July 15, 2015

Perfect Pick User Manual
Document Revision 15-01© 2015 OPEX® Corporation
All rights reserved. This publication is made available solely for use by the OPEX Service Organization. The information contained herein is proprietary, confidential and copyrighted by OPEX® Corporation. Copying, duplicating,selling, or otherwise distributing any part of this publication or the information contained herein without the express
written consent of OPEX® Corporation is strictly forbidden.

Document History
Doc
Rev

Date

Changes (click blue text to go to that page)

13-01

May 2013

Initial Release.

July 15, 2015

Page 22 - Updated Diagnostic screen (Fig. 7)
Page 26 - Added FCC rules and regulations as well as
Industry Canada Information
Page 2 - New Document History table implemented

15-01

If you find errors, inaccuracies, or any other issues or concerns with thisdocument, please contact the OPEX Technical Writers via email at:
GroupTechwriters@opex.com

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Perfect Pick User Manual - OPEX Corporation use only - not for distribution

Table of ContentsDocument History ................................................................................................ 2
Table of Contents ................................................................................................ 3
Chapter 1
Introduction
About this manual ................................................................................................ 6
Terminology .................................................................................................... 6
Overview .............................................................................................................. 8
The Perfect Pick™ Solution ............................................................................ 8
Base System ................................................................................................... 9
Safety ................................................................................................................ 10
Other Cautions .............................................................................................. 13
Ultra-capacitor Product Information ................................................................... 14Interlock system ................................................................................................. 15
Emergency Stop (E-Stop) switches .............................................................. 16
Light Tower ................................................................................................... 17
Using Perfect Pick ............................................................................................. 18
Inventory Control System software ............................................................... 18
OPEX software .................................................................................................. 22
Specifications .................................................................................................... 23
Physical Specifications: ................................................................................ 23
Tote/Tray Specifications: .............................................................................. 23iBOT Specifications: ...................................................................................... 25
Environmental Specifications: ....................................................................... 25
Wireless Transceiver ......................................................................................... 26
FCC information / informations FCC ............................................................. 26
Industry Canada information / Industrie Canada l'information ...................... 27

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4
Perfect Pick User Manual - OPEX Corporation use only - not for distribution

1

Introduction

About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ultra-capacitor Product Information . . . . . . . . . . . . . . . 14
Interlock system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Using Perfect Pick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPEX software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Perfect Pick
User ManualAbout this manual
The Perfect Pick manuals use the following conventions to describe certain
procedures and situations. Please be aware of these conventions whenreading the manuals and operating the machine:
DANGER: Indicates a hazardous situation that, if not avoided, will result indeath or severe injury. The use of this signal word is limited to the mostextreme situations.
WARNING: Indicates a hazardous situation that, if not avoided, could result
in death or serious injury.
CAUTIONCAUTION: Indicates a hazardous situation that, if not avoided, could resultin minor or moderate injury.
NOTICE: Indicates information considered important, but not hazardrelated.

Terminology
The following terms/concepts are used to describe the software and functionality of the Perfect Pick machine.
Warehouse Management System (WMS)Manages physical inventory locations, and provides automation:
conveyors, Automated Storage/Retrieval System (AS/RS), picking,restocking, etc.
Warehouse Control System
Controls and tracks inventory movements.
Inventory Control System (ICS)This term is used to describe the third-party software that provides both the
Warehouse Management System and the Warehouse Control System.

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Storagelocations(both sides ofthe machine)

Inventory
Control System
MonitorPick station

Tote
iBOT

Introduction
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7

Overview
WARNING: Read “Safety” on page 10 before attempting to operate thisequipment.

