300H O and M Manual Navy Medical.pdf

OPERATION AND MAINTENANCE MANUAL

NAVY MEDICAL CENTER

San Diego, CA

300H

**PRELIMINARY**

Proprietary Notice This manual, including the design and principles of construction disclosed within it, is the property of Jervis B. Webb Company. It is submitted with the understanding that it is not to be reproduced, nor copied in whole or in part, nor loaned or otherwise communicated to any third party, nor used in any manner detrimental to the interests of the Jervis B. Webb Company without its expressed consent.

The following are registered trademarks or trademarks of the Jervis B. Webb Company (JBW): SmartCart®, SAM™, CartTools®, SmartView™, and SmartServer™.

Jervis B. Webb Company 30100 Cabot Drive

Novi, MI 48377

Contact Customer Service at:

1-877-JB-Webb-1 (1-877-529-3221) webbservice@jerviswebb.com Document Revisions Date Version # By Description

02/07/2020 0 GAD Preliminary Draft for G.CAU0001

Document file name is: 300H O&M manual Navy Medical (G.CAU0001) V0 - Preliminary Date last saved: 02/06/2020

Table of Contents i

300H O&M manual Navy Medical (G.CAU0001) V0 - Preliminary

TABLE OF CONTENTS

CHAPTER 1. INTRODUCTION .................................................................. 1-1

1.1 User Information ........................................................................................................... 1-1

1.2 Applicable Standards and Directives ............................................................................. 1-1

1.2.1 European Committee for Standardization (CEN) .................................................... 1-1

1.2.2 Disclaimer ................................................................................................................ 1-1

1.3 Proper Use of the AGV ................................................................................................. 1-2

1.3.1 Qualified Personnel .................................................................................................. 1-2

1.3.2 Application of the AGV ........................................................................................... 1-2

1.3.3 Foreseeable Misuse .................................................................................................. 1-3

1.4 Specifications, Features and Limitations ....................................................................... 1-4

1.4.1 Model 300H ............................................................................................................. 1-4

1.4.2 Shipping Weights ..................................................................................................... 1-4

1.4.3 Travel Tolerances ..................................................................................................... 1-5

1.4.4 AGV Uptime ............................................................................................................ 1-5

1.5 Lifting the AGV ............................................................................................................ 1-6

1.5.1 Safety ....................................................................................................................... 1-6

1.5.2 Lift Holes ................................................................................................................. 1-6

1.5.3 Recommended Hooks .............................................................................................. 1-7

CHAPTER 2. SAFETY .................................................................................. 2-1

2.1 Overview ....................................................................................................................... 2-1

2.1.1 General Safety Guidelines........................................................................................ 2-2

2.1.2 Personal Safety ......................................................................................................... 2-6

2.1.3 Electrical Safety ....................................................................................................... 2-7

2.1.4 Personnel Training ................................................................................................... 2-8

2.1.5 Commissioning, Testing and Modification Safety .................................................. 2-8

2.2 Lockouts/Interlocks ..................................................................................................... 2-10

2.2.1 Lock-Out Removal ................................................................................................. 2-11

2.3 Emergency Stops ......................................................................................................... 2-12

CHAPTER 3. HARDWARE COMPONENTS ............................................ 3-1

3.1 Batteries and Charging .................................................................................................. 3-3

3.1.1 Batteries.................................................................................................................... 3-3

3.1.2 Charging Shoes ........................................................................................................ 3-3

3.1.3 Manual Battery Charge Connector .......................................................................... 3-4

3.2 Control Compartment .................................................................................................... 3-5

3.2.1 Vehicle Control Computer 4 (VCC4) ...................................................................... 3-6

3.2.2 Safety Relay ............................................................................................................. 3-8

3.2.3 Bumper Bypass Relay .............................................................................................. 3-8

3.2.4 Auto Shut Off Relay (RMP) .................................................................................... 3-9

3.2.5 Wireless Radio and Antennas .................................................................................. 3-9

Table of Contents ii

3.2.6 Master Control Relay (CRM)................................................................................. 3-10

3.2.7 Charging Relay (CRC) ........................................................................................... 3-10

3.2.8 (+) Buss .................................................................................................................. 3-10

3.2.9 (-) Buss ................................................................................................................... 3-10

3.2.10 I/O Module ........................................................................................................... 3-10

3.3 Inputs and Outputs ....................................................................................................... 3-11

3.3.1 Inputs ...................................................................................................................... 3-11

3.3.2 Outputs ................................................................................................................... 3-12

3.4 Power and Guidance .................................................................................................... 3-13

3.4.1 Steering/Traction Assembly ................................................................................... 3-14

3.4.2 Steer Limit Switches .............................................................................................. 3-14

3.4.3 Steering Encoder .................................................................................................... 3-14

