Opex Perfect Pick Cortex User manual

© 2020 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
intended use without the express, written consent of OPEX Corporation.
August 2020
Perfect Pick® Cortex™ Operator Manual
WARNING
Read this manual thoroughly before attempting to operate or service this
equipment. Keep a current copy for your reference.
9146910OM-EN Revision 20-01 Original Instructions
Cortex™

2ContactingOPEX
Perfect Pick Cortex™ Operator Manual
OPEX Corporation
Contacting OPEX
For technical support:
OPEX Technical Support
835 Lancer Drive
Moorestown, NJ 08057 USA
Americas: 1 800.673.9288 -OR- 856.727.1950
EMEA: +1 800.673.9288
Australia: +1 800.945247
[email protected]
https://www.opex.com/support-service
For other inquiries:
OPEX®Corporation
305 Commerce Dr.
Moorestown, NJ 08057-4234 USA
Tel: [phone]
Fax: [phone]
https://www.opex.com/
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]
For help with opexservice website-related issues, please contact the OPEX
Web Developers via email at: [email protected]

Document History 3
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
Document History
Translation History
Language codes:
Doc
Rev Date Changes (click blue text to go to that page)
20-01 Aug. 25, 2020 Initial release.
Table 1: Revision history for translated manuals
Source
(English version) Date Translation Revision
Details (click blue text to
go to that page)
DE German ES Spanish IT Italian PL Polish
EN English FR French JA Japanese

4 Table of Contents
Perfect Pick Cortex™ Operator Manual
OPEX Corporation
Table of Contents
Chapter 1
Introduction
1.1. About This Manual .................................................................................. 8
1.1.1. Manual navigation ........................................................................... 8
1.1.2. Safety message conventions .......................................................... 9
Chapter 2
Safety
2.1. Safety Guidelines .................................................................................. 12
2.1.1. Arc flash and electrical safety ........................................................ 13
2.1.2. Electrostatic discharge precautions ............................................... 14
2.2. Personal Protective Equipment (PPE) .................................................. 15
2.3. Safety Labels ........................................................................................ 16
2.3.1. Workstation Labels ........................................................................ 17
2.3.2. Perfect Pick Operator Station Labels ............................................ 23
2.4. Emergency Stops (E-stops) .................................................................. 27
2.5. Light Tower ........................................................................................... 29
2.6. Lock-out Tag-out (LOTO) Procedures .................................................. 30
2.6.1. What is Lockout Tag-out? ............................................................. 30
2.6.2. Lock-out/Tag-out devices required ................................................ 31
2.6.3. LOTO - Machine Maintenance and Repair .................................... 32
2.6.4. Fully de-energizing AC power ....................................................... 36
2.6.5. Restoring the machine to normal operation .................................. 37
2.7. Ergonomics ........................................................................................... 39
Chapter 3
Overview
3.1. Overview ............................................................................................... 42
3.2. Cortex Workflow .................................................................................... 43

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3.2.1. Cortex workflow ............................................................................. 44
3.3. The OPEX Integrated Workstation ........................................................ 47
3.4. Perfect Pick ........................................................................................... 48
3.4.1. Cortex Computer ........................................................................... 49
3.4.2. WRTC Computer ........................................................................... 49
3.4.3. Bin Locator Light ........................................................................... 49
3.5. Cortex Software .................................................................................... 50
3.5.1. Workstation User Interface (WUI) ................................................. 50
3.5.2. Warehouse Real Time Controller (WRTC) .................................... 50
3.5.3. Aisle Controller (AC) ...................................................................... 51
3.6. Understanding Zones ............................................................................ 52
3.6.1. Zone sensors ................................................................................. 53
Chapter 4
Operation
4.1. Starting up the system .......................................................................... 58
4.1.1. Launching the Perfect Pick host software ..................................... 58
4.2. Starting the Cortex system .................................................................... 62
4.3. Operating the Cortex system ................................................................ 64
4.3.1. Pick mode ...................................................................................... 73
4.3.2. Put-away mode ............................................................................. 76
4.4. Workstation User Interface tabs ............................................................ 83
4.4.1. Order Info tab ................................................................................ 83
4.4.2. Details tab ..................................................................................... 84
4.4.3. Selected tab .................................................................................. 84
4.4.4. Work Queue tab ............................................................................ 85
4.4.5. Options tab .................................................................................... 86
4.4.6. System Status tab ......................................................................... 87
4.5. Hot Actions ............................................................................................ 88
4.5.1. Cycle Count ................................................................................... 89
4.5.2. Audit ............................................................................................ 100
4.5.3. Consolidate ................................................................................. 101
4.5.4. Cubing ......................................................................................... 102

