VertiDrive V400 Series User manual
VertiDrive V400 Series Robot
User Manual
This is the original English manual to be used by VertiDrive on-site user training certified operators.
REVISION: 1.1
ISSUE DATE: 20-06-2023
APPLIES TO: VertiDrive V400 Series robot
VERTIDRIVE B.V.
Gieterijweg 15
3089JZ, Rotterdam
The Netherlands
Phone: +31(0)10 76 30 200
Website: www.vertidrive.com
E-Mail: sales@vertidrive.com
Copyright © VertiDrive B.V. All rights reserved. VertiDrive is a trade name of VertiDrive B.V.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any
means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the
manufacturer.
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 2 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
FOREWORD
This manual is written to inform you, as a user, how to work safely with our product. The manual provides information
on the level of a technical specialist. The system should not be operated by unauthorized personnel or technical
specialist without training.
Read and fully understand these instructions before using the equipment. Make sure all security recommendations
and precautions have been read and understood. Also, read the security recommendations of complementary
supplier’s documents. The users remain responsible for supervision and compliance with this manual.
This manual applies to the “V400 Series Robot”. Upon request, different tools for the V400 Series robot are available,
such as a safety winch system. Contact the support department of VertiDrive B.V. for more information.
As a manufacturer, we strongly recommend to:
Contact VertiDrive B.V. for urgent questions.
Keep the manual in a dry, safe, and available place for everyone who’s involved.
Keep all security marks on the system visible, replace them if needed.
Equipment supplied by VertiDrive B.V., to which the machine directive is applicable, complies with the EU declaration
of conformity.
Contents of manual
This manual contains the following subjects:
Product specification.
Product certification.
Safety information.
System description.
Installation instructions.
Operation instructions.
Maintenance instructions.
Storage and transport instructions.
Notice
All applicable procedures, described in this manual, have been verified by VertiDrive B.V. The provided images are
meant to represent the actual product, but the image content may vary from reality.
Revision history
Rev. No. Issue date Description Created
Checked
1.0 02-06-2023 First release for new V400 Series robot
YVE
MVP
1.1 20-06-2023 Minor modification section 9.4 and residual risks implementation YVE MVP
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 3 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
CONTENTS
1. CONTACT INFORMATION ................................................................................................................................................. 5
Supplier....................................................................................................................................................................... 5
Support and service .................................................................................................................................................. 5
2. TERMS AND DEFINITIONS ................................................................................................................................................... 6
3. MACHINE SPECIFICATION ................................................................................................................................................. 7
General specifications ............................................................................................................................................. 7
CE marking and identification ................................................................................................................................. 7
Technical specifications ........................................................................................................................................... 7
Documentation ......................................................................................................................................................... 8
4. PRODUCT CONFORMITY AND LIABILITY ........................................................................................................................... 9
General ...................................................................................................................................................................... 9
Intended and non-intended use of the machine ................................................................................................. 9
Responsibilities for owner and user .......................................................................................................................... 9
Warranty .................................................................................................................................................................... 9
Liability ...................................................................................................................................................................... 10
Guarantee (= warranty), or other claims ............................................................................................................. 11
5. SAFETY .............................................................................................................................................................................. 12
Symbols in this document ....................................................................................................................................... 12
Safety signs on the system ...................................................................................................................................... 12
General safety instructions ..................................................................................................................................... 13
5.3.1. Job functions, tasks, certification, and team line-up .................................................................................. 13
5.3.2. Before starting ................................................................................................................................................. 13
5.3.3. During operation ............................................................................................................................................. 14
5.3.4. During maintenance / service ....................................................................................................................... 14
Safety provisions ...................................................................................................................................................... 15
5.4.1. Emergency stop .............................................................................................................................................. 15
5.4.2. Wall contact sensor (WCS)............................................................................................................................. 15
5.4.3. Whip checks .................................................................................................................................................... 15
Hearing protection ................................................................................................................................................. 15
Risk for personal injury ............................................................................................................................................. 16
5.6.1. Electrocution / Electric shock ........................................................................................................................ 16
5.6.2. Electrical safety earth ..................................................................................................................................... 16
5.6.3. Cuts, injuries on head and feet ..................................................................................................................... 16