3.4.4 Steering Motor ....................................................................................................... 3-14

3.4.5 Traction Motor/Wheel ............................................................................................ 3-14

3.4.6 Traction Encoder .................................................................................................... 3-14

3.4.7 Traction Brake ........................................................................................................ 3-14

3.4.8 Traction Motor Controller ...................................................................................... 3-15

3.5 Laser Safety Bumper ................................................................................................... 3-16

3.5.1 Zone Monitoring .................................................................................................... 3-16

3.6 Fixed Casters ............................................................................................................... 3-17

3.7 Navigation Laser ......................................................................................................... 3-18

3.8 Lift ............................................................................................................................... 3-19

3.8.1 Lift Pedal Switch .................................................................................................... 3-19

3.8.2 Table Top ............................................................................................................... 3-20

3.8.3 Scissor Lift ............................................................................................................. 3-21

3.8.4 Linear Actuator ...................................................................................................... 3-21

CHAPTER 4. SOFTWARE COMPONENTS ............................................. 4-1

4.1 CartTools Programming Tool ........................................................................................ 4-1

4.2 System Automation Manager (SAM) ............................................................................ 4-2

CHAPTER 5. CONTROLS AND INDICATORS ....................................... 5-1

5.1 Operator Control panel .................................................................................................. 5-1

5.1.1 Power Switch ........................................................................................................... 5-1

5.1.2 Start Pushbutton ....................................................................................................... 5-2

5.1.3 Stop Pushbutton ....................................................................................................... 5-2

5.1.4 Ethernet Port............................................................................................................. 5-3

5.1.5 Horn Baffle............................................................................................................... 5-3

5.2 Emergency Stop Pushbutton .......................................................................................... 5-3

5.2.1 How to Restart an E-Stopped AGV ......................................................................... 5-4

5.3 Operator Indicators ........................................................................................................ 5-4

5.3.1 Warning Light .......................................................................................................... 5-4

5.3.2 Warning Horn........................................................................................................... 5-5

Table of Contents iii

5.4 HMI ............................................................................................................................... 5-6

5.4.1 Main Screen ............................................................................................................. 5-6

5.4.2 Function Menu Screen 1 ........................................................................................ 5-10

5.4.3 Function Menu Screen 2 ........................................................................................ 5-11

5.4.4 Navigation Data Screen 1....................................................................................... 5-12

5.4.5 Navigation Data Screen 2....................................................................................... 5-13

5.4.6 Navigation Data Screen 3....................................................................................... 5-14

5.4.7 Steering Data Screen .............................................................................................. 5-14

5.4.8 Motor Info Screen .................................................................................................. 5-15

5.4.9 Laser Data Screen 1&2 .......................................................................................... 5-16

5.4.10 Bumper Info Screen ............................................................................................. 5-17

5.4.11 IP Address Screen ................................................................................................ 5-18

5.4.12 Inputs & Outputs Screens .................................................................................... 5-19

5.4.13 Module Revisions 1 & 2 Screens ......................................................................... 5-20

5.4.14 Lift Control Screen ............................................................................................... 5-21

5.4.15 Lift Calibration Screens ....................................................................................... 5-22

5.5 Manual Control Pendant .............................................................................................. 5-23

5.5.1 Conditions of Operation ......................................................................................... 5-24

5.5.2 Pendant Controls .................................................................................................... 5-25

5.5.3 Dongle .................................................................................................................... 5-27

CHAPTER 6. AGV OPERATION ................................................................ 6-1

6.1 Emergency Stop ............................................................................................................. 6-1

6.2 Auto Mode ..................................................................................................................... 6-1

6.2.1 Starting or Restarting an AGV ................................................................................. 6-1

6.2.2 Stopping an AGV ..................................................................................................... 6-1

6.2.3 Removing an AGV from a SAM System ................................................................. 6-2

6.2.4 Inserting an AGV into a SAM System ..................................................................... 6-3

6.2.5 Forcing an AGV Release after a SAM System Error .............................................. 6-4

6.2.6 Lift Table Operation ................................................................................................. 6-5

6.3 Driving an AGV Using a Pendant ................................................................................. 6-6

6.3.1 Standard Pendant ...................................................................................................... 6-6

6.3.2 Wireless Pendant ...................................................................................................... 6-8

6.3.3 Condition Code C73 ................................................................................................. 6-9

6.4 Auto-Shutoff ................................................................................................................ 6-10

6.5 Sleep Mode .................................................................................................................. 6-10

6.5.1 Sleep / Wake Schedule ........................................................................................... 6-10

6.5.2 Putting AGVs to Sleep ........................................................................................... 6-11

6.5.3 Powering Off AGVs ............................................................................................... 6-12

6.5.4 Waking Vehicles .................................................................................................... 6-12

