For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral equipment installed in a work cell.

For safe use of Mujin Systems, you must read and follow the instructions in the “Operations Manual” provided with your system.

System Users

The personnel can be classified as follows.

Operator:

Turns the robot controller power on/off.

Starts the robot program from operator panel.

Trained maintenance worker:

Operates the robot.

Services the System from inside the safety fence

Performs maintenance (repair, adjustment, replacement)

*Operators are not allowed to service the system from within the safety fence.

**Trained maintenance worker is allowed to work in the safety

fence. Works carried out in the safety fence include transportation, installation, teaching,

adjustment, and maintenance.

***To perform functions inside the safety fence, the person must be trained in proper system operation.

The following table lists the work outside the safety fence. In this table, the symbol “” means the work allowed to be carried out by the worker.

Task	Operator	Trained Maintenance
Turn Power ON/OFF to System	x	x
Select Robot Operation Mode		x
Reset Alarms	x	x
Reset Safety Functions	x	x
Start / Stop System	x	x
Emergency Stop System	x	x
Service System according to Operation Manual	x	x
Maintain System according to Maintenance Manual		x

Safety Notations

To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is indicated by "NOTE". Read the contents of each "WARNING", "CAUTION" and "NOTE" before using the robot. Warning labels play a critical role in communicating potential hazards associated with operating the robot cell and outlining necessary safety precautions. These labels are strategically placed throughout the system to ensure clear visibility and to serve as a constant reminder to operators and maintenance personnel of potential risks. It is crucial that all personnel working with or around the system familiarize themselves with the warning labels and adhere to the safety precautions they recommend. Regularly inspect the labels for any signs of wear, damage, or fading that may impact its legibility. If a label is damaged or missing, promptly report the issue and replace the label to ensure continuous safety awareness. Some of the warning labels around the system have been mentioned below:

Description	Labels
Robotic Area: Danger sign to protect and caution operators from entering the cell.
Not an Entrance: Sign to notify operators not to enter through the opening.
Compressed air: Warning sign to caution operators to bleed off air before servicing.
Falling material: Danger sign to warn operators of falling material from the pallets.
Stay clear of moving conveyors: Sign to caution operators to stay clear of running conveyors. Follow LOTO procedure before servicing or repairs.
Pinch point warning: Alerts operators to areas where moving parts may cause crushing or pinching injuries if hands or fingers are caught between them.
Rotating machinery: Danger sign located around the cell to caution operators of AMR’s rotating.
High voltage warning: Indicates that a specific area or component of the robot cell contains electrical hazards that may cause electric shock or electrocution if not responsibly managed.
LOTO: Signs located near every device where LOTO procedure is required.

In addition to understanding and adhering to the information on warning labels, all personnel should follow the general and robot cell-specific safety guidelines provided in this manual to ensure a safe and efficient working environment.

Lockout-Tagout Best Practices

Lockout-tagout (LOTO) is an essential safety measure that must be followed when servicing or maintaining the Mujin system. LOTO is the process of disconnecting and isolating equipment from its energy source to prevent unexpected start-up or release of energy that could cause harm to personnel.

Before servicing or maintaining the system, the operator must ensure that the equipment is de-energized and cannot be restarted until the maintenance or servicing work is completed. LOTO procedures require locks and tags to prevent the equipment from being accidentally energized or re-energized during maintenance or servicing work.

A close-up of a lock on a box

Description automatically generated

Figure 35: LOTO for Power Disconnect

Close-up of a machine with a pressure gauge

Description automatically generated

Figure 36: Pressure relief valve

The LOTO process for the Mujin system involves the following steps:

Notify affected personnel: Inform all relevant personnel that maintenance or servicing work is about to take place.
Shut down the equipment: Follow the shutdown procedure outlined in the manual to cease equipment operation.
Door interlock lockout: After entering the system through the door, keep the door interlock key on you.
Disconnect the power sources: Ensure all energy sources are isolated.
There are multiple electrical power disconnects located in the system:
1. Robot cell: Each robot cell will have a main power disconnect located next to the panel.
2. Primary control panel: There will be a disconnect next to it.
3. Each PDP in the robot cell has a quick disconnect.
4. Each blower panel in the robot cell has a quick disconnect.
5. Pallet Stacker: The pallet stacker is powered through the power disconnect located near the pallet stacker.
6. AMR chargers: Each AMR charger is powered by a power disconnect located near it.

There are three pressure relief valves installed in each robot cell next to the blower.

Lock and tag: Lock and tag the equipment to prevent it from being accidentally energized or re-energized during maintenance or servicing work.
Test the equipment: Confirm the equipment is de-energized and cannot be restarted until the maintenance or servicing work is completed.
Conduct the maintenance or servicing work: Proceed with the required tasks safely.
Remove the locks and tags: Once maintenance or servicing work is complete, the operator can remove the locks and tags, then restore power to the equipment.

[MK1]

Figure 37: LOTO locations

By following LOTO procedures, the operator can ensure that the Mujin system is safely maintained or serviced without the risk of unexpected start-up or release of energy that could cause harm to personnel.

Revision

Revision	Date	Name	Comments
V 0.1	07/15/2024	Don Harmon	Initial Release
V 1.0	11/20.2024	Jonathan Abernethy	Pre-warranty release
V2.0	11/25/2024	Jonathan Abernethy	Project Release

System Overview

This section provides a comprehensive overview of the system components, their roles, and operational interactions to enable safe and effective use. The system integrates advanced robotics, handling mechanisms, and user interfaces to optimize material handling and palletization tasks.

Robot Cell

Robot Arm (CP500L):
1. Central to the automation process, performing high-precision pick-and-place, stacking, and palletizing tasks.
2. Specifications:
  - Max Payload: 500 kg
  - Reach: 3255 mm
  - Position Repeatability: ±0.5 mm.
  - Operational Environment: 0–45°C, 35–85% humidity.
3. Key Features:
  - End-of-Arm Tool (EOAT) for product handling.
  - Dress Pack for managing cables and hoses.
  - Vision System for object recognition and precise positioning.

Pallet Dispenser (PD1/PD2)

Functionality:
1. Automates the stacking and destacking of pallets.
2. Integrated with lifting arms and sensors for consistent operation.
Key Adjustments:
1. Air pressure.

Material Handling and Labeling Systems

Stretch Wrapper (WRTA200):
1. Wraps palletized loads with modifiable parameters for load stability during transportation.
2. Includes emergency stop features and intuitive user controls.
Labeling System (Fox IV 6955/6957):
1. Automated print-and-apply functionality with diagnostics and customizable application methods.
2. Includes Zebra print engines (ZE511/ZE521) with user-friendly touch screens for maintenance and setup.

Safety and Controls

Electrical Panels:
1. Centralized system for power distribution, emergency stops, and status monitoring.
2. Access restricted to authorized personnel.
User Interfaces:
1. Goods-to-Person (GTP) and Warehouse Execution Systems (WES) interfaces for real-time task management and device health monitoring.

Integrated Software Systems

Vision and Navigation:
- Autonomous Mobile Robots (AMRs)[MK2] for pallet transport, equipped with safety and status indicators.

Preventive Maintenance Highlights

Diagnostics for print-and-apply systems to ensure operational continuity.
Maintenance logs and schedules are integrated to predict and avoid downtime.

References

Operation Manual (230118_V1).

Glossary of Terms

AMR	Autonomous Mobile Robot
Cell	Subsystem/component
Container	Pallet, conveyor, etc.
DC	Destination container
Destination	Place container for robot
E-stop	Emergency Stop
HMI	Human Machine Interface
IBOB	Inbound-Outbound Station
LED	Light Emitting Diode
LOTO	Lockout-Tagout
MHE	Material Handling Equipment
PCP	Primary Control Panel
PDP	Power Distribution Panel
RCP	Robot Control Panel
SC	Source container
SKU	Stock Keeping Unit
Source	Picking container for robot

Preface

The purpose of this manual is to describe the workload and frequency of regular inspections, hygiene, and care for your Mujin System. Mujin is here every step of the way to ensure success and maximized return through various training and maintenance programs. For more information regarding training classes or maintenance support programs contact; [email protected].

Below topics will discuss the various tasks associated with inspection and hygiene for each major mechanical component. These tasks are vital to efficient and reliable fictionality. A clean machine is an efficient machine, and a clean work cell is a safe work cell.

Contact Information

Mujin NA

Phone: 1.888.501.MUJN (6856)

Email: [email protected]

Website: https://support.mujin-corp.com

(Customer Support Portal credentials to be provided)

Address: 7250 McGinnis Ferry Rd, Suwanee GA 30024

Mujin Asia

Phone: +81.3.4577.7638

Email: [email protected]

Website: https://support.mujin-corp.com

(Customer Support Portal credentials to be provided)

Address: 3-8-5 Tatsumi, Koto-Ku, Tokyo 135-0053 Japan

Mujin EU

Phone: +31.970.102.05814

Email: [email protected]

Website: https://support.mujin-corp.com

(Customer Support Portal credentials to be provided)

Address: Mujin Netherlands B.V. Achtseweg Zuid 241B 5651 GW Eindhoven NL

General Use and Safety
Safety and General Operations Manual for CP500L

Terminology List

Understanding key terms associated with the CP500L robot is critical for safe operation and maintenance. Below are key terms, along with concise descriptions to ensure that all users, regardless of expertise, have a solid grasp of the equipment’s functionality:

CP500L: An advanced Kawasaki CP series industrial robot designed primarily for palletizing and other material handling tasks. It is highly suited for heavy-duty and high-speed operations in industrial environments.
Controller: The unit that controls the robot's functions, akin to the brain of the system. It processes commands from the user and manages the robot's movements and operational parameters.
Safety Fence: A protective barrier surrounding the robot's operational area, ensuring that personnel do not accidentally enter while the robot is in motion, thus preventing injury.
Lockout-Tagout (LOTO): A critical safety procedure employed to ensure that the robot is completely deactivated during maintenance or repair, eliminating any possibility of accidental restart or power-up.
Brake Release Unit: A manual control mechanism used to move the robot’s joints (axes) without power in case of an emergency or system failure.
Axes (JT1 - JT4): The points of movement in the robot, each axis controlling different rotational and linear movements—e.g., JT1 rotates the base, while JT3 raises and lowers the arm.
Valve Harness: An essential utility that provides air to operate the robot's tools through built-in tubing, ensuring seamless integration of external devices.

Machine Layout and Specifications

To ensure optimal performance and safety, it’s important to familiarize yourself with the technical specifications and layout of the CP500L. This section provides key technical details about the robot's capabilities, ensuring that operators and technicians have a complete understanding of its operational limits:

Model: CP500L-A (Kawasaki CP series)
Type: Articulated industrial robot, designed to handle high payloads and repetitive tasks with precision.
Degrees of Freedom: 4 (The robot has four axes, allowing it to rotate and articulate for maximum reach and flexibility).
Maximum Payload: The robot is rated to handle up to 500 kg, ideal for high-demand palletizing tasks.
Maximum Reach: The robot’s arm can extend up to 3255 mm, providing a significant working radius.
Position Repeatability: The robot can consistently return to a specific position within ±0.5 mm, ensuring high precision even in repetitive operations.
Palletizing Capacity: Approximately 1000 cycles per hour, optimizing throughput in material handling applications.
Mass: 1650 kg (robot weight without additional options).
Operating Speed: Axes (JT1-JT4) have specific rotational speeds, with JT4 operating at up to 180° per second for rapid wrist movement.
Built-in Utilities: Includes an air tube valve harness for operating pneumatic tools.

Visual Aid: A comprehensive machine layout diagram should be provided in the appendix, detailing key parts like the base, arm, wrist, control panel, and emergency stops.

[MK3]

Intended Use and Prohibited Uses
1. Intended Use

The CP500L is a high-performance robot specifically engineered for industrial applications requiring high payload capacity and precision. Its key uses include:

Material Handling: Transporting, lifting, and positioning heavy objects such as boxes, containers, or materials on assembly lines.
Palletizing: Automatic stacking of materials on pallets in a systematic and efficient manner, allowing for rapid and repetitive cycles without manual intervention.
Repetitive High-Speed Tasks: The CP500L excels in operations that require consistent, high-speed movement over extended periods.

Operators should always adhere to the recommended applications to ensure optimal robot performance and operational safety.

Prohibited Uses

It is critical to avoid using the CP500L in applications outside of its design parameters, which include:

Lifting Humans or Living Beings: The robot is not designed for lifting or interacting with humans directly under any circumstances.
Operation in Extreme Environments: Avoid using the robot in areas where temperatures drop below 0°C or exceed 45°C, as extreme temperatures can degrade performance and damage internal components.
Unauthorized Tooling or Payloads: Attaching third-party or unauthorized tools, or exceeding the payload limit of 500 kg, may cause malfunctions or mechanical failure.
Exposure to Dust, Oil, or Corrosive Substances: Such environments can degrade components and pose electrical safety hazards, compromising long-term reliability.

User Types and Qualifications
1. Operator

The operator is responsible for overseeing daily operation, ensuring that the robot functions correctly, and executing basic commands such as starting and stopping. Operators must be trained to handle the controller and understand emergency stop procedures.

Minimum Qualification: Basic operational training on robot controls, safety features, and emergency procedures.

Mechanical Installer

This role involves setting up and installing the robot. The mechanical installer must be proficient in assembling the robot and ensuring its proper alignment and mechanical stability.

Minimum Qualification: Experience with mechanical systems, with the ability to follow detailed setup and alignment procedures as described in the installation manual.

Electrical Installer

The electrical installer ensures that all electrical systems are correctly connected, and that power is safely routed to the robot’s systems.

Minimum Qualification: Certification in industrial electrical systems, with specific training on the robot’s electrical connections and safety systems.

Maintenance Worker

Maintenance personnel are responsible for conducting routine inspections, repairs, and component replacements. They must also handle emergency situations, such as system malfunctions or breakdowns.

Minimum Qualification: Advanced training in industrial robotics, with an emphasis on safety protocols, including Lockout-Tagout (LOTO) and emergency procedures.

Improvement: Incorporate a responsibility matrix, outlining the duties of each user role along with the required training level, ensuring clarity in team-based environments.

Safety Instructions

Safety is of utmost importance when operating the CP500L. This section provides critical safety instructions that must be followed at all times to prevent injury, damage to equipment, or operational downtime.

General Safety Guidelines

Pre-Operation Inspection: Before starting the robot, ensure all components are intact and functioning correctly. Inspect cables for wear, ensure that no tools or materials are left inside the robot’s work area, and check that all safety fences and emergency stops are in place.
Workspace Preparation: The area around the robot must always remain clear of personnel and materials during operation. Only authorized personnel should be within the vicinity of the robot when it is active.
Personal Safety: Operators must wear appropriate protective gear, including safety shoes, gloves, and helmets, to minimize the risk of injury in the event of an operational error.

Startup Procedures

System Boot-Up: Follow the controller's startup sequence as described in the operating manual. Always ensure the emergency stop system is tested before initiating any operations.
Initial Movements: During the initial run, observe the robot’s movements to ensure smooth, uninterrupted motion. Any irregularities should be addressed immediately by qualified personnel.

Shutdown Procedures

Standard Shutdown: At the end of a shift or operational period, follow the standard shutdown sequence on the controller. Ensure that all movement has ceased, and the robot is powered down before entering the work area.
Emergency Stop: If a hazardous situation arises, activate the emergency stop button to immediately cut power to the robot. Familiarize yourself with the location of all emergency stop buttons in the work area

Startup Procedure

[Inspect System]
- Check for loose components or visible damage.
- Verify that all safety guards and interlocks are functional.
- Ensure the area is clear of unauthorized personnel.

↓

[Power On]
- Activate the main power switch at the control panel.
- Confirm that all emergency stop buttons (EMOs) are released.
- Check for green status lights on the HMI indicating readiness.

↓

[Initialize Equipment]
- Use the HMI to home robotic arms, pallet dispensers, and labeling systems.
- Run initial system diagnostics to confirm all sensors and actuators are operational.

↓

[Start Operations]
- Begin the production process by pressing the “Start” button on the control panel or HMI.
- Monitor the system for any unusual behavior during startup.

Shutdown Procedure

[Stop Operations]
- Cease all active tasks by pressing the "Stop" button on the HMI or control panel.
- Allow the system to finish ongoing processes (e.g., moving pallets to the correct positions).

↓

[Power Off]
- Turn off non-essential systems using the Mode Selector Switch.
- Power down the main control panel.
- Disconnect the power source if maintenance is required.

↓

[Post-Inspection]
- Clean the equipment to remove debris or residue.
- Inspect for signs of wear or damage on mechanical components.
- Log any observations in the maintenance record.

Installation and Maintenance
1. Installation Guidelines

Proper installation is crucial for ensuring the CP500L operates safely and efficiently. The robot should be mounted on a stable, vibration-free surface, using high-tension bolts to prevent any movement during operation. Ensure that the floor’s flatness is within ±5° to maintain proper alignment.

Preventive Maintenance Schedule

To ensure long-term reliability and optimal performance, regular maintenance is required. The following schedule outlines key tasks to be performed at specific intervals:

Daily: Visually inspect the robot for any signs of wear or damage. Test emergency stop buttons and ensure that all cables are properly connected.
Weekly: Tighten any loose bolts or fasteners.

Monthly: Perform a detailed inspection of the motor seals, cables, and harnesses. Replace any worn or damaged components as necessary. Test the brake release unit to ensure it functions correctly in an emergency.
1. Daily Maintenance Checklist

General:

Perform a visual inspection of the equipment for any visible damage, debris, or contamination (Section 1.6.2, Section 2.5.2).
Clean all surfaces, ensuring no dust or dirt obstructs sensors or moving parts (Section 2.5.1, Section 3.10.1).
Check that emergency stop buttons (EMO) are functional (Section 1.7.1, Section 3.6.1).

Equipment-Specific Tasks:

CP500L Robot:
- Inspect joints and wiring for wear, damage, or leaks (Section 1.6.2).
- Listen for unusual sounds during operation and investigate any grinding or vibrations (Section 1.6.2).
AMR QuickTron M150:
- Test LIDAR sensors for obstacle detection (Section 2.4.2).
- Inspect wheels and ensure smooth rotation (Section 2.3.3).
WRTA200 Stretch Wrapper:
- Inspect rotary arm and film carriage for wear or damage (Section 3.2.1).
- Verify alignment of sensors and functionality of the cut and wipe system (Section 3.10.1).
Fox IV M6955L Labeler:
- Clean the printhead with approved cleaning solutions (Section 4.7.2).
- Check pneumatic systems for air pressure (80–100 psi) and leaks (Section 4.9.2).

Weekly Maintenance Checklist

General:

Clean all sensors and verify proper alignment (Section 1.8.1, Section 2.2.2).
Tighten bolts and fasteners to specified torque values (Section 1.6.1, Section 3.10.2).
Lubricate moving parts where recommended (Section 1.6.2, Section 3.10.2).

Equipment-Specific Tasks:

CP500L Robot:
- Inspect air system connections for leaks and check pressure (0.147 to 0.588 MPa) (Section 1.6.2).
- Clean joints and cables to prevent debris accumulation (Section 1.6.2).
AMR QuickTron M150:
- Clean LIDAR and cameras, ensuring unobstructed operation (Section 2.4.2).
- Inspect chassis and wheels for wear (Section 2.5.2).
WRTA200 Stretch Wrapper:
- Lubricate the rotary arm, chain drives, and rollers (Section 3.10.2).
- Check film roll tension and alignment (Section 3.10.2).
Fox IV M6955L Labeler:
- Verify air pressure regulators and check for leaks (Section 4.9.2).
- Calibrate sensors for accurate label application (Section 4.7.2).

Monthly Maintenance Checklist

General:

Conduct a detailed inspection of all components, including electrical connections, mechanical parts, and safety systems (Section 1.6.2, Section 2.5.3).
Replace any worn filters or parts to maintain operational efficiency (Section 1.6.2, Section 4.7.2).

Equipment-Specific Tasks:

CP500L Robot:
- Lubricate all joints and inspect air filters for clogging (Section 1.6.2).
- Test and recalibrate safety interlocks (Section 1.5.2).
AMR QuickTron M150:
- Perform diagnostics on the battery and charging systems (Section 2.7.1).
- Check the lifting mechanism for smooth operation (Section 2.5.3).
WRTA200 Stretch Wrapper:
- Inspect pneumatic connections for leaks (Section 3.10.3).
- Tighten all mechanical fasteners (Section 3.10.3).
Fox IV M6955L Labeler:
- Lubricate the applicator arms and inspect the vacuum system (Section 4.7.2).
- Replace worn components such as rollers or belts (Section 4.7.2).

Emergency Procedures and Troubleshooting
1. Emergency Stop

The CP500L is equipped with several emergency stop buttons located around its operational area. In the event of a malfunction or hazardous condition, pressing any of these buttons will immediately stop all robot movements, cutting off power to the system.

Troubleshooting Common Issues

To ensure smooth operation, the following troubleshooting steps can help resolve common issues:

Issue: The robot fails to start.
- Solution: Check the power supply, ensure the emergency stop is not engaged, and inspect the controller for error messages.
Issue: The robot’s movements are erratic or sluggish.
- Solution: Verify that all mechanical parts are free from obstruction, inspect the controller’s movement settings, and reset the system if necessary.

Improvement: Provide a detailed troubleshooting guide that addresses more complex issues, with step-by-step instructions for diagnosing and resolving them.

Personal Safety and Required PPE

The following personal protective equipment (PPE) is mandatory for all personnel working with or near the CP500L:

Safety Helmet: Protects against head injuries from falling objects or accidental collisions.
Safety Gloves: Prevents cuts or abrasions when handling sharp or heavy materials.
Protective Eyewear: Shields the eyes from dust, debris, or accidental fluid spills.
Hearing Protection: Required in environments where noise levels exceed 80 dB during operation.

Noise Levels and Environmental Conditions
1. Noise Levels

Under normal operating conditions, the CP500L emits noise levels below 80 dB (A). However, in prolonged or high-intensity operations, operators should wear hearing protection if noise levels become uncomfortable. Regular maintenance of moving parts can also help reduce excess noise.

Environmental Conditions

The CP500L is designed for use in controlled industrial environments. Ensure that the workspace is free of excessive dust, oil, and debris. The robot should not be exposed to corrosive substances, and it must be kept away from extreme temperatures and humidity levels. Regular environmental monitoring is recommended to maintain optimal working conditions.