5.6.4. Injuries on face and eyes ............................................................................................................................... 16
5.6.5. Hearing damage ............................................................................................................................................ 17
5.6.6. Liquid injection by UHP water jet ................................................................................................................... 17
5.6.7. Crushing hand ................................................................................................................................................. 17
5.6.8. Magnetism ....................................................................................................................................................... 17
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In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
6. SYSTEM DESCRIPTION ...................................................................................................................................................... 18
General .................................................................................................................................................................... 18
V400 Series robot ..................................................................................................................................................... 18
Control box (incl. optional transport frame) ........................................................................................................ 19
Remote control ....................................................................................................................................................... 20
Umbilical and (optional) extension kit .................................................................................................................. 21
Fall arrester and (optional) winch system ............................................................................................................. 22
7. INSTALLATION ................................................................................................................................................................... 24
General .................................................................................................................................................................... 24
Pump control connection ...................................................................................................................................... 24
Handling of the Robot ............................................................................................................................................ 26
8. OPERATION ...................................................................................................................................................................... 27
Operating procedure ............................................................................................................................................. 27
8.1.1. Magnet distance adjustment ........................................................................................................................ 27
8.1.2. Vacuum shroud positioning ........................................................................................................................... 28
8.1.3. Robot placement ........................................................................................................................................... 30
8.1.4. Connection ...................................................................................................................................................... 31
8.1.5. Robot operation .............................................................................................................................................. 31
8.1.6. UHP application operation ............................................................................................................................ 32
8.1.7. Shutting down ................................................................................................................................................. 33
8.1.8. Adjustment of vacuum ................................................................................................................................... 33
8.1.9. WCS overrule ................................................................................................................................................... 34
8.1.10. Recover from an emergency stop ................................................................................................................ 34
9. MAINTENANCE AND CLEANING .................................................................................................................................... 35
General .................................................................................................................................................................... 35
Frequency of inspection and maintenance ........................................................................................................ 35
Inspection and maintenance activities ................................................................................................................ 35
Part replacement instructions ................................................................................................................................ 37
9.4.1. Replacement vacuum shroud wear plate ................................................................................................... 37
Cleaning .................................................................................................................................................................. 38
10. TROUBLESHOOTING ..................................................................................................................................................... 39
11. STORAGE AND TRANSPORT ........................................................................................................................................ 41
General ................................................................................................................................................................ 41
12. DISMANTLING AND DISPOSAL .................................................................................................................................... 41
General ................................................................................................................................................................ 41
APPENDIX A - EU DECLARATION OF CONFORMITY .............................................................................................................. 42
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 5 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
1. CONTACT INFORMATION
Supplier
VertiDrive B.V.
Gieterijweg 15
3089JZ, Rotterdam
The Netherlands
Telephone: +31(0)10 76 30 200
E-Mail: [email protected]m
Support and service
VertiDrive B.V.
Gieterijweg 15
3089JZ, Rotterdam
The Netherlands
Telephone: 31(0)10 76 30 200
E-Mail: [email protected]
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 6 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
2. TERMS AND DEFINITIONS
The following definitions, abbreviations, and units are used in this manual.
Definition Description
Emergency shut-off A stop button that ensures a safe situation when activated.
Jetting area This is the area where the cleaning is carried out and where people are
exposed to the water jets or jetting components.
Nozzle A head with one or more discharge openings through which the water jet
spray emerges.
Ultra-high-pressure
water jetting system
A system that consists of a pump, hoses, and high-pressure jetting equipment,
that can jet water under ultra-high pressures of more than 2000 bar.
Ultra-high-pressure
water blasting
A process of smoothing or cleaning a surface using ultra-high-pressure water
jets.