The Perfect Pick™ Solution
Opex Perfect Pick™ is a fast, compact and highly scalable automated aisle
storage and piece picking solution. Ultra-capacitor powered wireless iBOTs™
(Intelligent Robotic Wireless Vehicles) navigate along a track system
integrated within the storage rack. Every iBOT can access every location anddeliver trays or totes directly to pick stations at either end of the aisle. Aisle
throughputs are highly scalable up to 1000 dual cycles per hour.
Perfect Pick is a unique, automated, goods-to-man, picking solution that
achieves superior throughput in a self-contained aisle that relies on a single
component – the iBOT.
• Perfect Pick employs proven iBOT delivery technology to pick and stock
inventory simultaneously.
• Every iBOT has access to 100% of the inventory.
• iBOTs deliver totes or trays with precise sequencing directly to ergonomically designed pick stations located at one or both ends of the aisle at rates
up to 1000 dual cycles per hour.
• As ultra-capacitor powered iBOTs navigate along a track system integrated
within the storage rack, they capture regenerated energy.
• iBOTs operate on the principle of redundancy, so Perfect Pick has no single
point of failure.
• The iBOTs can be tilted for ergonomic picking.

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Base System
The Perfect Pick base system includes:• Front pick station• Host PC with Inventory Control System software• OPEX PC with OPEX software• Two Storage columns (the number of tote locations varies with height andload size).
• 5 iBOTs
The Perfect Pick can be expanded over time by adding racking modules and/or
additional iBOTs.

Note: See “Specifications” on page 23 for configuration details.

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9

Safety
Follow these safety precautions to avoid injury when operating the Perfect
Pick. Failure to follow these precautions may result in severe personal injury or
damage to the machine.
Machine Entry Do not go inside the Perfect Pick rack system for any reason.
Only approved OPEX technicians can enter the machine.
The following label is found on both sides of the pick station(s).

CAUTION
Automatedmachinery
DO NOT ENTERCUIDADO
Maquinaria
automatizada
NO ENTRE

Charging rail Hands should be kept clear of the charging rails at all times.
Shorting of the charging rails with either a watch or ring may result in electricalshock.
TIP: One of the easiest ways to determine the front of the machine is to notethe location of the vertical charge rail. The vertical charge rail will always be in
the front of the machine.

Verticalcharge rail

Horizontal
charge rail

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Climbing the structure Do not use the scissor lift, fork lifts, ladders, or climb
the structure. Only approved OPEX technicians and qualified personnel areauthorized to use the scissor lifts and iBOT recovery tools.

Structure

Scissor lift

CAUTION
DO NOT CLIMBSTRUCTURE

This label is found on the exposed ends of every otherladder, just above where the exterior cover ends. If themachine has no rear pick station, another set of theselabels goes on the backs of the rear ladders.
CUIDADONO SE TREPEA LAESTRUCTURA

Moving parts Keep loose objects away from any exposed, moving parts ofthe machine. The moving parts of the Perfect Pick can become jammed and/or
damaged by foreign objects. Also, keep hands, hair, loose clothing or jewelryaway from the moving parts.
This label can be found on bothsides of each pick station, on
the metal plate above thediagonal track.

CAUTION
KEEP HANDSAWAYIntroduction
Perfect Pick User Manual - OPEX Corporation

CUIDADO
MANTENGALAS MANOSALEJADAS

11

Main Power Enclosure Only approved OPEX technicians and qualified
personnel are authorized to access the main power enclosure for troubleshooting and/or servicing the machine.

WARNING
Arc Flash andShock Hazard
Follow all requirements in NFPA 70E
for safe work practices and for
personal protective equipment

ADVERTENCIA
Riesgo de descarga
y arco eléctrico
Siga todos los requisitos
en NFPA 70E para prácticas
de trabajo seguras y equipos
de protección personal

This warning label is found on thefront of the Main Power Enclosure

Main Power Enclosure

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Perfect Pick User Manual - OPEX Corporation

iBOT safety The iBOT was designed to carry loads of up to 60 pounds. In
order to function properly, the iBOT incorporates automated machinery alongwith potentially hazardous voltages. Therefore, it should be treated with care.

This label is found on the exposed metalon the top of the iBOT. One facing front,
one facing back.

There are two of these labels on the iBOT,
next to the hazardous voltage labels.

This label is on the iBOT's cover. Oneon each side, on the slanted surface.