Safety and General Operations Manual for AMR QuickTron M150
1. Introduction

The AMR QuickTron M150 is a highly advanced Autonomous Mobile Robot specifically designed for automated material handling in industrial environments such as warehouses and production facilities. This manual outlines critical safety guidelines, detailed operational instructions, and a comprehensive maintenance schedule to ensure the efficient and safe use of the equipment.

The primary goal of this manual is to ensure that operators and maintenance personnel are fully informed about the features, limitations, and safe handling practices of the M150 to prevent accidents and ensure the longevity of the equipment.

Intended Audience

This manual is intended for the following personnel:

Operators: Individuals trained to handle the AMR under both normal and exceptional circumstances, including troubleshooting and emergency stop procedures.
Maintenance Personnel: Certified professionals responsible for the routine maintenance, troubleshooting, and repair of the robot, with specific expertise in Lockout-Tagout (LOTO) procedures.

Safety Instructions
1. Terminology List

To ensure that all operators and maintenance personnel fully understand the various components and safety mechanisms of the AMR QuickTron M150, the following terminology is used throughout this manual:

AMR (Autonomous Mobile Robot): A self-navigating robot designed for automated load transportation in a structured environment such as a warehouse.
EMO (Emergency Off): A critical safety feature, the EMO button is located on the robot’s exterior and is used to instantly stop the robot in the event of an emergency.
LIDAR (Light Detection and Ranging): A laser-based sensor system employed by the robot to detect obstacles, monitor surroundings, and navigate safely through predefined paths.
Mode Selector Switch: A switch that enables the robot to toggle between automatic mode (used during regular operations) and maintenance mode (used during servicing).
LOTO (Lockout-Tagout): A safety procedure that ensures the robot is completely powered off and cannot be activated during maintenance activities. This involves locking the power source and tagging it to prevent accidental reactivation.

General Safety Guidelines

The following safety protocols must be followed at all times to avoid accidents and ensure the safe operation of the AMR QuickTron M150:

Pre-Operation Safety Check: Before initiating the robot, inspect all safety-critical systems such as the LIDAR sensors, EMO buttons, and battery systems. Ensure that there are no obstructions in the robot’s path and that the operating environment meets all prescribed conditions (e.g., flat, dry surfaces free from debris and liquids).
Operational Environment: The M150 should only be operated on smooth, dry surfaces. Avoid areas with oil spills, excessive dust, or moisture, as these conditions may lead to malfunction or pose a safety hazard. The floor should meet the specific tolerances outlined in this manual (e.g., cracks should not exceed 8 mm in width, and steps should be no more than 5 mm).
Safety Distance: During operation, ensure that personnel remain at least 500 mm away from the robot. The robot’s path must be clearly marked, and personnel should not enter the designated operating zone while the robot is in motion.
Emergency Stop Functionality: Test the Emergency Off (EMO) buttons located on both sides of the robot before each use. These buttons halt all movements immediately, and the robot cannot be restarted until the EMO button is reset and the system verified for safety.

General Operation
1. Intended Use

The QuickTron M150 is engineered for the autonomous transportation of goods within a structured industrial environment. It is equipped with inertial navigation and QR code-based positioning, enabling it to follow predefined routes with high precision.

The robot's design allows for seamless integration into automated workflows, where it autonomously loads, transports, and unloads materials while minimizing human intervention. It is optimized for warehouse and factory settings that adhere to specific environmental conditions such as flat, dry floors and a controlled ambient temperature.

Prohibited Uses:

Transporting personnel: The AMR is strictly designed for the transport of goods and must not be used to carry people under any circumstances.
Hazardous environments: The AMR should not be operated in environments that contain extreme dust, water, or explosive gases, as these conditions exceed its design specifications and may lead to malfunctions or serious safety hazards.

Key Specifications

The performance and physical specifications of the QuickTron M150 are critical to its proper operation. Below are the key metrics for reference:

Model: QuickTron M150
Dimensions: 1182 mm (L) x 832 mm (W) x 260 mm (H)
Weight: 225 ± 5 kg
Rated Load Capacity: 1500 kg.
Navigation Method: Inertial navigation coupled with QR code-based positioning for high accuracy.
Battery Life: Up to 9 hours of continuous operation after a full charge, with a charging time of approximately 1.5 hours.

Machine Configuration
1. Machine Layout and Components

The M150 is composed of several key systems, all designed to ensure smooth and safe operations:

Emergency Stop Buttons: Located on both sides of the robot, these buttons are highly visible and accessible in case of emergencies. Pressing any EMO button will immediately halt the robot’s movements.
LIDAR Sensors: These sensors are located at strategic points around the robot and provide real-time data to avoid obstacles. The sensors have a detection range of up to 500 mm and will stop the robot if an obstruction is detected within this range.
Mode Selector Switch: This switch toggles between automatic mode, where the robot follows pre-programmed instructions, and maintenance mode, where manual operations such as diagnostic checks and inching movements can be performed safely by trained personnel.

Detailed Safety Features

The QuickTron M150 is equipped with a robust array of safety features to prevent accidents and ensure smooth operation:

Emergency Stop Function: When the EMO button is pressed, the robot’s power is cut off instantly, bringing all movements to a complete halt. The system remains non-operational until the EMO button is manually reset and all conditions for safe operation are confirmed.
LIDAR Obstacle Detection: The LIDAR system detects obstacles in real time, and upon detection, the robot slows down and stops before reaching the obstacle. The obstacle must be cleared before the robot can resume its path. If an object smaller than 200 mm is in the robot’s path, the LIDAR may not detect it, so the operating environment must be kept free of small debris.

Maintenance and Safety
1. Lockout-Tagout (LOTO) Procedures

Before any maintenance tasks can be performed, it is essential to engage the LOTO procedure. This procedure ensures that the robot is completely powered off and physically locked to prevent accidental startup during servicing. The following steps must be adhered to:

Shut down the robot using the Mode Selector Switch.
Apply LOTO locks to the power source, ensuring that no unauthorized personnel can re-energize the robot during maintenance.
Tag the robot clearly to indicate that it is under maintenance and must not be reactivated until the work is complete.

Only personnel who have received formal LOTO training and certification should perform these tasks.

Routine Maintenance Tasks

Regular maintenance ensures the long-term reliability of the QuickTron M150 and helps prevent costly breakdowns. The following tasks should be performed routinely:

Daily Inspections: Before each use, check for any visible damage to the robot, especially around the wheels, sensors, and exterior casing. Ensure that the EMO buttons and LIDAR sensors are operational.
Weekly Maintenance: Clean the LIDAR sensors and ensure that the wheels rotate smoothly without obstruction. Check for wear and tear on moving components such as the lifting mechanism and the drive system.
Monthly Maintenance: Perform a more detailed inspection of the robot's battery, wiring, and internal systems. Ensure that the charging port is free from dust and debris and verify that all electrical connections are secure.

Residual Risks

Despite the extensive safety features built into the QuickTron M150, there are certain residual risks that operators and maintenance personnel must be aware of:

Obstacle Collision: Although the LIDAR system detects most obstacles, objects smaller than 200 mm may not be detected, leading to potential collisions. The operating environment should be kept free of such objects to minimize this risk.
Battery Hazards: Using a non-approved charger or incorrectly charging the battery may lead to overheating, resulting in a fire hazard or damage to the internal battery system.

Personal Protective Equipment (PPE)

To ensure the safety of personnel working near the AMR, the following PPE should always be worn:

Safety Gloves: To protect against sharp edges or hot surfaces.
Protective Footwear: Steel-toe boots are recommended to protect against potential impacts from moving parts or falling objects.
High-Visibility Clothing: Ensures that operators and maintenance personnel are easily visible within the robot’s operating environment.

Electrical Safety
1. Battery and Charging Safety

The M150 is powered by a high-capacity battery, and proper care must be taken during charging. Only use the original QuickTron charger to avoid overcharging or overheating.
Charging Process: The robot must be connected to the charger after each operational cycle. The charging port is located at the rear of the unit and is protected by a dust cover, which must be kept clean and dry to prevent malfunction.
Emergency Shutdown: In case of overheating or overcharging, the robot is equipped with an automatic shutdown mechanism. If this occurs, allow the battery to cool down before attempting to recharge.

Safety and General Operations Manual for Stretch Wrapper WRTA200
1. Terminology List

Understanding the terminology related to the Stretch Wrapper WRTA200 is crucial for safe, efficient operations:

Rotary Arm: The mechanical arm that rotates around the pallet, applying stretch film. It is controlled by the PLC for precision and uniform wrapping.
Film Carriage: The assembly that holds the stretch film and manages its tension during application. It includes rollers and a pre-stretch system to optimize film usage.
Cut and Wipe System: The mechanism that cuts the film at the end of the wrapping cycle and secures it to the load. This system reduces manual intervention and enhances operational efficiency.
PLC (Programmable Logic Controller): The core control system that manages all machine functions, including cycle times, pre-stretch levels, rotation speed, and emergency stop functions.
EMO (Emergency Off): A safety feature located at strategic points on the machine. When pressed, it stops all movement immediately, ensuring operator safety in emergencies.
Pre-stretch: The mechanism that stretches the film before application, allowing for reduced film usage and better load stability. The WRTA200 offers pre-stretch ratios of up to 250% for optimal efficiency.

Machine Layout and Specifications

The WRTA200 is engineered for high-speed, automatic wrapping of palletized loads, making it ideal for busy distribution centers and industrial environments. Below are its key specifications:

Model: WRTA200
Maximum Load Size: Can accommodate loads up to 2.4 meters (94.5 inches) in height and 1.2 meters (47.2 inches) in width.
Maximum Load Weight: Supports loads up to 4000 lbs (1814 kg).
Film Carriage Pre-stretch Ratio: Adjustable pre-stretch ratio of up to 250%, ensuring optimal film usage and securing the load with minimal waste.
Power Supply: Requires 120V/1ph/60Hz, 15A power source.
Pneumatic Requirements: Operates with an air pressure of 80-100 psi (550-690 kPa).
Film Roll Capacity: Holds film rolls up to 20 inches (508 mm) in diameter.

Key Components

Rotary Arm: Encircles the pallet during wrapping, driven by the PLC to provide even film application.
Film Carriage: Equipped with adjustable rollers that allow for a pre-stretch ratio to minimize film waste.
Cut and Wipe System: This system automates the end of the wrap cycle by cutting the film and securing it to the pallet, eliminating the need for manual tying or cutting.
Touchscreen Control Panel (HMI): Provides operators with control over machine settings, including film tension, wrapping modes, and emergency stop activation.

Intended Use

The WRTA200 is specifically designed for automated pallet wrapping in environments requiring consistent, efficient operation, such as large warehouses, distribution centers, and manufacturing plants.

Approved Uses:

Palletized Loads: The machine is designed to wrap stable, balanced loads, which can include boxes, containers, or other solid goods stacked onto pallets.
Multiple Wrapping Modes: The WRTA200 supports various wrapping patterns, including single or double wraps, top and bottom reinforcement wraps, and customized wrapping cycles for odd-shaped loads.

Prohibited Uses:

Unstable Loads: The machine should not be used to wrap loads that are loosely packed or unbalanced, as the rotating arm may displace or damage them.
Protruding Objects: Avoid wrapping pallets with protruding or sharp objects that may interfere with the film carriage or rotary arm and cause damage to the machine or pose safety risks.

User Types and Qualifications

To ensure safe and effective operation, the WRTA200 should only be used by trained and qualified personnel:

Operators: Trained staff responsible for loading and unloading pallets, initiating, and monitoring wrapping cycles, and making minor adjustments to the film carriage or tension settings.
Maintenance Personnel: Certified technicians authorized to perform repairs, conduct system diagnostics, and replace or adjust mechanical and electrical components. Maintenance personnel must be proficient in Lockout-Tagout (LOTO) procedures and safety standards.

General Safety Instructions
1. Before Use

Before initiating the wrapping cycle, the following steps must be performed to ensure safe operation:

Inspect the Machine: Perform a thorough visual inspection of the machine for any damage, loose components, or signs of wear. Ensure all moving parts, including the rotary arm, film carriage, and rollers, are in proper working order.
Check Safety Devices: Verify the functionality of all EMO buttons and ensure that protective guards are securely in place. Test the emergency stop function to confirm that it immediately halts all operations.
Load Stability: Ensure that the palletized load is centered and stable on the turntable before beginning the wrapping cycle. An unbalanced or off-center load may cause tipping or uneven film application.

During Operation

Operators must adhere to strict safety guidelines while the machine is in operation:

Stay Clear of the Wrap Zone: Do not enter the wrapping area while the machine is running. The rotary arm rotates at high speeds and can cause serious injury if someone is in the area.
Monitor Film Application: Ensure that the film is being applied smoothly, without wrinkles, tears, or breaks. Use the control panel to adjust film tension and rotation speed based on the load's size, weight, and fragility.
Emergency Procedures: Be prepared to stop the machine by pressing the EMO button in the event of any operational irregularity, such as a film jam, machine malfunction, or safety breach.

Maintenance and Repairs

Lockout-Tagout (LOTO): Always follow the LOTO procedure before performing any maintenance or repair work. This involves disconnecting the machine from its power and pneumatic supply and tagging it to prevent accidental startup during repairs.
Inspect and Clean: Regularly inspect the film carriage, rotary arm, and cut and wipe system for signs of wear or damage. Clean the rollers, sensors, and film dispensing mechanisms to prevent dust or film residue buildup.
Replace Worn Parts: Components like film rollers, gears, and the applicator pad should be inspected frequently and replaced as needed to prevent failure during operation.

Safety Provisions
1. Emergency Stop (EMO)

The WRTA200 is equipped with Emergency Stop (EMO) buttons located at strategic points on the machine. These buttons allow for immediate cessation of all machine operations in the event of an emergency. After engaging the EMO button, the machine will remain inactive until the issue is resolved, and the system is manually reset by a qualified technician.

Protective Fencing

The machine is designed with protective fencing around the wrapping zone to prevent personnel from entering the area while the rotary arm is in motion. This fencing must remain closed and locked during machine operation. Safety interlocks ensure that the machine will not operate if the fence is open.

Residual Risks

Even with built-in safety features, the following residual risks remain during operation:

Rotary Arm Movement: The rotary arm moves quickly during wrapping cycles. Operators must remain outside the wrapping zone to avoid injury from the fast-moving arm.
Film Application: Improper loading of the stretch film may cause it to snap, posing a hazard to nearby personnel and potentially interrupting the wrapping process.

Personal Protective Equipment (PPE)

All personnel operating or maintaining the WRTA200 must wear the following Personal Protective Equipment (PPE):

Safety Glasses: To protect against potential film debris or dust during operation.
Protective Gloves: To safely handle film rolls and machine components during maintenance.
Steel-Toe Boots: To protect against potential foot injuries from heavy pallets or machine components.

Electrical Safety

Grounding: Ensure the machine is properly grounded to avoid electrical shocks. Electrical malfunctions can cause injury and damage to the machine’s components if the system is not adequately grounded.
Power Supply: Ensure the machine is connected to a dedicated power source that meets its voltage and current requirements. Avoid using extension cords or power strips, which may not provide sufficient power or could lead to electrical hazards.

Maintenance Schedule

Routine maintenance is critical to the safe and efficient operation of the WRTA200. Below is the recommended maintenance schedule:

Daily Maintenance:

Clean the Film Rollers: Remove any dust or film residue from the rollers to ensure smooth operation.
Inspect the Film Carriage: Check for proper tension and alignment. Ensure that the film is loaded correctly and that the rollers are spinning freely.

Weekly Maintenance:

Inspect the Rotary Arm: Check for wear or damage to the rotary arm and its components. Tighten any loose bolts or connections.
Lubricate Moving Parts: Lubricate the film carriage rollers, rotary arm gears, and the chain drive to ensure smooth operation.

Monthly Maintenance:

Check the Electrical and Pneumatic Systems: Inspect all electrical connections, sensors, and pneumatic lines for signs of wear or damage. Perform a full diagnostic test to ensure the machine's PLC and safety systems are functioning properly.
Replace Worn Components: Identify and replace any worn or damaged parts, including the film rollers, cut and wipe components, and applicator pad, to prevent malfunctions.

Safety and General Operations Manual for Fox IV Pallet Labeler M6955
1. Introduction

The Fox IV Pallet Labeler M6955 is an advanced print-and-apply labeling system designed for high-volume industrial applications, particularly pallet labeling. This system integrates Zebra ZE511/ZE521 print engines, allowing for precise label printing at high speeds. With a programmable logic controller (PLC) and sophisticated pneumatic components, the machine is capable of operating continuously in demanding environments. This manual outlines comprehensive safety protocols, operation procedures, and maintenance schedules to ensure safe, efficient, and long-term operation.

Safety Instructions
1. Terminology List

The following terminology is essential for understanding and safely operating the Fox IV Pallet Labeler M6955:

LPA (Label Printer Applicator): The core system that prints and applies labels to pallets. It automates the labeling process to ensure efficiency and precision, minimizing the need for manual handling.
ZE511/ZE521 Print Engines: These print engines from Zebra Technologies are responsible for the high-quality printing process. The ZE511 offers a print width of 4.1 inches, while the ZE521 provides 6.6 inches, supporting print resolutions of 203, 300, or 600 dpi.
PLC (Programmable Logic Controller): The controller automates the entire labeling process, managing inputs such as sensor data, user commands, and operational safety protocols.
Applicator Pad: The mechanical arm or pad that physically applies the label onto the pallet. The pad is powered by the pneumatic system and operates at high speeds.
Air Cylinder: This pneumatic component drives the movement of the applicator. Correct air pressure ensures smooth operation, but too high or too low a pressure can result in mechanical failure or inconsistent labeling.
Touchscreen HMI: The Human-Machine Interface allows the operator to control the machine, input settings, view status updates, and troubleshoot errors. It is the primary interface for interacting with the system.

General Safety Guidelines

To ensure safe operation of the M6955, all personnel must strictly follow these safety guidelines:

Pre-Operation Safety Checks:
- Inspect the machine for visible damage or loose components. Pay particular attention to the printhead, pneumatic lines, and applicator pad.
- Ensure all safety guards are in place, especially around moving components such as the applicator pad and air cylinder.
- Test the EMO buttons to confirm they halt all operations when pressed. If any safety system is malfunctioning, the machine should not be used until repairs are completed.
Operating Environment:
- The M6955 should be installed in a clean, dry environment with ambient temperatures between 40°F and 104°F (5°C to 40°C) and relative humidity below 95%. Exposure to extreme conditions, such as dust, excessive moisture, or chemicals, can impair performance.
- Ensure the workspace is clear of obstacles and hazards that may interfere with the robot’s pneumatic and electrical systems.
Air Supply: The machine requires a consistent pneumatic supply of 80–100 psi (550–690 kPa). Verify the air pressure is within the correct range and check the system for leaks or unusual noises during operation.

General Operation
1. Intended Use

The Fox IV M6955 is specifically designed for high-speed pallet labeling in automated workflows. It is engineered to handle continuous operations in industrial settings, where pallets move along conveyor lines for precise label application.

Prohibited Uses:

The machine should not be used for labeling in hazardous environments containing excessive dust, liquids, or chemical vapors, as these may damage the print engine or compromise safety.
Unapproved labels or ribbons can cause print quality issues, ribbon jams, or even damage to the printhead. Only use materials specified by the manufacturer.

Machine Layout and Specifications

The M6955 is equipped with several critical components designed to handle high-volume labeling. Below are the key specifications:

Print Engines: Zebra ZE511 (4.1-inch) or ZE521 (6.6-inch) print engines, supporting print speeds of up to 18 inches per second (457 mm/s).
Print Resolution: Available in 203 dpi, 300 dpi, or 600 dpi, depending on the model and application requirements.
Label Roll Capacity: Capable of holding label rolls up to 16 inches (406 mm) in outer diameter, enabling long production runs without frequent refills.
Weight: Approximately 110 lbs (49 kg), ensuring a sturdy build suited for industrial environments.
Pneumatic Supply: Requires an air supply between 80 and 100 psi (550–690 kPa) to operate the applicator pad efficiently.
Power Supply: Operates on 90V–264V AC, 48–62 Hz, allowing for universal compatibility in various industrial settings.

Safety Provisions
1. Emergency Stop (EMO)

The machine is equipped with multiple Emergency Stop (EMO) buttons, located at key points on the machine. These buttons can immediately halt the machine’s operations when pressed. The system cannot resume operation until the EMO button is manually reset and the issue causing the emergency is resolved.

Protective Covers and Guards

All moving parts, including the applicator pad and pneumatic systems, are covered by protective guards. It is critical that these covers are not removed while the machine is in operation. Operating the M6955 without these guards can result in serious injury.

Maintenance and Repairs
1. Lockout-Tagout (LOTO) Procedures

To ensure safety during repairs and maintenance, the Lockout-Tagout (LOTO) procedure must be followed rigorously:

Power down the machine using the HMI.
Disconnect the air supply and apply LOTO locks to ensure that no unauthorized personnel can re-energize the system during repairs.
Tag the system clearly to indicate that it is undergoing maintenance.

Routine Maintenance Tasks

Routine maintenance ensures the continued efficiency and safety of the M6955. Adhering to the following schedule will help prevent breakdowns and extend the life of the equipment:

Daily Maintenance:

Inspect the label and ribbon supplies to ensure they are loaded correctly.
Clean the printhead using non-abrasive cleaning agents to remove adhesive residue, dust, and debris.
Check the rollers for build-up of dust or labels, as this can cause feeding issues.

Weekly Maintenance:

Inspect all pneumatic lines for leaks or signs of wear. Pneumatic failures can cause the applicator pad to malfunction.
Check for misalignment in the label feeds and ensure the printhead and rollers are properly aligned.

Monthly Maintenance:

Perform a full inspection of the machine’s electrical and pneumatic systems, including the PLC, HMI, and sensor networks.
Replace any worn parts, particularly in the applicator pad and air cylinder assemblies, to prevent breakdowns.

Troubleshooting Common Issues

Despite regular maintenance, issues may occasionally arise. Below are some common problems and their recommended solutions:

Print Quality Issues:
- Problem: Labels are printed faintly or are missing parts of the image.
- Solution: Check the printhead for dirt or debris, and ensure the ribbon and labels are compatible and correctly loaded. Increase printhead pressure if necessary.
Misaligned Labels:
- Problem: Labels are not being applied in the correct position on the pallet.
- Solution: Adjust the media sensors and applicator pad position using the HMI. Ensure the pneumatic system is functioning within the specified pressure range.

