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Opex Sure Sort Operator's Manual

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Table of Contents

  • English

  • Français

    • Chapter 2 
      • Safety
        • Introduction
        • Safety Guidelines
        • Consignes de Sécurité - Traduction Française
        • Machine Labels
          • Induct Conveyor Module Labels
          • Return Conveyor Module Labels
          • Scan Tunnel Labels
          • Base Stacker Module Labels
          • Expansion Module Labels
          • Ibot Labels
          • Ultracapacitor Product Information
        • Emergency Stops and Interlock Switches
          • Emergency Stop Buttons (E-Stops)
          • Interlock System
          • Emergency Exit Handle
          • Reset Buttons
        • Light Tower
        • Lockout-Tagout (LOTO) Procedures
          • What Is Lockout-Tagout
          • Lock-Out/Tag-Out Devices Required
          • LOTO - Machine Maintenance and Repair
          • Fully De-Energizing AC Power (Plug-In Machines)
          • Fully De-Energizing AC Power (Hard-Wired Machines)
          • LOTO - Clearing Jams and Removing Ibots
          • Restoring the Machine to Normal Operation
        • Ergonomics
        • Personal Protective Equipment
      • Overview
        • System Overview
        • Options and Configurations
          • Base Configuration
          • Options
        • How Sure Sort™ Works
          • OPEX Host Software
          • OPEX Induct ELC
          • The Optional OPEX Barcode Tunnel
          • Fix-Mount Scanner
          • Pack-To-Light Feature
          • Stop Light Feature
        • Specifications
          • Basic Configuration
          • Material Handling (Inventory Items)
          • Options
          • Module Dimensions
          • Environmental Specifications
        • Equipment Layout and Required Floor Space
        • Electrical Requirements - North American
        • Electrical Requirements - Europe (EU)
        • Electrical Requirements - Japan
        • Wireless Transceiver
          • FCC Information / Informations FCC
          • Industry Canada Information / Industrie Canada L'information
        • Regulatory Compliance Testing
          • Standards that Equipment was Evaluated against
          • FCC Standards
        • Equipment Serial Number Locations
      • Operation
        • Overview
          • Order of Operation
          • Turning the Power On/Off
          • Logging in to the Host Software
          • Navigating the Host Software
          • Run Screen Details
          • Information Tabs
          • Clearing Jams
        • Product-Related Jams
        • Toggling between the Host & Inductelc Software
      • Chapter G Glossary
        • List of Acronyms
        • List of Terms

    • Chapter 3 

    • Chapter 4 

    • Chapter 5 
      • Overview
      • Creating Reports
        • Setting the Time Range
      • Reject and Jam Definitions
        • Rejects
        • Jams
        • Safety-Related Jams

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

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Summary of Contents for Opex Sure Sort

  • Page 1 © 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...
  • Page 2 Fax: +1 856.727.1955 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: GroupTechwriters@opex.com For help with opexservice.com website-related issues, please contact the OPEX Web Developers via email at: GroupWebDev@opex.com...
  • Page 3 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 EU Declaration of Conformity Sure Sort™ Operator Manual OPEX Corporation...
  • Page 4 Page 101 - Compliance specs updated Page 107 - corrected machine S/N location figure; Page 109 updated label - “lockout switch” changed to “main Page 114 disconnect switch” handle (continued next page) Document History Sure Sort™ Operator Manual OPEX Corporation...
  • Page 5 - warning about hard-wiring Page 101 removed - Added Japan electrical specs Page 103 - Estop restart: increased heading; added Page 63 step w/reference to LOTO. 19-07 May 16, 2019 (continued next page) Document History Sure Sort™ Operator Manual OPEX Corporation...
  • Page 6 & hard-wired 19-07 May 16, 2019 procedures. - Condensed opening statement. Page 75 - Clarified step 5 interlock delay ensures Page 78 iBOTs stopped - Added “remove caution sign” Page 81 Document History Sure Sort™ Operator Manual OPEX Corporation...

  • Page 7: Table Of Contents

    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 Table of Contents Sure Sort™ Operator Manual OPEX Corporation...
  • Page 8 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.
  • Page 9 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 Table of Contents Sure Sort™ Operator Manual OPEX Corporation...
  • Page 10 (Page intentionally blank) Table of Contents Sure Sort™ Operator Manual OPEX Corporation...
  • Page 11 1.1.1. Manual navigation aids ....... . 13 1.1.2. Safety message conventions......14 Sure Sort™ Operator Manual...

  • Page 12: Introduction

    • 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...

  • Page 13: Manual Navigation Aids

    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 Sure Sort™ Operator Manual OPEX Corporation...

  • Page 14: Safety Message Conventions

    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). See important safety information in Chapter 2: “Safety“. Introduction Sure Sort™ Operator Manual OPEX Corporation...

  • Page 15: Safety

    2.8. Ergonomics ......... . . 82 2.9. Personal Protective Equipment......83 Sure Sort™ Operator Manual...

  • Page 16: Introduction

    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.

  • Page 17: Safety Guidelines

    - The Keep loose objects away from any exposed, moving parts of the machine 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.