6.5.5 Low Battery While Sleeping .................................................................................. 6-12

6.5.6 Vehicle Maintenance .............................................................................................. 6-12

6.5.7 Sleep Failure........................................................................................................... 6-13

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6.5.8 CartTools Auto Shutoff .......................................................................................... 6-13

6.6 Restarting the Laser Bumper ....................................................................................... 6-13

6.6.1 Manually ................................................................................................................ 6-13

6.6.2 Automatically ......................................................................................................... 6-13

6.7 Charging the Battery .................................................................................................... 6-14

6.7.1 Charger Phases ....................................................................................................... 6-14

6.7.2 How the VCC Determines Battery Status .............................................................. 6-14

6.7.3 Automatic Charging ............................................................................................... 6-15

6.7.4 Use of Pendant During Charge Cycle .................................................................... 6-16

6.8 Traffic Control and Blocking ...................................................................................... 6-16

6.8.1 Accumulative Blocking .......................................................................................... 6-16

6.8.2 Sample Zone Blocking Operation .......................................................................... 6-17

CHAPTER 7. MAINTENANCE ................................................................... 7-1

7.1 Recommended Maintenance Equipment ....................................................................... 7-2

7.1.1 Grounding Kit .......................................................................................................... 7-3

7.2 Lifting the AGV ............................................................................................................ 7-3

7.3 Recommended Preventive Maintenance Inspections .................................................... 7-4

7.3.1 Initial AGV 50 Hour Inspection ............................................................................... 7-4

7.4 Floor Maintenance ......................................................................................................... 7-8

7.4.1 General ..................................................................................................................... 7-8

7.4.2 Cleanliness ............................................................................................................... 7-8

7.5 Laser Safety Bumper ..................................................................................................... 7-9

7.5.1 Lens Cleaning........................................................................................................... 7-9

7.5.2 Lens Replacement .................................................................................................... 7-9

7.5.3 Programming the Laser Safety Bumper ................................................................. 7-10

7.5.4 Laser Bumper Fault ................................................................................................ 7-10

7.6 Charging the Battery .................................................................................................... 7-11

7.6.1 Setting up the Manual Charger .............................................................................. 7-11

7.6.3 Manually Charging Batteries in the AGV .............................................................. 7-12

7.6.4 Swapping Batteries from the AGV ........................................................................ 7-12

7.7 Traction / Steering Assembly ...................................................................................... 7-13

7.7.1 Traction/Steering Assembly Replacement ............................................................. 7-13

7.7.2 Traction Motor ....................................................................................................... 7-14

7.7.3 Steering Motor ....................................................................................................... 7-16

7.7.4 Traction Motor Controller Replacement ................................................................ 7-18

7.8 Off-line Operational Testing ....................................................................................... 7-19

7.9 HMI Replacement ....................................................................................................... 7-20

7.9.1 Transferring Files using GP-Pro Ex ....................................................................... 7-22

7.9.2 Transferring Files using the Transfer Tool ............................................................ 7-23

7.9.3 Transferring Files Using a USB Flash Drive ......................................................... 7-23

7.9.4 Reconfiguring Pro-face .......................................................................................... 7-24

Table of Contents v

7.10 Programming the Wireless Radio .............................................................................. 7-26

7.10.1 Setting up the Computer....................................................................................... 7-26

7.10.2 Setting up a New Radio ....................................................................................... 7-26

7.10.3 Radio Failure ........................................................................................................ 7-27

7.11 Long Term Storage .................................................................................................... 7-28

7.12 Before Scrapping a SmartCart AGV ......................................................................... 7-28

CHAPTER 8. SPARE PARTS ....................................................................... 8-1

Table of Contents vi

ABBREVIATIONS AND ACRONYMS

The following is a list of abbreviations and acronyms used throughout this manual.

• AC Alternating Current

• AGV Automated Guided Vehicle

• AH Ampere Hour

• ANSI American National Standards Institute

• CAN Controller Area Network (CAN Bus)

• CCC AGV Count Calculator

• CF Compact Flash

• CVS Coded Vehicle Status

• DOD Depth Of Discharge

• E-Stop Emergency Stop

• GS Guide Safe

• HMI Human Machine Interface

• I/O Input/Output

• IP Internet Protocol

• LED Light Emitting Diode

• mA Milliampere

• MSDS Material Safety Data Sheet

• NEMA National Electrical Manufacturer's Association

• PC Personal Computer

• PID Proportional, Integral and Derivative

• PLC Programmable Logic Controller

• PM Preventive Maintenance

• SAM System Automation Manager

• SSID Service Set Identifier

• USB Universal Serial Bus

• VCC Vehicle Control Computer

Table of Contents vii

GLOSSARY

AGV (Automatic Guided AGV): A vehicle that is used to automatically transport loads within the system.