Electrical Safety
1. Electrical Precautions

Ensure the M6955 is properly grounded to avoid electrical shocks. Grounding also protects the system from power surges or spikes that may damage the PLC or print engine.
Always use a surge suppressor to protect the machine from sudden voltage fluctuations.

Battery and Charging Safety

For components that require power backup, ensure all batteries are inspected regularly, and replace them if necessary. Use only manufacturer-approved chargers.

Required Personal Protective Equipment (PPE)

The following Personal Protective Equipment (PPE) is required for personnel operating or maintaining the M6955:

Safety Glasses to protect against airborne debris and label dust.
Protective Gloves to prevent cuts or injuries while handling machine parts, particularly during maintenance.
Hearing Protection if operating in environments where noise levels exceed 85 dB(A), as prolonged exposure to high noise levels can cause hearing damage.

Pallet Dispenser PD1/PD2 Safety and General Operations Manual
1. Introduction

The Pallet Dispenser PD1/PD2 is designed for efficient stacking and de-stacking of empty pallets within automated conveyor systems. This manual provides safety guidelines, operational procedures, and maintenance instructions to ensure the safe and effective use of the machine.

Audience: This manual is intended for operators, installers, and maintenance engineers responsible for handling the Pallet Dispenser PD1/PD2.
Purpose: To ensure the safe operation and proper maintenance of the Pallet Dispenser PD1/PD2.

Safety Instructions
1. Terminology List

Pallet Dispenser PD1/PD2: Automated equipment designed for stacking and de-stacking empty pallets in a conveyor system.
Machine: The Pallet Dispenser PD1/PD2 unit and its components.
Operator: Qualified personnel trained to safely operate the machine.
Lifting Arms: Mechanized arms that handle pallets during stacking or de-stacking.
Forks: Components attached to the lifting arms that support pallets.
Carrier: The platform that moves vertically to handle the pallet stacks.
Conveyor: The external system that feeds and removes pallets from the machine.
Side Restraints: Mechanisms that prevent pallets from tipping sideways.

General Safety Guidelines

Always ensure the emergency stop functions are operational before using the machine.
Safety fences must surround the machine to protect unauthorized personnel from entering the operational area. All doors must be interlocked to prevent operation while they are open.
Personal Protective Equipment (PPE) must be worn at all times, including safety shoes, protective clothing, and a helmet when necessary.
Never operate the machine if it is overloaded or if pallets are of poor quality.

Specific Safety Instructions
1. Before Use

Inspect the machine for any visible damage.
Ensure all safety interlocks are functioning correctly.
Check that all personnel are outside the fenced area before starting the machine.
Make sure the machine is anchored securely to the floor.

Operation

Operate within the machine's pallet size and weight limits as specified on the machine's type plate.
Never bypass safety interlocks or remove safety fencing while the machine is running.
Monitor the machine to ensure pallets are properly stacked and the lifting arms are aligned correctly.

Maintenance and Repair

Always follow the Lockout-Tagout (LOTO) procedure before performing any maintenance tasks.
Inspect the machine regularly and replace worn or damaged parts as needed.
Only qualified personnel should perform repairs.

Emergency Stop and Safety Circuits

The machine must have one or more emergency stops integrated into its safety circuits. Pressing the emergency stop will immediately cut off both power and compressed air to the machine.
Ensure that interlocks on all doors and safety fencing are functioning and stop the machine if any safety provisions are not in place.

Fork and Lifting Arm Adjustments

To ensure safe operation, the forks and lifting arms must be correctly adjusted to match the size of the pallets. Incorrect settings can lead to pallet instability and accidents.

Fork Positioning: Adjust the forks according to pallet size. For example:
- Pallet width 800 mm: Position 1
- Pallet width 1000 mm: Position 2
- Pallet width 1200 mm: Position 3
Warning: Incorrectly adjusted forks may cause pallets to fall or stacks to become unstable. Always ensure the forks are properly positioned based on pallet size.

Residual Risks

Despite the safety measures in place, certain residual risks exist:

Falling pallets: Poor-quality pallets or improper stacking can cause pallets to fall.
Pneumatic hazards: Trapped air in the system can lead to unexpected movements. Always vent air from cylinders before maintenance.

General Operation
1. Intended Use

The Pallet Dispenser PD1/PD2 is exclusively designed to stack and de-stack empty pallets within automated conveyor systems. It is not to be used for any other purposes.

Prohibited Uses:

Do not lift people or objects other than empty pallets.
Never overload the machine beyond its specified capacity.
Do not operate the machine with pallets that are out of specification.

Pallet Handling and Stack Safety

Pallet Quality: Use only high-quality pallets that are suitable for automated handling. Pallets with missing parts, nails, or other defects may disrupt the machine's operation.
Load Stability: Ensure that the load on each pallet is stable and able to support additional pallets stacked on top.

Machine Configuration
1. Machine Layout and Specifications

Working Load Limit (WLL): The machine’s maximum load capacity is indicated on the type of plate and by a warning sticker. Ensure that this limit is not exceeded during operation.
Fork and Lifting Arm Adjustments: Refer to the provided table to adjust the lifting forks based on pallet size.

Fork Position Table:

Pallet Width (mm)	Fork Position
800	1
1000	2
1200	3

Side Restraints and Safety Adjustments

Ensure side restraints are positioned properly to prevent pallet stacks from falling sideways. The gap between the pallets and the side restraints should be minimal (approximately 25 mm).

Installation and Setup
1. Setup Instructions

Ensure the machine is installed according to local regulations and securely anchored to the floor.
Verify that the system is integrated into the conveyor system properly and all necessary safety measures are in place.

Fencing and Safety Provisions

The fenced area must comply with all relevant safety standards, ensuring it is strong enough to withstand any potential impact from falling pallets.

Maintenance and Troubleshooting
1. Lockout-Tagout (LOTO) Procedures

Before Maintenance: Follow all LOTO procedures to lock and tag the machine, ensuring it cannot be started during maintenance.
Post-Maintenance: After completing maintenance, inspect all safety equipment and ensure it is in place before resuming operation.

Preventive Maintenance Schedule

Daily: Inspect for visible damage or dirt.
Weekly: Check the integrity of the lifting arms, forks, and side restraints.
Monthly: Verify that all safety devices are operational.
Warning: Do not use corrosive or flammable solvents when cleaning the machine.

Troubleshooting Common Issues

Forks do not open/close: Check air pressure and sensor alignment.
Pallets do not stack correctly: Verify that the lifting arms and forks are properly adjusted to match the pallet size.

Responsibility Chart with Maintenance Schedule
1. Operator Tasks

Task	Frequency	Description
Visual inspection	Daily	Inspect for visible damage, debris, or contamination (all equipment).
Emergency Stop (EMO) test	Daily	Verify functionality of all EMO buttons.
Monitor noise and vibrations	Daily	Report unusual noises or excessive vibrations during operation.
Workspace safety	Daily	Ensure the workspace is clean, organized, and free of obstructions.
System readiness	Daily	Confirm no alarms or error codes before starting operations.

Maintenance Team Tasks

Task	Frequency	Assigned Role	Description
Daily Maintenance
Clean sensors and surfaces	Daily	Maintenance Technician	Remove dust and debris from sensors, joints, and accessible components.
Check pneumatic system	Daily	Maintenance Technician	Inspect pneumatic lines and ensure proper air pressure (specific equipment).
LIDAR and wheels inspection	Daily	Maintenance Technician	Clean LIDAR and ensure wheels rotate smoothly (AMR).
Weekly Maintenance
Tighten bolts and fasteners	Weekly	Maintenance Technician	Ensure proper torque on fasteners across all equipment.
Inspect electrical connections	Weekly	Maintenance Technician	Check cables, connectors, and sensors for wear or loose connections.
Check filters and air systems	Weekly	Maintenance Technician	Replace dirty filters and check for leaks in pneumatic systems.
Calibration of sensors	Weekly	Maintenance Technician	Recalibrate sensors for accurate performance (Labeler).
Monthly Maintenance
Full system inspection	Monthly	Maintenance Engineer	Conduct a detailed check of all components, including mechanical and electrical.
Replace worn components	Monthly	Maintenance Technician	Replace worn-out filters, belts, or rollers across all equipment.
Perform diagnostics	Monthly	Maintenance Engineer	Run full diagnostics on AMR systems, including battery and navigation.
Test and recalibrate interlocks	Monthly	Maintenance Engineer	Ensure safety systems like interlocks are fully functional.
Annual Maintenance
Comprehensive system servicing	Annually	Maintenance Engineer	Inspect, service, and replace critical components for all equipment.
Overhaul pneumatic systems	Annually	Maintenance Engineer	Clean and replace components like air cylinders and valves (Stretch Wrapper).

Roles and Responsibilities Summary
1. Operator:

Responsible for monitoring the system during daily operations.
Performs visual inspections and ensures safety measures are in place.
Reports issues promptly to the maintenance team.

Maintenance Team:

Handles detailed inspections, cleaning, calibration, and diagnostics.
Performs repairs, replacements, and system servicing.
Ensures compliance with all maintenance schedules and safety protocols.

Care and Maintenance[DH4]

Preventative maintenance is an ongoing process that should be practiced daily to ensure optimum performance of your Mujin system. Small disruptions in the work cell environment can cause unwanted end results when the system is not properly maintained. Therefore, regular cleaning and upkeep of your system is related to the efficiency of your system. Cleaning schedules for each mechanical unit require Daily, Weekly, Monthly, Quarterly, and yearly maintenance to be performed. The schedule for each system is defined below by subsystem specific to your Mujin system.

Robot - CP500L

The CP500L is a high-performance palletizing robot designed for industrial applications. Proper maintenance and care ensure the robot operates efficiently and safely, minimizing downtime and prolonging its lifespan. This section provides a detailed guide on preventative maintenance, general care, and troubleshooting for the CP500L robot. Even if you are new to this, following these steps will help you keep the robot in top condition.

Preventative Maintenance for CP500L

Preventative maintenance is essential to avoid unexpected failures. The following tasks should be completed at specific intervals to ensure the robot's components remain in optimal working condition.

Daily Maintenance:

Visual Inspection:
- Walk around the robot and inspect it for any visible signs of wear, damage, or leaks. Look at the robot’s arms, joints, and wiring. If any parts look worn or damaged, report this immediately for further inspection.
- Example: Look for any cracks on the robot’s casing, wear on cables, or fluid leaks, which may indicate damaged seals.
Unusual Noises/Vibrations:
- Listen for any unusual sounds while the robot is operating. Abnormal sounds such as grinding, squealing, or rattling could indicate a mechanical issue.
- If the robot vibrates excessively during operation, this might suggest misaligned parts or worn components that need immediate attention.
- Action: Stop the robot immediately if abnormal noises or vibrations are detected and investigate the cause.
Safety Guards:
- Ensure all safety guards, such as protective barriers and fences, are in place. These are critical for preventing accidents by keeping operators away from moving parts.
- Test emergency stops and other safety mechanisms to confirm they are functional. Never operate the robot if safety mechanisms are compromised.
- Tip: Check that all interlocking safety switches are working and ensure no one is inside the robot’s operating zone while it is running.

Weekly Maintenance:

Cleaning and Dust Removal:
- Dust and debris can accumulate on the robot’s joints and moving parts, causing friction and wear. Wipe down these areas with a dry or slightly damp cloth to prevent dust buildup.
- Important: Do not use water directly on the robot as it can damage electrical components.
Bolt Tightness:
- Using a torque wrench, check the tightness of bolts, especially around the base and arm sections. Loose bolts can affect the robot’s stability and precision.
- Torque Values: Refer to the manual for the specific torque values required for different bolts.
Air System Inspection:
- The CP500L uses an air system to operate certain components. Check for any leaks in the air lines, and make sure that the pressure is within the recommended range (0.147[MK5] [DH6] to 0.588 MPa).
- Tip: Listen for hissing sounds around air connectors, which may indicate leaks. If you find a leak, replace the affected part, or tighten the connection.

Monthly Maintenance:

Filter Replacement:
- Inspect the air filters. If they are dirty or clogged, replace them to maintain the efficiency of the air system. A clogged filter can reduce air pressure and affect the robot's operation.
- Tip: Keep a few spare filters in stock to ensure quick replacements when needed.
Emergency Stop Testing:
- Test the emergency stop functions and other safety systems, such as light curtains and sensors, to ensure they respond quickly and effectively.
- Safety Note: This test should be done in a controlled environment to avoid sudden halts causing damage to the robot or the workpiece.

Annual Maintenance:

Comprehensive Inspection:
- Perform a full inspection of the robot, including all mechanical and electrical components. Look for any signs of wear, corrosion, or damage, especially on parts that experience frequent movement.
- Example: Check the condition of the robot’s bearings, seals, and gaskets. Replace any worn parts immediately to prevent breakdowns.
Software and Firmware Update:
- Ensure the robot’s software and firmware are up to date. Manufacturers release updates that can improve the robot's performance, security, and compatibility with other systems.
- Tip: Schedule a time when the robot is not in use to apply the updates to avoid interruptions in production.

General Care for CP500L

Taking care of the CP500L is not just about fixing issues—it is about maintaining a proper working environment for the robot.

Environmental Conditions:
- Ensure the robot operates in a clean, dry environment with temperatures between 0°C and 45°C and humidity levels between 35% and 85% (non-condensing).
- Tip: Avoid installing the robot in environments with excessive dust, chemicals, or vibrations, as this can shorten its lifespan.
Mounting:
- The robot must be securely mounted to a flat, stable surface. Verify that the mounting bolts are tightened to the recommended torque and that the base is level within ±5 degrees.
- Safety Note: Ensure there are no vibrations in the floor, as this can affect the robot’s precision during operation.
Air and Electrical Connections:
- Regularly check the air system and electrical connections to ensure there are no leaks, wear, or loose wires. Make sure the air pressure is stable and that all connections are properly insulated.
- Tip: If the robot is exposed to frequent starts and stops, inspect the wiring harness and connectors for signs of wear.

Troubleshooting
1. Common Issues and Solutions:

Power Supply Problems:
- Issue: The robot may not start or could experience intermittent power failures.
- Solution: Check the power supply and verify that all electrical connections are secure. Look for loose wires or blown fuses and replace them if necessary.
Motor and Joint Issues:
- Issue: Motors may overheat, or joints may not move smoothly.
- Solution: Inspect the motors for overheating, and make sure the joints are properly lubricated. If a motor fails, replace it according to the manual’s instructions.
Air System Leaks:
- Issue: Low air pressure or leaks can affect the robot’s performance.
- Solution: Verify the air pressure is within the specified range (0.147 to 0.588 MPa). Replace any faulty air filters or damaged hoses.

Troubleshooting Steps:

Error Code Identification:
- If the robot displays an error code, consult the manual to identify the problem. The manual provides detailed descriptions and recommended actions for each error.
Basic Checks:
- Before calling for technical support, check all connections, including power, air, and data cables. Ensure the robot is securely mounted, and that all safety barriers are in place.
- Tip: Restart the robot after fixing the issue to confirm that it is back in working order.

Gripper & Blower

Gripper

Inspection item	Content	Inspection frequency
Flange	Confirm that the flange screws are not loosening	Monthly
Suction cups	Confirm that the Cups are not damaged or dislodged (Replacement is required if the cups are damaged or dislodged. Check Changing the Suction Cup)	Monthly
Suction cup module	Confirm that the solenoid and pressure signal work normally (To remove there are 4 M4 SHCS bolts holding the module to the gripper with purple Loctite. Remove the bolts with a 3mm allen key. Replace the purple Locktite when running the bolts back in.)	Monthly
Suction cup filter	Confirm that there is no dust or other things blocking the filter in the suction cups (Replacement or cleaning is required if the blockage or significant flow reduction occurs. Check Changing and Cleaning the Suction Cup Filter) (To remove filter there are 4 bolts with purple Loctite. Remove the bolts with 2.5mm allen key. Replace Loctite when running the bolts back.)	Monthly
Pressure sensor filter	Replace the filter cotton pressure sensor (Check Replacing the Filter Cotton for the Pressure Sensor The best tool for this is a pair of fine tip tweezers)	Every 3 months

Blower

Inspection item	Content	Inspection frequency
Air breaker silence	Confirm that the dust does not block the silencer, if so then blow off with air nozzle.	Daily
Vacuum filter	Replace filter (Replacement is required for each inspection period. Check Changing the Vacuum Filter)	1500 working hours
Filter screen in the air inlet of vacuum blower	Confirm the filter screen is not blocked	Monthly
Filter screen in the muffler outlet of vacuum blower	Confirm the filter screen is not blocked	Monthly
Vacuum hose	Confirm that there is no wear or air leakage in the vacuum hose from the gripper to the vacuum blower (Require Mujin support for replacement if above situation happens)	Monthly
Fireproof cloth	Confirm that there is no wear or other major damage to the fireproof cloth. If so, replace the cloth.	Monthly
F.R.L. Filter	Confirm that the air pressure in the outlet of the F.R.L. is not less than 0.6MPa (Replacement is required if the pressure is less than the expected or filter used over 2 years. Check Changing the F.R.L. Filter)	Monthly
Precision Filter	Confirm that the filter element is functioning normally and has not been changed for over 1 year (Replacement is required if the filter element is in use for 1 year or in an unusual work environment. Check Replacing the Filter Element for the Precision Filter)	Every 3 months
Control panel filter	Confirm that there is no dust or other things blocking the filter in the vacuum blower silence box (Replacement is required if the dust blocks or accumulates on the filter. Check Replacing the Filter on the Grill)	Every 6 months

2.3. Vacuum Supply Inspection

Turn off the vacuum channel for all vacuum modules on the [DH7] [JA8] controller. Open the vacuum blower. The value of the vacuum pressure switch should be above 65kpa (-65kpa to -70kpa) as Figure 41 shows.

A machine with many parts

Description automatically generated with medium confidence [MK9] [DH10] [JA11]

Figure 41: Vacuum Pressure Switch on the gripper

If the value of the vacuum pressure is lower than expected, go through the following steps to normalize it.

Check the vacuum hose from the gripper beginning to the vacuum blower end in Figure 43 to ensure[DH12] [DH13] [DH14] [DH15] there is no vacuum leakage.

A large industrial machine in a warehouse

Description automatically generated [MK16] [DH17] [JA18]

Figure 43: Vacuum Hose Clamps on the Dress pack

Check the vacuum hose on the blower unit indicated in Figure 45 on the robot base to ensure there is no vacuum leakage. Also, ensure the filter element has not reached its service life (Replacement required if service life reached. Check Replacing the Filer Element for the Precision Filter)

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Figure 45: Vacuum Clamps on the Vacuum Blower

Adjust the vacuum relief pressure as shown in Figure 47. The pressure relief valve is pre-set and should not be adjusted without guidance. If the device is not functioning properly, Mujin Support may request the user to make adjustments as needed. Otherwise, the image and instructions are for reference only.

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Figure 47: Vacuum Relief Valve

Flange Inspection

Check the torque marks on flange’s screws are not moved (Figure 48); these eight M8x25 screws should be torqued with 41Nm and use red Loctite during the gripper installation.

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Figure 49: Torque Marks on the Flange

Suction Module Inspection

Module Pressure Switch Inspection
1. Set the vacuum pump and the vacuum shut-off valve for all modules of the mega gripper to “ON” on the controller output interface.
2. Set the vacuum shut-off valve for each module to “OFF” one at a time and block the corresponding hole with a carton or a piece of cardboard to make the local suction cup in a tight state. Then observe whether the pressure switch signal of the module is “ON” by the controller Input interface. If it is “OFF,” the module is judged to be damaged. (Replacement required if the vacuum module is damaged. Check Changing the Vacuum Module)
  1. Module Solenoid Valve Inspection
    1. Set the vacuum shut-off valve for all 63 modules to “OFF” on the controller output interface and set the vacuum pump to “ON”.

Set each of the module blowing valve to “ON” one at a time and block the corresponding hole by hand to determine if it is blowing. If the module is not blowing, then the module is judged to be damaged and needs to be replaced. (Replacement required if the vacuum module is damaged. Check Changing the Vacuum Module)

Filter Screen Inspection

Filter Screen in the Air Inlet of Vacuum Blower Inspection

Clean the dust or other debris accumulated on the filter screen with a brush.

A machine with many pipes and a few other objects

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Figure 50: Air Inlet Filter Screen

Dress Pack Inspection
Check that the dress pack is not twisted or failing out. Check that each joint of the IGUS is not decoupling.

[MK19] [DH20] [JA21]

Check whether the IGUS chain on the dress pack is worn or damaged. Ensure the edge of each section of IGUS chain has no curling.
Check spring assembly on joint 5 of robot every day before every shift.[MK22] [DH23] [JA24]

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Figure 52: IGUS Chain Inspection

Precision Filter Element Inspection

Check the gauge indicator to ensure that the filter elements function normally, the pointer should not exceed the red range (Condition suits for DD45+, PD45+).

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Figure 53: Precision Filter Gauge Indicator Inspection

Check the usage time of the filter on the filter element to ensure that it has not been used for more than 1 year (Condition suits for DD45+, PD45+, QD45+).

(Replacement is required if the filter element is used for more than 1 year or in a usual work environment. Check Replacing the Filer Element for the Precision Filter)

Air Breaker Silence Inspection

Check the Quick-Change Silencer for the air breaker, ensure it is not blocked by dust. Replacement required if it happens. (Replacing Component part number: Silencer_SMC_AN20-C10).

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Figure 54: Quick-Change Silence Inspection

Changing the Suction Changing the Suction Cup

Replacing Component part number:

Type 1 & Type 2: Round corrugated suction cup (no metal parts)_Schmalz_SPB2 40 ED-65 SC050

Type 3: Schmalz suction cup with filter_MUJIN_SPB2 40 ED-65 G14-AG-F

1. Remove the damaged suction cups with a hexagonal wrench and replace it with a new one ( Figure 2‑1 and Figure 2‑2).

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Figure 2‑1：Suction Cup Replacement (1/2)

A computer screen shot of a computer

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Figure 2‑2：Suction Cup Replacement (2/2)

Please remember to install the filter when installing the new suction cups. (Refer to Error! Reference source not found.Error! Reference source not found.)