Whip check A safety cable, used on high-pressure air or water hoses to prevent the hoses
from flying around if the connection inadvertently separates.
Abbreviation Description
CE Conformité Européenne: CE marking ensures that the product is
manufactured according to European standards.
EN European Norm: A set of unified standards for products, services, testing
procedures, or systems recognized by the European Union.
IP Ingress Protection: The IP code indicates how well a device is protected
against water and dust.
LMRA Last-Minute Risk Analysis: This is a short assessment performed immediately
before the start of work to identify and exclude all potential safety, health, and
environmental hazards at the workplace.
PPE Personal Protective Equipment: Anything a worker uses or wears to keep them
healthy and safe.
UHP Ultra-High Pressure: In this manual refers to ultra-high pressure water jetting.
Working pressures from 2000 bar and up.
Unit Description
°C Degrees Celsius.
°F Degrees Fahrenheit.
A Ampere; SI unit of electrical current.
bar Unit of pressure; 1 bar = 100,000 Pa (pascals).
cm Centimeter = 0.01m.
dB(A) Decibels (absolute); a weighted scale for judging loudness that corresponds to
the hearing threshold of the human ear.
Hz Hertz, SI unit of frequency of one cycle per second.
kg Kilogram.
m Meter; SI unit for length.
mm Millimeter = 0.001m.
V Volt; SI unit for electric potential difference.
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In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
3. MACHINE SPECIFICATION
General specifications
Product description: V400 Series.
Country of origin: The Netherlands.
CE marking and identification
The product has a CE mark, to indicate that it complies with the fundamental safety and health requirements as
written in the EU Declaration of Conformity.
The mark is located on the type plate, placed on the robot at the location shown below as well as on the inside of
the door of the control box. The type plate also shows the unique identification number of the robot, the year of
manufacture, and electrical specification.
CE mark V400 Series on robot and control box
Technical specifications
Robot
Robot dimensions l x w x h: 900 x 990 x 420 mm.
Weight: 88 kg.
Payload capacity: 150 kg max.
Driving speed: max 5 m/min.
Umbilical
Umbilical dimensions: ø18mm, length 50 m.
Umbilical weight: 25 kg (0.5 kg / m).
Umbilical extension: Max 100m (use 2nd 322035 umbilical + 323018 extension kit).
Control box (CB4.0)
Dimensions h x w x d: 600 x 600 x 260 mm (600 x 690 x 260 mm with cooling).
Weight: 35 kg (44 kg for ‘high temperature’ systems with cooling).
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In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
Electrical specifications
Input voltage range: 230V systems: 200-240 VAC, 120V systems: 100-120 VAC.
Input frequency range: 50/60 Hz.
Input current (without cooling): 230V systems: 5A, 120V systems: 10A.
Input current (with cooling): 230V systems: 7A, 120V systems: 14A.
Output voltage to the robot: 70 VDC (motors) and 24 VDC (logic).
Remote control system: Hetronic Nova XL.
Range remote control: 100 meters.
UHP application specifications
Maximum operating pressure: 3000 bar (43500 psi).
Maximum flow rate: 45 l/min (12 gal/min).
Maximum rotation speed (nozzle cross): 3000 rpm.
Cleaning width: 400 mm.
Vacuum pressure: -150 to -200 mbar (-2.2 to 2.9 psi) typical, -250 mbar (3.6 psi) max.
Vacuum air flow: 1000 – 1300 m³/hr (590 – 765 cfm) typical.
Environmental conditions
Working temperature (without cooling): -20 to +35°C (0 to +95°F).
Working temperature (with cooling): -20 to +50°C (0 to +120°F).
Storage temperature: -40 to +85°C (-40 to +185°F).
IP rating robot: IP65.
IP rating control box: IP66.
IP rating remote control: IP66.
Documentation
V400 Series robot system (standard)
User Manual VertiDrive V400 Series robot (supplied with robot system).
Control system wiring diagram (supplied with control box).