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OPEX Corporation
4.5.5. Reprint ......................................................................................... 107
4.5.6. Reconfigure Tote ......................................................................... 107
4.5.7. Sequence .................................................................................... 108
4.6. Preventive Maintenance ..................................................................... 109
4.6.1. Mirrors ......................................................................................... 109
4.6.2. Sensors ....................................................................................... 109
Chapter 5
Troubleshooting
5.1. Overview ............................................................................................. 112
5.2. Workstation interruptions .................................................................... 114
5.2.1. Interrupted zone - stage sensor blocked ..................................... 114
5.2.2. Missed window ............................................................................ 115
5.2.3. Interrupted zones with missed windows ...................................... 117
5.2.4. Missed barcode read ................................................................... 118
5.2.5. Unknown containers .................................................................... 120
5.2.6. Duplicate Scan ............................................................................ 121
5.2.7. Last Zone Interruption ................................................................. 123
5.2.8. Container Collision ...................................................................... 124
5.2.9. All interrupted zones .................................................................... 125
Chapter G
Glossary
G.1. List of Acronyms ................................................................................. 128
G.2. List of Terms ...................................................................................... 129

Perfect Pick® Cortex™
Operator Manual
1. Introduction
1.1. About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.1. Manual navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.2. Safety message conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8Introduction
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
1.1. About This Manual
This manual contains information about the OPEX Cortex™ system and its
operational procedures and safety-related components, including:
•safety information, safety hazards and precautions
•component identification and function
•system specifications
•operation and use
This information is required to ensure proper and safe operation of the
machine.
This manual will be updated to reflect equipment design changes, part number
changes, or to correct errors (a table detailing the document revision history
can be viewed on page 4). Be sure to retain the latest electronic release of the
manual for your reference. The latest release can be downloaded in PDF
format at www.opexservice.com (authorized, registered users only).
1.1.1. Manual navigation
This manual is designed primarily for use on a tablet device. To improve
navigation, the manual contains blue underlined links you can click on or tap to
go directly to a particular page or web address. In addition, all items in the
“Table of Contents”as well as the bookmarks in the side bar of the PDF file can
be clicked or tapped to navigate directly to a particular page. Make sure to use
the latest version of Adobe®Acrobat Reader®* for optimal performance.
*Adobe and Acrobat Reader are registered trademarks of Adobe Systems Incorporated.

Introduction 9
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
1.1.2. Safety message conventions
This manual uses the following conventions to alert you about safety hazards
associated with certain procedures and situations. Please be aware of these
conventions when reading the manual and operating the equipment:
See important safety information in Chapter 2: “Safety”.
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
Indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury.
NOTICE
Indicates information considered important, but not hazard related (e.g.
messages relating to property damage).

