staying within the danger zone and have
sufficient instructions for the safe use of the equipment.
It is the responsibility of employers and supervisors to ensure that installation and
maintenance personnel only handle the parts they have been instructed or trained on.
Eligibility of the commuter operation.
Only authorized and qualified personnel have access to the workplace of the production
cell.
Before start, the operator must always ensure that no persons are within the risk areas of
the machine/cell.
Pendant with conditions for operation within danger area.
In the case of manual/teaching operation, with some protective devices set out of function
the automatic control mode is not possible.
It allows the operation of dangerous moving parts only under enhanced safety conditions,
hold/three-mode, reduced speed, and reduced force, step by step operation i.e. a sequential
process at a time.
The operator shall, from the place where the work is carried out, control the operation of
the parts involved.

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THE PROCESS
General function
The facility is divided into 3 zones. They are normally started in Auto together as one zone
on HMI.
Separate mode selection and start per zone is possible. See Error! Reference source not
found. Error! Reference source not found..
Tub, nest, and rack handling
Tub, Nest loading
1. Tubs arrive on Flexlink conveyor 101 to unloading station in zone 1, unloading.
2. Tub is fixed and nest picked up by robot 110 and placed on nest stand 1 or 2, places 1-5.
3. When 5 nests is standing in nest stand, robot 120 pushes a sleeve on the nests and load
them onto the rack on roller conveyor.
4. Robot 110 places nests on the other nest stand.
5. Empty tubs travel to unloading side, zone 2.
Tub buffer
First phase in the buffer is filling up buffer conveyors with empty tubs until first batch is
ready from autoclave. This thus no tubs are needed in unloading until a rack with sterilized
syringes are ready for unload.
During filling tubs is stacked in zone 3, by robot 310. On each conveyor the robot stacks
a predefined amount of tubs on it based on reachability and collision factors.
Loading is done by stacking one tub on the conveyor that currently has the
lowest number of tubs on the front row and according to a priority order, from conveyor 1
to 6.
When a stack is full, it moves back to make way for a new stack on current conveyor.
Unloading is done by the robot picking from the conveyor with the highest number of tubs
on the front row in reversed priority order, from 6 to 1.
When unloading, a search is done in the tub stack in an adjustable interval to determine
the position of the stack due to the risk of the stack leaning one way or the other. This
position search is also done for every new stack that arrives to unloading position and
when the buffer station is switched over to destacking mode.
Following preventative measures are incorporated in tub buffer when handling tubs:
Conveyor:
Tub amount on
conveyor:
1
44
2
45
3
47
4
47
5
45
6
42

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1.Search error (Position search outside of limit)
2.Tub stacks are too close to each other in leaving or picking position on the buffering
conveyors.
For more details about problems and error handling see section ERROR HANDLING
Rack handling
1. Filled racks travel from pos. 515 to autoclave on roller and chain conveyors in zone
1.
2. Four racks form one batch together, they are loaded together.
3. After autoclave, the group of four travel in unloading zone 2, to pos. 508.
4. Robot 210 unloads a sleeve to nest stand 1 or 2 by robot 220.
If problem with transportation see section: General errors
Tub, Nest unloading
1. Tubs start to pass by buffer and continue to unload side.
2. Tubs get filled with nests and pass on to the following process.
3. After each batch, robot R310 puts empty extra tubs to signal to end of batch to
following system. Number of empty tubs is an adjustable parameter from Scada.
Extra tubs are manually placed in a pile inside zone 3.
4. At the end of a batch or whenever tubs stop coming in, the empty tubs stored in the
buffer are placed back on the Flexlink by robot 310.

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OPERATION INSTRUCTIONS
General
Before start
Before start-up, all those working at or adjacent to the installation must have taken
part in and understood all the manuals supplied with the installation.
Make sure the plant is free from loose and foreign objects.
Review protective and safety devices so that no visible defects can be identified.
Make sure that protection is in the correct position.
Otherwise see separate maintenance instructions.
Start
Check that no persons are in the danger zone.
Make sure all the guards and gates are in the correct position.
Turn on the control voltage on the operator panel of the overall control system.
Start up the robots if they have been turned off by the cabinet switch or put in
manual mode.
Acknowledge any alarms.
See below for manual and automatic control.

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Auto mode
When the zones are in operation mode Auto, all movements are controlled automatically
by PLC and robot. When global Auto is selected, all 3 zones go to Auto. It is possible to
switch one zone back to Manual or Semi-auto mode.
Activate operation mode Auto
1. Reset all alarms: Reset all active errors and alarms by pressing the reset alarm
button on the HMI. When all errors and alarms have been reset, the light beacon is
not solid red.
2. Select Auto: select Auto by pressing the auto button in the menu bar of the HMI
3. Start Auto: in order to activate auto mode, press the Start auto button on HMI
4. Auto Started: indicated by the light beacon that is turned solid green
5. Special case, Restart button on HMI, resume cycle after pause
Deactivate operation mode Auto
Disabling operation mode Auto can be done in one of the following ways:
1. Pause button on HMI, cycle stop without Haake keys unlocked.
2. Request Access: Press the Request entry-button for the zone.
3. Manual: Press the manual button in the HMI. Operation mode Auto is no longer
selected. This is indicated by the green light on the zones traffic light is off. Note:
If possible, use 1. or 2. above before going to Manual.
4. B and D alarms: Disabling operation mode Auto is done if any B or D alarms
become active in the zone. Drift mode Auto is still selected, but not active. The red
light in the traffic light shines steady. The green light is off.
Semi-auto for a zone
Semi-auto is a special kind of Auto, to enable special handling when it is necessary to
solve problems in the process.
Semi-auto can only be selected for each zone, one by one. Not for the entire system.
Everything runs as in auto when you are in semi-auto mode, except that you can change
the destination on the rack in semi-auto on the HMI. The racks and rack destinations are
visualized on the Scada screen, any other wanted destination of a specific rack is changed
on the screen.