Opex Sure Sort User manual

© 2017 - 2019 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.
May 2019
Sure Sort™ Operator Manual
WARNING
Read this manual thoroughly before attempting to operate this equipment.
Keep a current copy for your reference.
9166900OM-EN Revision 19-07 Original Instructions
Sure Sort™

2ContactingOPEX
Sure Sort™ 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
https://www.opex.com/support-service
Please have the model name and serial number of the product ready (see
“Equipment Serial Number Locations” on page 109).
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.com website-related issues, please contact the
OPEX Web Developers via email at: [email protected]

EU Declaration of Conformity 3
Sure Sort™ Operator Manual
OPEX Corporation
EU Declaration of Conformity
EU Declaration of Conformity
Sure Sort
This declaration of conformity is issued under the sole responsibility of the manufacturer.
1.0 Manufacturer NAME OPEX Corporation
ADDRESS 305 Commerce Drive, Moorestown, NJ 08057, USA
2.0 Technical File Technical documentation is compiled in accordance with Part B of Annex VII of the machinery directive. This documentation is available on a
reasoned request by appropriate national authority to our authorized representative:
NAME Andre Bernhardt
ADDRESS Auf der Lug 8
71726 Benningen am Neckar
3.0 Description and
identification
Description Item Sorter
Model Sure Sort
Serial Number
Year Manufactured From 2019
4.0 Directives 2006/42/EC Machinery Directive
2014/53/EU Radio Equipment Directive
2014/30/EU Electromagnetic Compatibility Directive
5.0 Harmonized
Standards used
EN 61000-6-2: 2005 Electromagnetic compatibility (EMC). Generic standards. Immunity for industrial environments
EN 61000-6-4: 2011 Electromagnetic compatibility (EMC) -- Part 6-4: Generic standards - Emission standard for industrial
environments
EN 619: 2002+A1:2010 Continuous handling equipment and systems. Safety and EMC requirements for equipment for
mechanical handling of unit loads
EN ISO 12100-2:2003 Safety of machinery - Basic concepts, general principles for design - Part 2: Technical principles
EN 60204-1:2006+A1:2009 Safety of machinery. Electrical equipment of machines. General requirements
ETSI EN 300 328 V2.1.1 (2016-11) Wideband transmission systems; Data transmission equipment operating in the 2,4 GHz ISM band
and using wide band modulation techniques; Harmonised Standard covering the essential
requirements of article 3.2 of Directive 2014/53/EU
ETSI EN 301 489-1 V1.9.2 (2011-09) Electromagnetic compatibility and Radio spectrum Matters (ERM); ElectroMagnetic Compatibility
(EMC) standard for radio equipment and services; Part 1: Common technical requirements
6.0 Technical
Standards used
NFPA 79:2018 Electrical Standard for Industrial Machinery
UL 2011:2006 Outline of Investigation for Factory Automation Equipment
CSA C22.2 No. 301-2016 Industrial electrical machinery
UL 61800-5-1 (iBOT only) Standard for Adjustable Speed Electrical Power Drive Systems: Safety requirements – Electrical,
Thermal and Energy
7.0 Approval I, the undersigned, hereby declare that the equipment specified above conforms to the above Directive(s) and Standard(s).
Place of issue Moorestown, NJ, USA
Date of issue Feb 19, 2019
Authorized Scott Maurer,
Title President, International Division

4DocumentHistory
Sure Sort™ Operator Manual
OPEX Corporation
Document History
Doc
Rev Date Changes (click blue text to go to that page)
19-01 Feb 25, 2019 Preliminary Release
19-02 Mar 14, 2019
Initial release with the following updates:
Page 27 - interior ground symbol for AC enclosure
removed
Page 29 - photo of high-leakage current label updated
Page 30 - machine ratings/SN labels updated
Page 62 - descriptions of left & right E-stops changed
to 100 & 200 to match S/W diagnostics.
Page 63 - step 7 revised to state pull up E-stop to
deactivate; was twist. Added step 8: restart host
Page 69 - Section 2.7 LOTO procedures updated:
added EU lockout device; plug lockout device
procedure placed in separate section; “lockout switch”
changed to “main disconnect switch” handle; power
restoration steps moved to separate section
Page 86 & 90- iBOT images updated
Page 99 - BTU specs removed
Page 101 & 102- NA & EU electrical req’mts updated
Page 107 - Compliance specs updated
Page 109 - corrected machine S/N location figure;
updated label
Page 114 - “lockout switch” changed to “main
disconnect switch” handle
(continued next page)