10 Introduction
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
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Perfect Pick® Cortex™
Operator Manual
2. Safety
2.1. Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.1. Arc flash and electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.2. Electrostatic discharge precautions. . . . . . . . . . . . . . . . . . . . . . . 14
2.2. Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . 15
2.3. Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.1. Workstation Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.2. Perfect Pick Operator Station Labels . . . . . . . . . . . . . . . . . . . . . 23
2.4. Emergency Stops (E-stops) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.5. Light Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.6. Lock-out Tag-out (LOTO) Procedures . . . . . . . . . . . . . . . . . . . . . 30
2.6.1. What is Lockout Tag-out? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.6.2. Lock-out/Tag-out devices required . . . . . . . . . . . . . . . . . . . . . . . 31
2.6.3. LOTO - Machine Maintenance and Repair . . . . . . . . . . . . . . . . . 32
2.6.4. Fully de-energizing AC power . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6.5. Restoring the machine to normal operation. . . . . . . . . . . . . . . . . 37
2.7. Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

12 Safety
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
2.1. Safety Guidelines
This section provides safety guidelines to be observed when working with this
equipment.
The Perfect Pick HD® and OPEX Workstation adhere 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.
Familiarize yourself with the location of the Emergency Stop (E-stop) switch
and pull-cord.
The E-Stop switches and E-stop pull-cord enable a quick stop of all motors in
the machine, in the event of an emergency involving potential personnel injury.
Pressing an E-Stop switch or pulling the E-stop pull-cord stops movement of
the conveyor.
Electrical Safety - Always assume electrical wiring is hot any time the machine
is plugged in. Failure to use caution may result in severe bodily injury or death
from electric shock.
Use caution to avoid contact with exposed, non-insulated areas of any
electrical devices or wiring.
Never handle or place a tool on the exposed terminals of any electrical device,
such as a circuit breaker, transformer, switch, relay, terminal block, fuse block,
for example, without first shutting off all power to that device.
Ensure that all electrical outlets and extension cords are equipped with a third
earth grounding conductor-to-chassis ground.
Keep loose objects away from any exposed, moving parts of the machine - The
moving parts of the Perfect Pick Integrated Work Station can become jammed
and/or damaged by foreign objects. Keep hands, hair, loose clothing and
jewelry away from the moving parts.
CAUTION
Follow these safety guidelines whenever installing, operating, servicing, or
maintaining the equipment described in this manual.

Safety 13
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
Proper Tool Usage - Keep loose tools and other objects away from any
electrical and mechanical components of the machine. Use and maintain tools
properly, according to manufacturer’s instructions.
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.
Do not use flammable, high pressure, “canned air” to clean dust and debris
from the machine.
Keep away from children - This equipment is not suitable for use in locations
where children are likely to be present.
Personal Protective Equipment (PPE) - Wear personal protective equipment
that is appropriate to the job being performed. Requirements for personal
protective equipment such as face masks, vests, safety glasses, and gloves
may vary with the build site, depending on local code and end-user customer
safety policies.
2.1.1. Arc flash and electrical safety
The owner of this equipment is responsible for developing and maintaining
safe work policies and practices to minimize employee exposure to arc flash
and electrical shock hazards. These practices should be in accordance with
applicable workplace safety codes and should include: a) evaluation of the
equipment for arc flash and electrical shock hazards; and b) proper labeling of
the equipment to alert employees to the hazards, arc-flash boundaries, and
PPE requirements.
For more information, refer to applicable electrical safety publications of the
country or region where the equipment is operating.
USA customers: refer to publication NFPA 70E, Standard for Electrical Safety in
the Workplace
Canada customers: refer to CSA Z462-15, Workplace Electrical Safety
EU customers: refer to British Standards BS EN 50110-1:2013 Operation of
electrical installations- General requirements

14 Safety
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
2.1.2. Electrostatic discharge precautions
The printed circuit boards used in the Perfect Pick Integrated Work Station are
particularly susceptible to damage from electrostatic discharge (ESD). For this
reason, basic precautionary measures must be taken while handling these
devices:
•Always wear an anti-static wrist strap when handling circuit boards.
•Always handle circuit boards by their edges, never putting your fingers on
edge connectors or components.
•After removing a circuit board, place it either on an ESD-grounded mat or
into an electrostatic shielding bag.
•Always store and ship circuit boards in electrostatic shielding bags.
•Never place anything else in the electrostatic shielding bag with the board.