Be aware that the suction cups are fixed with three different types of fixers even though they all use same suction cups.

Figure 2‑3: Fixers Type 1 & Type 2 & TYpe3

Changing the Vacuum Module

Replacing Component part number: MCG: Vacuum Control Unit_MJSF_VC55-HD-G14-B

Unscrew the four M4 anti-release bolts around the module from the gripper to remove the vacuum module as shown in Error! Reference source not found..
Note: The M4 anti-release bolts is not necessary to be unscrewed from the module

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Description automatically generated

Figure 58: Housing Screws for the Vacuum Module
Install the new vacuum module on the gripper and tighten the bolts diagonally. Ensure the O-ring do not fall off. (Error! Reference source not found.)
Replacing Component part number: O-ring_MISUMI_NPA20

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Description automatically generated

Figure 60: O-Ring on the Vacuum Module

3. Ensure the module switches to the right number when replaces the new one. Please see the electrical drawing for detailed information for each module.
A screenshot of a computer

Description automatically generated

Changing and Cleaning the Suction Cup Filter[MK25] [DH26] [JA27]

Replacing Component part number: 316 stamping metal filter (304 edge)_JD_outer diameter 9mm 30 mesh without support (Type 3 Fixer)

Customized 40 mesh high pressure valve block filter stainless steel G1/4_MUJIN_30000773 Type 2 Fixer

1. Take out the suction cup & filtering stage from the vacuum module.

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Figure 61: Disassemble the Suction Cup and Filtering Stage

2. Use compress air to clean any accumulated dust on the filter, and replace them with new ones if they are damaged or if replacement is necessary. Then reassemble it to the suction cup and insert it back into the vacuum module.

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Description automatically generated

Figure 62: Clean or replace the filter in the filtering stage.

3. For the mesh filter on the outer two rows of vacuum module with one by two division vacuum module, the mesh filter is directly installed in the vacuum module. Disassemble the pink part for mesh clean.

A screenshot of a computer

Description automatically generated

Type 2 Fixer Mesh Clean

Replacing the Filter Cotton for the Pressure Sensor

Replacing Component part number: YG12 filter cotton Φ4.5x5_MUJIN_10000952

1. Disassemble the vacuum module from the gripper as Error! Reference source not found.Error! Reference source not found. discussed.

2. Disassemble the indicated two bolts with the hex key.

A computer screen shot of a computer

Description automatically generated

Figure 63: Disassemble the locater Pins (1/2)

Push out the location pins and filter cotton from the vacuum module, replace the cotton with the new one and assembly it back.

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Description automatically generated

Figure 64: Disassemble the Locater Pin (2/2)

4. Repeat above procedure to all 118 vacuum module.

Blower Removal and Service

To maintain the blower, maintenance personnel can pull the entire blower assembly out. To do that, go to the side of the pedestal where you can see the vacuum filter (see below).

Figure 65: Vacuum Filter Side View of Blower

Remove the location pin and the screw cap. And you can pull using the handle on the left.

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Figure 66: Pin and Screw Cap

Once the pin is removed the blower assembly can then roll out from under the riser for easier access to blower components.

Changing the Vacuum Filter

Remove the vacuum filter from the vacuum pump (Figure 67).

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Figure 68: Vacuum Filter

Open the vacuum filter by opening the four quick release buckles as Figure 69 shows.

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Figure 70: Quick Release buckles in Vacuum Filter

Replace the filter element and install the new vacuum filter back into the vacuum pump as Figure 71 shows.

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Figure 72: Filter Element

Replacing the Filter on the Grill

Check the dust accumulated on the six-grill filter. Replace with new filter (Fluted Filter Mat Pfannenberg FF PF 2x 000). Cut the air filter roll to make it fit.

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Figure 73: Replacing Grill Fan Filter (1/2)

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Figure 74: Replacing Grill Fan Filter (2/2)

Replacing the Filter Element for the Precision Filter

Remove the metal cylinder (twists off) from filter and replace the filter element with the corresponding one.

Filters to replace:

Filter Element Atlas PD45+2901207933 for second stage
Filter Element Atlas DD45+2901207913 for first stage
Filter Element Atlas QD45+2901208033 for third stage

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Description automatically generated

Figure 75: Replacing Precision Filter Element

Changing the F.R.L Filter

Remove the transparent cover of the F.R.L. Pull down on grey tap and twist.

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Description automatically generated

Figure 76: F.R.L.

Replace the element and install the vacuum filter back into the F.R.L.

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Description automatically generated

Figure 77: Filter Element

Automated Mobile Robot (AMR) - Quicktron M150

The Quicktron M150 is a state-of-the-art autonomous mobile robot (AMR) designed for use in industrial environments, such as warehouses and production lines. This section outlines the essential maintenance procedures and safety precautions to ensure its smooth and efficient operation.

General Maintenance
1. Service and Maintenance:

Regular maintenance ensures the AMR remains efficient and prolongs its service life. Neglecting routine service may lead to unexpected breakdowns.
All maintenance tasks must be performed by trained personnel familiar with the robot’s operation and safety protocols.
Maintenance records should be meticulously documented. This includes logging routine checks, repairs, and any parts replaced to ensure a detailed history of the robot’s service.

Precautions for Maintenance:

Effective communication between on-site and off-site personnel is crucial during maintenance. Ensure all staff are aware of when the AMR is being serviced.
Only use Quicktron-approved parts for any repairs or replacements to guarantee compatibility and maintain the robot’s warranty.
During maintenance, the working environment must be clean and suitable for the robot. Avoid areas with excessive dust, moisture, or debris that could interfere with the robot's sensors or moving parts.

Preventative Maintenance
1. Weekly Routine Service and Maintenance:

Clean the robot's surface to remove dust and dirt. Accumulation of debris can damage sensors or affect performance.
Ensure all lamps are functioning correctly, including indicator lights for power, error status, and operational mode.
Test emergency stop buttons and motor enabling buttons to confirm they are fully operational.
Check the laser radar system for obstacle avoidance. Make sure the radar is functioning correctly to avoid operational hazards.
Inspect the wheels for any abnormal noise, wear, or damage. Ensure the lifting mechanism operates smoothly without unusual sounds.
Conduct a visual inspection of the robot shell for defects, cracks, or other visible damage.
Check and clean the charging port, ensuring that the pins are aligned, and no dirt or foreign objects obstruct the connection.

Annual Service and Maintenance

Once a year, a more thorough inspection should be conducted to ensure the robot remains in optimal condition.

Overall Robot Condition:
- Ensure the AMR runs smoothly without sticking, deviation, or skidding.
- Verify that the robot charges correctly, without the need for repeated attempts to dock at the charging station.
- Test the lifting mechanism for proper function, ensuring that it moves smoothly without delays.
- Check the radar system for accuracy in obstacle detection and verify that there are no false alarms during operation.
Appearance and Structural Integrity:
- The robot’s exterior should be clean and free from damage.
- Confirm that emergency stop buttons, selectors, and control panels work as expected.
- Inspect the driving wheels for flexibility, ensuring they rotate smoothly without resistance. Remove any debris and apply lubricating oil to the necessary components.
- Inspect the driven wheels for wear and tear. Replace any damaged wheels as needed.
Fasteners and Electrical Systems:
- Check that all fasteners are tight and inspect wiring to ensure there are no loose connections or signs of damage.
- Remove dust from inside the robot using appropriate methods to prevent buildup that can interfere with sensors or electrical systems.
- Perform a voltage check to ensure the battery and other electrical components are functioning within specified parameters.

Simple Troubleshooting
1. Common Issues and Solutions:

Robot Stops During Operation:
- Cause: Unrecognizable or dirty QR codes.
- Solution: Inspect and clean the QR codes. Use a cloth to remove dirt or smudges that may be obstructing the code.
Abnormal Obstacle Avoidance:
- Cause: Radar misconfiguration or malfunction.
- Solution: Check the radar parameters. If incorrect, adjust them. If the radar is malfunctioning, replace it.
Indicator Light Issues:
- Cause: Emergency stop button pressed or low battery.
- Solution: Verify the emergency stop button status. Recharge the battery if necessary.
Route Congestion/Deadlock:
- Cause: Multiple robots in the same area or conflicting routes.
- Solution: Move one of the robots manually or restart the RCS to reset the routes.
Lifting and Lowering Errors:
- Cause: Misaligned rack or faulty QR code.
- Solution: Realign the rack or adjust the QR code. If the issue persists, reset the lifting mechanism.
Skidding with Load:
- Cause: Dirty or uneven floor, or stuck driving wheels.
- Solution: Inspect the wheels and clean the floor surface. Reset the error using the wired controller.
Upper Computer Interface Stuck:
- Cause: Software malfunction.
- Solution: Restart the upper computer and reconnect it to the system.

Mechanical Maintenance

Inspect mechanical parts for wear or damage and replace them as needed. This prevents issues that could lead to mechanical failures during operation.

Electrical Maintenance

Regularly inspect the robot’s electrical components, including wiring, control boards, and sensors.
Ensure all power and communication cables are secure and functioning properly. Loose or damaged wires can lead to operational failures.

Routine Service

Follow the weekly and annual service schedules outlined to ensure that the AMR operates efficiently. Routine checks help to identify and address potential issues before they escalate.

Safety Instructions
1. General Safety Instructions:

Pay close attention to electrical safety. All maintenance tasks involving the robot's electrical components must follow proper grounding procedures to avoid electric shock.
Only certified components should be used to ensure compliance with safety standards.
Batteries must be handled and stored according to the manufacturer’s instructions to avoid exposure to extreme conditions.

Operational Safety:

Ensure no persons or obstacles are within the robot’s working range during operation. If an emergency arises, press the emergency stop button immediately.
Use barriers and warning signs to prevent unauthorized access during robot operation.

Emergency Procedures:

Familiarize yourself with the location and operation of the emergency stop buttons. In case of an emergency, pressing the stop button will immediately halt the robot.

Error Codes and Recovery:

Refer to the error codes displayed by the robot’s sensors or interface. Consult the troubleshooting guide to address issues based on the code provided.

Advanced Troubleshooting:

Use the robot’s sensors and error indicators to diagnose problems. Isolate whether the issue is mechanical, electrical, or software-related and address it accordingly.

Frequency of Inspections, Maintenance, and Cleaning
1. Inspections:

Daily: Perform a visual inspection for any visible damage, dirt, or debris.
Weekly: Check cables, the e-chain for broken links, and inspect the robot's shell for wear.

Maintenance:

Weekly: Inspect and replace damaged parts as needed. Clean all mechanical components.
Every 6 months: Tighten all bolts and inspect the integrity of key mechanical and electrical parts.

Cleaning:

Daily: Clean the robot’s surface to remove visible dirt and debris.
Weekly: Clean the robot’s sensors and ensure that the lenses are free of dust.

Stretch Wrapper –Wulftec WRTA-200

The Wulftec WRTA-200 is an industrial-grade stretch wrapper designed to secure palletized loads using stretch film. This machine, like all Wulftec products, is built for strength and durability. Regular maintenance ensures optimal performance, extends equipment life, and minimizes downtime.

General Maintenance
1. Service and Maintenance:

Regular inspections help prevent major issues. Routine checks allow operators to identify potential problems early, reducing costly downtime.
Maintenance should be handled by qualified technicians who understand the safety protocols and machine components.
Keep a detailed log of all maintenance actions, including dates, parts replaced, and inspection notes. This can help track performance and provide insights for proactive repairs.

Precautions for Maintenance:

Follow Lock-Out/Tag-Out (LOTO) procedures before performing any service to avoid accidents. Disconnect all power sources, including pneumatic and electrical supplies.
Use Wulftec-approved parts exclusively for repairs. Non-standard parts may void warranties and cause operational inconsistencies.
Ensure the machine is maintained in a clean environment and remove any debris around moving parts and sensors.

Preventative Maintenance
1. Daily Maintenance:

Visual Inspection: Inspect the rotary arm, film carriage, and sensors for signs of wear or damage. Clean any debris around the machine.
Check Sensors: Ensure that all proximity and photoelectric sensors (such as the photo eye) are clean and aligned. Dirt or misalignment can affect the machine’s performance.
Test Safety Features: Verify the functionality of all emergency stop buttons and safety interlocks. This is critical to prevent accidental operation.

Weekly Maintenance:

Tension Checks: Inspect the belts and chains for proper tension. Loose or overtightened components can lead to operational inefficiencies.
Inspect Film Roll and Tension: Ensure that the film roll is properly aligned and tensioned. Misalignment can cause the film to tear during operation.

Monthly Maintenance:

Pneumatic System: Inspect all air connections, checking for leaks or pressure drops. Check the pressure gauge to ensure it is within the recommended range.
Inspect Carriage Components: Ensure that the film carriage rollers and gears are clean and moving freely. Adjust any loose components.

Annual Service and Maintenance
1. Comprehensive Annual Service:

Perform a detailed inspection of the entire machine. Look for signs of wear on the rotary arm, film carriage, and cut-and-wipe system.
Gearbox and Bearing Check: Inspect the ring gear and bearing assemblies for wear. These components are subject to constant motion and require periodic checks. Lubricate the bearings using the machine’s automatic greasing system.
Calibration: Ensure that sensors, limit switches, and the HMI (Human-Machine Interface) are properly calibrated to maintain accuracy in operations.

Sensor and Electrical Checks:

Inspect the proximity sensors for alignment and responsiveness. Sensors should trigger at the correct points to avoid machine faults.
Control Panel Inspection: Clean the control panel and check for loose connections. Verify that the PLC and HMI are functioning without error.

Advanced Troubleshooting Techniques:

Film Wrap Errors (Film Tear or Overstretching):
- Cause: Incorrect pre-stretch settings, film type mismatch, or worn rollers.
- Solution: Verify the pre-stretch settings on the HMI and adjust as needed. Ensure the correct film type is loaded and check the rollers for wear.
Rotary Arm Malfunctions:
- Cause: Misalignment of the rotary arm or sensor issues.
- Solution: Inspect the ring gear and pinion assembly for wear or damage. Re-align sensors to ensure proper detection of the arm's position.
Film Not Cutting Properly:
- Cause: Obstruction or malfunction in the cut-and-wipe arm.
- Solution: Clean the cut-and-wipe system and ensure the film clamp is functioning properly. If necessary, adjust the heat wire preheat timer to ensure sufficient heat for cutting the film.
HMI Error Codes:
- Cause: Faulty sensor, electrical connection, or software issue.
- Solution: Consult the error code on the HMI to identify the problem. Perform a system reset if the issue persists, and check sensor connections.

Mechanical Maintenance

Film Carriage Rollers: Inspect and lubricate the rollers and ensure they are aligned to prevent uneven film distribution.
Alignment Check: Ensure that the rotary arm and film carriage are properly aligned. Misalignment can lead to improper wrapping and potential damage to loads.

Electrical Maintenance

Wiring and Connections: Inspect all electrical wiring for signs of wear or loose connections. Damaged wiring can result in machine downtime and safety hazards.
Voltage Stability: Ensure that the power supply remains stable and within the machine’s voltage specifications. Voltage surges can damage the PLC and other electrical components.

Safety Instructions
1. General Safety Instructions:

All personnel must undergo safety training before operating or servicing the WRTA-200. This includes familiarity with emergency stop buttons, safety interlocks, and the Lock-Out/Tag-Out procedures.
Always wear the recommended personal protective equipment (PPE), including gloves, safety glasses, and steel-toed boots, when working near the machine.
Never attempt to bypass or disable safety features such as sensors, interlocks, or light curtains. These features are essential for preventing accidents.

Emergency Procedures:

In the event of an emergency, press any of the emergency stop buttons located around the machine to halt operation immediately.
After activating the emergency stop, follow standard facility protocols for incident reporting and machine lockout.

Inspection and Cleaning Frequency

Daily:

Visually inspect the machine for any loose parts, debris, or misaligned components.
Clean the surface of the machine and sensors to prevent operational errors.

Weekly:

Lubricate the rotary arm, film carriage rollers, and pinion gears.
Check pneumatic systems for proper air pressure and connection integrity.

Monthly:

Inspect the cut-and-wipe system for cleanliness and proper operation.
Test and recalibrate any sensors that appear unresponsive or misaligned.

Annually:

Perform a full machine calibration, including sensor alignment, proximity sensors, and the HMI control system.

Replace any worn bearings, belts, or chains to ensure continuous, smooth operation.

Pallet Stacker and Dispenser - Qimarox PD1 and PDx Models

This section covers the general care and preventative maintenance of Qimarox pallet stackers and dispensers, ensuring they operate safely and efficiently. The following instructions apply to both PD1 and PDx models, used for stacking and de-stacking empty pallets in industrial environments.

General Maintenance
1. Service and Maintenance:

Regular maintenance is critical to maintaining the efficiency and safety of the pallet stacker or dispenser.
Only trained personnel should perform maintenance on the machine. All maintenance actions must comply with the manufacturer’s safety guidelines.
Ensure that all maintenance records are documented. This includes routine inspections, repairs, and any parts replaced.

Precautions for Maintenance:

Communication between on-site and off-site personnel is essential during maintenance to avoid accidental activation of the machine.
Use only Qimarox-approved parts for any repairs or replacements to ensure machine integrity and maintain the warranty.
The working environment should be clean and free of debris during maintenance to avoid accidents and ensure optimal working conditions.
Always ensure that the machine is powered off and secured before starting any maintenance tasks. This includes locking out the main power supply and venting the pneumatic system.

Preventative Maintenance
1. Daily Maintenance:

Visually inspect the machine for any damage or wear.
Check for dirt or debris on the machine’s surface and clean as necessary to avoid interference with sensors or mechanical components.

Weekly Maintenance:

Inspect the e-chain and cable carrier for broken links. Replace any damaged components immediately.
Check all cables and tubes for signs of wear or damage. Replace them as needed.
Ensure the safety devices are functioning properly, such as emergency stop buttons and interlocking doors.

Monthly Maintenance:

Inspect the carrier wheels for damage or wear and replace them if necessary.
Verify that the cylinders are working correctly and check for any leaks. If a cylinder rod is bent, it should be replaced.
Clean the sensors and ensure they are functioning correctly to prevent operational errors.

Annual Service and Maintenance

Once a year, or after 10,000 running hours, a more thorough inspection should be conducted:

Inspect the lifting mechanism for wear and ensure the cylinders are functioning without leaks.
Test the machine’s sensor alignment to ensure it operates smoothly. Misaligned sensors can result in dangerous situations.
Clean the entire machine, including internal parts, to remove any dust or debris that may have accumulated over time.
Inspect the fasteners on all parts of the machine to ensure they are secure. Loose fasteners can lead to malfunctioning equipment.
Perform a thorough check of pneumatic systems, ensuring that all valves, including the quick exhaust valve, are working properly.

Simple Troubleshooting
1. Common Issues and Solutions:

The arms do not open or close:
- Cause: No air pressure or faulty connection.
- Solution: Check the air supply and ensure all connections to the cylinders are intact.
The carrier does not move up or down:
- Cause: Lack of air pressure or damaged cylinder connections.
- Solution: Inspect the air pressure system and replace damaged connections.
Pallets are not stacking properly:
- Cause: Misalignment of the lifting arms or forks.
- Solution: Adjust the lifting arms or forks to ensure proper alignment.
Pallets are stuck in the machine:
- Cause: Bad pallet or misaligned position.
- Solution: Use manual controls to safely release the pallet.

Mechanical Maintenance

Regularly lubricate all moving parts, including the lifting arms and carrier wheels, to ensure smooth operation.
Check the alignment of the lifting arms and forks regularly to ensure they are properly positioned for the size of pallets being used.
Inspect the back and side restraints to ensure that they are properly positioned to prevent pallet stacks from falling over.

Electrical Maintenance

Regularly inspect the wiring and electrical components for wear or damage.
Ensure the electrical installation complies with local safety regulations and the wiring diagrams provided by Qimarox.

Safety Instructions
1. General Safety:

Never operate the machine if any of the safety devices are faulty or missing.
Ensure that all safety fencing is properly installed around the machine to prevent unauthorized access.
Only trained and qualified personnel should operate or maintain the machine.

Emergency Procedures:

Always familiarize yourself with the location and operation of the emergency stop buttons.
In case of emergency, press the emergency stop immediately to halt the machine.

Frequency of Inspections, Maintenance, and Cleaning

Daily: Perform a visual inspection and clean the machine’s surface.
Weekly: Inspect cables, e-chains, and safety devices.
Monthly: Conduct a more in-depth inspection of mechanical and pneumatic components.
Every 6 months: Check and tighten all bolts and connections.
Every 2 years or after 10,000 running hours: Replace worn lift fingers and inspect all critical components for wear.

Pallet Labeler – Fox IV M6955L

The Fox IV M6955L Pallet Labeler integrates advanced print engines for high-volume, precise labeling. Ensuring its longevity and efficient operation requires following proper maintenance and troubleshooting procedures. This section provides a detailed guide for preventive care, safety, and troubleshooting of the Fox IV M6955L, focusing on key components like the Zebra ZE511/ZE521 print engines.

General Maintenance
1. Service and Maintenance:

Regular maintenance ensures smooth operation, prevents unexpected downtime, and prolongs the lifespan of the machine.
Key Actions:
- Inspect all components for wear and tear.
- Clean the printhead daily to ensure optimal print quality.
- Ensure labels are properly loaded and free from defects such as wrinkles or tears.
Maintenance logs are essential. Keep detailed records of each maintenance activity, including the date, tasks performed, parts replaced, and any adjustments made. This helps track trends and prevents recurring issues.

Precautions for Maintenance:

Before performing any maintenance, follow the Lock-Out/Tag-Out (LOTO) procedures to ensure the machine is powered down and cannot accidentally start during service.
Use Fox IV and Zebra-approved parts for replacements. Using unauthorized parts may void the warranty and could result in suboptimal performance.
Maintain a clean work environment around the labeler, ensuring that dust, debris, or moisture does not interfere with sensors or moving components.

Preventative Maintenance
1. Daily Maintenance:

Visual Inspection: Inspect the printhead, rollers, and label applicator for visible signs of wear, damage, or contamination.
- Pro Tip: Pay close attention to the label roll for any misalignment, tears, or wrinkles that could cause jamming during operation.
Clean the printhead with an approved cleaning solution to remove dirt, adhesive, and label residue. This prevents streaks, smudges, and poor-quality prints.[MM28]
Check for air leaks in pneumatic systems to ensure the applicator operates at the correct pressure for label application.