WARNING
Hazardous
Voltage
InsideCAUTION
KEEP AWAY
moving parts

CAUTION
Automatedmachinery

ADVERTENCIA
Voltaje Peligrosa
AdentroDe esta Caja

CUIDADO
MANTENGASEALEJADOpartes móviles

CUIDADO
Maquinaria
automatizada

Other Cautions

CAUTIONCAUTION: The ultra-capacitors that power the iBOTs contain acetonitrile. In
the event that an ultra-capacitor should leak, avoid contact with or breathing
the acetonitrile. For information on ultra-capacitor safety, refer to “Ultracapacitor Product Information” on page 14.

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Perfect Pick User Manual - OPEX Corporation

13

Ultra-capacitor Product Information

Product Information Sheet
An MSDS is not required. This information sheet is provided as a service to our customers. An MSDS for the active chemical inside the listed products isavailable upon request. For US Customers: The products referenced herein are exempt articles and are not subject to the OSHA Hazard
Communications Standard Requirement 29 CFR 1910.1200. For EU Customers: The products referenced herein are not submitted to 91-155 EEC, as
they are considered as components and not as a chemical substance. Notice: The information and recommendations herein contained are made in goodfaith and are believed to be accurate at the date of preparation. Maxwell Technologies Inc. makes no warranty expressed or implied.

Product Information
Manufacturer
Maxwell Technologies Inc.
9244 Balboa Avenue San Diego, CA 92123
Phone: 858-503-3300
Fax:
858-503-3333
EMERGENCY PHONE:
North America
Chemtrec Hazmat Communication Center
EuropeSwiss Toxicological Information Centre

1 800 424 9300
+ 1 703 527 3887

Product:

Ultracapacitors

Models:All configurations and versions ofPC5, PC10, PC5-5, BCAP0005 andBCAP0010

Date:

June 19, 2009

Asia
Chemtrec Hazmat Communication Center

1 800 424 9300
+ 1 703 527 3887

+41 (0)44 251 5151

Product Components
Important Safety Note: Ultracapacitors should not be opened, disassembled, crushed, burned, or exposed to high temperatures (>85°C, 185°F), andshould be operated only within their defined operating specifications. Failure to adhere to operating specifications could result in poor device
performance or unsafe operating conditions. Exposure to the components contained within the ultracapacitor could be harmful under certain
circumstances. In case of exposure to ultracapacitor contents, wash affected area for at least 15 minutes with generous amounts of water and seek medical
attention. Fires involving these types of ultracapacitors should be extinguished with CO2, dry chemical, alcohol foam, or all purpose AFFF extinguishingmedia. Water may be ineffective but should be used to cool fire-exposed containers, structures and to protect personnel.

BOOSTCAP® ultracapacitors are composed of the following major components:
Electrodes:
Separator:
Electrolyte:
Other:

Activated Carbon
Polypropylene or Cellulose
Quaternary salt (tetraethylammonium tetraflouroborate)
Organic solvent (acetonitrile)
Aluminum, steel

Disposal
BOOSTCAP ultracapacitors are neither specifically listed nor exempted from government hazardous waste regulations. The only materialof possible concern is the organic solvent, which when discarded or disposed of, is a hazardous waste according to Federal regulations (40CFR 261). It is listed as Hazardous Waste Number U003, so listed due to its toxicity and ignitability. Disposal can occur only in properly
permitted facilities. Check state and local regulations for any additional requirements, as these may be more restrictive than federal laws
and regulations.
Transportation
Ultracapacitors as articles are not specifically listed nor exempted from hazardous materials regulations (HMR). The U.S. Department ofTransportation has provided Maxwell Technologies a written determination regarding Maxwell’s PC5 and PC10 BOOSTCAP
ultracapacitor products that the materials comprising the ultracapacitors are “…in a quantity and form that does not pose a hazard intransportation. Therefore, the ultracapacitors are not subject to the HMR.”
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Document #1004596.4

14Introduction
Perfect Pick User Manual - OPEX Corporation

Interlock system
The system interlocks include the drop-away panel (Figure 1), the light curtain(shown in Figure 2), and the E-Stop switches. The light curtain is used to stop
just the iBOTs in the pick station area, should you have your hands in the iBOT
travel areas when the iBOTs are in motion.

