Opex Perfect Pick HD User manual

© 2017, 2018 OPEX®Corporation
All rights reserved. This document is provided by OPEX for use by their customers, partners and dealers. No portion
of these materials may be reproduced, published, or stored in a database or retrieval system, other than for its in-
tended use without the express, written consent of OPEX Corporation.
Document Revision 18-01
Original Language Instructions
Perfect Pick HD User Manual
April 27, 2018

2
Perfect Pick HD User Manual - OPEX Corporation
Document History
If you find errors, inaccuracies, or any other issues or concerns with this
document, please contact the OPEX Technical Writers via email at:
[email protected]
Doc
Rev Date Changes (click blue text to go to that page)
17-01 Nov. 8, 2017 Draft Release, Rev 2
18-01 April 27, 2017 Initial Release

Table of Contents 3
Perfect Pick HD User Manual - OPEX Corporation
Table of Contents
Document History ........................................................................................... 2
Chapter 1
Safety
About this manual ........................................................................................... 6
Safety conventions used in this manual .......................................................... 6
Safety Guidelines ............................................................................................ 7
Safety labels ................................................................................................... 9
Other Cautions ......................................................................................... 15
Ultra-capacitor Product Information .............................................................. 16
Emergency Stop (E-Stop) buttons ................................................................ 17
Safety interlocks ............................................................................................ 19
Break-away panel interlocks .................................................................... 19
Light curtain .............................................................................................. 20
Clear-to-Pick indicators ................................................................................. 21
Light Tower ............................................................................................... 22
Ergonomics ................................................................................................... 23
Chapter 2
Introduction
Overview ....................................................................................................... 26
Terminology .............................................................................................. 26
Main Components ......................................................................................... 27
Chapter 3
Operation
Overview ....................................................................................................... 34
Starting up the system .................................................................................. 34
Navigating the Host software ................................................................... 36
Continuous mode .......................................................................................... 40
Replenish mode ............................................................................................ 49
Zeros ........................................................................................................ 53

4 Table of Contents
Perfect Pick HD User Manual - OPEX Corporation
The OPEX Integrated Workstation ................................................................ 57
How to park the iBOTs .................................................................................. 58
Chapter 4
Specifications
Specifications ................................................................................................ 62
Physical Specifications: ............................................................................ 62
iBOT Specifications: ................................................................................. 62
Wireless Transceiver .................................................................................... 64
FCC information / informations FCC ........................................................ 64
Industry Canada information / Industrie Canada l'information .................. 65
Contacting OPEX Service ............................................................................. 66

Perfect Pick HD
User Manual
Safety
About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety conventions used in this manual . . . . . . . . . . . . . 6
Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ultra-capacitor Product Information . . . . . . . . . . . . . . . 16
Emergency Stop (E-Stop) buttons . . . . . . . . . . . . . . . . 17
Safety interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Clear-to-Pick indicators. . . . . . . . . . . . . . . . . . . . . . . . . 21
Ergonomics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6Safety
Perfect Pick HD User Manual - OPEX Corporation
About this manual
The information provided in this chapter is intended to educate you on various
safety issues regarding the operation and maintenance of the OPEX
equipment described in this manual.
This chapter provides an explanation of the safety conventions used
throughout this manual, as well as safety guidelines to be observed when
working with this equipment.
Safety conventions used in this manual
OPEX documents use the following conventions to describe certain
procedures and situations. Please be aware of these conventions when
reading the manuals and operating the machine:
WARNING: Read this chapter thoroughly before working with this
equipment.
DANGER: Indicates a hazardous situation that, if not avoided, will
result in death or severe injury. The use of this signal word is limited to
the most extreme situations.
WARNING: Indicates a hazardous situation that, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION: Indicates a hazardous situation that, if not avoided, could
result in minor or moderate injury.
NOTICE: Indicates information considered important, but not hazard
related.