AUTOMATIC CHARGING: Type of battery charging that occurs when the vehicle's battery voltage has dropped below a predetermined level. At this time, SAM routes the vehicle to a designated station where its battery is automatically charged. The battery charger continues the charge cycle until the battery charge reaches a predetermined level.

AUTO MODE: This is the normal mode of operation, so that the AGV operates under the control of SAM with a minimum amount of intervention by personnel.

AMPERE-HOUR: Battery storage capacity that is the product of amperes and hours.

Conditions such as discharge rate, ambient temperature and final voltage are specified.

BATTERY - PRIMARY: Term that refers to one or more industrial batteries which are used to supply power to the AGV. If more than one battery is used, they may be connected in series, parallel or series/parallel combination. Typically, power is supplied to the AGV's from a 24, 36, 48 or 72 VDC battery source.

BLOCKING: Blocking is the process of automatically starting and stopping AGVs in response to adjacent traffic. Blocking which occurs when the vehicle's object detection sensors detect an object is referred to as accumulative blocking. When SAM does not issue a Release Command to a vehicle at a hold-stop location, this is referred to as zone blocking.

BUMPER: Laser sensors have a detection area that is used as a safety zone and immediately stops the AGV if an object is detected in the area. A little further out, there is a warning zone detection area that is used to bring the AGV to a controlled stop if an object is detected. The furthest detection zone is a slowdown zone which slows the speed of the AGV if it detects an object. Note that AGVs that use bidirectional travel will have bumpers located on the front and rear.

CONDITION CODE: A code which the AGV transmits to SAM when it has stopped. The cause for the stop is expected, but not necessarily desired. Examples of these codes include bumper trips and the Auto Stop Pushbutton being pressed. In most cases the AGV terminates automatic operation when a condition code is recorded. If the AGV terminates operation in Auto Mode, operator intervention is required to restart the vehicle.

CVS (Coded Vehicle Status): A numeric code generated by the vehicle when specific conditions are met, or when the vehicle is executing or has completed executing a specific operation. This code is transmitted by the vehicle to SAM when a status request is made.

DRIVE MOTOR: The drive motors primary use is to propel the vehicle or to steer the vehicle. Depending on the application, there may be more than one drive motor on the vehicle.

DRIVE MOTOR BRAKE: Each drive unit is equipped with a brake. The microcomputer (VCC) issues the command for the brake to release, however, the motion control board must sense that the brake is released before the vehicle can travel.

Table of Contents viii

DRIVE/STEERING UNIT: Sometimes also called the Traction Motor, this is a modular assembly which typically consists of a drive motor and drive transmission, a speed encoder, a steering encoder, electromagnetic brake, a steering motor, and gear reducer.

EMERGENCY STOP: The rapid, controlled, deceleration stopping of all drive and transfer devices, and the travel and transfer controls are disabled. Once the vehicle is stopped, the brakes are set. Auto Mode terminates at this time. Manual intervention is required to restart the AGV.

EQUALIZING CHARGE: An equalizing charge is a charge that should be periodically applied to a battery in order to maximize the battery's usable life span. During the process, the charge level in each battery cell is equalized. Manufacturer's literature specifies the recommended interval at which an equalizing charge should be applied, or if it is even required. The automatic battery charger is able to apply an equalizing charge when the function is selected.

ERROR CODE: A code that the AGV transmits to SAM when it has stopped due to a hardware or software fault. The vehicle terminates operation in Auto Mode when an error code is recorded. In all cases, operator intervention is required to restart the AGV.

FUNCTION: An operation the AGV executes automatically as part of a pre-programmed routine when it reaches a position that corresponds to a location. The function, which is executed, is determined by the information in the AGV’s database. A function is also executed when a function code is entered via on-board keypad when the Function Input Mode is selected.

GUIDEPATH: The point-to-point surveyed course around the plant floor that an AGV follows as it travels from one destination to another within an AGV System. The AGVs accurately maintain a virtual guidepath with intended routes. Two guidepath points define a guidepath segment. Multiple guidepath segments comprise a guidepath. There is a laser used by the AGV to guide the vehicle between stations.

IMMEDIATE HOLD-STOP: A position along the guidepath where an AGV stops imme-diately and waits for a release command from SAM. The vehicle requires a Release Command (to travel) from SAM before it can resume automatic travel.

IN-POSITION: This is a function code that the AGV executes when it reaches a specified position on the guidepath, when it arrives at a station. The in-position can also be based on a specific travel distance. An example of this is when the AGV travels a predetermined distance after sensing a station code. One of the functions associated with in-position, is for the AGV to set its brake immediately. In certain applications, in-position also refers to a target that the AGV senses when it is entering a station and causes it to stop immediately.

LOCATION: A unique position along the guidepath that is assigned an address. The AGV's database contains the operations that the AGV is to perform upon arriving at a position that matches a location. Each location has a unique address associated with it.