Magnetic system interlock

Figure 1: Drop-away Panel (removed from the machine)
Note: The magnetic sensor is located at the bottom left side of the panel andcan be easily tripped by kicking the panel. When this panel is removed, alliBOT motion will stop. This panel must be removed when the service
technician needs to install/remove an iBOT from the system.
WARNING: If an iBOT is completely discharged and away from thecharging rail, moving the iBOT so that it comes in contact with a live rail
could cause an arc capable of damaging the iBOT. Protections are in place
to prevent this from happening, but if the interlocks or e-stops are bypassed,
the potential for damage exists.

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15

Emergency Stop (E-Stop) switches
The Perfect Pick system incorporates emergency-stop buttons and interlocks
to help keep the operator safe. Familiarize yourself with the location of themachine Emergency Stop (E-stop) switches. The E-Stop should be used prior
to entering the machine, in the event of an emergency, or situations which may
result in personnel injury. The E-stops are installed on the front and back of themachine. The big, red, mushroom-shaped emergency stop switches enable aquick stop of all motors in the machine. If necessary, push one of the e-stops
and the machine will stop immediately and kill power to the charging rails. To
restart the machine, have the OPEX technician clear the machine (if needed),pull the E-Stop knob out, and restart the machine by pressing the green Start
button. The Clear to Pick light is also a safety feature and only lights when it issafe for the user to pick an item from the presented tote.

E-Stop Switch
Start button
Clear to Pick lightLight Curtain

Figure 2: E-stop and interlock locations

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Light Tower
The light tower shows the status of the machine:

No Lights - Stopped/Off
Green - running normallyBlue - jammed/maintenance required
Flashing Blue - maintenance mode (see note)Flashing Yellow - starting
Red - Interlock/E-Stop tripped

Beeping Audible - Starting

Note: From Maintenance mode, the machine is restarted which willbring the solid green light on in addition to the flashing blue light.
Once the technician determines that the machine is operating properly,
he/she will turn off the flashing blue light by exiting Maintenance mode,leaving only the solid green light.

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17

Using Perfect Pick
Inventory Control System software
It is not the scope of this document to describe the functionality and operationof the third-party Inventory Control System (ICS) software. However, it isimportant to understand the basics, since the ICS provides the main interface
with the Perfect Pick system.
The inventory control software can operate in several modes. In normal
operations, the user will primarily use Continuous mode. This mode presents a
number of order-request containers to the picker along a conveyor, with eachcontainer being replaced as soon as it is completed.
Another mode that may be used (depending on your setup) is Put-away mode,
which is used for restocking inventory. Put-away is initiated when an operator
selects put-away from the ICS user interface. The procedure is similar toContinuous mode. A container with inventory items is presented to theoperator, who then puts the specified amount of items into the iBOT-delivered
tote.
Item detail

Item location

Quantity

Container detail

Control buttons

Figure 3: Inventory Control System - example

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Overview of operation (refer to Figure 3)
1 The monitor identifies the next item to be picked (Item detail), the Pick
Quantity, and the item location within the tote - an iBOT could present one
large tote, or a compartmentalized tote. Figure 3 (Item location) shows atote broken up into thirds, and the picker is directed to pick from the middle.
2 Pick the quantity identified in the interface (in this example, the quantity is4). Depending on your operation, you might also have to bag the items andplace a label on the bag (the labeler is shown in Figure 5).
3 To the right of the Perfect Pick is a conveyor with containers. As thecontainers advance toward the Perfect Pick, they pass a scanner (seeFigure 4), which reads the bar code on each container. The scanned
information is used to determine in which container to place the picked
parts.

Scanner
Figure 4: Scanner
4 The monitor identifies the location of the container on the conveyor where
the user needs to place the picked part. There are four available locations
which are identified by the light bar (see Figure 5).