  • Page 18: Consignes De Sécurité - Traduction Française

    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 Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 19 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.
  • Page 20 - Cet équipement ne convient pas aux endroits où Tenir à l'écart des enfants les enfants sont susceptibles d'être présents. Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 21: Machine Labels

    2.4. Machine Labels Labels are used in specific locations throughout the Sure Sort to alert you to certain safety hazards and provide important information about the machine. These labels may appear in various languages or styles depending on the region or country where the machine is operating: •...

  • Page 22: Induct Conveyor Module Labels

    Front of induct conveyor near operator station (Table 2-1). Location: Advises personnel to read Instruction Manual for safe use. Purpose: Table 2-1: Safe use notice label Label location Description English/Spanish (8074300) Front of induct module English/French (8074310) EU (8074330) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 23 2.4.1.2. E-Stop ring label Front of induct conveyor near operator station (Table 2-2).  Location: Draws attention to location of Emergency Stop button. Purpose: Table 2-2: E-Stop Ring label Label location Description All (8156400) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 24 Advises purchaser of machine to follow all arc flash and Purpose: electrical safety requirements per applicable standards. Table 2-3: Arc Flash and Shock Hazard label Label locations Description English/Spanish (8165700) Left front panel of Induct module English/French (8165710) EU (8165730) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 25 Warns about electrical hazard inside, and to disconnect power before Purpose: removing panel. Table 2-4: Shock Hazard label Label locations Description Operator Side English/Spanish (8170100) Rear Side English/French (8170110) End panel of Induct module EU (8170130) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 26 Warns that the machine can only accept items up to 5 lbs. (2.27 kg) Purpose: maximum. Table 2-5: Weight limit label Label location Description English/Spanish (8159900) Rear wall of Induct module English/French (8159910) EU (8159930) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 27 AC distribution enclosure, rear (Table 2-6).  Location: Identifies protective earth cable connection point for Canadian Purpose: machines. Table 2-6: Ground Symbol label Label locations Description Back of the AC Power Enclosure ALL (P24835-01) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 28 Warns about residual electrical hazard inside, and to disconnect UPS Purpose: power before servicing. Table 2-7: UPS voltage warning label Label locations Description English/Spanish (8136300) Rear of Induct module English/French (8136310) EU (8136330) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 29 Purpose: Table 2-8: Power cord caution label Label locations Description English/French only (8166500) High leakage Current Earth connecton essential before connecting supply Courant de Fuite élevé Terre connecton indispensable avant de connecter l'alimentation Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 30 Rear wall of conveyor near monitor (Table 2-9).  Location: Identifies product electrical ratings, machine serial number, NRTL Purpose: logo for U.S. & Canada; CE for EU. Table 2-9: Ratings/Serial Number label Label locations Description English only (8160200) EU (8160230) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 31 30).  Rear wall of conveyor near monitor (Table 2-9 on page Location: Identifies product electrical ratings, machine serial number for Japan Purpose: 60Hz or 50Hz machines. Japan 60Hz (8160240) Japan 50Hz (8160245) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 32 Warns about electrical hazard inside, and to disconnect power before Purpose: opening enclosure. Table 2-10: Shock Hazard warning label Label locations Description Front of Safety Enclosure English/Spanish (8159700) English/French (8159710) Front of I/O Enclosure EU (8170130) Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 33: Return Conveyor Module Labels

    Location: panel latch (Table 2-11).  Warns about electrical hazard inside, and to disconnect power before Purpose: opening panel. Table 2-11: Shock Hazard label Label locations Description English/Spanish (8170100) English/French (8170110) EU (8170130) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 34 Location: Warns about pinch hazards at gaps near conveyor belt. Purpose: Table 2-12: Pinch point hazard label Label locations Description End of return conveyor on front wall and left side panel All (1637200) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 35 Table 2-13: Return Conveyor Height Adjustment label Label locations Description Right Side adjustment, All (8166600) Back of return conveyor p/n 8166600 Rev A Left Side adjustment, All (8166700) Right Side label Left Side label p/n 8166700 Rev A Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 36 2.4.2.4. Serial Number label Return conveyor rear (Table 2-14).  Location: Indicates base machine serial number. Purpose: Table 2-14: Serial number label Label locations Description SURE SORT SS00081 Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 37: Scan Tunnel Labels

    Front of electrical relay housing (Table 2-15).  Location: Warns about electrical hazard inside, and to disconnect power before Purpose: opening enclosure. Table 2-15: Scan Tunnel - Shock Hazard warning label Label locations Description English/Spanish (8159700) English/French (8159710) EU (8170130) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 38 2.4.3.2. Serial Number label Front of electrical relay housing (Table 2-16).  Location: Associates module with machine. Purpose: Table 2-16: Serial number label Label locations Description SURE SORT SS00081 Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 39 Advises purchaser of machine to follow all arc flash and electrical Purpose: safety requirements per applicable standards. Table 2-17: Arc Flash and Shock Hazard label Label locations Description English/Spanish (8165700) Scan Tunnel IO boxes English/French (8165710) Scan Tunnel relay housing EU (8165730) Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 40: Base Stacker Module Labels