Safety 7
Perfect Pick HD User Manual - OPEX Corporation
Safety Guidelines
This section provides safety guidelines to be observed when working with this
equipment.
The Perfect Pick HD® adheres to the NFPA 79 electrical standard for industrial
machinery, which provides safeguards to protect operators, equipment,
facilities, and work-in-progress from fire and electrical hazards.
Charging rail - Hands should be kept clear of the charging rails when the doors
are closed. Shorting of the charging rails with either a watch or ring may result
in electrical shock.
Rail de chargement - Les mains doivent être éloignées des rails de
chargement lorsque les portes sont fermées. Le court-circuit des rails de
charge avec une montre ou une anneau peut provoquer un choc électrique.
Do not remove the plastic, protective covers from the bottom of the iBOTs -
The covers protect the iBOT’s ultracapacitors and circuitry from damage. The
covers also protect the operator from harm if the ultracapacitors should leak.
For information on ultracapacitor safety, refer to “Ultra-capacitor Product
Information” on page 16.
Ne retirez pas le plastique, les capots de protection du bas des iBOTs - Les
couvertures protègent les ultracapacités et les circuits des iBOT contre les
dommages. Les couvertures protègent également l'opérateur des dommages
si les ultracapacités doivent se faufiler. Pour plus d'informations sur la sécurité
des ultracapaciteurs, reportez-vous à la section «“Ultra-capacitor Product
Information”» à la page 16.
Keep loose objects away from any exposed, moving parts of the machine - The
moving parts of the Perfect Pick HD, such as the conveyor, can become
jammed and/or damaged by foreign objects. Keep hands, hair, loose clothing
and jewelry away from the moving parts.
Gardez les objets lâches à l'écart des parties exposées et mobiles de la machine
- Les parties mobiles du Perfect Pick HD, telles que le convoyeur, peuvent être
bloquées et / ou endommagées par des objets étrangers. Gardez les mains,
les cheveux, les vêtements lâches et les bijoux loin des pièces mobiles.
CAUTION
CAUTION: Follow these safety guidelines whenever installing,
operating, servicing, or maintaining the equipment described in this
manual.

8Safety
Perfect Pick HD User Manual - OPEX Corporation
Do not attempt to clean the machine while it is running - A cloth (or similar
material) should never be used to clean moving parts such as belts or rollers.
The use of such material on moving mechanisms can result in damage to the
machine or severe personal injury. If a belt, roller, gate or similar part needs to
be cleaned, hand-crank the part during cleaning or clean it while stationary.
N'essayez pas de nettoyer la machine pendant son fonctionnement - Un
chiffon (ou un matériau similaire) ne doit jamais être utilisé pour nettoyer les
pièces mobiles telles que les courroies ou les rouleaux. L'utilisation d'un tel
matériau sur les mécanismes de déplacement peut endommager la machine
ou subir des blessures graves. Si une ceinture, un rouleau, une grille ou une
pièce similaire doivent être nettoyés, faire manivellez la pièce pendant le
nettoyage ou la nettoyer en stationnaire.
Do not use flammable, high pressure, “canned air” to clean dust and debris
from the machine.
N'utilisez pas d'air comprimé inflammable, à haute pression pour nettoyer la
poussière et les débris de la machine.
Familiarize yourself with the location(s) of machine Emergency Stop switches -
The E-Stop switches enable a quick stop of all motors in the machine, in the
event of an emergency involving potential personnel injury.
Familiarisez-vous avec le (s) emplacement (s) de la machine Interrupteurs
d'arrêt d'urgence - Les interrupteurs E-Stop permettent d'arrêter rapidement
tous les moteurs de la machine en cas d'urgence impliquant des blessures
potentielles.
Keep away from children - This equipment is not suitable for use in locations
where children are likely to be present.
Tenir à l'écart des enfants - Cet équipement ne convient pas aux endroits où
les enfants sont susceptibles d'être présents.

Safety 9
Perfect Pick HD User Manual - OPEX Corporation
Safety labels
Machine Entry Only approved OPEX technicians and qualified personnel
can enter the machine. The “Automated machinery DO NOT ENTER” label
shown in Figure 1 is found on both sides of the pick station(s).
Figure 1: Machine Entry label
CAUTION
CAUTION: Follow the safety precautions on all labels to avoid injury
when operating the Perfect Pick HD. Failure to follow these
precautions may result in severe personal injury or damage to the
machine.
Maquinaria
automatizada
NO ENTRE
Automated
machinery
CUIDADOCAUTION
DO NOT ENTER

10 Safety
Perfect Pick HD User Manual - OPEX Corporation
Main Power Enclosure Only approved OPEX technicians and qualified
personnel are authorized to access the main power enclosure (Figure 2) for
troubleshooting and/or servicing the machine.
Figure 2: Main Power Enclosure - Warning label
The “WARNING Arc Flash and
front of the Main Power Enclosure
WARNING
ADVERTENCIA
Arc Flash and
Shock Hazard
Follow all requirements in NFPA 70E
for safe work practices and for
personal protective equipment
Riesgo de descarga
y arco eléctrico
Siga todos los requisitos
en NFPA 70E para prácticas
de trabajo seguras y equipos
de protección personal
Shock Hazard” label is found on the