Introduction
Perfect Pick User Manual - OPEX Corporation

19

Document printerLabeler

10 items
30 items

In this example, 10 items are needed for the 3rd container,and 30 items are needed for the 4th container.
Figure 5: Light bar
5 Put the selected quantity in the correct container(s).
6 Press the light bar button to advance to the next item.
7 When an order has been completed (all parts picked), a packing list is automatically printed and the monitor displays a “Place document in container”
message (see Figure 6).
Note: Depending on your operation, your system may not require a printer.

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The screen
displays amessagethat the orderis completed.

Figure 6: Inventory Control System - end of order message
8 Place the packing list in the container.
9 Press the light bar button to send the container off for further processing.

The Inventory Control System will provide information as to when the job isfinished.

Note: When running in “put away” mode, you should never restock a tote withitems piled higher than the top of the tote. Overfilling the tote will likely
cause jams in the machine.

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21

OPEX software
The OPEX software is used for troubleshooting the Perfect Pick system. In
diagnostics, it shows the status of the iBOTs and their locations, as well as thelocations of the totes in real time. Though primarily used by the OPEX
technician, there may be situations where you need to use this software, suchas to park the iBOTs.
How to park the iBOTs

CAUTIONCAUTION: The actual removal and installation of iBOTs should only bedone by a qualified Opex technician. These instructions are provided for
informational purposes only.

1 At the Perfect Pick controls, if the Diagnostics screen is not displayed, click
the Diagnostics button.
Note: If you are on the Run Screen, clicking the iBOTs tab will also display
the following information.

Diagnostics
buttonPark iBOTs

Figure 7: Diagnostics screen
2 This screen offers three buttons to park the iBOTs at different locations:
Park Top, Park Vertical, or Park Bottom. Click the appropriate button.
Note: If functional iBOTs are sent to wait at the top of the machine, you will
have approximately 2 hours before they lose their charge. The ConserveiBOT Power button in Diagnostics makes the iBOTs stop sending
constant status updates to the machine to save energy.
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Specifications
Physical Specifications:
Height16 ft. 6 in. to 32 ft. 4 in., in approx 4 ft. increments• 3 bay module: 74.2 in.

Length• Front pick station: 145 in. (includes two storagebays)• Optional rear pick station: 88 in. (includes nostorage bays)• Expandable up to 200 feet

WidthPower Requirements

Minimum space
between aisles

9 feet• 440VAC 60HZ 3-phase - at location of mainelectrical enclosure• 115VAC 1-phase - one to the UPS for computers infront, one to the UPS for computers in back
6 inches• Rear Pick Station

Options• In-Rack sprinkler system• Side Covers

Tote/Tray Specifications:• Dimensions: 20.8785 in. x 29.75 in. (inside: 19 in. X
28.625 in.)• Internal height: 10.875 in.
12 in. Tote

• Weight: Tote: 12 lbs.
Short divider: 0.8 lbs.
Long divider: 1.25 lbs.
Note: Other size totes may now be available. Multiple
tote heights can be intermixed within an aisle.

Introduction
Perfect Pick User Manual - OPEX Corporation23

• 20.6 in. x 30.0 in.
• 2.0 in. high (1 in. reinforced floor thickness, with 1 in.
rim)

Tray

• Weight: 6 lbs.
Picking module

Double ended

long divider
1 position

Short dividers (up to 3 per tote) - 5 available positions
Figure 8: Tote dividers (drawing not to scale)

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iBOT Specifications:
Speed

Up to 75 ips

Acceleration

Configurable by tote, up to 1/2 g

Max load

60 lbs. (including tray/tote)

Performance
Safety Features
Wireless Communications• Scalable Throughput• Up to 1,000 Dual Cycles Per Hour• “Safe move only” centralized traffic control system• Dual fail-safe braking systems
2.4 GHz wireless communication