When the vehicle is polled by SAM for a status update, it transmits this address to SAM. In this manner SAM is informed of the vehicle's last known location.

Table of Contents ix

MANUAL MODE: When the AGV is under the control of an operator.

SAM (System Automation Manager): Computer hardware and associated software used to control vehicle routing and guidepath traffic flow within the Automatic Guided Vehicle System.

SPEED CONTROL: The hardware and software that forms a closed-loop system for controlling vehicle travel speed. These components include, but are not limited to, the following:

• joystick (only in Manual Mode)

• microcomputer and navigation board

• motor controller (AC motors)

• speed shaft encoder

STATION: A destination to which the AGV is to travel to perform a transfer operation or to have its battery charged or exchanged. In Auto Mode, the vehicle receives a destination/transfer operation from the SAM.

TIMED HOLD-STOP: A position along the guidepath where the AGV must receive a Release Command from the SAM in a predetermined amount of time, otherwise, it will stop and wait to receive one.

VCC: The control boards that controls the operation of an AGV.

Chapter 1: Introduction Page 1-1

CHAPTER 1. INTRODUCTION

1.1 USER INFORMATION

Jervis B. Webb manufactures many different standard and custom models of AGVs, and may use a generic photo to reference an option or location on the AGV. This manual may have information on options not installed on your AGV.

Only personnel who have been qualified through training should operate or repair SmartCart AGV equipment.

Jervis B. Webb does not recommend making modifications to the AGV that may affect the safety and operation of the AGV. Modification of the AGV voids the warranty and could create unforeseen safety hazards.

1.2 APPLICABLE STANDARDS AND DIRECTIVES

In the design of the AGV, the following standards have been applied.

1.2.1 European Committee for Standardization (CEN)

Note: The following standards only apply to SmartCart models with CE options.

• BS EN 1525-1:1998 Safety of Industrial Trucks – Driverless Trucks and Their Systems

• BS EN 60204-1:2006+A1-2009 Safety of machinery, Electrical equipment of machines.

General requirements

• BS EN 61000-6-1:2001 Electromagnetic compatibility (EMC). Generic standards. For immunity residential, commercial and light-industrial environments

• BS EN 61000-6-1:2001 Electromagnetic compatibility (EMC). Generic standards.

Emission Standard for residential, commercial and light-industrial environments

• BS EN 13849-1:2008 Safety of Machinery – Safety related parts of control systems part 1

• BS EN 13849-2:2012 Safety of Machinery – Safety related parts of control systems part 2

1.2.2 Disclaimer

Jervis B. Webb makes no claim that the final AGV configuration and system are designed and installed in compliance with any applicable Federal, State, and Local laws, regulations, and codes or any other applicable safety requirements governing AGV equipment and systems, including but not limited to ANSI/ITSDF B56.5.

Chapter 1: Introduction Page 1-2

1.3 PROPER USE OF THE AGV

1.3.1 Qualified Personnel

The AGV must be installed, commissioned and serviced only by qualified personnel.

Qualified personnel are defined as persons who:

• Due to their specialist training and experience have adequate knowledge of the electrical control and configuration of automation.

• Have been instructed by the responsible AGV owner in the operation of the AGV.

• Are sufficiently familiar with the applicable ANSI, EU Standards/Directives and generally recognized engineering practice.

• Have access to these operation and maintenance instructions and have read them.

1.3.2 Application of the AGV

The AGV is to be only used for the following applications:

• To transport carts around the customer’s facility, picking up and dropping off full and empty cart in designated areas.

The AGV should only be operated in a system that meets the clearance and safety requirements as defined in applicable industrial standards.

Chapter 1: Introduction Page 1-3

1.3.3 Foreseeable Misuse

The AGV must be used only as defined in this document (sections 1.3.1 and 1.3.2) and in design documents and reference drawings.

• The AGV must not be used for personnel transport.

• No riding of the AGV is ever allowed under any circumstances.

• The AGV must not be used to carry loads exceeding rated capacity.

• The AGV must be used only by qualified personnel and only on the systems where it has been installed and commissioned by qualified personnel in accordance with these operating instructions.

• The AGV may only be used in systems that meet the applicable standards for safe operation with proper signage, safety markings and necessary clearances for safe operation in place.

• The AGV battery must not be voltage tapped to power other devices. Only Webb-provided and approved battery chargers shall be used.

If the AGV is used for any other purposes, or modified in any way, any warranty claim against Jervis B. Webb shall become void.

Chapter 1: Introduction Page 1-4

1.4 SPECIFICATIONS, FEATURES AND LIMITATIONS

• AGV is not NEMA or IP rated. No water or outdoor operation is allowed.

• Unit operates in temperature ranges of 32 – 104°F (0 - 40°C), 25% - 95% humidity (non-condensing).