322025 V400 Series Robot – IPM (Illustrated Parts Manual).
3.4 F-03 Startup Checklist.
3.4 F-04 Inspection and Maintenance Schedule.
V400 Series ancillary equipment (optional)
Optional: Transport frame - User Manual and IPM.
Optional: Vacuum system – User Manual.
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CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
4. PRODUCT CONFORMITY AND LIABILITY
General
The VertiDrive V400 Series fulfills all relevant requirements to be used safely. To achieve this, important safety
instructions are described in this manual that must be followed throughout the whole lifecycle of the product.
See the EU Declaration of Conformity, appendix A to this document, for details on directives and standards used.
The original Declaration of Conformity (DoC) and the full Technical Construction File (TCF) are held at the
manufacturer's office in Rotterdam.
Intended and non-intended use of the machine
The VertiDrive V400 Series robot is a remote-controlled vehicle that uses powerful permanent magnets to adhere to
steel surfaces. This permanent adhesion allows operation on flat or slightly curved steel surfaces at any angle, e.g.,
vertically to, or underneath a horizontal surface (upside down). The robot is designed for surface treatment. The
possibilities and limitations are shown in this document.
By intended use means that the operations on this system must be carried out following the instructions given in this
manual and other ancillary equipment manual(s). Tools and materials used for this purpose must be applicable to
this product and approved by VertiDrive.
Only trained and certified personnel who are duly qualified are authorized to operate the system. Before the use of
the robot, VertiDrive and/or an authorized VertiDrive representative / trainer will demonstrate the product and
provide training on the safe use of the robot and equipment. Participants receive a signed and dated certificate of
participation, which is obligatory to operate and/or maintain the robot. The minimum operator age is 18.
Maintenance engineers must be instructed by VertiDrive or an authorized VertiDrive representative. VertiDrive
maintenance instructions and procedures must be adhered to.
Responsibilities for owner and user
Any changes made to the VertiDrive V400 Series robot may lead to severe damage and injury to the operator or
other personnel in the vicinity of the robot.
The VertiDrive V400 Series robot must not be changed in any way without the written permission of VertiDrive B.V. The
risks and consequences related to adaptations are explicitly excluded from the responsibility of VertiDrive B.V.
VertiDrive B.V. cannot be held responsible for failures or any damage caused by improper use of the equipment, or
overdue maintenance. Personnel will always remain responsible for their actions and the consequential results.
Warranty
Delivery takes place according to the delivery terms specified in “Terms and conditions of the Metaalunie.” The
warranty applies according to Article 14: ‘Guarantee and other claims’ from these terms and conditions unless
agreed upon in writing otherwise.
In all cases, the Warranty does not cover defects that are the result of:
normal wear and tear.
improper use.
lack of maintenance or maintenance carried out incorrectly.
At all times VertiDrive start-up checklists, inspection- and maintenance checklists, including registration and
execution of resulting needed maintenance work, need to be consistently used and stored for reference.
installation, assembly, modification, or repairs carried out by the Client or third parties.
faulty or unsuitable goods originating from or prescribed by the Client.
faulty or unsuitable materials or tools used by the Client.
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In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
No warranty is given for:
goods delivered that were not new at the time of delivery.
inspections and repairs carried out on goods owned by the Client.
parts that are subject to a manufacturer’s guarantee.
Defects due to use improper use and / or maintenance by uncertified (operations and/or maintenance)
personnel.
Liability
VertiDrive B.V. accepts no liability for unsafe situations, accidents, and / or damage resulting from any of the following
points:
poor or improper inspection and/or maintenance of the product.
the robot is explicitly NOT suitable for carrying people and/or objects.
it is NOT permitted to modify the robot (including ancillaries) in any way without prior consultation and prior
written permission from VertiDrive B.V.
the working surface must be ferritic to provide sufficient adhesion of the permanent magnets. The metal
thickness of the working surface needs to be a minimum of 8 mm. Lower values will decrease the holding
force of the permanent magnets and increase the risk of the robot getting detached from the surface.
for optimal adhesion, the distance between the magnets and metal should not exceed the boundary
conditions described in this document. VertiDrive advises using the default configuration when possible.
coating thickness and / or surface contamination can affect the holding force. Prior to starting operation,
the holding force of the robot must always be checked.
the magnets are temperature sensitive and will lose holding force when exposed to elevated temperatures.