Document History 5
Sure Sort™ Operator Manual
OPEX Corporation
19-03 Mar 18, 2019
Throughout - eliminated UI features not visible at
operator level
Page 86 thru 88- minor edits to System Overview
image & relocated text to above image; streamlined
feature descriptions
Page 134 - updated photos for product-related jams
Page 142 - updated reject and jam list & descriptions
19-04 Apr 3, 2019
Page 21 thru 59- machine labels updated per Product
Label Map rev A.
Page 97 - Basic config specs updated
Page 100 - Equip footprint diagram updated
Page 109 - Corrected description of iBOT rear S/N
location
19-05 Apr 22, 2019 Translated manuals only: Section 2.3 French Safety
Guidelines required for North America omitted.
19-06 May 10, 2019
Page 31 - added section “Ratings/ Serial Number
labels, continued”; labels for Japan
Page 24 and 39 - added Arc Flash warning labels
Page 49 and 59 - added radio compliance label for
Japan
Page 69 - LOTO procedures updated to include hard-
wired machines
Page 83 - added PPE arc-flash rated equipment list
Page 101 and 102 - warning about hard-wiring
removed
Page 103 - Added Japan electrical specs
19-07 May 16, 2019
Page 63 - Estop restart: increased heading; added
step w/reference to LOTO.
(continued next page)
Doc
Rev Date Changes (click blue text to go to that page)

6DocumentHistory
Sure Sort™ Operator Manual
OPEX Corporation
19-07 May 16, 2019
Page 69 - LOTO procedures: revised warning
message & added introduction “What is LOTO?”
Page 70 - Japan machine added to description of
power cord lockout device.
Page 72 - Added Danger message de-energize AC
enclosure with links to plugged & hard-wired
procedures.
Page 75 and 77 - Condensed opening statement.
Page 78 - Clarified step 5 interlock delay ensures
iBOTs stopped
Page 81 - Added “remove caution sign”
Doc
Rev Date Changes (click blue text to go to that page)

Table of Contents 7
Sure Sort™ Operator Manual
OPEX Corporation
Table of Contents
Chapter 1
Introduction
1.1. About This Manual ................................................................................ 12
1.1.1. Manual navigation aids .................................................................. 13
1.1.2. Safety message conventions ........................................................ 14
Chapter 2
Safety
2.1. Introduction ........................................................................................... 16
2.2. Safety Guidelines .................................................................................. 17
2.3. Consignes de sécurité - traduction française ........................................ 18
2.4. Machine Labels ..................................................................................... 21
2.4.1. Induct conveyor module labels ...................................................... 22
2.4.2. Return conveyor module labels ..................................................... 33
2.4.3. Scan tunnel labels ......................................................................... 37
2.4.4. Base stacker module labels .......................................................... 40
2.4.5. Expansion module labels .............................................................. 50
2.4.6. iBOT labels .................................................................................... 55
2.4.7. Ultracapacitor product information ................................................ 60
2.5. Emergency stops and interlock switches .............................................. 61
2.5.1. Emergency stop buttons (E-Stops) ............................................... 61
2.5.2. Interlock system ............................................................................ 64
2.5.3. Emergency Exit Handle ................................................................. 66
2.5.4. Reset Buttons ................................................................................ 67
2.6. Light Tower ........................................................................................... 68
2.7. Lockout-Tagout (LOTO) Procedures .................................................... 69
2.7.1. What is Lockout-Tagout? .............................................................. 69
2.7.2. Lock-out/Tag-out devices required ................................................ 70
2.7.3. LOTO - Machine maintenance and repair ..................................... 72

8 Table of Contents
Sure Sort™ Operator Manual
OPEX Corporation
2.7.4. Fully de-energizing AC power (plug-in machines) ......................... 75
2.7.5. Fully de-energizing AC power (hard-wired machines) .................. 77
2.7.6. LOTO - Clearing Jams and Removing iBOTs ............................... 78
2.7.7. Restoring the machine to normal operation .................................. 81
2.8. Ergonomics ........................................................................................... 82
2.9. Personal Protective Equipment ............................................................. 83
Chapter 3
Overview
3.1. System Overview .................................................................................. 86
3.2. Options and Configurations .................................................................. 89
3.2.1. Base Configuration ........................................................................ 89
3.2.2. Options .......................................................................................... 89
3.3. How Sure Sort™ Works ........................................................................ 91
3.3.1. OPEX Host software ..................................................................... 92
3.3.2. OPEX Induct ELC .......................................................................... 93
3.3.3. The Optional OPEX Barcode Tunnel ............................................ 94
3.3.4. Fix-Mount Scanner ........................................................................ 95
3.3.5. Pack-to-Light feature ..................................................................... 95
3.3.6. Stop Light feature .......................................................................... 96
3.4. Specifications ........................................................................................ 97
3.4.1. Basic Configuration ....................................................................... 97
3.4.2. Material Handling (inventory items) ............................................... 97
3.4.3. Options .......................................................................................... 97
3.4.4. Module Dimensions ....................................................................... 98
3.4.5. Environmental specifications ......................................................... 99
3.5. Equipment Layout and Required Floor Space .................................... 100
3.6. Electrical Requirements - North American .......................................... 101
3.7. Electrical Requirements - Europe (EU) ............................................... 102
3.8. Electrical Requirements - Japan ......................................................... 103
3.9. Wireless Transceiver .......................................................................... 104
3.9.1. FCC information / informations FCC ........................................... 104
3.9.2. Industry Canada information / Industrie Canada l'information ..... 105