    Electrical enclosure access cover, floor of base stacker module Location: (Table 2-18). Warns about electrical hazard inside, and to disconnect power before Purpose: opening enclosure. Table 2-18: Shock Hazard Warning label Label locations Description English/Spanish (8159700) English/French (8159710) EU (8170130) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 41 On the thin side panel of the machine at the Induct conveyor side of the base stacker module. English/French (7686210) On the side panel, on the right side of the machine. EU (7686230) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 42 Caution to keep hands away from interior of machine due to crush Purpose: hazard from moving parts. Table 2-20: Crush Hazard label Label locations Description English/Spanish (7686000) Center above left track upright. English/French (7686010) EU (7686030) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 43 Reset button housing, next to front and rear door (Table 2-21).  Location: Identifies Reset button. Purpose: Table 2-21: Reset label Label locations Description Front Door Location English/Spanish (8159600) English/French (8159610) Rear Door Location EU (8159630) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 44 Right side of reject bin enclosure; column behind return conveyor Location: (Table 2-22).  Draws attention to location of Emergency Stop button. Purpose: Table 2-22: E-Stop Ring label Label location Description All (8156400) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 45 Instructs how to open the door to exit the machine. Purpose: Table 2-23: “PUSH TO OPEN” label Label locations Description English/Spanish (8075400) Inside handle, front and rear stacker door English/French (8075410) EU (8075430) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 46 Warning that entry into the machine is not permitted except by Purpose: authorized personnel. Table 2-24: Access Forbidden warning label Label locations Description English/Spanish (8074400) Front and rear stacker door English/French (8074410) EU (8074430) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 47 Exterior of front and rear stacker door (Table 2-25).  Location: Instructs authorized personnel how to open the door. Purpose: Table 2-25: Delayed Access label Label locations Description English/Spanish (8164100) Front and rear stacker door English/French (8164110) EU (8164130) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 48 NON PERMIT NON PERMIT CONFINED CONFINED SPACE SPACE AVISO AVIS NO PERMISO ESPACE ESPACIO CONFINÉ CONFINADO SANS PERMIS p/n 8167330 RevA p/n 8167300 RevA p/n 8167310 RevA Figure 2-2: Confined Space Notice label Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 49 (2) this device must accept any interference received, including interference that may cause undesired operation. ® Contains FCC ID: VDM2054710 Contains IC: 7175A-2054710 Model: 205471010 OPEX Corporation Japan only: MIC registration (7682640) Safety Sure Sort™ Operator Manual...

  • Page 50: Expansion Module Labels

    Cautions not to climb structure due to falling hazard. Purpose: Table 2-27: Falling Hazard label Label locations Description English/Spanish (7686200) Expansion end module, right side English/French (7686210) Expansion end module, left side EU (7686230) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 51 Electrical enclosure access cover, floor of stacker module (Table 2- Location: 28). Warns about electrical hazard inside, and to disconnect power before Purpose: opening enclosure. Table 2-28: Shock Hazard Warning label Label locations Description English/Spanish (8159700) English/French (8159710) EU (8170130) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 52 Caution to keep hands away from interior of machine due to crush Purpose: hazard from moving parts. Table 2-29: Crush Hazard label Label locations Description English/Spanish (7686000) Expansion module, left side English/French (7686010) Expansion module, right side EU (7686030) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 53 Last expansion module, left and right side (Table 2-30).  Location: Draws attention to location of Emergency Stop button. Purpose: Table 2-30: E-Stop Ring label Label location Description End expansion module, left side All (8156400) End expansion module, right side Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 54 2.4.5.5. Serial Number label Bottom frame structure, each expansion module (Table 2-31).  Location: Associates module with machine. Purpose: Table 2-31: Serial number label Label locations Description SURE SORT SS00081 Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 55: Ibot Labels

    (Table 2-32).  Location: Identifies iBOT associated with machine. Purpose: Table 2-32: iBOT Serial Number label Label locations Description Center front of iBOT All (7242807) Left side of chassis, as viewed from rear of iBOT Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 56 2.4.6.2. iBOT Control Panel label iBOT control panel, front of iBOT (Table 2-33).  Location: Identifies indicator lights and switches. Purpose: Table 2-33: iBOT Control Panel label Label locations Description All languages (7242710) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 57 2.4.6.3. iBOT Stored Energy Caution label iBOT bottom safety cover (Table 2-34).  Location: Cautions personnel about stored electrical charge inside. Purpose: Table 2-34: iBOT Stored Energy label Label locations Description English/Spanish (8157500) English/French (8157510) EU (8157530) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 58 Cautions personnel about hazardous substance contained inside. For Purpose: additional information on ultra-capacitor safety, refer to “Ultracapacitor product information” on page Table 2-35: iBOT Chemical hazard label Label locations Description English/Spanish (8156300) English/French (8156310) EU (8156330) Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 59 (2) this device must accept any interference received, including interference that may cause undesired operation. ® Contains FCC ID: VDM2054710 Contains IC: 7175A-2054710 Model: 205471010 OPEX Corporation Japan only: MIC registration (7682640) Safety Sure Sort™ Operator Manual...