The robot is NOT suitable for applications that result in a magnet temperature above 80° C (175° F). Do NOT
use the robot on hot surfaces (> 80°C) or in applications where the robot is directly exposed to temperatures
above the 80°C limit.
pay attention when driving on curved surfaces. The robot is designed for flat and large radius curved surfaces
only. The robot can handle certain curved surfaces as instructed by authorized VertiDrive personnel. The
exact limits are application and situation dependent. Practical instruction on how to avoid and /or cope
with curved surfaces is explained during (mandatory) training.
Driving on a surface with a radius
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In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
Guarantee (= warranty), or other claims
Unless otherwise agreed in writing, VertiDrive guarantees the proper execution of the agreed delivered
product performance for a period of six months after delivery or completion, as detailed in the following
paragraphs.
If the parties have agreed to deviating guarantee conditions, the provisions of this article will remain in full
force, unless this is in conflict with those deviating guarantee conditions.
The Client (=product user) is responsible for sending parts or materials that are to be repaired or replaced by
VertiDrive to VertiDrive or a regional VertiDrive partner’s business location.
The following are for the Client’s account:
All transport or shipping costs.
Costs for dismantling and assembly.
Travel and subsistence expenses and travel time.
VertiDrive is only obliged to implement the guarantee if the Client has fulfilled all its obligations.
The following do not qualify for compensation:
consequential damages. Consequential damages include inter alia business interruption losses, loss
of production, loss of profit, penalties, transport costs and travel and subsistence expenses.
damage to property in the care, custody or control of, but not owned by the insured party. Among
other things, this damage includes damage caused by or during the performance of work with the
products to goods that are being worked on or to goods that are located in the vicinity of the place
where the work is being carried out.
damage as a result of intent or willful recklessness by the Clients’ staff or Clients’ auxiliary staff or non-
managerial subordinates.
The provisions in 4.6 apply by analogy to any of the Client’s claims based on breach of contract, non-
conformity or any other basis whatsoever;
The Client no longer has the right to invoke a defective part or product if it has not complained to VertiDrive
or the regional VertiDrive partner concerned, in writing, within fourteen days after it discovered or should
reasonably have discovered the defect.
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 12 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
5. SAFETY
Safety instructions in this manual are based on risk assessment according to the EU Machine Directive 2006/42/EC
and SIR (Stichting Industriële Reiniging), the Foundation for Industrial Cleaning) guidelines. SIR guidelines are based
on the Dutch and Belgian legislation and regulations, plus the European regulation (EU) 2016/425 of the European
Parliament and the Council dated 9 March 2016 regarding personal protection equipment (superseding European
directive 89/656/EEC).
Symbols in this document
Below is an explanation of the symbols used in this document to draw the reader's attention to specific situations.
DANGER OF LIFE!
The life of the user is at risk.
DANGER!
There is a risk that the user gets (seriously) injured and/or the system incurs serious damage. This warning
alludes to the risk that occurs if the user does not follow the procedures in this manual carefully.
CAUTION!
The system may be damaged if it is used or operated incorrectly.
ATTENTION!
The remark gives additional information concerning the occurrence of possible problems.
It is important to read these instructions.
Safety signs on the system
Meaning: High voltage.
Risk: Electrical hazard (electrical shock).
Location: Control box (when opened).
Meaning: Strong magnetic field.
Risk: Magnets produce a far-reaching, strong magnetic field. They could damage any devices
that are sensitive to magnetism (e.g., phones, watches, credit cards, etc.)
Location: In between the front and back wheels, see figure below.
Meaning: Pinch point.
Risk: Pinching of hands or fingers due to moving parts.