• The operating surface must be smooth, dry, and clean; expansion joints shall not exceed ±¼”, static dissipative less than 3.5 x 107 Ohms (floor resistance to ground).

Note:

Floor dissipative testing should be performed per ANSI/ESD S7.1- 2005 as defined in section 6.2.1 Resistance to Ground.

Contact Jervis B. Webb for the document entitled "Floor Resistance Measurement Instructions" which provides guidelines on how to verify the floor resistance.

• 0% grade rated. No running on ramps.

• Casters added for load handling frames must achieve 2% friction factor or less.

1.4.1 Model 300H

Upright profile AGV equipped with a low profile lift deck. The AGV is designer to pick up a cart from underneath. The AGV can move in forward and reverse. The AGV can transport a load up to TBD lb. (TBD kg).

1.4.2 Shipping Weights

The following shipping weight is approximate and includes batteries.

• AGV Model 300H: TBD lbs.

Chapter 1: Introduction Page 1-5

1.4.3 Travel Tolerances

• Guidance Tolerance = ±½”, measured at the guidance sensor.

• Skew Angle = ±3°, measured from the unit side frame parallel to the intended travel direction.

Note:

Holding a skew angle tighter than ±3 degrees can be achieved, but is affected by varying load weight and placement, which requires extra effort in setting up.

• The Guide safe width is 6” (measured lateral to the intended drawn path of the pivot point of the vehicle in AutoCAD).

1.4.4 AGV Uptime

To attain a 98% AGV uptime, it is critical that all preventive maintenance be performed following the recommended schedule.

Chapter 1: Introduction Page 1-6

1.5 LIFTING THE AGV

To prevent critical damage to new AGVs, please read and heed the following warning.

Caution:

If present, check for and remove all shipping dry packs from the AGV.

AGV’s heating elements can cause moisture absorbing packets to melt and damage the electronic components.

1.5.1 Safety

• Use a fork truck or overhead crane to lift the AGV. Use safe fork truck/hoist operation practices as specified in OSHA regulations 1910.178 and 1910.179.

• When using a crane, employ proper lift straps and crane hooks for the weight of the

AGV.

• Wear all necessary personal protective equipment.

1.5.2 Lift Holes

The AGV has two lift holes on either side of the AGV. The Table Top must be removed to access the lift holes.

Figure 1-1: Lift Holes on Right Side of AGV

Lift Holes Same on LH side

Chapter 1: Introduction Page 1-7

1.5.3 Recommended Hooks

It is recommended that you use McMaster-Carr narrow body eye hooks (Part #3786T46) to lift the AGV.

Figure 1-2: Lift Hooks

Chapter 1: Introduction Page 1-8

This page is intentionally left blank.

Chapter 2: Safety Page 2-1

CHAPTER 2. SAFETY

2.1 OVERVIEW

Only properly trained personnel should be permitted to perform maintenance and service tasks on the AGV.

WARNING:

ALWAYS FOLLOW COMPANY SAFETY

PROCEDURES. FAILURE TO DO SO MAY RESULT

IN INJURY OR DEATH TO PERSONNEL, AND

DAMAGE TO THE EQUIPMENT.

Note: You, the user, are ultimately responsible for the safe operation of your AGV.

The safety procedures contained in this manual must be followed to prevent injury to personnel during operation or maintenance of the AGV. It is essential that all personnel involved in the assembly/installation, maintenance and operation of the AGV understand the importance of the listed instructions. The safety guidelines in this manual are only a summary and may or may not include any Company guidelines. All personal should be aware of all safety guidelines when working around the AGV.

Safety equipment provided with your Automatic Guided Vehicle (AGV) includes the front and rear safety bumpers, emergency stop pushbuttons, and flashing light and horn. All safety equipment should receive inspection on a daily basis. Be alert to hazardous conditions such as sharp edges and protruding objects, and replace any broken parts causing these conditions. Maintain good housekeeping practices. Clean up spilled lubricants and other materials immediately. Report all accidents resulting in damage to AGV and material, and irregularities in AGV operation, to the proper authority.

Do not attempt to install components, perform maintenance, or make adjustments on any AGV without first consulting the Operations and Maintenance Manual.

Chapter 2: Safety Page 2-2

The noise level at the operator panel should not exceed 70 dBA.

DO NOT USE THE AGV IN AN EXPLOSIVE

ENVIRONMENT AS IT IS NOT EXPLOSION-

PROOF. BE SURE FIRE EXTINGUISHERS

SUITABLE FOR ELECTRICAL FIRES ARE

AVAILABLE IN THE AREA OF OPERATION.

SERIOUS PERSONAL INJURY OR DAMAGE TO

EQUIPMENT MAY RESULT.