  • Page 60: Ultracapacitor Product Information

    3KRQH     )D[       6KDQJKDL  35 &KLQD )D[     3KRQH     LQIR#PD[ZHOOFRP ± ZZZPD[ZHOOFRP )D[     Document #1004596.4 Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 61: Emergency Stops And Interlock Switches

    Figure 2-3) can be used to stop the machine in an emergency. One E-Stop is located at the operator station of the Sure Sort, and another behind the return conveyor. If necessary, push one of the E-Stops and the machine will stop immediately.
  • Page 62 (box mounted) E-Stop button with red activation indicator light Side 100 front Side 200 front Side 200 front (reject bin enclosure): E-Stop button with red activation indicator light Figure 2-4: Stacker E-Stop locations Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 63 9. If the front and/or rear stacker door was opened, press the Reset button to reset the interlock. 10. In the Run screen of the host software, clear the jam and restart the machine. Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 64: Interlock System

    WARNING Door interlock switches do not remove power from all electrical devices within the Sure Sort. Power to the computer and other AC devices such as power supplies remains energized after an interlock has been opened. To remove all power from the machine, follow the “Lockout-Tagout (LOTO) Procedures”...
  • Page 65 Figure 2-6: Door interlock LED Before the machine can be restarted, an Authorized Employee must confirm that no one is inside the aisle and then push the blue Reset button (see “Reset Buttons” on page Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 66: Emergency Exit Handle

    An emergency exit handle (egress) is located on the inside of both the front and rear stacker doors (see Figure 2-7). Simply push the handle to open the door and exit the stacker section. Figure 2-7: Emergency Exit (Egress) handle Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 67: Reset Buttons

    Authorized Employee must visually confirm that no one is inside the aisle and then reset the machine by pushing the Reset button. Reset button rear Reset button Reset button front Figure 2-8: Reset button locations Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 68: Light Tower

    Figure 2-9. No Lights - Idle/Off Red - E-Stop/Interlock Yellow - Jammed Blue flashing - Starting Green - Running Beeping Audible - Starting Figure 2-9: Light tower color coding Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 69: Lockout-Tagout (Loto) Procedures

    (see examples in Figure 2-10). The LOTO devices must only be removed by the Authorized service personnel, once they determine that the work is complete and the machine is safe to operate. Figure 2-10: Examples of LOTO devices installed Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 70: Lock-Out/Tag-Out Devices Required

    Full de-energization of AC power is required in, but not limited to, the following situations: • machine assembly, dismantling or relocation • performing maintenance or repairs to the main AC distribution enclosure Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 71 North America, EU and Japan. Installation instructions are located in “Fully de-energizing AC power (plug-in machines)” on page For North American machines and Japanese machines with plug For EU machines Figure 2-12: Power cord lockout device Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 72: Loto - Machine Maintenance And Repair

    2.7.3. LOTO - Machine maintenance and repair This procedure should only be performed by an Authorized Employee. It describes how to shut down and lock out the Sure Sort when maintenance or repair by an authorized service technician is required.
  • Page 73 Open hasp and attach it to tab of handle..then close hasp, so that a padlock can be attached through one of the six holes Hasp attached to disconnect switch handle Figure 2-15: Hasp detail Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 74 (Figure 2-16). The key must be kept in the possession of that person. Figure 2-16: Lockout tab with hasp, padlock and tag Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 75: Fully De-Energizing Ac Power (Plug-In Machines)

    “LOTO - Machine maintenance and repair” on page 2. Disconnect the AC main power cord from the receptacle. 3. Install the OPEX lockout device over the AC plug as follows (refer to Figure 2-17 on page 76): a. Place the AC plug inside the device and close the device. Slide the two halves of the device as directed on the cover to lock them together (refer to the arrows and labels on the device).
  • Page 76 Device for North American machines: Device for EU machines: Figure 2-17: OPEX lockout devices Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 77: Fully De-Energizing Ac Power (Hard-Wired Machines)

    AC power. At some customer sites, the Sure Sort is hard-wired to a dedicated AC main disconnect switch located near the machine. To safely de-energize the Sure Sort AC Distribution enclosure, the incoming power must be shut off by turning off and locking out the customer’s main disconnect switch.

  • Page 78: Loto - Clearing Jams And Removing Ibots

    Door interlock switches do not remove power from all electrical devices within the Sure Sort. Power to the computer and other AC devices such as power supplies remains energized after an interlock has been opened. To fully power down the machine, see “LOTO - Machine maintenance and repair”...
  • Page 79 Insert hasp here Figure 2-19: Door interlock detail 6. Insert a hasp into the hole in the door handle (Figure 2-20). Figure 2-20: Hasp in door handle Safety Sure Sort™ Operator Manual OPEX Corporation...
  • Page 80 Figure 2-21: Padlock and hasp on door handle 8. Make sure that: a. The interlock LED is on to indicate interlock is open (see Figure 2-22). b. The door will not close. Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 81: Restoring The Machine To Normal Operation

    7. Restore equipment to service, and verify that the machine is safe to operate. 8. Notify operators and affected persons that LOTO devices have been removed and equipment is now ready for use. Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 82: Ergonomics

    Listed below are some guidelines to help you minimize the risk of physical discomfort and injury while operating the equipment. NOTICE Always observe the following guidelines when operating the Sure Sort. When at the main operator station: • Maintain an upright body posture.

  • Page 83: Personal Protective Equipment

    Personal protective equipment (PPE) refers to wearable safety items such as gloves, safety glasses, hard hats, and high-visibility vests. Sure Sort falls within Arc Flash PPE Category 1 for Alternating Current (AC) systems. The following PPE items are advised for Arc Flash Category 1: •...
  • Page 84 (Page intentionally blank) Safety Sure Sort™ Operator Manual OPEX Corporation...