Safety 15
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
2.2. Personal Protective Equipment (PPE)
Personal protective equipment (PPE) refers to wearable safety items such as
gloves, safety glasses, hard hats, and high-visibility vests.
The Perfect Pick/Cortex system falls within Arc Flash PPE Category 1 for
Alternating Current (AC) systems, per NFPA 70E standards.
The following PPE items are advised for Arc Flash Category 1, per NFPA 70E,
and are recommended during the period beginning with machine installation
and commissioning, prior to completion of the machine owner’s (customer’s)
arc flash and electrical hazard assessment and labeling.
•Arc-Rated Clothing, Minimum Arc Rating of 4 cal/cm2(16.75 J/ cm2)
-Arc-rated long-sleeve shirt and pants or arc-rated coverall
-Arc-rated face shield or arc flash suit hood
-Arc-rated jacket, parka, rain wear, or hard hat liner (AN)
•Protective Equipment
-Hard hat
-Safety glasses or safety goggles (SR)
-Hearing protection (ear canal inserts)
-Heavy-duty leather gloves
-Leather footwear (AN)
Check with local law and the specific job site to find out what additional PPE is
required before starting.

16 Safety
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
2.3. Safety Labels
Safety labels are used in specific locations throughout the Cortex system to
alert you to certain safety hazards. These labels may appear in various
languages or styles depending on the region or country where the machine is
operating:
•Bilingual English/Spanish labels for US machines
•Bilingual English/French labels for Canadian machines
•Graphics-only labels for EU and various international machines (no text).
Although they appear different, the locations of these labels are identical.
Note: Only those labels found within the Cortex system will be described here.
Please refer to the Perfect Pick Operator Manual for all Perfect Pick labels and
their locations.
WARNING
Follow the safety precautions on all labels when operating and maintaining
the Cortex system. Failure to follow these precautions may result in severe
bodily injury or death as well as damage to the machine.

Safety 17
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
2.3.1. Workstation Labels
2.3.1.1. Arc Flash and Shock Hazard Warning label
Location: Front of Workstation Control Panel (Table 2-1).
Purpose: Advises owner of machine to follow all arc flash and electrical safety
requirements per applicable standards.This is a temporary label to be
removed by the employer only, after completion of arc flash and
electrical hazard assessment and labeling (see “Arc flash and electrical
safety” on page 13).
Table 2-1: Arc Flash and Shock Hazard warning label
Label location Description
US (8165700)
CA (8165710)
AU, EU, JP (8165730)
Front of Workstation Control Panel

18 Safety
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
2.3.1.2. Ratings / Serial Number label
Location: Underneath power switch on Workstation Control Panel (Table 2-2).
Purpose: Identifies product electrical ratings, machine serial number for U.S. &
Canada; EU; Japan.
Table 2-2: Ratings/Serial Number label
Label locations Description
All (6088000)
Front of workstation control panel
VOLTAGE:
480VAC
CORPORATION
MOORESTOWN, NJ (USA)
R
MANUFACTURER:
CURRENT:
6A
SCCR:
200kA
DRAWING NUMBER:
6055400
SERIAL NUMBER:
#####
FREQUENCY:
60Hz
PHASES:
3P+E
BUILD DATE:
08/2020

Safety 19
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
2.3.1.3. Fuse Chart label
Location: Inside hinged cover of Workstation Control Panel (Table 2-3).
Purpose: Identifies the correct fuses needed within the control panel.
Table 2-3: Fuse Chart label
Label location Description
All (6088100)

20 Safety
Perfect Pick® Cortex™ Operator Manual
OPEX Corporation
2.3.1.4. Agency Approval label
Location: Front of Workstation Control Panel (Table 2-4).
Purpose: Identifies that the system has met agency approval qualifications. The
ETL label is not an OPEX label; it is provided by Intertek after field inspection is
completed.
Table 2-4: Agency Approval label
Label location Description
All (N/A)