2.1.1 General Safety Guidelines

2.1.1.1 Preparation for Use

• The Warning Horn should be configured to sound for two (2) seconds upon start-up and prior to travel.

• Mark AGV path as non-pedestrian and keep zones clear.

• Where pivot turns are used, the area must be restricted from personnel.

• Post automatic AGV warning signs; particularly in areas where there is other traffic, e.g., fork lift, pedestrian, etc.

• Personnel who work in the vicinity of the AGVs must be provided basic safety training; personnel who are operating AGVs must be provided operator training;

personnel who are maintaining AGVs must be provided operator and maintenance training.

• Provide adequate lighting of 20-lux minimum in AGV traffic areas.

• Laser bumper patterns should be configured for AGV speed and load.

• Make sure all covers are in place and the battery compartment is closed before operating the AGV.

• Ensure all starting and stopping devices are kept free of obstructions.

• Periodically inspect and functionally test all equipment that has safety interlocks for proper operation.

Chapter 2: Safety Page 2-3

2.1.1.2 Operation

• Do not operate this AGV unless you are authorized and trained to do so. Read all instructions contained in this manual before attempting operation.

• Do not operate this AGV until all systems on the AGV are checked to ensure they are operating properly. Report any problems and be sure they are corrected before operating the AGV.

• Before operating the system in Auto Mode, verify in all areas of the guide path that AGV and trailer have a side clearance, from peripheral equipment or structures, of a minimum of 19.6 inches/500 mm, and have overhead floor clearance of 2.3 meters/7 feet 6 inches. Paint the floor to distinguish the “swath” of the AGV (and trailer) path.

Exception: In load and unload zones, where reduced speed and clear warnings are provided, designate these areas as restricted, fenced, or hazard zones.

Exception: The AGV can travel along side a fence at a minimum of 0.1 meters as long as there is 500 mm side clearance and 2.3 meters meter overhead clearance on the opposite side of AGV.

FIRE HAZARD

Do not stand or place any objects on the battery cover.

A disfigured battery cover can cause shorted battery terminal circuits, which can lead to a fire.

• Do not touch the Drive Unit when the power is applied; the wheel can turn suddenly and seriously injure fingers and hands.

• Do not touch any internal parts of the Control Panels, internal electrical controls, battery compartment, or wire terminals while the battery is connected. This may lead to shorted circuits, arc flash, electrocution, or ground leakage; causing equipment damage, personal injury, or fire.

• An AGV that is stopped in Auto Mode may resume travel at any time. So, if the warning light is flashing, be cautious when approaching the AGV.

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2.1.1.3 Maintenance

• Only trained personnel should perform maintenance service.

• Follow preventive maintenance instructions and safe maintenance practices.

Note: When working on the AGV, personnel shall wear all necessary personal protective equipment for that task.

• When adding or removing an AGV in the system, stop other AGVs or AGVs in the area, or be fully aware of their locations. Be certain to enable or disable the AGV in SmartView.

• Only trained personnel should be permitted to remove or insert an AGV in the system.

• Only insert an AGV at designated insert locations.

• Press the Stop Pushbutton before using diagnostics display on the HMI.

• Only trained and qualified personnel should handle batteries.

• Use a crane or hoist to remove batteries.

FIRE

HAZARD

Make certain that the battery terminals are securely covered.

Loose terminal covers or exposed terminals can lead to shorted circuits, causing equipment damage or fire

• The AGV must always be situated on a flat surface when performing maintenance and replacing batteries.

• Always locate the emergency stops for the equipment prior to beginning maintenance operations. Communicate with equipment operators to prevent needless injury.

• Before restarting a piece of equipment that has been shut down for any reason, ensure all personnel are clear and that everyone within the area is aware the machine is about to be started.

SHOCK HAZARD

Disconnect batteries and lock out power prior to performing maintenance or servicing the AGVs.

• The American National Standard (ANSI) Z244.1-1982 for Personnel Protection – Lockout/Tagout of Energy Sources gives minimum safety requirements. These requirements should be used as a reference in developing a lockout procedure.

• Do not exceed the load center or capacity.

Chapter 2: Safety Page 2-5

2.1.1.4 Miscellaneous

• Do not walk in the AGV guide paths. Walk across AGV guide paths only after checking for approaching AGVs.

2.1.1.5 Pendant Operation

• Do not operate the AGV with the pendant unless properly trained or having read and understood Section 5.5 of this manual.

• When dealing with an AGV in the maintenance area, the foremost thought should be the safety of personnel and equipment.

• When operating the AGV manually, special care should be taken to travel slowly and operate the AGV only as prescribed.

• Inattentive operation is dangerous to personnel and equipment and must never be allowed.

• Always keep your feet clear of the AGV’s wheels.

• Never park the AGV on a slope.