Table of Contents 9
Sure Sort™ Operator Manual
OPEX Corporation
3.10. Regulatory Compliance Testing ........................................................ 107
3.10.1. Standards that equipment was evaluated against: .................... 107
3.10.2. FCC standards: ......................................................................... 108
3.11. Equipment Serial Number Locations ................................................ 109
Chapter 4
Operation
4.1. Overview ............................................................................................. 112
4.1.1. Order of Operation ...................................................................... 113
4.1.2. Turning the power on/off ............................................................. 114
4.1.3. Logging in to the Host software ................................................... 115
4.1.4. Navigating the Host software ...................................................... 123
4.1.5. Run Screen details ...................................................................... 124
4.1.6. Information tabs ........................................................................... 125
4.1.7. Clearing jams .............................................................................. 130
4.2. Product-related jams ........................................................................... 134
4.3. Toggling between the Host & InductELC software ............................. 137
Chapter 5
Statistics
5.1. Overview ............................................................................................. 140
5.2. Creating Reports ................................................................................. 140
5.2.1. Setting the Time Range ............................................................... 141
5.3. Reject and Jam Definitions ................................................................. 142
5.3.1. Rejects ........................................................................................ 142
5.3.2. Jams ............................................................................................ 146
5.3.3. Safety-Related jams .................................................................... 151
Chapter G
Glossary
G.1. List of Acronyms ................................................................................. 156
G.2. List of Terms ...................................................................................... 156

10 Table of Contents
Sure Sort™ Operator Manual
OPEX Corporation
(Page intentionally blank)

Sure Sort™
Operator Manual
1. Introduction
1.1. About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1.1. Manual navigation aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1.2. Safety message conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

12 Introduction
Sure Sort™ Operator Manual
OPEX Corporation
1.1. About This Manual
This manual contains information about the OPEX Sure Sort automated sorter
and its operational procedures and safety-related components, including:
•safety information, safety hazards and precautions
•main component identification and function
•system specifications
•operational and statistical reporting procedures
This information is intended for use by the main operator of the Sure Sort
machine. The operator can power up the machine, start a job and feed product
onto the conveyor for sorting into bins. Note that the operator is not qualified to
perform the following duties (additional training is required for these skill
levels):
•Affected Employee - An employee whose job requires him or her to operate
or use a machine or equipment on which the servicing or maintenance is
being performed under lockout or tagout, or whose job requires him/her to
work in an area in which such servicing or maintenance is being performed.
•Authorized Employee - Aperson who locks out or tags out machines or
equipment in order to perform servicing or maintenance on the machine or
equipment.
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).
WARNING
Read all information thoroughly before attempting to operate this equipment.

Introduction 13
Sure Sort™ Operator Manual
OPEX Corporation
1.1.1. Manual navigation aids
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.

14 Introduction
Sure Sort™ 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).

Sure Sort™
Operator Manual
2. Safety
2.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2. Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3. Consignes de sécurité - traduction française . . . . . . . . . . . . . . . 18
2.4. Machine Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.1. Induct conveyor module labels . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4.2. Return conveyor module labels . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.4.3. Scan tunnel labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.4. Base stacker module labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.5. Expansion module labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4.6. iBOT labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4.7. Ultracapacitor product information. . . . . . . . . . . . . . . . . . . . . . . . 60
2.5. Emergency stops and interlock switches . . . . . . . . . . . . . . . . . . 61
2.5.1. Emergency stop buttons (E-Stops) . . . . . . . . . . . . . . . . . . . . . . . 61
2.5.2. Interlock system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.5.3. Emergency Exit Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.5.4. Reset Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.6. Light Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.7. Lockout-Tagout (LOTO) Procedures. . . . . . . . . . . . . . . . . . . . . . . 69
2.7.1. What is Lockout-Tagout?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.7.2. Lock-out/Tag-out devices required . . . . . . . . . . . . . . . . . . . . . . . 70
2.7.3. LOTO - Machine maintenance and repair . . . . . . . . . . . . . . . . . . 72
2.7.4. Fully de-energizing AC power (plug-in machines). . . . . . . . . . . . 75
2.7.5. Fully de-energizing AC power (hard-wired machines). . . . . . . . . 77
2.7.6. LOTO - Clearing Jams and Removing iBOTs . . . . . . . . . . . . . . . 78
2.7.7. Restoring the machine to normal operation. . . . . . . . . . . . . . . . . 81
2.8. Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.9. Personal Protective Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . 83

16 Safety
Sure Sort™ Operator Manual
OPEX Corporation
2.1. Introduction
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.
WARNING
Read this chapter thoroughly before using this equipment.