Weekly Maintenance:

Pneumatic System Check: Verify that all air pressure regulators are within the specified range (80-100 psi). Check for loose fittings and air leaks around the pneumatic valves.
Sensor Calibration: Ensure that sensors, including product-detect and gap sensors, are clean and properly aligned to detect products accurately and apply labels correctly.
- Tip: Wipe sensors with a lint-free cloth to remove dust, which can affect their precision.
Label Feed Check: Inspect the label path for any obstructions or worn parts, and ensure the media is loaded properly.

Monthly Maintenance:

Inspect the vacuum system: Make sure the vacuum pads are free of dust or debris that could reduce their effectiveness in holding and applying labels.
Inspect and tighten all electrical connections to ensure there are no loose wires or faulty components that could lead to system errors.

Annual Service and Maintenance
1. Comprehensive Annual Check:

Perform a complete system calibration, adjusting sensor sensitivity, printhead alignment, and label application timing. Ensure the HMI settings are optimized for your operational needs.
Pneumatic System Overhaul: Inspect air filters, lubricate air valves, and replace any worn or damaged parts in the pneumatic system to maintain consistent applicator performance.
Replace Worn Parts: Check components like the printhead, rollers, belts, and applicator cylinders for wear. Replace any parts that show signs of damage to prevent sudden breakdowns.

Troubleshooting Common Issues
1. Common Issues and Solutions:

Labels Not Applying Correctly:
- Cause: The applicator may be misaligned, or sensors may not be detecting the product correctly.
- Solution: Re-align the applicator. Check and clean sensors and re-calibrate them if necessary. Ensure the vacuum system is operating correctly.
- Example: If the label is being applied off-center, check that the product-detect sensor is positioned correctly and recalibrate the timing of label application.
Print Quality Degradation:
- Cause: A dirty printhead or incorrect print settings.
- Solution: Clean the printhead and adjust the print darkness and speed settings in the print engine’s control panel.
- Pro Tip: Use the self-test labels feature on the Zebra print engine to evaluate print quality and adjust settings accordingly.
Label Jam or Misfeed:
- Cause: Misaligned labels, worn rollers, or incorrect tension on the label roll.
- Solution: Clear any jams, re-align the label roll, and inspect the rollers for wear. Replace any damaged rollers.
- Prevention: Regularly check the label path to ensure smooth feeding and adjust the label roll tension if necessary.
Pneumatic Cylinder Not Activating:
- Cause: Low air pressure or a faulty air valve.
- Solution: Check the air supply and verify that the pressure regulators are set correctly. Replace or repair any faulty valves.

Mechanical Maintenance

Applicator System: Inspect the applicator pad and cylinder for signs of wear. Regularly clean the pads to remove any label adhesive or dirt buildup that can affect label placement.
Print Engine Rollers and Spindles: Ensure that the ribbon take-up spindles and rollers are properly aligned and free of debris. Clean and lubricate regularly to maintain print quality.
Platen Roller: Inspect the platen roller for damage or wear and clean it with the appropriate solution to ensure smooth label feeding and avoid print defects.

Electrical Maintenance

Print Engine Electrical System: Periodically inspect and tighten all electrical connections. Ensure that there is no fraying or damage to wiring that could lead to power outages or inconsistent performance.
Control Panel Inspection: Test the HMI control panel for responsiveness and ensure all settings can be adjusted correctly. If the panel malfunctions, perform a soft reset and recalibrate the touch screen if necessary.

Safety Instructions
1. General Safety Instructions:

Operators should always wear appropriate personal protective equipment (PPE), including gloves and safety glasses, when interacting with the labeler.
Keep safety guards in place at all times to protect against moving parts. Never bypass safety interlocks or emergency stop systems.
Ensure that all employees are trained on the proper operation of the emergency stop button, located near the applicator.

Emergency Procedures:

In case of an emergency, operators should press the emergency stop button immediately to halt the machine. Once stopped, the machine should not be restarted until the issue is diagnosed and resolved.
After an emergency stop, inspect the machine for faults before reactivating. Follow the appropriate reboot and diagnostic procedures to ensure safety.

Inspection and Cleaning Frequency

Daily: Clean the printhead, rollers, and ensure all moving parts are free from dust and debris.
Weekly: Inspect the pneumatic system, check air pressure, and recalibrate sensors.
Monthly: Lubricate moving parts such as the applicator arm and rollers and inspect belts and spindles for wear.
Annually: Replace worn components, calibrate the sensors and print engine, and perform a comprehensive inspection of electrical and pneumatic systems.

Inbound Outbound - IBOB

Component	Schedule suggested action	Frequency
Motor	Check for noise	Daily[MK29]
	Check temperature	Daily
	Check mounting bolts	Quarterly
Rollers	Clean rollers of debris and packaging materials[MM30]	Daily
Photo eyes	Clean all photo eyes and reflectors	Weekly

Basic Manual Operations

Basic Manual Operations for CP500L Robot
1. Introduction to CP500L Robot

The CP500L robot is a high-performance, 4-axis articulated robot engineered for advanced palletizing tasks. Capable of handling payloads of up to 500 kg with a maximum reach of 3,255 mm, it delivers exceptional speed, precision, and durability for the most demanding industrial applications. Whether in material handling, palletizing, or machine tending environments, the CP500L is designed to function consistently with minimal downtime, ensuring operational efficiency.

This robot is well-suited to fast-paced production lines, where its ability to operate continuously and handle heavy payloads ensures maximized throughput. Its robust design and advanced control system enable it to handle large and awkwardly shaped loads while maintaining precise placement, cycle after cycle.

Key Specifications:

Maximum Payload: 500 kg
Maximum Reach: 3,255 mm
Degrees of Freedom: 4-axis articulated.
Speed:
- JT1 (Base Rotation): 85°/s
- JT2 (Arm Lift): 80°/s
- JT3 (Arm Extension): 80°/s
- JT4 (Wrist Rotation): 180°/s
Position Repeatability: ±0.5 mm.
Operating Environment:
- Temperature: 0°C to 45°C
- Humidity: 35% to 85% (non-condensing)

With these specifications, the CP500L robot excels in environments where high-speed operation, precision, and repeatability are paramount. Its versatility makes it ideal for a wide range of applications, particularly in palletizing where it can handle diverse load sizes and shapes.

Image Reference: Refer to Figure 3.1 on page 15 for a detailed visual representation of the CP500L robot and its key components.[MK31]

Manually Jogging the Robot

The manual jogging feature allows operators to take precise control of the robot’s movements for setup, alignment, or troubleshooting tasks. Jogging is especially important when positioning the robot for calibration, maintenance, or handling complex operations where exact positioning is critical. Operators can use either Joint Mode to control individual joints or Cartesian Mode to move the robot along the X, Y, and Z axes.

Power On the Controller

Before any manual jogging can be performed, the robot’s controller must be properly activated:

Activate the Controller: Ensure the robot’s main power supply is connected and the controller is powered on. The control panel should display the robot’s status, confirming that it is ready for operation.
Verify Safe Operating Conditions: Before initiating any movement, visually inspect the work area to ensure that no personnel or objects are within the robot’s operational range. This is particularly important during manual operation, as unexpected movements could result in injury or damage to equipment.

Image Reference: Refer to Figure 3.2 on page 18 for the layout of the robot’s controller and indicator lights.

Selecting Jogging Mode

Once the robot is powered on and the workspace has been cleared, the operator can choose from two jogging modes depending on the task at hand:

Manual Mode Activation: Use the robot’s HMI (Human-Machine Interface) or pendant to switch from automatic to manual mode. This will allow direct manipulation of the robot’s joints or overall position.
Jogging Modes:
- Joint Mode: In this mode, operators can control each joint of the robot individually (JT1 to JT4), allowing for precise adjustments to the robot's posture. This mode is particularly useful when fine-tuning the robot’s orientation or setting it up for specific tasks.
- Cartesian Mode: This mode provides more intuitive control by allowing the operator to move the robot’s end-effector along a straight line in the X, Y, and Z directions. This mode is best used when positioning the tool in space for tasks like picking, placing, or palletizing.

Jogging Controls and Movements

With the mode selected, operators can now control the robot’s movements:

Joint Movements: In Joint Mode, the operator can adjust each joint independently:
- JT1 (Base Rotation): Controls the rotation of the robot’s base, allowing it to turn left or right. Movement range: ±160° (or ±180° without mechanical stoppers).
- JT2 (Arm Lift): Controls the vertical movement of the robot’s arm. Movement range: +95° to -46°, enabling the arm to raise and lower.
- JT3 (Arm Extension): Adjusts the arm’s forward and backward reach. Movement range: +15° to -110°, providing extensive reach.
- JT4 (Wrist Rotation): Controls the rotational movement of the robot’s wrist. Movement range: ±360°, allowing full rotation of the end-effector.

Each joint can be controlled individually using the pendant’s joystick or buttons, providing fine control over the robot’s position.

Cartesian Movements: In Cartesian Mode, operators can move the robot’s end-effector along the X, Y, and Z axes. This is particularly useful when performing tasks that require the robot to move in a straight line or when positioning the tool at a specific location.
- X-axis: Moves the tool forward or backward along a horizontal plane.
- Y-axis: Moves the tool left or right along a horizontal plane.
- Z-axis: Moves the tool up or down along a vertical plane.

Operators can adjust the speed of these movements using the pendant to ensure that the robot moves at a controlled pace, which is crucial when working in confined spaces or handling fragile materials.

Control Speed: For both Joint and Cartesian Modes, the pendant allows the operator to select movement speeds, providing the option to make slow, deliberate adjustments or faster, sweeping movements depending on the task.

Image Reference: Detailed control layouts are provided in Figure 3.3 on page 22.

Frames of Reference and Cartesian Coordinates

To fully utilize the Cartesian coordinate system and frames of reference when operating the CP500L robot, it is essential to understand how movements are calculated and executed relative to different reference points.

Cartesian Coordinate System

The Cartesian coordinate system defines movement in terms of three-dimensional space using three primary axes:

X-axis: Defines forward and backward movement relative to a fixed point.
Y-axis: Defines left and right movement across a horizontal plane.
Z-axis: Defines vertical movement, allowing the robot to move up or down.

These axes provide a consistent reference framework for positioning the robot’s end-effector, ensuring precise movements that are essential in palletizing operations where spatial accuracy is crucial.

Frames of Reference

Different frames of reference provide additional context for the robot’s movements, allowing operators to define custom points or orientations for various tasks.

World Frame: The world frame is a fixed, stationary reference point that is typically aligned with the floor of the workspace. The X, Y, and Z axes are fixed relative to the world frame, and all movements can be measured from this global point. This is the default frame used when positioning the robot relative to its overall environment.
Tool Frame: The tool frame is attached to the robot’s end-effector, meaning it moves with the tool as the robot operates. The X, Y, and Z axes are defined relative to the tool’s position and orientation, making this frame particularly useful for fine-tuning the tool’s movements or performing tasks where tool precision is paramount.
User Frame: A user-defined frame that allows operators to create custom reference points within the workspace. This is useful in repetitive tasks, such as palletizing, where the operator can define a consistent point on a pallet or machine to streamline the robot’s movements. Once set, the robot can move relative to the user frame, ensuring repeatable accuracy.

Practical Use: For example, in palletizing, the operator might define a user frame that corresponds to the corner of a pallet. All subsequent movements can then be calculated relative to this fixed point, ensuring consistency throughout the stacking process.

Calibrating and Homing the Robot

Calibration and homing procedures are crucial for ensuring that the robot’s movements are precise and repeatable. Calibration aligns the robot’s joints and sensors with their correct reference points, while homing ensures the robot begins its operation from a known, consistent position.

Calibration

Calibration routines align the robot’s joints and sensors to ensure that movements and positions match the software’s internal reference points:

Access Calibration Menu: Use the teach pendant or HMI to navigate to the calibration menu.
Perform Joint Calibration: Follow the on-screen instructions to move each joint to its reference point. The system will guide you through calibrating JT1 to JT4, ensuring that each joint is properly aligned.
Fine-Tune Calibration: For precision applications, operators can use the fine calibration feature to make smaller, more accurate adjustments to the robot’s positioning. This is particularly useful after mechanical adjustments or following maintenance on key components.

Homing the Robot

After calibration, the robot must be homed to its default starting position:

Home Command: Initiate the Home command using the pendant. The robot will automatically move each joint to its predefined home position.
Safety Check: Before homing, ensure that there are no obstacles in the robot’s range of motion. The homing sequence involves the movement of all joints, and any interference could result in inaccurate calibration or potential damage.

Image Reference: Calibration and homing procedures are illustrated in Figure 3.4 on page 25.

Error Handling

The CP500L robot is equipped with advanced diagnostic systems that help operators quickly identify and resolve issues that may arise during operation. Understanding common error codes and how to address them is essential for maintaining smooth operations.

Common Error Codes

Overload Error: This occurs when the robot’s payload exceeds its maximum capacity of 500 kg.
- Solution: Reduce the load on the robot’s end-effector and reset the system using the pendant. If the issue persists, inspect the tool and payload configuration to ensure compliance with the robot’s load limits.
Temperature Warnings: If the robot is operating in an environment where the temperature exceeds 45°C, it may issue a warning to prevent overheating.
- Solution: Pause operations to allow the robot to cool or adjust the environmental conditions. If necessary, ensure that ventilation is adequate to prevent overheating during continuous operation.

Resetting Errors

The robot’s HMI will display detailed error codes and descriptions when an issue arises:

Review Error Code: On the teach pendant, navigate to the error log to view the specific error and recommended actions.
Clear the Error: Once the issue is resolved, use the pendant to reset the error and return the robot to normal operation.

Image Reference: Troubleshooting and error resolution steps are detailed in the Troubleshooting Section on page 30.

Safety During Operation

Ensuring safe operation of the CP500L robot requires strict adherence to safety protocols, both to protect personnel and to prevent damage to the robot and surrounding equipment.

Personal Protective Equipment (PPE)

All operators and maintenance personnel must wear appropriate PPE, including:

Safety helmets
Protective gloves
Steel-toed boots
Eye protection (where applicable)

Emergency Stops

The robot is equipped with multiple emergency stop buttons, located both on the control panel and on the pendant. These buttons immediately halt all robot movements when pressed.

Location: Familiarize yourself with the location of all emergency stop buttons in the workspace. In an emergency, pressing any of these buttons will immediately stop the robot.

Lockout-Tagout (LOTO)

To prevent accidental startup during maintenance or adjustments, always follow proper Lockout-Tagout (LOTO) procedures:

Power Down the Robot: Before performing any mechanical or electrical maintenance, disconnect the robot from its power source and engage the lockout device.
Tag the Equipment: Ensure that the robot is properly tagged as under maintenance to prevent accidental operation by other personnel.

Image Reference: Emergency stop and LOTO procedures are outlined in Figure 3.5 on page 35.

Maintenance and Calibration Schedule

Regular maintenance ensures the CP500L robot continues to operate at peak efficiency and reduces the risk of unexpected breakdowns. Follow the recommended schedule for routine inspections and calibration.

Weekly Maintenance

Visual Inspection: Check for signs of wear or damage on all joints, cables, and moving parts.

Monthly Maintenance

Calibration: Perform a full calibration of all axes to ensure the robot maintains accurate positioning and repeatability. This step is critical if the robot has been in heavy operation or subjected to significant wear and tear.[MM32]
Check Bolts and Fasteners: Tighten any loose bolts or fasteners around the robot’s base and joints to prevent mechanical instability.

Annual Maintenance

Electrical Inspection: Have a certified technician inspect all wiring and connectors for signs of wear, corrosion, or damage.
Firmware Update: Ensure the robot’s control software and firmware are up to date, incorporating any necessary performance improvements or bug fixes.

Image Reference: Maintenance tasks and schedules are detailed in Table 3.1 on page 40.

Introduction to M150 ETL AMR

The M150 ETL is an Autonomous Mobile Robot (AMR) developed by Quicktron for use in warehouse and logistics environments. It autonomously navigates, moves items, and avoids obstacles, reducing the need for manual labor.

Key Features:

Payload Capacity: Can carry loads up to 1,500 kg.
Size: The robot measures 1182 x 832 x 260 mm.
Battery: Equipped with a 48V Lithium-Ion battery, providing up to 9 hours of operation.
Charging Time: Takes approximately 1.5 hours to fully charge.
Navigation: Uses LIDAR sensors for environmental scanning and QR code positioning for precise navigation.

Image Reference: Refer to Figure 5.1 on page 19 for a front and rear view of the M150 ETL robot, and Figure 5.2 for a top view, showing the layout of external components.

Manually Jogging the Robot

Manual jogging is required when the robot needs to be repositioned for maintenance or calibration. The M150 ETL can be controlled using the pendant for precise manual movements.

Power On the Robot

Power On: Press the power switch, located in the middle of the robot, to turn it on.
Safety Check: Ensure the workspace is clear of obstacles.

Image Reference: See Figure 7.1 on page 30 [MM33] [DH34] for the power switch location.

Access the Pendant (Maintenance Mode)

Use the Wired Remote: Plug the wired remote control into the debug port on the front panel.
Mode Selection: Turn the mode selector switch to maintenance mode.

Image Reference: The mode selector switch and debug port are detailed in Figure 7.1 on page 31.

Moving the Robot

Enable the Jogging Function: Press the enable switch halfway on the remote control.
Directional Controls: Use the directional buttons to move the robot in small, controlled steps.

Image Reference: For a full layout of the remote-control buttons, refer to Figure 7.1 on page 32.

Calibrating and Homing the Robot

Calibration ensures that the robot’s sensors and motors are aligned correctly. Homing brings the robot back to its starting position, allowing it to resume normal operations from a known location.

Calibration

Access Calibration Menu: Navigate to the calibration menu using the remote control.
Follow the On-Screen Instructions: Follow the system prompts to calibrate each axis (wheels, LIDAR, etc.).
Fine Adjustments: Use calibration tools if needed to achieve accurate positioning.

Image Reference: Detailed instructions for calibration can be found starting on page 52 of the manual.

Homing the Robot

Switch to Auto Mode: Turn the mode selector to auto mode.
Initiate Homing: Release all emergency stops and press the blue reset button, followed by the green start button.

Image Reference: Refer to Figure 6.1 on page 47 for a detailed layout of the homing buttons on the pendant.

Error Handling

The M150 ETL has built-in error detection that alerts operators to issues via the control system.

Common Error Codes

Obstacle Detection Error: The LIDAR sensorsmay detect an obstruction.
- Solution: Remove any obstacles in the path of the robot and clean the sensors.
QR Code Recognition Failure: The robot relies on QR codes for navigation. If a code is not recognized, an error is triggered.
- Solution: Check and clean the QR code on the floor to ensure it is readable.

Image Reference: A visual representation of the obstacle avoidance system and LIDAR placement can be seen in Figure 5.2 on page 19.

Safety During Operation

To ensure safe operation of the M150 ETL, always follow these safety procedures:

Wear Proper PPE: Ensure you wear safety glasses, gloves, and protective footwear when operating or working near the robot.
Emergency Stops: The robot is equipped with emergency stop buttons at all four corners, which immediately halt all operations.
Lockout-Tagout (LOTO): Use the LOTO procedure when performing maintenance to ensure the robot is fully powered down before starting.[MM35]

Image Reference: The location of the emergency stop buttons is shown in Figure 5.1 on page 19.

Maintenance and Calibration Schedule

Regular maintenance is critical to keeping the M150 ETL in optimal condition.

Weekly Maintenance

Clean the Robot: Wipe down the LIDAR sensors and cameras to ensure unobstructed vision and navigation.
Test Controls: Test all emergency stop buttons and motor controls for proper function.
Inspect Wheels and Chassis: Check for wear or damage.

Image Reference: Refer to Figure 9.1 on page 39 for a detailed view of the components to inspect during maintenance.

Annual Maintenance

Check Lifting Mechanism: Test the robot’s lifting and lowering functions to ensure they operate smoothly.
Inspect Battery Health: Perform a full diagnostic to ensure the battery holds a charge and charges correctly.
Inspect Drive Motors: Listen for any unusual sounds and check for smooth operation. Lubricate if necessary.

Image Reference: For more detailed visuals on motor inspection, see Figure 9.1 on page 40.

Introduction to Pallet Stretch Wrapper WRTA200
1. Basic Machine Knowledge

The WRTA200 Pallet Stretch Wrapper is an automated system designed to wrap palletized loads with stretch film, ensuring stability and protection during transport. The rotary arm system allows for uninterrupted operation, wrapping loads of various sizes without manual intervention.

Key Components:

Main Frame: The robust steel structure providing stability to the machine, designed for industrial environments.
Rotary Arm: This arm rotates around the pallet to apply the stretch film uniformly. The speed and direction of the rotary arm can be adjusted depending on the load size and wrapping needs.
Film Carriage: The motorized film carriage controls the tension of the stretch film as it is applied to the load. Film tension can be adjusted to optimize for different types of loads, ensuring a secure wrap without overuse of material.
Cut and Wipe System: The automatic cut and wipe feature eliminates the need for manual film handling. After wrapping, the machine cuts the film and secures it to the load.
Control Panel: Equipped with an intuitive HMI (Human Machine Interface), the control panel allows operators to adjust wrapping parameters, monitor the machine’s status, and run diagnostics.
Safety Features: Includes emergency stop buttons, light curtains, and safety fencing to ensure the operator is protected during operation. The system will automatically halt if an unauthorized entry is detected in the operational area.

Image Reference: Refer to Figure 5.1 on page 21 for a visual representation of the WRTA200 and its main components.

Manually Jogging the Wrapper

Manual jogging allows operators to position specific parts of the machine during maintenance, troubleshooting, or adjustments. This feature is crucial for tasks such as repositioning the rotary arm or reloading the film carriage.

Power On the Wrapper

Power On: Ensure the wrapper is powered on by switching the main power switchlocated on the control panel.
- Location: The main power switch is clearly marked on the control panel’s upper left side.
Safety Check: Make sure the area around the wrapper is clear of any personnel or obstacles to avoid accidental collisions during movement.

Image Reference: Refer to Figure 6.1 on page 31 for the control panel layout.

Access the Control Panel

Manual Mode: Set the machine to manual modeusing the control panel. This allows each component to be controlled independently.
- In manual mode, the machine’s HMI will display available components (e.g., rotary arm, film carriage) for manual control.