Safety 11
Perfect Pick HD User Manual - OPEX Corporation
Climbing the structure Do not climb on any part of the Perfect Pick HD (see
Figure 3).
Figure 3: Do Not Climb Structure
NO SE TREPE
A LA
ESTRUCTURA
DO NOT CLIMB
STRUCTURE
CUIDADO
CAUTION
The “DO NOT CLIMB STRUCTURE” label is found
where the exterior cover ends.
If the machine has no rear pick station, another set
of these labels goes on the back of the rear ladders.
on the exposed ends of every other ladder, above

12 Safety
Perfect Pick HD User Manual - OPEX Corporation
Scissor Lift and Fork Lift Operation Use of a scissor lift (Figure 4) or forklift
requires appropriate certification. Do not operate or ride in either of these
machines unless you have taken the corresponding training course. Only
approved OPEX technicians and qualified personnel are authorized to use the
scissor lifts and iBOT recovery tools.
Figure 4: Scissor Lift

Safety 13
Perfect Pick HD User Manual - OPEX Corporation
Keep Hands Away Keep hands and loose objects away from any exposed,
moving parts of the machine (see label in Figure 5). The moving parts of the
Perfect Pick HD can become jammed and/or damaged by foreign objects.
Also, keep hair, loose clothing or jewelry away from the moving parts.
Figure 5: Keep Hands Away Caution label
MANTENGA
LAS MANOS
ALEJADAS
KEEP HANDS
AWAY
CUIDADOCAUTION
The “KEEP HANDSAWAY” label can be found on both sides of
each pick station, on the metal plate above the diagonal track.
Pick station - left side
Pick station - right side

14 Safety
Perfect Pick HD User Manual - OPEX Corporation
Charging rail Hands should be kept clear of the charging rails (Figure 6) at
all times. Shorting of the charging rails with either a watch or ring may result in
electrical shock.
TIP: One of the easiest ways to determine the front of the machine is to note
the location of the vertical charge rail. The vertical charge rail will always be in
the front of the machine.
Figure 6: Charging Rails
iBOT safety The iBOT (Figure 7) was designed to carry loads of up to 80
pounds. In order to function properly, the iBOT incorporates automated
Vertical
charge rail
Horizontal
charge rail

Safety 15
Perfect Pick HD User Manual - OPEX Corporation
machinery along with potentially hazardous voltages. Therefore, it should be
treated with care. Take note of the labels shown in Figure 7.
Figure 7: iBOT safety labels
Other Cautions
Voltaje Peligrosa
Adentro
De esta Caja
Hazardous
Voltage
Inside
ADVERTENCIA
WARNING
1. The “Hazardous Voltage Inside” label
control panel side.
MANTENGASE
ALEJADO
partes móviles
KEEP AWAY
moving parts
CUIDADOCAUTION
2. There are two of the “KEEPAWAY
on the top metal surface (the
Maquinaria
automatizada
Automated
machinery
CUIDADOCAUTION
3. The “Automated machinery” label is
side, on the slanted surface.
second label is hidden in the photo).
is found on the cover beneath the
1
2
3
“Automated machinery” label on the
moving parts” labels on the iBOT,
on the iBOT’s cover. One on each
CAUTION
CAUTION: The ultra-capacitors that power the iBOTs contain acetoni-
trile. In the event that an ultra-capacitor should leak, avoid contact with
or breathing the acetonitrile. For information on ultra-capacitor safety,
refer to “Ultra-capacitor Product Information” on page 16.