• Before operating any AGV, check that all the covers are in place and the doors are closed. If the AGV has a problem and is being moved to a maintenance area, be sure the AGV is safe to move.

• When an AGV is being manually operated, maintain a safe distance from the AG to allow for changes in direction, stops and starts.

Never leave an AGV in Manual Mode or disabled on or around the guide path. An AGV that is not enabled or in manual mode is not identified by the SAM. A collision could occur between the AGV and another traveling in Auto Mode.

2.1.1.6 Housekeeping

• Clear work areas and paths of debris to prevent personnel injury.

• Remove tools, rags, and machine parts from the conveyor prior to operation.

• Place absorbent materials on spills to prevent slipping hazards.

Small parts or hard debris in the path digs into the casters or the drive tires, causing the AGV to stall or go off course.

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2.1.2 Personal Safety

Note: When working on the AGV, personnel shall wear all necessary personal protective equipment for that task.

• Sparks or open flames around the equipment and are prohibited.

• Material spillage in significant quantities may require spill containment and the initiation of the site spill plan.

• Ensure tools and assembly equipment are in good working condition.

• Use the correct tool for the job.

• Use mechanical aids, hoists, cables, and other equipment in good working condition while performing installation or maintenance functions.

• Check out any abnormal noises from the AGV as it may indicate excessive vibration of the AGV.

• Cease work on jobs that indicate or have the potential of causing personal injury or equipment damage.

• Obtain the proper safety permits and instruction when performing tasks such as welding burning, grinding, or confined space entries.

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2.1.3 Electrical Safety

• Only qualified personnel shall perform electrical installation and maintenance.

SHOCK HAZARD

Just because the equipment has been turned off does not mean it is electrically safe to work on.

The Control Panels and AGVs have energy storage devices that could still contain electrical energy.

The only safe way to ensure there are no unaccountable energy sources is to measure those sources with a meter.

• Ensure the performance of electrical work conforms to National Electrical Codes and local regulations.

• Equipment required to be energized for testing shall have a trained personnel present and all operators or personnel involved with the equipment must be aware of the testing.

BYPASSING A SAFETY CIRCUIT IN ANY

MANNER CAUSES A HAZARDOUS CONDITION

AND IS PROHIBITED. SERIOUS INJURY OR

DEATH TO PERSONNEL OR SEVERE DAMAGE

TO EQUIPMENT MAY RESULT.

• Motionless equipment with operating prime mover motors shall be considered live or operational until the power source is disconnected or the equipment is disabled to prevent operation.

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2.1.4 Personnel Training

Personnel operating or maintaining the AGV shall be trained in the safe use of the AGV.

Training should include instructions on removing guide path hazards and energy source lockout procedures. Personnel should be trained in compliance with local and national safety regulations when operating and maintaining the system.

2.1.4.1 Emergency Procedure

If the AGV must be stopped due to an emergency condition:

• In case of injury, take immediate action to obtain aid from competent personnel.

• If there is no injury, make certain the area is safe and a supervisor in notified immediately.

When an AGV stops:

• Determine the reason the AGV stopped.

• Take the corrective action required to eliminate the reason for the stoppage.

• Restart the AGV once all emergency conditions have been rectified and all personnel are clear of equipment.

2.1.5 Commissioning, Testing and Modification Safety

Commissioning and testing of the system must be performed by qualified personnel. Refer to Section 1.3.1. The same steps and practices must be followed for modifications to the system as for new system installation. Upon commissioning, or when modifications are being implemented, the following matters should be addressed to ensure the safety of the system.

A new or modified system must be validated to meet the application industry's directives and standards. Refer to Section 1.2.1.

Commissioning technicians and/or any personnel undertaking the modification of the system should review AGV training material or have participated in AGV training.

Chapter 2: Safety Page 2-9

2.1.5.1 Bumper Pattern Selections

• Check all locations and virtual locations for proper bumper pattern selection for the load on AGV and AGV speed.

• Check all load and drop stations for proper bumper pattern selection.

2.1.5.2 Station Functions

• Check that all path, AGV functions, and transfer stations are tested and functioning properly.

• Check that all pick and load stations are operating safely.

• Check clearances and designations for restricted areas.

• Ensure proper bumper pattern are selected for both load and drop stations.

• Make certain operator safeguards and instructions are implemented in stations where an operator is required to position or to remove the load.

• Ensure that proper operator interface instructions are provided and reviewed.

• When a reduced bumper pattern is necessary to pick, a load area should be marked as restricted. The operator interface should be properly defined if required for load removal.

2.1.5.3 Manual Interface and Interaction

• Check for safe operation in Manual Mode.

• Check clearances and designations for restricted areas.

• Ensure proper bumper pattern is selected.

• Make sure proper operator interface instructions are provided and have been reviewed.

2.1.5.4 Charge Stations

• Validate that charge…