Safety 17
Sure Sort™ Operator Manual
OPEX Corporation
2.2. Safety Guidelines
This section provides safety guidelines to be observed when working with this
equipment.
Normal operations - Only authorized personnel shall start, operate, or interfere
with the normal working of the machine. Operator training is required, and
training is provided in “Operation” on page 111.
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.
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 “Ultracapacitor product
information” on page 60.
Standing under an iBOT - Do not stand under an iBOT while it is carrying a
load. No one may remain underneath iBOTS with loads.
Keep loose objects away from any exposed, moving parts of the machine - The
moving parts of the Sure Sort, 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.
Conveyor systems - The conveyor system is designed for items that are 5 lbs.
(2.27 kg) or less. Do not sit, stand, or travel on any part of the conveyor system
while it is in motion.
Machine Entry - Do not enter the machine while it is in operation. Only
Authorized service maintenance personnel should enter the aisle.
Machine design - Do not modify the design or configuration of the equipment
without consulting OPEX or your authorized representative.
WARNING
Follow these safety guidelines whenever operating or maintaining the
equipment described in this manual.

18 Safety
Sure Sort™ Operator Manual
OPEX Corporation
Machine Maintenance - Machine maintenance, particular operations, and all
adjustments, whether mechanical or electrical, shall be carried out by persons
authorized to do so in accordance with a safe system of work.
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.
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. Note that the E-
Stops should not be used for normal stopping. For more on proper operations
of the machine, refer to “Operation” on page 111.
Machine access - Keep all areas around the machine clear of obstacles.
Keep away from children - This equipment is not suitable for use in locations
where children are likely to be present.
2.3. Consignes de sécurité - traduction française
Opérations normales - Seul le personnel autorisé doit démarrer, opérer ou
interférer avec le fonctionnement normal de la machine. La formation de
l'opérateur est requise et la formation est fournie dans "Opération" à la
page 111.
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.
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 "Information produit sur les
ultra-condensateurs" à la page 60.

Safety 19
Sure Sort™ Operator Manual
OPEX Corporation
Debout sous un iBOT - Ne restez pas sous un iBOT pendant qu'il porte une
charge. Personne ne peut rester sous iBOTS avec des charges.
Gardez les objets lâches à l'écart des parties exposées et mobiles de la machine
- Les parties mobiles du Sure Sort, 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.
Systèmes de convoyeur - Le système de transport est conçu pour les articles
de 5 lb. (2,27 kg) ou moins. Ne vous asseyez pas, ne vous tenez pas debout
ou ne voyagez pas sur une partie du système de convoyeur lorsqu'il est en
mouvement.
Entrée de la machine - Ne pas entrer dans la machine pendant son
fonctionnement. Seul le personnel d'entretien autorisé doit entrer dans l'allée.
Conception de la machine - Ne modifiez pas la conception ou la configuration
de l'équipement sans consulter OPEX ou votre représentant autorisé.
L'entretien des machines - La maintenance de la machine, les opérations
particulières et tous les réglages, qu'ils soient mécaniques ou électriques,
doivent être effectués par des personnes autorisées à le faire conformément à
un système de travail sûr.
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.
N'utilisez pas d'air comprimé inflammable, à haute pression pour nettoyer la
poussière et les débris de la machine.
Familiarisez-vous avec le (s) emplacement (s) de la machine Interrupteurs
d'arrêt d'urgence - Les interrupteurs E-Stop permettent un arrêt rapide de tous
les moteurs de la machine, en cas d'urgence impliquant des blessures
potentielles du personnel. Notez que les E-Stops ne doivent pas être utilisés
pour un arrêt normal. Pour plus d'informations sur le bon fonctionnement de la
machine, voir "Fonctionnement" à la page 111.
Accès à la machine - Gardez toutes les zones autour de la machine sans
obstacles.

20 Safety
Sure Sort™ Operator Manual
OPEX Corporation
Tenir à l'écart des enfants - Cet équipement ne convient pas aux endroits où
les enfants sont susceptibles d'être présents.