Select Jogging Mode

Jogging Mode: On the control panel, select the jogging mode. This mode gives the operator the ability to move individual components using directional controls.
- Ensure that Manual Override is active, which will disable the automatic functions of the machine and allow jogging.

Use the Jogging Controls

Control Movements: Use the multi-function joystick [MM36] or control buttons to move specific components (such as the rotary arm or film carriage) to the desired position.
- Rotary Arm Control: The arm can be moved clockwise or counterclockwise by using the directional controls on the panel. Adjust speeds to slow down movements for precise positioning.
- Film Carriage Control: The vertical movement of the film carriage can be adjusted using the up/down buttons to ensure proper alignment with the pallet load.
- Safety Note: Always move components slowly and monitor their positioning to avoid collisions or overstretching the film.

Image Reference: Detailed instructions for manual control are found in Figure 6.2 on page 32.

Calibrating and Homing the Wrapper

Calibration ensures the machine operates at peak accuracy, and homing returns components to their default positions after each operation. Both functions are crucial for maintaining consistent wrapping quality and reducing wear on the machine.

Calibration

Access Calibration Menu: Use the HMI (Human Machine Interface) to navigate to the calibration menu.
- Functionality: The system will display calibration options for each major component (e.g., rotary arm, film carriage).
Calibrate Rotary Arm: The rotary arm’s position and speed can be fine-tuned to ensure even wrapping around the load.
- Procedure: Follow the on-screen instructions to adjust the arm’s starting and ending points, ensuring it does not interfere with pallet edges or nearby obstacles.
Calibrate Film Carriage: The film carriage must be calibrated to apply consistent tension and coverage.
- Procedure: Adjust the carriage’s vertical movement to match pallet heights and wrapping requirements. Ensure proper alignment with the rotary arm’s movement.

Homing

Home Command: After completing the calibration, select the Home command on the control panel. This returns the rotary arm and film carriage to their default positions, ensuring they are ready for the next operation.
Verification: Always verify that both the rotary arm and film carriage have successfully returned to their home positions before starting a new wrapping cycle.

Image Reference: Refer to page 34 for the homing process and associated controls.[MM37] [DH38]

Error Handling

The WRTA200 is equipped with an advanced diagnostic system that displays error messages on the HMI when an issue arises. These messages include detailed error codes and recommended actions for resolving the issue.

Common Error Codes

Film Break Error: Indicates that the stretch film has torn or depleted during operation.
- Solution: Stop the wrapping cycle, re-thread the film, and restart the cycle. If the problem persists, check the tension settings on the film carriage.
Emergency Stop Activated: The machine halts if any emergency stop button is pressed.
- Solution: Inspect the machine and surrounding area for safety risks, reset the emergency stop, and resume operation.
Rotary Arm Blockage: Occurs when an obstruction is detected during the rotary arm’s movement.
- Solution: Remove the obstruction, reset the error on the HMI, and manually jog the arm to ensure it is clear before restarting the operation.

Safety During Operation

Operating the WRTA200 safely requires adherence to established protocols to prevent accidents and injuries.

Wear Appropriate PPE: Operators should wear appropriate personal protective equipment (PPE), including gloves, safety glasses, and steel-toed boots.
Emergency Stop Buttons: The machine is equipped with emergency stop buttons that can immediately halt the operation if pressed. Make sure you are familiar with their locations on the machine.
Light Curtains and Fences: The machine uses light curtains and safety fencesto prevent unauthorized access to the wrapping zone during operation.
- Important: If the light curtain is broken during operation, the machine will stop. The area must be cleared, and the system reset before continuing.

Image Reference: Emergency stop button locations are shown in Figure 8.1 on page 45.[MM39] [DH40]

Maintenance and Calibration Schedule

To maintain the efficiency and longevity of the WRTA200, a strict maintenance schedule must be followed.

Weekly Maintenance

Inspect Film Roll: Check that the film roll is loaded correctly and aligned with the film carriage.
- Tension Check: Verify that the film tension is set properly to avoid excessive film usage or tearing during wrapping.
Clean Sensors: Ensure that sensors (such as the film break sensor) are clean and free from debris.

Monthly Maintenance

Lubricate Moving Parts: Apply lubricant to the rotary arm’s drive system and film carriage tracks to ensure smooth operation.
Check Bolts and Fasteners: Tighten any loose bolts, especially around the frame and motor assemblies.

Annual Maintenance

Full Calibration: Perform a complete calibration of the machine, including the rotary arm, film carriage, and cut and wipe system, to ensure continued accuracy.
Inspect Electrical Systems: Have a certified technician inspect the machine’s electrical components to ensure all connections are secure and operating efficiently.

Image Reference: Maintenance points are detailed in Figure 9.1 on page 50.

Operator Requirements

To ensure safe and efficient operation, only trained and certified personnel should operate the WRTA200.

Certification Required: All operators must undergo machine-specific training that includes operation, safety protocols, and emergency procedures.
Ongoing Safety Training: Operators should participate in periodic safety training to stay updated on any new safety features or changes in operational protocols.

Handling Power Failures and Emergency Stops
1. Power Failure

Response: In the event of a power failure, the machine will halt. Once power is restored, perform a homing procedure to ensure all components return to their default positions before resuming operation.

Emergency Stop Activated

Response: If an emergency stop button is pressed, inspect the machine and surrounding area for safety issues before resetting the stop and resuming operation.

Image Reference: Emergency stop locations are shown in Figure 8.1 on page 45.

Visual and Audio Alerts

The machine provides a variety of visual and audio indicators to help operators understand its current status and any potential issues.

Flashing Red Light: Indicates a critical error or emergency stop.
Continuous Beeping: Alerts the operator to a non-critical error, such as a film break or end of film.
Green Light: Signals that the machine is operating normally in automatic mode.

Image Reference: Indicator light locations and their meanings are outlined in Figure 9.2 on page 51.

Introduction to Foxiv Pallet Labeler M6955
1. Basic Machine Knowledge

The Foxiv M6955 Pallet Labeler is an industrial-grade automated labeling system designed for high-volume pallet labeling applications. This system integrates a Zebra ZE511/ZE521 print engine to print and apply labels in various orientations, making it suitable for complex production lines. The system offers flexibility, high performance, and easy maintenance, making it a reliable choice for 24/7 operation.

Key Components:

Zebra Print Engine (ZE511 or ZE521): The print engine handles label generation with resolutions of 203 dpi, 300 dpi, and 600 dpi, and print widths of up to 6.6 inches depending on the model. It is equipped with a full-color touchscreen display for easy interaction and monitoring.
Applicator Assembly: The pneumatic applicator applies labels to pallets via tamp, blow-on, or tamp-roll methods. It can be configured for top, side, or bottom labeling based on production needs.
Allen-Bradley PLC Controller: The PLC (Programmable Logic Controller) manages the labeling cycle, including timing, pressure control, and label placement accuracy. It also enables integration with warehouse control systems (WCS) for seamless operation.
Media and Ribbon Handling: The system supports both thermal transfer and direct thermal printing methods and can handle label rolls up to 16 inches in diameter for extended production runs.

Image Reference: Refer to Figure 6.1 on page 15 for the layout of the Foxiv M6955 Pallet Labeler and its main components.

Manually Jogging the Labeler

Jogging the Foxiv M6955 labeler allows for manual movement of the applicator and print engine to facilitate maintenance, adjustments, and troubleshooting. This feature is especially useful when aligning the label applicator with the product or performing test prints.

Power On the Labeler

Power On: Ensure that the labeler is powered on using the main switch located on the control panel.
Safety Check: Verify that the work area is clear of personnel and any obstructions that could interfere with the machine’s movement.

Image Reference: See Figure 6.2 on page 18 for the control panel layout.

Access the Control Panel

Manual Mode: Set the system to manual mode on the touch panel display. This will allow individual components, such as the applicator and print engine, to be controlled manually.

Select Jogging Mode

Jogging Mode: Use the HMI (Human Machine Interface) to select the Jogging Mode. You can control the movement of the applicator and print head from here.

Use the Jogging Controls

Applicator Movement: Use the joystick or buttons on the control panel to move the applicator to the desired position. You can manually position the applicator for alignment with pallets or other products.
- Speed Adjustments: Adjust the applicator speed using the speed control on the HMI for precise movements.
- Safety Note: Always monitor the movement of the applicator closely to avoid damaging the machine or product.

Image Reference: Refer to Figure 6.3 on page 21 for detailed instructions on the jogging controls.

Calibrating and Homing the Labeler

Calibration ensures that the Foxiv M6955 labeler places labels accurately on pallets, while homing returns the machine to a known reference position after adjustments or restarts.

Calibration

Access Calibration Menu: Use the HMI to navigate to the calibration menu.
Calibrate Applicator: Follow the on-screen instructions to adjust the position and stroke length of the applicator. Ensure the cylinder pressure and timing are set to match the product line requirements.
- Applicator Stroke Adjustment: Set the cylinder extend time and vacuum delay to optimize label placement for the pallet configuration.

Image Reference: Calibration procedures are described in Figure 6.4 on page 23.

Homing

Home Command: Once calibration is complete, select the Home command on the control panel to return the applicator and print engine to their default positions.
Verification: Ensure that the applicator has returned to its home position before starting a new labeling cycle.

Image Reference: Homing instructions can be found in Figure 6.5 on page 25.

Error Handling

The Foxiv M6955 Pallet Labeler is equipped with a comprehensive diagnostic system that displays errors and alerts on the touch screen. Common errors include label jams, sensor issues, and applicator faults.

Common Error Codes

Label Jam Error: This occurs when a label fails to dispense or apply correctly.
- Solution: Check for any obstructions in the label path, and ensure the media is properly loaded. Follow the on-screen prompts to clear the error.
Printhead Error: Indicates an issue with the printhead, such as a misalignment or overheating.
- Solution: Allow the printhead to cool down or check the alignment. Replace the printhead if necessary.

Image Reference: Error codes and solutions are detailed in Table 7.1 on page 30.

Safety During Operation

Operating the Foxiv M6955 requires adherence to strict safety protocols to ensure the safety of operators and the integrity of the machine.

Wear Appropriate PPE: Operators must wear gloves, safety glasses, and protective clothing to prevent injury during operation.
Emergency Stop: The labeler is equipped with emergency stop buttons that immediately halt operation if pressed.
Safety Guards: Ensure that all safety guards are in place before operating the machine. These include covers for the applicator and print engine.

Image Reference: Refer to Figure 7.1 on page 35 for emergency stop locations.

Maintenance and Calibration Schedule

Regular maintenance of the Foxiv M6955 ensures optimal performance and minimizes downtime. Follow the schedule below for routine checks.

Weekly Maintenance

Inspect Label Roll: Ensure that the label roll is loaded correctly and aligned with the applicator. Check for any signs of wear or damage to the media.
Clean Sensors: Clean the sensors and applicator regularly to remove dust or debris that could affect label placement.

Monthly Maintenance

Lubricate Moving Parts: Apply lubricant to the applicator’s pneumatic components to ensure smooth operation. Follow manufacturer recommendations for lubricants.
Check Pneumatic Pressure: Ensure that the air supply is properly regulated and free of moisture to prevent damage to the pneumatic system.

Annual Maintenance

Calibrate the Applicator: Perform a full calibration of the applicator to ensure it is placing labels correctly. Verify that the printhead is functioning properly and replace it if necessary.

Operator Requirements

Only trained and certified personnel should operate or maintain the Foxiv M6955. Operators must be familiar with the machine’s control systems and safety protocols.

Certification Required: Operators must complete training specific to the Foxiv M6955 labeler and demonstrate proficiency in operating the print engine and applicator.
Ongoing Training: Regular refresher courses should be provided to ensure operators are up to date with safety procedures and machine updates.

Introduction to Pallet Stacker PD1
1. Basic Machine Knowledge

The UM Pallet Stacker PD1 is a machine designed to stack or de-stack empty pallets as part of a pallet conveyor system. It ensures smooth operations and reduces manual handling, increasing efficiency and safety in warehousing environments.

Key Components:

Pallet Stacker Frame: The main structure supporting the stacker’s operations.
Beam with Lifting Forks: Lifting mechanism used for stacking or de-stacking pallets.
Covers: Safety covers to prevent access to hazardous areas during operation.
Sliding Plates: Support the smooth movement of the lifting beam.
Timing Belt and Pulleys: Drive the movement of the lifting forks with precision.
Gear Motor: Powers the lifting mechanism, ensuring smooth vertical movement.

Image Reference: Refer to Figure 4.1 on page 25 for the visual representation of the Pallet Stacker and its components.

Manually Jogging the Stacker

Manual jogging allows for the precise positioning of the stacker during maintenance, troubleshooting, or adjustment operations. Careful handling is essential to prevent injury or equipment damage.

Safety Checklist Before Manual Operation

Before starting any manual operation, make sure to:

Ensure all safety guards and protective covers are securely in place.
Confirm that no personnel or obstructions are within the stacker’s operating range.
Operators must wear appropriate personal protective equipment (PPE) such as safety gloves, helmets, and steel-toed boots.
Verify that all emergency stop buttons are functional and accessible before beginning any manual operation.

Access the Control Panel

Manual Mode: Use the control panel to switch the stacker to manual mode for jogging operations.

Select Jogging Mode

Jogging Mode: Select the jogging mode on the control panel to initiate manual movement.

Use the Jogging Controls

Manual Movement: Use the joystick or buttons on the control panel to move the stacker slowly and carefully to the desired position.

Image Reference: Refer to Figure 6.1 on page 31 for a detailed layout of the control panel and its buttons.

Notes

Always review the detailed instructions and safety precautions in the UM Pallet Stacker PD1 product manual before operating or maintaining the machine.
For additional assistance, refer to the troubleshooting section in the manual for guidance on common issues.

Maintenance Schedule

Proper maintenance ensures the longevity of the stacker and prevents unexpected breakdowns. Follow the schedule below for regular inspections and maintenance.

Weekly Maintenance

Visual Inspection: Check the valve bodies, and shafts for wear or tension issues[MM41] . Inspect the sliding plates for any debris or damage that could impede movement.
Emergency Stops: Test the emergency stop buttons to ensure they function correctly.

Monthly Maintenance

Tighten Components: Check for any loose bolts or connections on the pallet stacker frame and tighten them as necessary.

Quarterly Maintenance

Calibration Check: Perform a full calibration of the stacker to ensure precise operation.

Troubleshooting Common Issues

The stacker’s control system will display error codes for operational issues. Use the following guide to troubleshoot common problems.

Fork Misalignment

Error: Forks are misaligned during operation.
Solution: Stop the machine immediately and perform manual calibration of the forks. Ensure that they are level and aligned correctly with the pallet.

Operator Requirements

To ensure safe and efficient operation, only trained and certified personnel should operate or manually jog the stacker.

Certification: Only operators with proper certification and training specific to the UM Pallet Stacker PD1 are permitted to operate the machine.
Safety Training: Operators must complete safety training before operating the stacker, covering topics such as manual jogging, calibration, and emergency stop usage.

Handling Power Failures and Emergency Stops

In case of power failures or emergency stop activation, follow these steps to safely restore operations.

Power Failure

Response: If the stacker loses power, it will automatically stop. Once power is restored, perform a homing procedure before resuming operation.

Emergency Stop Activated

Response: When an emergency stop is pressed, inspect the surrounding area for any safety concerns. Reset the emergency stop button and recalibrate the machine before resuming operations.

Image Reference: See Figure 5.1 on page 25 for the location of emergency stop buttons on the stacker.[MM42]

Visual and Audio Alerts

The stacker uses visual and auditory signals to indicate its operational status and alert operators to potential issues.

Flashing Red Light: Indicates that the emergency stop has been activated.
Flashing Green Light: The stacker is in automatic mode and functioning normally.

HMI Error Codes[DH43]
1. Overview

An alarm in the Mujin context is an issue or problem that will or has already caused an equipment or subsystem to produce incorrect, unexpected results, or to behave in unintended ways. Alarms can stop production and require intervention from external entities. Alarms can describe hardware failures, communication issues between subsystems, runtime execution problems, emergency stops, and upcoming maintenance requirements.

The Mujin Controller collects alarms and provides a unified way to view the alarm related to various devices, robots, grippers, sensors, and orchestrators in real-time. Additionally, the history of alarms is saved for future diagnostic, monitoring, and maintenance purposes. The alarm can be viewed on the Mujin Web UI and queried from the Mujin Controller.

An alarm can only be in one of two states: active or resolved.

An alarm is active when it is still being published by a module and remains so until it is no longer published by the module.
An alarm is resolved when it is no longer in the publish state of a module.

Severity Levels

An alarm produced by the Mujin Controller might require immediate attention or a delayed action depending on the severity level of the alarm. The alarm severity levels are mutually exclusive, and an alarm cannot be part of multiple severity levels at the same time.

Level	Description
Critical	The module is unusable. Action must be taken immediately.
Error	The module operates with degraded functionality and is close to failure. Action must be taken immediately.
Warning	The module operates as intended but an error will occur if no action is taken. Action must be taken as soon as possible.
Notice	The module operates as intended but improvements could be made through preventative maintenance. No immediate action is needed.

Alarm Origin

Each alarm is tied to a specified piece of equipment or subsystem in the Mujin Controller. The Alarm Origin contains details related to the equipment or subsystem that generated the alarm.

Querying Active Alarms

The active alarms can be queried from the Mujin Controller using the following GraphQL query. The query returns a list of AlarmLogEntry. More fields can be selected in the query if needed.

Filtering by Component

The previous query can be modified to filter the results by module type.

Alarm Resolved Log Entry

An AlarmResolvedLogEntry will be created automatically when an alarm is resolved, with its parentId being the corresponding AlarmLogEntry.

Querying Resolved Alarms

The real-time alarms become historical alarms once resolved. The resolved alarms can be queried from the Mujin Controller using the following GraphQL query. The query returns a list of AlarmResolvedLogEntry. More fields can be selected in the query if needed.

Alarm Statuses

An AlarmStatus can be one of the following:

Alarm Status	Level	Description
AirPressureAnomaly	Error	The current air pressure is outside the allowable range
ConfigurationError	Error	The current configuration of this module is invalid
ConfigurationWarning	Warning	The current configuration of this module is degraded
ConnectionLost	Error	Communication has been lost with the device
ConveyorDisconnected	Error	Conveyor disconnected
ConveyorFaulted	Error	Generic conveyor fault detected
ConveyorJammed	Error	Conveyor jammed
ConveyorMotorControllerBoardOverheat	Error	Board overheat
ConveyorMotorControllerLowVoltage	Error	Low voltage error
ConveyorMotorControllerOverVoltage	Error	Over-voltage
ConveyorMotorDisconnected	Error	Motor disconnected
ConveyorMotorHallSensorError	Error	Hall sensor error
ConveyorMotorMaxTorque	Error	Max torque exceeded
ConveyorMotorOverheat	Error	Motor over-heated
ConveyorMotorOverload	Error	Motor overloaded
ConveyorMotorShortCircuit	Error	Short circuit
ConveyorMotorStall	Error	Motor stalled
DeadManSwitchNotPressed	Error	The dead man’s switch is not in the active position
DeviceEstopped	Error	The emergency stop switch has been pressed
DoorFaulted	Error	Door faulted
DoorInterlockDoorFaulted	Error	Internal door interlock fault
DoorInterlockDoorOpened	Warning	Door opened
DoorInterlockDoorUnlocked	Error	Door unlocked
FireAlarmTriggered	Error	Fire alarm has detected a fire
FirmwareVersionNotSatisfied	Warning	Firmware version is not up to date
GenericErrorAlarm	Error	A generic error has occurred
GenericWarningAlarm	Warning	A generic warning has occurred
InboundOutboundStationFaulted	Error	Inbound outbound station is faulted
MobileRobotBumperTriggered	Error	The mobile robot bumper has been triggered by a collision
MobileRobotCannotCharge	Warning	The mobile robot has failed to charge despite arriving at a charger
MobileRobotDelocalized	Error	The mobile robot has become delocalized from the map
MobileRobotLowBattery	Warning	The remaining battery level for the mobile robot is below the safe threshold
MobileRobotObstacleDetected	Warning	An obstacle has been detected in the path of the mobile robot
MobileRobotOffline	Error	Connection cannot be established with the given mobile robot
MobileRobotOverweight	Error	The lifted payload is too heavy for the mobile robot to transport
MobileRobotPayloadDelocalized	Error	The mobile robot’s payload has become delocalized from the robot
MobileRobotUnknownError	Error	A non-specific error has occurred with the given mobile robot
MobileRobotUnresponsive	Error	The mobile robot is not responding to commands
MobileRobotZoneProhibited	Warning	Zone has been prohibited, no mobile robots inside it can move
MobileRobotZoneWarning	Warning	A mobile robot in this zone needs attention
NetworkLinkSpeedNotSatisfied	Warning	Network link-negotiation speed to the device is not satisfied
NonContactSwitchDoorFaulted	Error	Door faulted
NullAlarm	Error	Null alarm placeholder value
OperationTimeout	Error	The remote operation has timed out
OrderCycleFaulted	Error	OrderCycle has finished with an error
PalletStackerDownCenterPointNotFound	Error	Stacker down center point not found
PalletStackerDownTimeout	Error	Pallet stacker timed out lowering pallets
PalletStackerFrontSensorJammed	Error	Front sensor jammed
PalletStackerFull	Warning	Pallet stacker full
PalletStackerGripperExtensionTimeout	Error	Gripper extension timeout
PalletStackerGripperRetractionTimeout	Error	Gripper retraction timeout
PalletStackerNotInAutoMode	Warning	Pallet stacker not in auto mode
PalletStackerPalletMissing	Error	Requested pallet stacker to stack pallet while there is no pallet
PalletStackerUpCenterPointNotFound	Error	Stacker up center point not found
PalletStackerUpTimeout	Error	Pallet stacker timed out raising pallets
PhotoEyeDisconnected	Error	Disconnected
PhotoEyeFaulted	Error	Generic PhotoEye fault detected
PhotoEyeJammed	Warning	Jammed
ProductionCycleFaulted	Error	ProductionCycle has finished with an error
RobotArmCollision	Error	The robot arm has collided with an obstacle
RobotArmJointAccelerationLimitExceeded	Error	A joint on the robot arm has exceeded the safe acceleration limit
RobotArmJointDeviated	Error	A joint on the robot arm has deviated from the expected position
RobotArmJointJerkLimitExceeded	Error	A joint on the robot arm has exceeded the safe jerk limit
RobotArmJointVelocityLimitExceeded	Error	A joint on the robot arm has exceeded the safe velocity limit
RobotArmOverTravel	Error	A joint on the robot arm is out of safe travel range
RobotBridgeServerBridgeLoadError	Error	The configured provider bridge could not be instantiated
SafetyScannerProtectiveFieldFault	Error	The protective field on the safety scanner have been breached
SafetyScannerProtectiveFieldImproperSequence	Error	Protective Field muting photo-eyes not triggered in proper sequence
SafetyScannerProtectiveFieldTimeDiscrepancy	Error	Protective Field discrepancy time between muting photo-eyes has been exceeded
SafetyScannerProtectiveFieldTimeExceeded	Error	Protective Field max muting time exceeded
SafetyScannerWarningFieldFault	Error	Warning Field Fault
SensorNeedsToRestart	Error	Sensor needs to be restarted

7. Maintenance Support and Escalation

Overview: Maintenance support and escalation protocols follow a structured workflow, ensuring that all issues are addressed promptly, documented thoroughly, and escalated according to their severity. This workflow is designed to enhance communication and traceability from the moment a support event is created until its resolution. The escalation process uses clearly defined severity levels, response timelines, and prioritized actions to ensure effective issue management.