Location: Near the vacuum shroud tilt brackets, near the front and back magnets.
Meaning: Danger for pacemakers and implanted heart defibrillators
Risk: The strong magnetic field near the robot can affect the functioning of pacemakers and
implanted heart defibrillators.
Location: At close distance from the robot.
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These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
Locations of the magnetism
General safety instructions
The V400 Series robot complies with the fundamental safety and health requirements laid down in the relevant
European Union guidelines. However, careless, or inexpert use may lead to dangerous situations.
Always follow the safety rules as defined by local law and / or the company you are working for. Local safety rules
must always be followed in the first place. Please inform your supervisor in case there are contradictions to the safety
warnings and instructions given in this user manual.
The operator must be VertiDrive (or partner(s)) trained and certified to use the robot. All safety precautions and
instructions relevant for UHP hydro-blast equipment must be adhered.
Always observe the following general safety instructions:
5.3.1. Job functions, tasks, certification, and team line-up
Operator
Trained, educated, and certified according to local requirements for Robot and UHP hydro-blast equipment.
VertiDrive certified (or partner(s)).
Operates the robot from outside the jetting area.
Operates the emergency shut-off on the robot.
Pump engineer
Trained, educated, and certified according to local requirements.
Monitors the proper operation of the pumping unit and supply of high-pressure water.
Operates the emergency shut-off on the high-pressure system.
Monitors the jetting area and is in visual and/or audio contact with the operator.
5.3.2. Before starting
Always perform an LMRA in the following three steps:
Recognizing potential dangers that could be present despite all the measures taken.
Employees should first ask themselves if they are risking exposure to these dangers. They must not start the
work if they believe the risks are unacceptable.
Thinking up solutions or measures to remove the perceived risks or make them acceptable.
Taking measures to let them carry out the work activities safely. The employee carries out the required
control measures to eliminate or control the dangers. If necessary, they should ask for help in achieving this.
An LMRA never stops. It is a continuous awareness of the steps before performing a task or following a procedure.
Always secure the robot against falling with appropriate and certified fall arrest equipment.
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In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
When the robot does fall it may hit other objects, obstacles, or humans. Any consequent damage, injuries,
or cost resulting from inappropriate use and/or falling of the robot is NOT the responsibility of VertiDrive.
VertiDrive cannot be held liable for damages, injuries, or costs resulting from inappropriate use.
Before usage, mark an area- with yellow / black ribbon to ensure a distance to the robot of at least 6 meters. This
area should not be entered without the operator's permission and never when the robot is operating. Ensure proper
warnings by placing visual signage where necessary.
Caution should be taken when plugging and unplugging the power supply. Appropriate and approved power
cables must be used.
Before the use of the VertiDrive V400 Series robot, the user / operator must perform a check, see 3.4 F-03 Startup
Checklist. Initial training of users / operators is provided by VertiDrive and or VertiDrive certified trainers, upon delivery
of a new robot.
The robot can ONLY be used on a magnetic surface (steel) as the reaction force of the application can make the
robot jump up otherwise! The magnets will prevent this when it is placed on a magnetic surface and allows for safe
operation.
The UHP hydro-blast equipment on the robot will make loud noise. Always use appropriate hearing protection.
To decrease the weight to be carried by the robot, the umbilical cable, and hoses can be attached to a winch
safety line. See the VertiDrive transport frame manual for details and safety information.
5.3.3. During operation
Always keep visual contact with the robot during usage.
Never enter the area directly underneath the robot, keep a minimum 6-meter distance. Be aware: If the
robot falls it may swing towards the operator and or other people in the vicinity.
Always use protective clothing and appropriate facial protection.
Before approaching the robot or when in close vicinity make sure the power is safely turned off by pushing
the red emergency stop button on either the remote control or the control box.
When the robot system is NOT in use always switch off power (main switch on control box).
Ensure that the operator is not distracted while operating.
Keep at least 6 meters distance from the robot when activated (yellow system status LED on).