  • Page 85: Overview

    3.2.2. Options ..........89 3.3. How Sure Sort™ Works ....... . . 91 3.3.1.

  • Page 86: System Overview

    Optional Stop Light Feature (per column) Light Tower Light Tower Optional Return Conveyor Reject bin enclosure Optional OPEX Scan Tunnel iBOT loading area Host Computer/UPS Operator Station Delivery bins iBOT Figure 3-1: Main Components Overview Sure Sort™ Operator Manual OPEX Corporation...
  • Page 87 (under the OPEX Scan Tunnel) Overheight detector Pacing conveyor belts Pacing sensor Overheight optical sensor Image entry sensor Optional Line scanner (located inside OPEX Scan Tunnel) Overheight mechanical sensor Figure 3-2: Induct module - view from behind Overview Sure Sort™ Operator Manual OPEX Corporation...
  • Page 88 Chapter 2: “Safety“ operate this equipment. The OPEX Sure Sort™ is a sorting system that delivers a wide variety of items into a compact array of order bin locations in a single pass. ® Sure Sort™ employs robotic wireless vehicles known as iBOTs as its efficient means of delivery.

  • Page 89: Options And Configurations

    3.2. Options and Configurations 3.2.1. Base Configuration The Sure Sort™ base system, shown in Figure 3-3, includes: • A Host computer: ® - Microsoft Windows10 pro / 64bit / 8Gb / Raid1 SSD drives • Induct conveyor module • Stacker base module with bins (available in depths of 4”, 7”...
  • Page 90 Note: Bins may appear differently than those depicted in Figure 3-4. Figure 3-4: Expansion modules - The Sure Sort can support a total of 22 iBOTs (Figure 3-5). Additional iBOTs Figure 3-5: Sure Sort iBOT Overview Sure Sort™...

  • Page 91: How Sure Sort™ Works

    3.3. How Sure Sort™ Works The Sure Sort™ system uses two software applications installed on the OPEX host computer to control and run the system: the Host software and the OPEX Induct ELC (External Link Component). Here’s how they interact with the external Warehouse Management System (WMS): 1.

  • Page 92: Opex Host Software

    3.3.1. OPEX Host software The OPEX Host software (Figure 3-6) provides the operator’s main interface with the system’s controls. Use the Host software to select and run the machine, and view statistical reports. Figure 3-6: OPEX Host software Behind the scenes, the OPEX Host software communicates with the Controller (InTime).

  • Page 93: Opex Induct Elc

    3.3.2. OPEX Induct ELC The OPEX Induct ELC (External Link Component) shown in Figure 3-7, is a separate application which interfaces between the Sure Sort host application and the WMS. The Induct ELC also communicates with the optional scanners (the OPEX tunnel, wand, and fix-mount scanner). The ELC communicates with the WMS to receive bin destinations.

  • Page 94: The Optional Opex Barcode Tunnel

    3.3.3. The Optional OPEX Barcode Tunnel The optional OPEX barcode tunnel is an array of cameras meant to read barcodes from items on the imaging conveyor, regardless of their orientation (Figure 3-8). The OPEX tunnel uses seven cameras above the...

  • Page 95: Fix-Mount Scanner

    Figure 3-10: Pack to Light feature The PTL lights can be programmed to appear in a continuous solid color or blink. They can also blink alternating between two colors. Overview Sure Sort™ Operator Manual OPEX Corporation...

  • Page 96: Stop Light Feature

    In the example shown in Figure 3-11, only three bins per column were used, so the fourth light ring is disabled. Figure 3-11: Stop Light Feature Overview Sure Sort™ Operator Manual OPEX Corporation...

  • Page 97: Specifications

    Up to 22 Delivery Bins 4” (10.16 cm), 7” (17.78 cm), 12” (30.48 cm) Throughput Scalable up to 2,400 items/hour • 6-Sided Automated OPEX Scan Tunnel Barcode Readers • Fixed Mount Reader • Hand Scanner Automated Return Items recalled by WMS are returned for...

  • Page 98: Module Dimensions

    Note: Weights marked with an asterisk (*) include a maximum of 350 lbs per column per side, or 50 lbs of product per bin at 7 bins per column per side if anchored to the floor. Otherwise, the maximum per-column weight is 100 lbs. Overview Sure Sort™ Operator Manual OPEX Corporation...

  • Page 99: Environmental Specifications

    TÜV Rheinland (for U.S. and Canada), Agency approvals CE, FCC Average exposure levels based on multi-position sound measurements taken of a Sure Sort with 11 expansion modules*: • Overall range: 78.4 dB - 60.1 dB Noise emissions • Operator station (Induct module front): 74.3 dB Leq...

  • Page 100: Equipment Layout And Required Floor Space

    2. Allow for at least 36” (91.4 cm) walking/working space around all sides of machine. 3. There must be 18” (45.7 cm) minimum clearance from top of machine to any sprinklers in the area. Figure 3-12: System footprint Overview Sure Sort™ Operator Manual OPEX Corporation...

  • Page 101: Electrical Requirements - North American

    3.6. Electrical Requirements - North American North American Sure Sort units require an AC line voltage of 120/208 VAC, single phase, 60Hz (2 Lines + Neutral + Ground to Earth). • Line to Line voltage = 208VAC +6%/-10% • Line to Neutral voltage = 120VAC +6%/-10% The machine is supplied with a 15 ft.