Escalation Workflow

The escalation process follows these stages, with clear responsibilities at each level to ensure that all issues are appropriately addressed:

Operations Stage:
- Operators perform routine troubleshooting per maintenance manual instructions, identifying any issues that cannot be resolved with standard procedures.
Initial Troubleshooting by Maintenance:
- If operators are unable to resolve an issue, it is escalated to the internal maintenance team. Maintenance personnel troubleshoot using advanced diagnostic tools and procedures outlined in the manual.

Escalation to Mujin Support:
- If maintenance cannot resolve the issue, they escalate it through the Mujin Support Portal. A formal support event is created, including issue documentation and relevant logs.
- Response Management: Support events are prioritized according to the severity level, which defines response timelines and escalation paths. This enables systematic handling from initial analysis to potential on-site support if necessary.

Severity Levels and Escalation Protocol

Each support event is assigned a severity level to determine the response priority, action timeline, and escalation requirements. Below is a detailed breakdown of each severity level:

Severity Level	Definition	Response Time	Action	Escalation
Level 1: Urgent	Major functionality loss; operating at less than 70% capacity, or major physical damage causing system downtime.	1-3 Hours	Root Cause Analysis	Customer Support
3-6 Hours	Recovery Execution	Director of Support
6-8 Hours	Summary Report and Recovery Execution (mobilization for on-site support)	Global CTO
Level 2: High	Key functionality loss; operating at less than 85% capacity, major component failure without recovery estimate, or a systematic error affecting other systems.	1-8 Hours	Root Cause Analysis	Customer Support
8-16 Hours	Summary Report	Local Support Manager
16-24 Hours	Recovery Execution (on-site if required)	Acct Manager, Director of Support
Level 3: Medium	Minor functionality loss; component failure causing partial functionality loss with minimal operational impact.	1-8 Hours	Root Cause Analysis & Recovery Execution	Customer Support
16-48 Hours	Summary Report & Recovery Execution	Local Support Manager
48-72 Hours	Optional on-site mobilization	Acct Manager, Director of Support
Level 4: Six Sigma	Issues or missing functionality outside of defined design; enhancement requests or minor product adjustments.	TBD	Input Collection	Tier 1 Support
21 Days	Feature Proposal	Tier 1 Support
60 Days	Feature Prioritization	Product Development Team

Issue Documentation and Reporting Requirements

To ensure thorough tracking and effective response, operators and maintenance teams must document issues comprehensively:

Error Codes and Alarms: Record specific error codes, alarms, and related HMI messages. Detail affected components and include screenshots or logs if available.
Time and Frequency: Note the time and date of the incident and any patterns in occurrence frequency. This assists in identifying recurring issues and potential root causes.
Troubleshooting Steps Taken: Document all troubleshooting steps performed, including resets, recalibrations, and part replacements. This prevents redundancy and allows the maintenance team to pursue more advanced diagnostic steps.
Environment and Operational Context: Include details of operational conditions such as task load, environmental factors (e.g., temperature), and any recent configuration changes.

Escalation Protocol and Responsibilities

Step 1: Supervisor Notification:
- Action: Operators report unresolved issues to their immediate supervisor, providing a summary and key documentation.
- Additional Detail: Supervisors assess the impact on production and initiate formal escalation as required, helping prioritize resource allocation.
Step 2: Maintenance Request Submission:
- Action: The maintenance team creates a formal maintenance request, attaching complete documentation. They may also consult historical logs to identify if the issue is part of a pattern.
- Additional Detail: Clear, detailed requests ensure the maintenance team arrives prepared with the right tools and resources.
Step 3: Coordination with Maintenance Team:
- Action: Maintenance and support teams coordinate an on-site review. This may involve troubleshooting sessions, equipment adjustments, or part replacements.
- Additional Detail: On-site coordination allows for real-time insights and verification of fixes, especially for intermittent issues.
Step 4: Summary Report and Status Update:
- Action: Maintenance completes a summary report outlining root causes, corrective actions taken, and recommended future preventive measures.
- Additional Detail: Routine follow-ups ensure that both operators and maintenance teams are aware of any adjustments or procedural changes made, creating a feedback loop to prevent similar issues.

Examples of Escalated Issues and Priorities

Example 1: Persistent Robotic Arm Alignment Error:
- Severity Level: Level 2 – High. Frequent misalignments after recalibration indicate a possible mechanical fault or software calibration issue.
- Escalation Path: Initiate a Root Cause Analysis within 1-8 hours, followed by on-site intervention if necessary.
Example 2: Power Interruptions to Specific Components:
- Severity Level: Level 1 – Urgent if affecting safety-critical functions; Level 3 – Medium if impact is limited to non-critical components.
- Escalation Path: Conduct immediate troubleshooting within 1-3 hours, followed by on-site support if interruptions continue.
Example 3: Recurring VFD Fault on Stretch Wrapper:
- Severity Level: Level 2 – High, as it impacts wrapping consistency and operational efficiency.
- Escalation Path: Complete Root Cause Analysis within 8 hours and pursue repairs or replacement based on findings.

Operator Responsibilities Post-Escalation

Observing Equipment Behavior:
- Detail: After any maintenance intervention, operators should carefully monitor the equipment for recurrence of symptoms, performance deviations, or unusual sounds.
Logging Observations:
- Detail: Document all relevant observations in the maintenance log, especially if symptoms reappear within the same shift or operational cycle.
Implementing Preventive Measures:
- Detail: Follow all preventive instructions from maintenance, such as adjustments to operational procedures or updated calibration schedules. Ensure that procedural changes are clearly communicated to all relevant team members.[JA44]