Always pay attention to the umbilical and hoses on the floor, as these present a risk of tripping.
5.3.4. During maintenance / service
Always unplug the main power cable to the control box before starting any maintenance or service activity.
When working on the robot extra caution should be taken to avoid close proximity and more specifically
direct contact between steel tools and the magnets. The magnets are extremely strong and can result in
very high attraction forces on the steel tools. When body parts are trapped between the tool and the
magnet, this can cause serious injuries. Use non-magnetic tools when possible.
Ensure a safe distance between the magnets and any sensitive electronic and mechanical equipment like
cell phones, watches, and (bank) cards with magnetic strips.
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 15 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
Safety provisions
5.4.1. Emergency stop
Dangerous or undesirable situations may arise during the usage of the robot. A minimum of two emergency stops
are provided to immediately stop the operation and provide a safe situation:
For the robot system one emergency stop is available on the remote control and a second emergency stop
is placed on the control box. Activating either of these two emergency stops will immediately stop all robot
movements and the signal to the pump will be deactivated.
A separate emergency shut-off must be available on the high-pressure water system.
Depending on the working method and the circumstances, the emergency stops may be operated by the pump
engineer, operator, or additional emergency stop operator. Always follow instructions as provided by the equipment
supplier.
The emergency stops on the remote control and on the control box:
Stops all movements of the robot.
The adhesion of the robot to the surface will not be influenced (due to the use of permanent magnets).
The emergency stops on the high-pressure system:
Shuts off the high-pressure supply to the robot.
5.4.2. Wall contact sensor (WCS)
The robot is equipped with a wall contact switch. In case the robot loses contact with the (steel) surface, the wall
contact switch acts as an emergency shut-off for the robot system. For safe operation it is critical that this event
triggers the emergency stop of the pump as well. Refer to chapter “Installation” for how to connect the robot control
system to the pump. VertiDrive strongly recommends always integrating the pump control, including safety stop, with
the robot control system.
5.4.3. Whip checks
For machine operator protection whip-checks must be used on the UHP hydro-blast hoses to prevent hoses from
becoming fully detached from the machine and flying around if the connection inadvertently separates. These whip-
checks can be supplied by VertiDrive, or by a third party.
Hearing protection
The UHP hydro-blast equipment of the V400 Series robot will create significant noise: If the process causes a noise
level that exceeds 80 dB(A), the operation and any other personnel in the vicinity of the robot should wear hearing
protection.
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 16 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
Risk for personal injury
5.6.1. Electrocution / Electric shock
Where When Precaution Warning sign / Action sign
Control box. When the control box
is opened for
maintenance or
troubleshooting.
Always disconnect the main
power cord.
All electric cables. When moving the
cables around.
Always disconnect the main
power cord.
5.6.2. Electrical safety earth
Where When Precaution Warning sign / Action sign
Control box. Always. Never make any changes to
the control box and ensure
the power supply has a
proper earth connection.
5.6.3. Cuts, injuries on head and feet
Where When Precaution Warning sign / Action sign
Near robot. Always. Wear safety boots.
Near / underneath
robot.
During the operation
of the robot.
Wear a safety helmet.
Handling robot. During handling of
the robot.
Wear protective gloves.
5.6.4. Injuries on face and eyes
Where When Precaution Warning sign / Action sign
Near robot UHP
hydro-blast
equipment.
During operation with
UHP hydro-blast
equipment.
Keep at least 6 meters
distance.
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 17 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
5.6.5. Hearing damage
Where When Precaution Warning sign / Action sign
Near robot UHP
hydro-blast
equipment.
During operation with
UHP hydro-blast
equipment.
Wear hearing protection.
Always when noise level
exceeds 80 dB(A).
5.6.6. Liquid injection by UHP water jet
Where When Precaution Warning sign / Action sign
Near robot, hoses,
and UHP pump.
During operation with
UHP hydro-blast
equipment.
Wear protective clothing.
5.6.7. Crushing hand
Where When Precaution Warning sign / Action sign
Near moving parts
of the robot.