16 Safety
Perfect Pick HD User Manual - OPEX Corporation
Ultra-capacitor Product Information
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Document #1004596.4
Product Information Sheet
An MSDS is not required. This information sheet is provided as a service to our customers. An MSDS for the active chemical inside the listed products is
available upon request. For US Customers: The products referenced herein are exempt articles and are not subject to the OSHA Hazard
Communications Standard Requirement 29 CFR 1910.1200. For EU Customers: The products referenced herein are not submitted to 91-155 EEC, as
they are considered as components and not as a chemical substance. Notice: The information and recommendations herein contained are made in good
faith and are believed to be accurate at the date of preparation. Maxwell Technologies Inc. makes no warranty expressed or implied.
Product Information
Manufacturer
Maxwell Technologies Inc.
9244 Balboa Avenue San Diego, CA 92123
Phone: [phone]
Fax: [phone]
EMERGENCY PHONE:
North America
Chemtrec Hazmat Communication Center 1 800 424 9300
+ 1 703 527 3887
Europe
Swiss Toxicological Information Centre [phone]
Product: Ultracapacitors
Models: All configurations and versions of
PC5, PC10, PC5-5, BCAP0005 and
BCAP0010
Date: June 19, 2009
Asia
Chemtrec Hazmat Communication Center 1 800 424 9300
+ 1 703 527 3887
Product Components
Important Safety Note: Ultracapacitors should not be opened, disassembled, crushed, burned, or exposed to high temperatures (>85°C, 185°F), and
should be operated only within their defined operating specifications. Failure to adhere to operating specifications could result in poor device
performance or unsafe operating conditions. Exposure to the components contained within the ultracapacitor could be harmful under certain
circumstances. In case of exposure to ultracapacitor contents, wash affected area for at least 15 minutes with generous amounts of water and seek medical
attention. Fires involving these types of ultracapacitors should be extinguished with CO2, dry chemical, alcohol foam, or all purpose AFFF extinguishing
media. Water may be ineffective but should be used to cool fire-exposed containers, structures and to protect personnel.
BOOSTCAP® ultracapacitors are composed of the following major components:
Electrodes: Activated Carbon
Separator: Polypropylene or Cellulose
Electrolyte: Quaternary salt (tetraethylammonium tetraflouroborate)
Organic solvent (acetonitrile)
Other: Aluminum, steel
Disposal
BOOSTCAP ultracapacitors are neither specifically listed nor exempted from government hazardous waste regulations. The only material
of possible concern is the organic solvent, which when discarded or disposed of, is a hazardous waste according to Federal regulations (40
CFR 261). It is listed as Hazardous Waste Number U003, so listed due to its toxicity and ignitability. Disposal can occur only in properly
permitted facilities. Check state and local regulations for any additional requirements, as these may be more restrictive than federal laws
and regulations.
Transportation
Ultracapacitors as articles are not specifically listed nor exempted from hazardous materials regulations (HMR). The U.S. Department of
Transportation has provided Maxwell Technologies a written determination regarding Maxwell’s PC5 and PC10 BOOSTCAP
ultracapacitor products that the materials comprising the ultracapacitors are “…in a quantity and form that does not pose a hazard in
transportation. Therefore, the ultracapacitors are not subject to the HMR.”

Safety 17
Perfect Pick HD User Manual - OPEX Corporation
Emergency Stop (E-Stop) buttons
For operator safety, Perfect Pick HD incorporates big, red, mushroom-shaped
Emergency-Stop buttons (E-stops) to stop the machine in the event of an
emergency. E-Stops are located at all pick stations and on the front of the main
power enclosure. Pushing any of these E-stops cuts power to the charging
rails, tilts and wireless transceivers.
Pick station E-stops
An E-stop button is located at each pick station (Figure 8). If necessary, push
on the E-Stop to stop the machine immediately.
• To restart the machine, clear the machine (if needed), pull the E-Stop knob
out, and press the green Start button.
• The Clear-to-Pick light is an additional safety feature. See “Clear-to-Pick
indicators” on page 21.
Figure 8: Pick Station E-stop
WARNING: Emergency stop switches do not remove power from all
electrical devices within the Perfect Pick HD. Power to main enclosure
components, UPS, computers and other devices remains energized
after the E-Stop switch is pushed.
E-Stop Switch
Start button
Clear-to-Pick light

18 Safety
Perfect Pick HD User Manual - OPEX Corporation
Main power enclosure E-stop
An E-stop button is located on the front of the main power enclosure (Figure 8).
If necessary, push on the E-Stop to stop the machine immediately.
• To restart the machine, clear the machine (if needed), pull the E-Stop knob
out, and press the green Start button.
Figure 9: Main power enclosure E-stop
E-Stop SwitchStart button

Safety 19
Perfect Pick HD User Manual - OPEX Corporation
Safety interlocks
The safety interlocks include break-away panels with interlock switches and a
light curtain at each pick station.
Break-away panel interlocks
Entering the machine while it is running can pose a safety hazard due to the
rapidly-moving iBOTs. For your safety, interlocks have been installed on the
front and rear break-away panels (Figure 10) of the Perfect Pick HD machine.
The interlocks will stop the machine whenever a break-away panel is opened.
Figure 10: Break-away Panel (removed from the machine)
WARNING: Door interlock switches do not remove power from all
electrical devices within the Perfect Pick HD. Power to main enclosure
components, UPS, computers and other devices remains energized
after the E-Stop switch is pushed.
Magnet on breakaway panel,
Magnet-actuated
switch on
machine frame
lower left of interior side

20 Safety
Perfect Pick HD User Manual - OPEX Corporation
The intent of the break-away panel is to break the interlock circuit and stop the
machine should an operator’s hand or arm become wedged between the panel
and a downward moving iBOT.
A magnetic sensor is located at the bottom left side of the panel and can be
easily tripped by kicking the panel. When this panel is removed, all iBOT
motion will stop.
Light curtain
The light curtain is a sensor used to stop just the iBOTs in the pick station area,
should you have your hands in the iBOT travel areas when the iBOTs are in
motion (Figure 11).
Figure 11: Light curtain sensor
Light Curtain sensor