  • Page 102: Electrical Requirements - Europe (Eu)

    3.7. Electrical Requirements - Europe (EU) European Sure Sort units require an AC line voltage of 230 VAC, 1-phase, 50 Hz (Line + Neutral + Protective Earth). • Line to Neutral voltage = 230VAC +10%/-10% The machine is supplied with a 15 ft. (4.57 m) length of 10/3 HAR Cord with an IEC 309 Pin type plug (Walther Electric #230306), connected to the AC distribution enclosure of the Induct conveyor module.

  • Page 103: Electrical Requirements - Japan

    FOR GROUND BOND/ HI-POT TEST USE HUBBELL # HBL2713 RECEPTACLE MACHINE SIDE Machine ships with: NEMA L14-30P PLUG 30A 125/250V UL/CSA 2 (2) HP MACHINE (HUBBELL # HBL2711) Figure 3-15: Japan electrical requirements Overview Sure Sort™ Operator Manual OPEX Corporation...

  • Page 104: Wireless Transceiver

    The wireless transceiver antennae must not be modified or, replaced with that of a different type. Changes or modifications not expressly approved by OPEX Corporation could void the user’s authority to operate the equipment. Module cannot be co-located with other antenna or transmitter except as specified in the grant condition of equipment authorization;...

  • Page 105: Industry Canada Information / Industrie Canada L'information

    This device complies with Industry Canada’s license-exempt RSSs. Operation is subject to the following two conditions: 1. This device may not cause interference; and 2. This device must accept any interference, including interference that may cause undesired operation of the device. Overview Sure Sort™ Operator Manual OPEX Corporation...
  • Page 106 1. Ce dispositif ne peut causer des interférences; et 2. Ce dispositif doit accepter toute interférence, y compris les interférences qui peuvent causer un mauvais fonctionnement de l'appareil. IC : 7175A-2054710 Model 2048910 Overview Sure Sort™ Operator Manual OPEX Corporation...

  • Page 107: Regulatory Compliance Testing

    3.10. Regulatory Compliance Testing Note: As Sure Sort is tested against local and international standards, we will update this listing. 3.10.1. Standards that equipment was evaluated against: 2006/42/EC Machinery Directive 2014/53/EU Radio Equipment Directive 2014/30/EU Electromagnetic Compatibility Directive Electromagnetic compatibility (EMC). Generic EN 61000-6-2: 2005 standards.

  • Page 108: Fcc Standards

    2483.5 MHz, and 5725-5850 MHz. FCC 47CFR PT 15 SPT B - Title 47 CFR Part 15 Subpart B: Unintentional Radiators RSS 210 - Low Power License-Exempt Radiocommunication Devices (All Frequency Bands) - Category I Equipment Overview Sure Sort™ Operator Manual OPEX Corporation...

  • Page 109: Equipment Serial Number Locations

    Before contacting OPEX Technical Support, the Authorized Employee should locate the Service Tag on the machine so that they can provide the assisting OPEX Technician with the machine Serial Number (Figure 3-16) and/or iBOT serial number (Figure 3-17). See contact information on...
  • Page 110 The iBOT Serial Number label can be found on the iBOT’s chassis in two places, as shown in Figure 3-17. Center front of iBOT Left side of chassis, as viewed from rear of iBOT Figure 3-17: iBOT serial number location Overview Sure Sort™ Operator Manual OPEX Corporation...

  • Page 111: Operation

    4.2. Product-related jams ........134 4.3. Toggling between the Host & InductELC software ..137 Sure Sort™ Operator Manual...

  • Page 112: Overview

    4.1. Overview As shown in Figure 4-1, most functions of the Sure Sort™ system are accessible from the operator station, where the operator is within easy reach of the conveyor and the touchscreen monitor. The host computer displays the screens for the operator’s main interface with the Sure Sort™ system.

  • Page 113: Order Of Operation

    Sure Sort sends the barcode to the customer’s Warehouse Management System (WMS), which then tells Sure Sort which bin to deliver the item. Once the iBOT delivers the item, it will cycle back for another one.

  • Page 114: Turning The Power On/Off

    1. Finish the job, and log out or simply close the host software. 2. Shut down the host computer. 3. Press the Power button on the UPS. 4. Turn the red main disconnect switch handle to the Off position. Operation Sure Sort™ Operator Manual OPEX Corporation...