During magnet
adjustment and robot
movement.
Keep clear of all moving
parts, power off system for
any maintenance or service
activity.
5.6.8. Magnetism
Where When Precaution Warning sign / Action sign
Near magnets. During handling,
adjustment &
maintenance.
Use non-magnetic tools,
when possible, keep safe
distance from magnets and /
or shield magnets with e.g.,
wooden cover.
Near magnets Always. Do not approach the robot if
you have a pacemaker or
implanted heart defibrillator.
Keep minimum 60 cm
distance.
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 18 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
6. SYSTEM DESCRIPTION
General
The VertiDrive V400 Series robot is a remote-controlled vehicle containing strong permanent magnets that can work
on flat or slightly curved steel surfaces at any angle, e.g., vertically, or underneath a horizontal surface (upside down).
The robot is equipped with UHP hydro-blast equipment and is typically used for various degrees of surface cleaning
and surface preparation. The system consists of the robot, a (50m) umbilical cable, and a control box with remote
control. This chapter describes all system components in detail.
VertiDrive also offers options like a transport frame and a winch system. These products are only briefly mentioned in
this manual. For further details, please refer to the respective user manuals.
V400 Series robot
V400 Series robot
The robot provides the following functionalities:
Adhesion to the surface by two front magnets located next to the large wheels and a smaller magnet at the
back (between the caster wheels).
High traction and movement over the steel surface by the two large front wheels.
Controlled movement of the UHP hydro-blast equipment by remote control.
Protection of the robot by a fall guard, with attachment points for the fall arrester cable.
For a full detailed description of the robot assembly and part identification, see the Illustrated parts manual supplied
with the robot (322025 V400 Series Robot – IPM).
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 19 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
Control box (incl. optional transport frame)
Control box (shown with cooling option and optional transport frame)
# Part Description
01 Power indicator The green light turns on when the system is powered on.
02 System status indictor Yellow light turns on when the remote is connected and the system is
activated (ready for use). Light blinks when wall contact switch (WCS) is not
detecting a metal surface (all robot movement stops).
03 Drive fault indicator Red light turns on when a fault is detected in the motor drive circuit, see
troubleshooting section (chapter 10).
04 Emergency stop Button to shut-off the system in case of emergency, stops all movements.
05 Power switch Switches main power on / off.
06 Winch connectors Connectors for power and signals to the winch cabinet (optional).
07 Support legs Supports transport frame and prevents it from tipping over.
08 Winch cabinet Contains hardware to control the winch motors (optional).
09 Transport frame lever For moving the transport frame manually.
10 Mains & Pump connectors Connectors for mains power and connector to activate the UHP pump.
11 Robot umbilical connector For connecting the umbilical to the robot.
12 Door locks For opening and closing the control box.
13 Cooler module Cooling unit for use in high temperature environments (optional).
14 Cable winders Storage option for the umbilical on the transport frame.
15 Antenna For working distance up to 100m. Can be extended with extension kit.
16 WCS overrule Button to overrule the wall contact switch in case of emergency, see
troubleshooting section.
17 Operation hours counter The counter shows the hours of operation of the robot system.
For detailed information about the transport frame and / or winch system please consult the user manual for the
respective product.
VERTIDRIVE B.V. | GIETERIJWEG 15 | 3089 JZ ROTTERDAM | THE NETHERLANDS - 20 -
CHAMBER OF COMMERCE 24448205 | VAT NL 8201.77.064.B01
In all cases where we act as provider or supplier, our offers, orders placed with us, and agreements concluded with us are subject to the conditions and requirements laid down by the Netherlands Metal Association (the ‘Metaalunievoorwaarden’).
These conditions and requirements are filed with the registrar of the District Court of Rotterdam.
Remote control
The robot is controlled by a wireless remote with the following functions and controls.
Hetronic Nova XL remote control
01 02 03 04 05 06 07
08 09
11
10 11 12
14
13 15
16
Table of contents
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