Environmental Specifications:Temperature

50F - 90F

Humidity

0 - 95% RH non-condensing

Introduction
Perfect Pick User Manual - OPEX Corporation25

Wireless Transceiver
FCC information / informations FCC
This device complies with Part 15 of the FCC Rules. Operation is subject to thefollowing two conditions: (1) this device may not cause harmful interference,and (2) this device must accept any interference received, including interference that may cause undesired operation.
The wireless transceiver antennae must not be modified or, replaced with thatof a different type. Servicing of the transceiver is limited to properly trained
OPEX technicians. No end-user servicing is permitted.
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; other electronic
functions not associated with the certified module or certified transmitter may
require additional equipment authorization. The module should not bemarketed and sold in a way that have to be end-user accessible/replaceable. A
host product is required to comply with all applicable FCC equipment authorizations regulations, requirements and equipment functions not associated withthe transmitter module portion. To ensure compliance with all non-transmitter
functions the host manufacturer is responsible for ensuring compliance withthe module(s) installed and fully operational.
Users and persons nearby the equipment will maintain a minimum 20 cm (8”)
separation distance from device antenna.
FCC ID VDM2048910 Model 2048910
Cet appareil est conforme à la partie 15 des règles de la FCC. Son fonctionnement est soumis aux deux conditions suivantes: (1) ce dispositif ne doitpas causer d'interférences nuisibles, et (2) cet appareil doit accepter touteinterférence reçue, y compris les interférences qui peuvent provoquer un fonctionnement indésirable.
Les antennes d'émission-réception sans fil ne doit pas être modifié ou
remplacé par celui d'un autre type. Entretien de l'émetteur-récepteur est limitée
à une formation adéquate des techniciens OPEX. Pas de service de l'utilisateur final est autorisé.

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Les changements ou modifications non expressément approuvés par OPEX
Corporation pourraient annuler l'autorité de l'utilisateur à utiliser l'équipement.
Module ne peut pas être co-localisé avec autre antenne ou émetteur, saufcomme indiqué dans l'état de la délivrance de l'autorisation de l'équipement;
d'autres fonctions électroniques ne sont pas associés avec le module émetteur
certifié ou certifié peuvent exiger une autorisation de matériel supplémentaire.
Le module ne doit pas être commercialisé et vendu d'une manière qui doiventêtre l'utilisateur final accessible / remplaçable. Un produit d'accueil est tenu dese conformer à toutes les autorisations applicables FCC d'équipement
règlements, des exigences et des fonctions de l'équipement ne sont pas
associés avec la partie de module émetteur. Pour assurer la conformité avec
toutes les fonctions non-émetteur le fabricant hôte est responsable d'assurer laconformité avec le module (s) installé et pleinement opérationnel.
Les utilisateurs et les personnes à proximité de l'équipement seront demaintenir un minimum de 20 cm (8 ") de la distance de séparation de l'antenne
de l'appareil.
FCC ID VDM2048910 Model 2048910

Industry Canada information / Industrie Canada l'information
According to RSS-Gen Issue 4 Section 8.3:
This radio transmitter IC: 7175A-2048910 has been approved by Industry
Canada to operate with the antenna types listed below with the maximum
permissible gain indicated.
Antenna types not included in this list, having a gain greater than the maximum
gain indicated for that type, are strictly prohibited for use with this device.

Internal antenna: Inverted F PCB (gain: 2.2 dBi); or,External antenna: Digi-International A24-HASM-450 (gain 2.14 dBi)

According to RSS-Gen Issue 4 Section 8.4:
This device complies with Industry Canada’s license-exempt RSSs. Operation
is subject to the following two conditions:Introduction
Perfect Pick User Manual - OPEX Corporation27

1 This device may not cause interference; and2 This device must accept any interference, including interference that may
cause undesired operation of the device.

Selon RSS-Gen Numéro 4 Section 8.4:
Cet appareil est conforme aux CNR exempts de licence d'Industrie Canada.
Son fonctionnement est soumis aux deux conditions suivantes:
1 Ce dispositif ne peut causer des interférences; et
2 Ce dispositif doit accepter toute interférence, y compris les interférencesqui peuvent causer un mauvais fonctionnement de l'appareil.

IC : 7175A-2048910 Model 2048910

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