  • Page 115: Logging In To The Host Software

    4.1.3. Logging in to the Host software The Sure Sort™ host computer will launch the Host software (as well as the OPEX InductELC software) as part of the system’s start-up routine. If you mistakenly close the Host software, or if the Host software does not start with the machine, you can start it manually.
  • Page 116 Note: When powering up the system, the Sure Sort™ host computer will auto- matically launch the OPEX Induct ELC software as part of the system’s start-up routine. If you mistakenly closed the OPEX ELC software, or if the OPEX ELC software did not start with the machine, you will get an error message.
  • Page 117 Figure 4-6: OPEX Host Run screen 3. For the duration of the run, you will use the OPEX Induct ELC software to view the process (see “Toggling between the Host & InductELC software” on 137).
  • Page 118 When the system is ready for the first item to be entered, the ELC software interface will display the word “Ready” as shown in Figure 4-7. Figure 4-7: OPEX Induct ELC screen WARNING Keep loose clothing, hair, and jewelry away from the conveyor when placing items on the conveyor.
  • Page 119 5. The item is scanned for a barcode. If the barcode read was successful, “Good Read” will be displayed (Figure 4-8). Figure 4-8: OPEX Induct ELC - Good Read When the item is scanned, the Induct ELC will receive a bin assignment for the piece, and the software notifies the iBOT of the delivery bin destination.
  • Page 120 Note: If the barcode could not be read, the iBOT will send the item to the designated no-read bin (or the optional return conveyor). The OPEX Induct ELC Screen will display “No Read”, as shown in Figure 4-10. The operator can then use the optional hand scanner (Figure 4-11) to enter the barcode into the system, and send the item back through the machine.
  • Page 121 Figure 4-11: Optional hand scanner 8. When finished, on the OPEX Host screen, click STOP (Figure 4-12). This stops the conveyors and homes the iBOTs. Figure 4-12: OPEX Host Run Screen - STOP button Operation Sure Sort™ Operator Manual OPEX Corporation...
  • Page 122 9. To exit out of the Run screen, click End Job (Figure 4-13). Figure 4-13: OPEX Host Run Screen - End Job This displays the Main Interface window (Figure 4-14). Figure 4-14: Host software - Main Interface Operation Sure Sort™ Operator Manual...

  • Page 123: Navigating The Host Software

    4.1.4. Navigating the Host software The Sure Sort™ Host software provides the main interface with the system’s controls. Use the Host software to start, run and stop the job. The Host software interface consists of (see Figure 4-15 on page...

  • Page 124: Run Screen Details

    Go to Run Screen >> button to access the Run screen (Figure 4-16). Use the Run screen to: • Start and stop the job • View vital system information about the current job as the machine is running • View information about jams Operation Sure Sort™ Operator Manual OPEX Corporation...

  • Page 125: Information Tabs

    The default user will have limited access to settings and features while logged in. Features that are available in the information tab section are listed below. Operation Sure Sort™ Operator Manual OPEX Corporation...
  • Page 126 + Pieces delivered should equal Pieces input. Pieces delivered Number of items successfully delivered to a bin. Pieces rejected Number of items rejected. Note: Other fields displayed are irrelevant for the Sure Sort. Operation Sure Sort™ Operator Manual OPEX Corporation...
  • Page 127 Figure 4-18: Jams tab Jam time Total time the system was halted for a jam. Reports occasions when run was halted due to a jam or a Jam count processing problem that was machine related. Operation Sure Sort™ Operator Manual OPEX Corporation...
  • Page 128 In the example below, the iBOTs are shown parked at the front column while the machine is idle. Figure 4-19: iBOTs tab Operation Sure Sort™ Operator Manual OPEX Corporation...
  • Page 129 If it appeared red, it indicates that there is a problem with connectivity. Figure 4-21: ELC tab Note: The “Alerts/Events” tab shown in the above figure is not available at the operator level. Operation Sure Sort™ Operator Manual OPEX Corporation...

  • Page 130: Clearing Jams

    If an iBOT has become stuck in the machine (or is otherwise unusable) and needs to be removed, inform your supervisor, or contact an Authorized Employee or OPEX technician. When a jam occurs, the Run screen will alert you as to where the jam has taken place (see Figure 4-22).
  • Page 131 If not, the system assumes that something is wrong and the machine will stop. An example of this type of jam is shown in Figure 4-24. Figure 4-24: Sensor blocked jam Operation Sure Sort™ Operator Manual OPEX Corporation...
  • Page 132 You can also click Cancel Dlvry and the iBOT will return to the loading column and reject the item. Figure 4-25: iBOT waiting for bin Operation Sure Sort™ Operator Manual OPEX Corporation...
  • Page 133 At this point, you will need to contact an Authorized Employee to have them remove the item from the iBOT and place it into the bin. Warning Information Figure 4-27: iBOT failed to unload jam Operation Sure Sort™ Operator Manual OPEX Corporation...

  • Page 134: Product-Related Jams

    NOTICE For all of the product-related jams, you will need to contact an Authorized Employee or OPEX Technician to resolve the issue. Bulky items in soft plastic packaging can get knocked off the iBOT and fall to the aisle floor (Figure 4-28). An iBOT will eventually collide with it, causing a jam.
  • Page 135 When the iBOT tries to deliver an item to a bin, the item hits other items in the bin, preventing it from being completely removed from the iBOT (Figure 4-30). Figure 4-30: Product hits other items in bin Operation Sure Sort™ Operator Manual OPEX Corporation...
  • Page 136 Item doesn’t reach iBOT before timer expires, and the track stops. Load Failure Jam message appears Item kept rolling right through into the reject bin Figure 4-31: Load Failure Jam Operation Sure Sort™ Operator Manual OPEX Corporation...

  • Page 137: Toggling Between The Host & Inductelc Software

    4.3. Toggling between the Host & InductELC software Because the host software and the OPEX InductELC software need to be opened to operate the Sure Sort, this overlapping of software packages can sometimes be confusing. It’s possible to “lose sight” of one of the software screens - whether they are hidden behind each other or minimized.
  • Page 138 (Page intentionally blank) Operation Sure Sort™ Operator Manual OPEX Corporation...
  • Page 139 5.3.3. Safety-Related jams ....... . . 151 Sure Sort™ Operator Manual...

  • Page 140: Overview

    5.1. Overview The Sure Sort™ statistics provide information on the jobs run on the system. 5.2. Creating Reports On the Induct ELC screen, click the Counts tab (Figure 5-1). Figure 5-1: Induct ELC screen - counts tab The Counts tab will show amounts and percentages of the following fields: •...

  • Page 141: Setting The Time Range

    Click the Export button at the bottom of the Counts window to save a .csv file of your current report to the hard drive. The .csv file will be saved to the default directory: C:/OPEX/Export/Induct ELC. Statistics Sure Sort™ Operator Manual OPEX Corporation...

  • Page 142: Reject And Jam Definitions

    ELC's barcode request. The WMS back-end is not connected to the ELC. Any Back-End Not piece inducted while the back-end is not connected Connected will be rejected for this reason. Statistics Sure Sort™ Operator Manual OPEX Corporation...
  • Page 143 5.3.1.2. Host Rejects Reject message Description The pieces rejected after a jam condition. The pieces Jamsort that are past the imaging sensor when the system restarts after a jam will be rejected for this reason. Statistics Sure Sort™ Operator Manual OPEX Corporation...
  • Page 144 Unknown Bin The piece was given a destination bin that is not valid Location in the configured bin map. The Host has rejected the piece but has not assigned Unknown Reason a reject reason. Statistics Sure Sort™ Operator Manual OPEX Corporation...
  • Page 145 This Return Data should never occur. This code will only be used for the Sure Sort XL Invalid Destination machine. The destination assigned to the piece is not a valid location in the configured bin map.

  • Page 146: Jams

    ELC. The correct disposition of pieces that are in the system, but not yet delivered, needs to be determined. Statistics Sure Sort™ Operator Manual OPEX Corporation...
  • Page 147 Collision Jam drop in speed, while a stall jam is called when an iBOT does not travel an expected minimum distance over a period of time. Statistics Sure Sort™ Operator Manual OPEX Corporation...
  • Page 148 Stall Jam progress, something caught in the iBOT’s axle, an overweight item being placed onto the iBOT, or something dragging on the back of the iBOT. Statistics Sure Sort™ Operator Manual OPEX Corporation...
  • Page 149 If the mechanical Blocked lock is broken upon startup of the system, a jam will be triggered. Occurs when the Real-Time Controller cannot detect No iBOTs Detected any iBOTs in the system. Statistics Sure Sort™ Operator Manual OPEX Corporation...
  • Page 150 Open the system is open. Occurs if one of the Emergency Stop (E-Stop) Stacker Section 100- switches on the 100 side of the machine have been Side E-Stop Pressed pressed. Statistics Sure Sort™ Operator Manual OPEX Corporation...

  • Page 151: Safety-Related Jams

    This is a level 2 jam. This jam indicates that a fault has been detected by Guardian Brake the monitor of the brake control circuit. This is a level 2 Control Failure jam. Statistics Sure Sort™ Operator Manual OPEX Corporation...
  • Page 152 Speed Detected This is a level 2 jam. Indicates that one of the processors on the safety Guardian Relay module has detected a relay feedback error. This is a Feedback Error level 1 jam. Statistics Sure Sort™ Operator Manual OPEX Corporation...
  • Page 153 This is only generated Guardian Test Error from the debug menu while bench testing the safety module. This should never be seen while running in a live system. This is a level 2 jam. Statistics Sure Sort™ Operator Manual OPEX Corporation...
  • Page 154 (Page intentionally blank) Statistics Sure Sort™ Operator Manual OPEX Corporation...

  • Page 155: Chapter G Glossary

    G.2. List of Terms......... 156 Sure Sort™...

  • Page 156: List Of Acronyms

    - Transceiver XCVR G.2. List of Terms The following list of terms, used throughout the Sure Sort documentation, is sorted alphabetically. - This is the AC input module found in the Induct AC Distribution Enclosure section above the UPS.
  • Page 157 - This is the identifier on a package that is made up of a series of lines. Barcode These are read by the OPEX scan tunnel and/or optional barcode reader to identify the package. - Bins, totes, or boxes are the terms used for the container in which the product gets delivered.
  • Page 158 - This enclosure houses the main I/O board. This is the go I/O enclosure between for the system to talk to our host computer and the customer’s system. It is the source of the triggering, and pacing of the objects or packages. Glossary Sure Sort™ Operator Manual OPEX Corporation...
  • Page 159 - A collection of the settings and methods the system will use to process items in a similar fashion from run to run. In many cases, you will only see one job, which should be set up ahead of time, either by an OPEX technician or your site supervisor or IT department.
  • Page 160 Unload' and 'Bin Blocked' scenarios. - A layer of system software acting as the central coordinator Traffic Controller for the OPEX wireless network. - This is a computer monitor/user interface that does not Touch screen Monitor need a mouse or keyboard. You can touch the screen to choose what you want.
  • Page 161 Utilizing a vast global workforce of direct employees, OPEX serves a variety of industries including financial services, insurance, healthcare, government, retail, non-profits, utilities, telecommunication, service bureaus, educational institutions and fulfillment operations.
  • Page 162 Sure Sort™ Operator Manual OPEX Corporation...

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