Appendix

Spare Parts

Recommended Spare Parts List

Description	Mujin PN	OEM Part Number	Build Qty	Recommended Qty	Spare Type	Lead Time	Life Expectancy
M150 1500kg Payload AGV	MJP7Y1X5A	M150(B)U	36	1	Normal Spare	8 wks	10-15 Years
Drive Wheel, Outer diameter 200, width 42, hardness 92A	MJPYWX13Z	M11008368K010	72	4	Consumable	10 wks	3 years
Driven Wheel, 3-inch wheel, eccentric 26	MJP830020	M16006935K010	144	8	Consumable	10 wks	3 years
Tray rubber pad, Black matte silicone for M100	MJPY28749	M12007344K010	36	2	Consumable	6 wks	3 years
C-BOX component, Self developed C-BOX	MJPZXZ957	M000063030K010	36	2	Critical Spare	10 wks	3 years
D-BOX component, Self developed D-BOX	MJPW4604W	M00006922K010	36	2	Critical Spare	10 wks	3 years
LFP Battery, Lithium iron phosphate battery，48V，48AH	MJP3X7A04	B70006048K010	36	2	Consumable	10 wks	cycle life 1500 times
Front anti-collision strip, A-454 electric collision bar	MJP43Y287	M15006395K010	36	2	Normal Spare	10 wks	3 years
Rear anti-collision strip, A-454 electric collision bar	MJP73Z52W	M15006396K010	36	2	Normal Spare	10 wks	3 years
Laser radar, S30B-2011GB	MJP86X8YW	B74L03054K010	36	4	Critical Spare	10 wks	5 years
Front left emergency stop button, M100-J28J28-080-1	MJPWA9Y75	B69009703K010	36	2	Normal Spare	10 wks	5 years
Front right emergency stop button, M81-F10F10-006-2	MJPZAW578	B69006252K020	36	2	Normal Spare	10 wks	5 years
Rear left emergency stop button, M100-J25J25-165-1	MJP121830	B69007229K010	36	2	Normal Spare	10 wks	5 years
Rear right emergency stop button, M100-J26J26-240-1	MJP2Z7WXA	B69007230K010	36	2	Normal Spare	10 wks	5 years
Front shell, ABS flame retardant material	MJP0822ZZ	M12007113K010	36	2	Normal Spare	10 wks	3 years
Rear shell, ABS flame retardant material	MJPWAZ285	M12007114K010	36	2	Normal Spare	8 wks	3 years
Left wheel cover, ABS flame retardant material	MJP78X0A9	M15006397K010	36	2	Normal Spare	8 wks	3 years
Right wheel cover, ABS flame retardant material	MJPZ29489	M15006398K010	36	2	Normal Spare	8 wks	3 years
Top Cover, ABS flame retardant material	MJP689304	M12006560K010	36	2	Normal Spare	8 wks	3 years
AGV 1800W Charger	MJP54AX65	P1800	7	1	Critical Spare	12 wks	3 years
AGV Mobile Rack, 1320x1120, GMA Pallet	MJP50X1Z6	G263-98-1010-0-A	810	10	Normal Spare	12 wks	5 years
AGV Rack QR Codes	MJP098662	MJP098662	810	200	Normal Spare	2 wks	3 years
AGV Floor QR Codes	MJP1095ZW	MJP1095ZW	4000	1000	Normal Spare	2 wks	3 years
Reflectors, Safe Single Archway	MJP5W064Y	50022816	40	3	Critical Spare	1 wks
Photo-eyes, retroreflective	MJP3X1771	RK46C.DXL3/4P-M12	40	3	Critical Spare	1 wks
Area scanner Area scanner	MJP90Z993	SZ-V32NX	20	3	Critical Spare	1 wks	3 years
G4 Fan Filter Media 15MMx1Mx1M	MJPZY759Z	30001177	3	2	Normal Spare	1 wks	6-12 months
UL vortex air pump	MJP72851W	3RB 350-3AAT57 8.6KW/480V	3	1	Critical Spare	2 wks	3-5 years
Vacuum filter (2-inch inner wire)	MJP536600	2BX4-082	3	1	Normal Spare	4 wks	1-3 years
Blower brake, double acting pneumatic cylinder	MJP499651	CDQ2A50-75DZ	6	1	Normal Spare	2 wks	1-3 years
Silencer	MJP02018A	AN15-C08	3	3	Consumable	1 wks	1-3 years
Contactless magnetic switch	MJP456Y78	D-M9BWVL	12	1	Normal Spare	2 wks	3-5 years
Monolithic two-position five-way single solenoid valve	MJPX19953	SY3120-5MZE-M5	3	1	Normal Spare	2 wks	1-3 years
Round 304 filter mesh 68mm20 mesh	MJP6Y4584	30000977	3	1	Normal Spare	1 wks	3-5 years
Analog input unit	MJP2A7X9Z	KV-NC4AD	6	1	Normal Spare	2 wks	3-5 years
Switching power supply	MJPW00AWZ	DDR-15G-5	3	1	Normal Spare	2 wks	10 years
Door switch	MJP710XWA	2500470	3	1	Normal Spare	3 wks	3-5 years
Economical daylight color LED lighting	MJP9AWW24	CWA3S-24-CD	3	1	Normal Spare	2 wks	3-5 years
Ventilation filter	MJPX41249	FU9803AP3	6	1	Critical Spare	2 wks	1-3 years
Finger Guard	MJPA0Y025	E-SFG-120	2	1	Normal Spare	1 wks	3-5 years
DC cooling fan	MJPW156WZ	R1225X24BPLB-7	3	1	Critical Spare	1 wks	3-5 years
Network communication module	MJPA31ZZ9	KV-EP02	3	1	Normal Spare	2 wks	3-5 years
Input and output unit	MJP598851	KV-NC16EXT	3	1	Normal Spare	2 wks	3-5 years
Switching power supply	MJP86Y5Y0	TDR-480-24	3	1	Normal Spare	1 wks	10 years
Thermostat	MJP34101Z	E5CC-RX2DSM-800	3	1	Normal Spare	2 wks	3-5 years
Thermostat mounting adapter	MJPAYWY46	Y92F-52	3	1	Normal Spare	2 wks	3-5 years
Thermocouple	MJP9ZY435	E52-CA1DY M6 2M	3	1	Normal Spare	2 wks	3-5 years
VFD Frequency converter	MJPY4670A	25B-D030N114	3	1	Normal Spare	1 wks	3-5 years
Door switch	MJP710XWA	2500470	3	1	Normal Spare	3 wks	3-5 years
Economical daylight color LED lighting	MJP9AWW24	CWA3S-24-CD	3	1	Normal Spare	2 wks	3-5 years
Ventilation filter	MJPX41249	FU9803AP3	6	1	Normal Spare	2 wks	1-3 years
Finger Guard	MJPA0Y025	E-SFG-120	6	1	Normal Spare	1 wks	3-5 years
DC cooling fan	MJPW156WZ	R1225X24BPLB-7	6	1	Normal Spare	1 wks	3-5 years
Motor starting protector	MJPW63396	140MT-C3E-C25	3	1	Normal Spare	12 wks	3-5 years
M series molded case circuit breaker	MJP39143A	M1S40T3L	3	1	Normal Spare	3 wks	3-5 years
Switching power supply	MJP5AW656	DDR-120B-24	3	1	Normal Spare	2 wks	10 years
Filter element	MJPA6525Z	AF40P-060S	3	2	Normal Spare	2 wks	1-3 years
Filter element, FILTER KIT DD45+	MJP62Z489	2901207913	3	2	Normal Spare	7 wks	1-3 years
Filter element, FILTER KIT PD45+	MJPY8328Y	2901207933	3	2	Normal Spare	7 wks	1-3 years
Filter element, FILTER KIT QD45+	MJP2792W2	2901208033	3	2	Normal Spare	7 wks	1-3 years
UL489 three-phase circuit breaker	MJP76W77A	B1N3D10	3	1	Normal Spare	4 wks	3-5 years
UL489 three-phase circuit breaker	MJPYZW8XW	B1N3D20	3	1	Normal Spare	4 wks	3-5 years
0.4KW Servo Driver	MJPY22593	MBDLT25BF	3	1	Normal Spare	2 wks	3-5 years
1KW Servo Driver	MJP2WWZY3	MDDLT45BF	3	1	Normal Spare	2 wks	3-5 years
Door switch	MJP710XWA	2500470	3	1	Normal Spare	3 wks	3-5 years
Absolute EVE battery	MJPWY3A2A	(EVE)DV0P2990	6	2	Normal Spare	2 wks	1 years
Battery box for absolute encoder	MJPY240X9	DV0P4430	6	2	Normal Spare	2 wks	3-5 years
Varistor	MJP98ZX17	TNR15G271K	3	1	Normal Spare	1 wks	1 years
Terminal relay	MJP11XA0A	G6B-47BND DC24V	3	1	Normal Spare	2 wks	500000 operations
Economical daylight color LED lighting	MJP9AWW24	CWA3S-24-CD	3	1	Normal Spare	2 wks	3-5 years
Ventilation filter	MJPX41249	FU9803AP3	6	1	Normal Spare	2 wks	1-3 years
Finger Guard	MJPA0Y025	E-SFG-120	6	1	Normal Spare	1 wks	3-5 years
DC cooling fan	MJPW156WZ	R1225X24BPLB-7	6	1	Normal Spare	1 wks	3-5 years
M series molded case circuit breaker	MJP0X0X27	M1S35T3L	3	1	Normal Spare	4 wks	3-5 years
IO-Link Hub 4 port	MJPY3X58X	R90C-4B21-KQ	21	2	Critical Spare	3 wks
IO-Link Hub 8 port	MJPA9A9X4	R130C-8P22-KQ	4	1	Critical Spare	3 wks
Safety interlock w/ 4 buttons w/ estop	MJP6AA470	TA2-T6-RX-EKR2-SRP11-NHEIPBPBP3N-PF10-MPB91-MPB51	7	1	Normal Spare	4 wks
Safety interlock w/ 3 buttons wo/ estop	MJP7754A2	TA2-T6-RX-EKR2-SRP11-NH00PBPBP3N-PF10-MPB91-MPB51	12	1	Normal Spare	4 wks
1/4" x 3/4" self drilling screws, attach bracket to posts	MJPX95YA5	90064A610	456	20	Normal Spare	2 wks
Wire Protective Cover, DURA WRAP - 3" - BLACK	MJP25W6A7	DWN3.00BK	200	65	Consumable	2 wks	1-3 years
Wire Protective Cover, DURA WRAP - 3 1/2" - BLACK W/ YELLOW STRIPE	MJPYWX211	DWN3.50BKYS	200	65	Consumable	2 wks	1-3 years
Hose Clamp, Worm Gear (Diam 2-4in)	MJPZ26497	16P307	60	10	Consumable	1 wks	3-5 years
Fixed seat	MJPZ80Y40	SH-P/56-70	45	12	Critical Spare	2 wks	3-5 years
Locating Ring	MJP97A1Z5	SRF-70	48	12	Critical Spare	2 wks	3-5 years
Vacuum duct, AIRDUC PUR355AS 2,5in/Φ63-65	MJP430841	355-065-0000	35	10	Critical Spare	2 wks	1-3 years
Corrugated Tubing, Murriflex SW Cable Protectino Conduit	MJP84Y5A3	EW-PAE-70 Jumbo	50	16	Normal Spare	2 wks	1-3 years
Vacuum duct, AIRDUC PUR 355 AS 2in/Φ50-51	MJP458A88	355-050-0000	15	10	Critical Spare	2 wks	1-3 years
Wear ring	MJP7X0Z2A	PR/SV-UNI P70	21	7	Critical Spare	1 wks	1-3 years
24V Power Cord Asm (L=20M)	MJA1425Y3	30001169	6	2	Critical Spare	2 wks
High speed power cable	MJP518X9Z	MASWG-BP3KK-2.5-5	120	0	Normal Spare	1 wks	1-2 years
Upper shell	MJPA05WX1	H3A-TE-2B-M20	6	0	Normal Spare	2 wks
Female insert	MJPX27166	HA-004-F-V2	6	0	Normal Spare	2 wks	Plug and unplug 500 times
Metal waterproof connector	MJPWWX4Y1	WNA-M20(D8-14)	6	0	Normal Spare	2 wks
European terminal	MJPZX894Y	E2512-BLUE	48	0	Normal Spare	3 wks
R type pre-insulated terminal block	MJPZ3XX1X	RVL2-5	12	0	Normal Spare	3 wks
Torque Sensor Cable Asm (L=20M)	MJA85Y2Z4	30001170	3	1	Critical Spare	3 wks
Anti-twist network cable	MJP610348	CROB-20276 LANCABLE Cat.6A (black)	60	0	Normal Spare	1 wks	2-3 years
M12 screw crimping hole connector	MJPY1Y88W	M12-F05B-T-D8	3	0	Normal Spare	2 wks	Plug and unplug 100 times
M12 shielded screw crimp hole connector	MJPZ5YYX1	M12-F04B-T-D8-SH	3	0	Normal Spare	2 wks	Plug and unplug 100 times
European terminal	MJPZ0Z83X	E0208-VIOLET	36	0	Normal Spare	3 wks
R type pre-insulated terminal block	MJPZ3XX1X	RVL2-5	3	0	Normal Spare	3 wks
Flow Meter Cable Asm (L=20M)	MJAZWYA66	30001171	3	1	Critical Spare	3 wks
Ultra-high speed drag chain with shield	MJPAWW757	SS300RSB-22-2P	60	0	Normal Spare	1 wks	2-3 years
M12 screw crimp connector	MJP4Z3WX9	M12-F04A-T-D8-SH	3	0	Normal Spare	2 wks	Plug and unplug 100 times
European terminal	MJPZ0Z83X	E0208-VIOLET	24	0	Normal Spare	3 wks
R type pre-insulated terminal block	MJPZ3XX1X	RVL2-5	3	0	Normal Spare	3 wks
Motor Power Supply Line Asm (L=20M)	MJA2YW204	30001172	6	2	Critical Spare	3 wks
High speed motion cable	MJP49ZW4W	MASWG-BP3KK-0.75-4	120	0	Normal Spare	1 wks	2-3 years
M12 screw crimp connector	MJP4Z3WX9	M12-F04A-T-D8-SH	6	0	Normal Spare	2 wks	Plug and unplug 100 times
European terminal	MJP89Z621	E1010-RED	42	0	Normal Spare	3 wks
R type pre-insulated terminal block	MJPZAZ429	RV1-5	6	0	Normal Spare	3 wks
Motor Brake Line Asm (L=20M)	MJA569ZAX	30001173	6	2	Critical Spare	3 wks
High speed motion cable	MJP15W98Y	MASW-BSBD-0.3-2	120	0	Normal Spare	1 wks	2-3 years
M8 screw crimping hole connector	MJP9A192Y	M8-F04-T-D5	6	0	Normal Spare	2 wks	Plug and unplug 100 times
European terminal	MJPZ0Z83X	E0208-VIOLET	24	0	Normal Spare	3 wks
Motor Encoder Cable Asm (L=20M)	MJA6ZA9A5	30001174	6	2	Critical Spare	3 wks
Ultra-high speed drag chain with shield	MJPYA214Z	SS300RSB-22-3P	120	0	Normal Spare	1 wks	2-3 years
Circular connector	MJP8477X0	M12-F08A-T-D8-SH	6	0	Normal Spare	2 wks	Plug and unplug 100 times
European terminal	MJPZ0Z83X	E0208-VIOLET	36	0	Normal Spare	3 wks
R type pre-insulated terminal block	MJPZ3XX1X	RVL2-5	6	0	Normal Spare	3 wks
IO Line Asm (L=20M)	MJA234071	30001175	3	1	Critical Spare	3 wks
Ultra-high speed drag chain with shield	MJPAWW757	SS300RSB-22-2P	60	0	Normal Spare	1 wks	2-3 years
M8 screw crimping hole connector	MJPZ7767X	M8-F03-T-D5	3	0	Normal Spare	2 wks	Plug and unplug 100 times
European terminal	MJPZ0Z83X	E0208-VIOLET	18	0	Normal Spare	3 wks
Network Cable Asm (L=20M)	MJA3X628X	30001176	6	2	Critical Spare	1 wks
Anti-twist network cable	MJP610348	CROB-20276 LANCABLE Cat.6A (black)	120	0	Normal Spare	1 wks	2-3 years
H3A RJ45 male	MJP1301X9	H3A-TE/S-2B-M20-RJ45/M	12	0	Normal Spare	1 wks	Plug and unplug 100 times
Mega Gripper Multi Channel Gripper with Mechanized Side Pad	MJPY31W1A	MJP52129W	3	1	Critical Spare	12 wks	5 years
S5M timing upper pulley, high torque	MJP3X49A2	HTPP32S5M150-B-N19	3	1	Normal Spare	1 wks	1-3 years
S5M timing belt, high torque	MJP6Z33WW	HTBN400S5M-150	3	2	Critical Spare	1 wks	1-3 years
Customized screw	MJP7A58Y9	GBS#R20-5T4-FSI-480-573-0.05	3	1	Normal Spare	2 wks	1-3 years
S5M timing lower pulley, high torque	MJPX3631Y	HTLK32S5M150-E-12	3	1	Normal Spare	1 wks	1-3 years
Main control module board	MJP8161XY	MC16P4-E-A	6	2	Critical Spare	10 wks	1-3 years
Vacuum control unit	MJP54XA90	VC55-HD-G14-B	374	118	Critical Spare	8 wks	6-18 mouths
O-ring	MJP6X7AW9	NPA20	354	20	Critical Spare	1 wks	3 years
O-ring	MJPY11X3A	NSA3	708	10	Critical Spare	1 wks	3 years
O-ring inner diameter 4.5 wire diameter 1	MJP3Z154W	10012370	354	10	Critical Spare	2 wks	3 years
YG12 filter cotton Φ4.5x5	MJPYX3659	10000952	500	500	Consumable	1 wks	6 mouths
Customized copper sintered filter element Φ4.9xH5 (40~60 mesh)	MJP0X63A2	10013871	354	354	Consumable	4 wks	1-2 years
Micro solenoid valve	MJP5041WY	CPV10BP-050	708	50	Critical Spare	2 wks	6-18 mouths
Copper sintered filter Φ3 H6 60 mesh	MJP7XX5X0	30000870	708	708	Consumable	1 wks	1-2 years
Customized 40 mesh high pressure valve block filter stainless steel G1/4	MJP7A3282	30000773	142	20	Normal Spare	2 wks	3-5 years
Schmalz suction cup with filter	MJPYW7A36	SPB2 40 ED-65 G14-AG-F	198	60	Critical Spare	6 wks	1-3 years
Round corrugated suction cup	MJP13727X	SPB2 40 ED-65 G1/4-AG	198	60	Critical Spare	6 wks	1-3 years
316 stamping metal filter (304 edge) outer diameter 9mm 30 mesh without support	MJPXX68X1	10013174	198	60	Critical Spare	1 wks	3-5 years
Spur gear pressure angle 20°	MJP5208X1	GEAKBG2.0-30-20-B-16N	3	1	Normal Spare	1 wks	3-5 years
Round pillar	MJP9Y2966	E-PETHS10-200-F9-SC150-M6-N6	6	6	Normal Spare	1 wks	5 years
Constant load spring	MJP9238Z4	CFS5.7	36	12	Critical Spare	1 wks	1-3 years
Economical drag chain	MJPXXZ6A4	C-MPD20-40-48-29	6	3	Consumable	1 wks	1-3 years
Round corrugated suction cup (no metal parts)	MJP263823	SPB2 40 ED-65 SC050	352	60	Critical Spare	8 wks	1-2 years
Rack L size specified type	MJP80XA78	RGEAL2.0N-396	3	1	Normal Spare	2 wks	3-5 years
Panasonic servo motor	MJP57374Z	MSMF042L1V2M	3	1	Normal Spare	2 wks	3-5 years
1KW servo motor	MJPA5AWW9	MSMF092L1V2M	3	1	Normal Spare	2 wks	3-5 years
M12 Shielded Screw Crimp Connector	MJP93A598	M12-M08A-T-D8-SH	12	2	Normal Spare	2 wks	Plug and unplug 100 times
M8 screw crimp connector	MJP043X0Z	M8-M04-T-D5	12	2	Normal Spare	2 wks	Plug and unplug 100 times
Micro switch	MJP807X89	A-20GQ-B	6	2	Critical Spare	2 wks	1-3 years
6-axis torque sensor (large)	MJP2AW9WA	MJN160103501A00	3	1	Normal Spare	9 wks	5 years
M12 screw crimp connector	MJP2Y2W7W	M12-M04A-T-D8-SH	3	2	Normal Spare	1 wks	Plug and unplug 100 times
WEARABLE COMPUTER WRIST MOUNT	MJPX6Y0XW	WS5001-0W203D10ENA	4	1	Critical Spare	6 wks	3 years
LEVEL VI POWER SUPPLY FOR FOUR SLOT CRADLES	MJP25W8W0	PWR-BGA12V108W0WW	1	1	Critical Spare	6 wks	3 years
CBL-DC-382A1-01 DC LINE CORD FOR MULTI-SLOT CRADLES	MJP8WA50A	CBL-DC-382A1-01	1	1	Critical Spare	6 wks	3 years
ZEBRA EVM/EMC, WS50 REPLACEMENTDEFLECTOR FOR CONVERGED SHELL	MJP460702	SG-WS5X-DFLTC-01	4	1	Consumable	6 wks	3 years
ZEBRA SG-WS5X-SHLCS-01 WS50 CONVERGEDREPLACEMENT SHELL	MJP25254A	SG-WS5X-SHLCS-01	4	1	Consumable	6 wks	3 years
ZEBRA SG-WS5X-SCRNP1-01 WS50 GLASS SCREENPROTECTOR	MJPW6W8Y7	SG-WS5X-SCRNP1-01	4	1	Consumable	6 wks	3 years
ZEBRA 5-SLOT ETHERNET/17 CHARGE CRADLE	MJP00268Z	CRD-WS5X-5SECV-01	1	1	Critical Spare	6 wks	3 years
REPLACEMENT WRIST STRAP	MJP8X5Z7Z	SG-WS5X-WSTRP-01	4	1	Consumable	6 wks	3 years
SMALL, RIGHT HAND WRAP	MJPA93X8A	SG-WEARHNWPRS-01	4	1	Consumable	6 wks	1 years
SMALL, LEFT HAND WRAP	MJPYA4AZ0	SG-WEAR-HNWPLS-01	4	1	Consumable	6 wks	1 years
MEDIUM, RIGHT HAND WRAP	MJP6Z2975	SG-WEARHNWPRM-01	4	1	Consumable	6 wks	1 years
MEDIUM, LEFT HAND WRAP	MJP2W8Z25	SG-WEARHNWPLM-01	4	1	Consumable	6 wks	1 years
LARGE, RIGHT HAND WRAP	MJPYAZ244	SG-WEAR-HNWPRL-02	4	1	Consumable	6 wks	1 years
LARGE, LEFT HAND WRAP	MJP882Y71	SG-WEAR-HNWPLL-01	4	1	Consumable	6 wks	1 years
1300 MAH SPARE BATTERY CONVERGED	MJPX6AW0A	BTRY-WS5X-13MA-01	4	1	Critical Spare	6 wks	3 years
ZEBRA ZT411 Thermal Transfer Industrial Printer 203 dpi	MJP239ZZA	ZT411	1	1	Normal Spare	2 wks	5 years
HMI touch screen for hmi	MJPZ34607	VIO-217-PC100-KBL-U	7	1	Critical Spare	4 wks	5 years
Blue e+ fan-and-filter unit	MJP84265X	3237724	7	1	Normal Spare	2 wks	3 years
SK Chopped-fibre filter mat, for fan-and-filter units SK 3237.7xx/3237.3xx, WxHxD: 89 x 89 x 10 mm	MJPA61619	3237054	7	14	Consumable	2 wks	1 years
IO-Link Master	MJP925658	DXMR110-8K	1	1	Critical Spare	16 wks
Single beam safety device receiver	MJP7A4A4W	SLE46C-40.K4/4P	2	1	Critical Spare	1 wks
Single beam safety device transmitter	MJP7XZ258	SLS46C-40.K48	2	1	Critical Spare	1 wks
Mujin Controller Pendant, 10M Cable	MJP868312	MPXS-10	7	1	Critical Spare	1 wks	5 years
Mujin Controller, External Fan, Wifi	MJP7A8566	MCX1M3R5D7WF-00	7	1	Critical Spare	1 wks	5 years
Sensor IM12-04BPSZC1	MJP29W42X	1003398	4	4	Critical Spare	2 wks
Magnetic cylinder sensor	MJP908022	1007668	16	16	Critical Spare	2 wks
Magnetic cylinder sensor	MJP261323	1007850	8	8	Critical Spare	2 wks
Exact12 8xM12 5-pole terminal	MJP72YZ11	1003309	4	2	Normal Spare	2 wks
T-connector M12	MJPW08158	1003313	24	12	Normal Spare	2 wks
Sensor GTB6-P4211	MJPA2W477	1003365	4	2	Normal Spare	2 wks
Reflector PL20A	MJP45YYZ4	1003575	4	2	Normal Spare	2 wks
Sensor GL6-P4211	MJPZ79X7X	1005663	4	2	Normal Spare	2 wks
Prefab cable PVC-OB L=0.3m	MJP79WZ5Z	1005959	8	4	Normal Spare	2 wks
Prefab kabel PVC-OB L=2m	MJP2AZ9X1	1007649	4	2	Normal Spare	2 wks
Cylinder DSBC-63-100-PPVA-N3	MJPX2WAAW	AE0023414	8	4	Normal Spare	2 wks
Cylinder DSBG-160-320-PPVA-N3	MJP60Y225	AE0023457	4	2	Normal Spare	2 wks
Soft-start/quick exhaust valve	MJP43WX50	AE0066989	4	2	Normal Spare	2 wks
Silencer UOS-1-LF	MJP646Y7X	AE0068433	4	2	Normal Spare	2 wks
Prefab cable PVC-OB L=0.6m	MJPX0004A	AE0068488	8	2	Normal Spare	2 wks
Cam stopper plate PD1	MJPZ49A51	AE0145583	4	2	Normal Spare	2 wks
Prefab cable PVC-OB L=3m	MJPWZ0005	AE0146276	4	2	Normal Spare	2 wks
Prefab cable PVC-OB L=0.6m	MJP8Z9X99	AE0146277	8	4	Normal Spare	2 wks
Prefab cable PVC-OB L=1m	MJP3416Z5	AE0146278	4	2	Normal Spare	2 wks
Brake pad V2 Poly	MJP9X4Z69	F0024-007-01	1	1	Critical Spare	2 wks
Rewind belt XL wide	MJP41W6A5	PF062-093-00	1	1	Critical Spare	1 wks
3-way valve 24vdc	MJP222A22	PF032-054-00	1	1	Critical Spare	1 wks
Panel view 4 inch color TFT	MJPZ73Y6A	PF216-390-01	1	1	Normal Spare	1 wks
Allen Bradley Micro-850 Controller	MJPAA134Z	PF216-389-00	1	1	Critical Spare	1 wks
Air jet assembly 5 in	MJPX88AWY	F0130-509-00	1	1	Normal Spare	2 wks
ZE511 Print head kit 203DPI	MJP9817Z6	PF322-099-00	1	1	Critical Spare	1 wks
ZE511 203dpi	MJP99A7Y0	PF322-080-00	1	1	Critical Spare	2 wks
24 VDC Relay	MJP4430Z5	PF043-001-00	1	1	Critical Spare	1 wks
Rewind Assembly LLD	MJPWW0Z19	F0088-556-02	1	1	Normal Spare	2 wks
TopTherm fan-and-filter units, 24 V (DC), 255x255mm, 2 A	MJP277XZW	3241124	2	1	Critical Spare	1 wks
RJ45 coupling/Modular Connectors / Ethernet Connectors, IP20, 1A, CAT 6a	MJP45ZZZ3	1086108	12	1	Normal Spare	1 wks	5 years
Device connector front mounting, Power, 5-position, female connector, straight, M12: L coded, 2 m flying leads	MJP4Y56Z9	1329937	1	1	Normal Spare	2 wks
Panel mounting frames, IP67, for modular socket inserts, round panel cutout, with grommet, with thread and union nut	MJPA9XA51	1689844	12	1	Normal Spare	1 wks	5 years
Power supply unit, QUINT4-PS/1AC/24DC/40	MJP425AY5	2904603	2	1	Critical Spare	2 wks
Thermomagnetic device circuit breaker, TMC 81C, 2A, 120 V AC (277 V AC)\60VDC	MJP9W4Y64	2907559	2	1	Consumable	1 wks
Thermomagnetic device circuit breaker, TMC 81C, 10A, 120 V AC (277 V AC)\60VDC	MJP0Z05A1	2907566	3	1	Consumable	1 wks
Thermomagnetic device circuit breaker, TMC 81C, 16A, 120 V AC (277 V AC)\60VDC	MJPW695XZ	2907572	1	1	Consumable	1 wks
Thermomagnetic device circuit breaker, TMC 81C, 05A, 120 V AC (277 V AC)\60VDC	MJPYY8205	2907562	10	1	Consumable	2 wks	5 years
6 Port Universal Ground Bar	MJPW1A075	UGB2/0-414-6	2	1	Normal Spare	1 wks
Absence of Voltage Indicator	MJP5Z372A	VS2-AVT-1IB	1	1	Normal Spare	7 wks
VeriSafe Absence of Voltage Tester,8' (2.4m) system cable, Battery Indicator	MJP3XA143	VS2-AVT-1PB-08	1	1	Normal Spare	7 wks
Safety Relay,MSR126.1T,24V AC/DC,Automatic/Manual,One 2 N.C. Input,1 LC Input,2 Safety Output,CAT 4 Rated	MJP82Y07X	440R-N23114	3	1	Critical Spare	1 wks
Molded Case Circuit Breaker,125A Frame,40A,Thermal Magnetic,25kA@480V,36kA@415V,3 Pole	MJPA8610Z	140G-G2C3-C40	1	1	Consumable	2 wks
Flange Handle Accessories/Operating Mechanisms, 140G Flange Cable - Metal Bail, Non-Metalic Handle, 3 ft	MJP5Y2W5W	140G-G-FCXB03	1	1	Critical Spare	2 wks
1756-IB16S ControlLogix 16-Ch 10-30V DC Safety Input	MJP92WZ8Z	1756-IB16S	1	1	Critical Spare	1 wks
Stratix 5700, 16 copper 10/100 ports, 2 combo(copper or SFP slot) 10/100 ports, 2 SFP 10/100 slots, full FW	MJP246XY5	1783-BMS20CA	2	1	Critical Spare	1 wks	5 years
CompactLogix 5380 End Cap	MJPAW68W9	5069-ECR	1	1	Critical Spare	2 wks
Compact 5000 8 Channel Input Module	MJPYY9957	5069-IB8S	1	1	Critical Spare	1 wks
Compact GuardLogix SIL2 3.0/1.5M	MJP69X317	5069-L330ERS2	1	1	Critical Spare	1 wks
Compact5000 8 Channel 24VDC Configurable Safety Output Module (Sourcing or Bipolar)	MJP2471AA	5069-OBV8S	4	1	Critical Spare	2 wks
5069 Compact I/O 18 pins Screw type terminal block kit	MJPZ58930	5069-RTB18-SCREW	3	1	Critical Spare	1 wks
Transformer 3 KVa 480V primary 208V secondary	MJP6XZ9Y4	3T2F	3	1	Critical Spare	2 wks
Thermomagnetic device circuit breaker, TMC 81C, 01A, 120 V AC (277 V AC)\60VDC	MJP6Y4Y45	2907558	3	1	Consumable	1 wks	3-5 years
Thermomagnetic device circuit breaker, TMC 81C, 3A, 120 V AC (277 V AC)\60VDC	MJP80811A	2907560	3	1	Consumable	1 wks	3-5 years
Thermomagnetic device circuit breaker, TMC 81C, 15A, 120 V AC (277 V AC)\60VDC	MJP0AZW49	2907571	3	1	Consumable	1 wks	3-5 years
Thermomagnetic device circuit breaker, TMC 81C, 40A, 120 V AC (277 V AC)\60VDC	MJP829X21	2907578	3	1	Consumable	1 wks	3-5 years
Thermomagnetic device circuit breaker, TMC 83D, 3A, 240 V AC (277/480Y, 240D), 3P	MJP987388	2907609	3	1	Consumable	1 wks	3-5 years
Thermomagnetic device circuit breaker, TMC 83D, 8A, 240 V AC (277/480Y, 240D), 3P	MJPXZW692	2907683	3	1	Consumable	1 wks	3-5 years
Thermomagnetic device circuit breaker, TMC 83D, 13A, 240 V AC (277/480Y, 240D), 3P	MJP6WZWX1	2907686	3	1	Consumable	1 wks	3-5 years
Thermomagnetic device circuit breaker, TMC 83D, 20A, 240 V AC (277/480Y, 240D), 3P	MJP7Y49WW	2907689	3	1	Consumable	1 wks	3-5 years
Thermomagnetic device circuit breaker, TMC 83D, 25A, 240 V AC (277/480Y, 240D), 3P	MJP16327A	2907690	3	1	Consumable	1 wks	3-5 years
Absence of Voltage Indicator	MJP49Y7AY	VS-AVT-C08	3	1	Normal Spare	2 wks
VeriSafe Absence of Voltage Tester	MJP65XZ10	VS-AVT-C08-L10	3	1	Normal Spare	2 wks
Outlet filter, 255x255x25 mm, NEMA12	MJP4W54Y7	3240200	1	1	Consumable	1 wks
Power supply unit, TRIO-PS/3AC/24DC/40	MJP6AX2XW	2866404	3	1	Critical Spare	1 wks	3 years
Relay Module, RIF-0-RPT-24DC/21,	MJP69954W	2903370	3	1	Critical Spare	1 wks	2-3 years
Feed-through terminal block	MJP23XA5A	TU 35/4X6/6X2,5	3	1	Normal Spare	1 wks
Stratix 5700, 16 copper 10/100 ports, 2 combo(copper or SFP slot) 10/100 ports, 2 SFP 10/100 slots, full FW	MJP246XY5	1783-BMS20CA	3	0	Critical Spare	1 wks	5 years
TopTherm fan-and-filter units, AC, 115V, 8" x 8" Sq, 71CFM, 49dBA, 17W, 0.23A, Plastic	MJP0Z6X28	3239110	4	1	Critical Spare	1 wks	3 years
Outlet filter, 255x255x25 mm, NEMA12	MJP4W54Y7	3239200	4	1	Consumable	1 wks	12 Months
Thermomagnetic device circuit breaker, TMC 81C, 7A, 120 V AC (277 V AC)\60VDC	MJPZ49YXX	2907632	4	1	Consumable	1 wks	3-5 years
Thermomagnetic device circuit breaker, TMC 81C, 20A, 120 V AC (277 V AC)\60VDC	MJP2Z34Z5	2907640	4	1	Consumable	1 wks	3-5 years
VeriSafe 2.0 AVT 1P, 2' (0.6m) system cable, Battery Indicator	MJP113766	VS2-AVT-1PB-02	3	1	Normal Spare	8 wks
Stratix 5700, 8 copper 10/100 ports, 2 combo(copper or SFP slot) 10/100 ports, full FW	MJPZ85W44	1783-BMS10CA	4	1	Critical Spare	1 wks
CP500L Robot Arm	MJP7157X2	CP500LEE03	3	0	Normal Spare	10 wks	10 yrs
E03 Robot Controller	MJPY73101	E03	3	0	Normal Spare	6 wks	10 yrs
SHEET	MJPY821W9	60337-0266	3	0	Normal Spare	6 wks
CONNECTOR-ASSY	MJP34X95X	50651-1020	3	0	Normal Spare	6 wks
BATTERY	MJP55Y91W	60750-1016	3	1	Critical Spare	6 wks
HARNESS-ASSY-CONTROLLER	MJP1XZAXW	50977-4117	3	0	Normal Spare	6 wks
FUSE	MJPAX4Z73	60570-1129	3	1	Critical Spare	2 wks
HARNESS-ASSY-SEPARATE,WRI	MJPXZ7789	50979-0449L10	3	0	Normal Spare	6 wks
HARNESS-ASSY-SEPARATE,SIG	MJP59W64W	50979-0450L10	3	0	Normal Spare	6 wks
HARNESS-ASSY-SEPARATE,WRI	MJP397659	50979-0515L10	3	0	Normal Spare	6 wks
BREAKER	MJPZ9AWW1	60569-0106	3	1	Critical Spare	6 wks
BREAKER	MJP9X4951	60569-0144	3	1	Critical Spare	6 wks
HARNESS-ASSY-SEPARATE,ARM	MJPX86132	50979-011OL10	3	0	Normal Spare	6 wks
HARNESS-ASSY-SEPARATE,ARM	MJP691WXZ	50979-0448L10	3	0	Normal Spare	6 wks
HARNESS-ASSY-SEPARATE,SIG	MJP46072X	50979-0112L10	3	0	Normal Spare	6 wks
PRINTED CIRCUITBOARD-ASSY	MJP699203	50999-2863	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP6784W5	50999-0220	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP67AW17	50999-0088	3	0	Normal Spare	3 wks
HARNESS-ASSY-CONTROLLER	MJPA0W4XY	50977-4391	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP30569Z	50999-0137	3	0	Normal Spare	3 wks
BOX-ASSY-TEACH	MJP5XX0X0	50817-0096L05	3	0	Normal Spare	3 wks
BOX-ASSY-TEACH	MJP26078Z	50817-0077L05	3	0	Normal Spare	3 wks
BOX-ASSY-TEACH	MJP14Y0X5	50817-0097L05	3	0	Normal Spare	3 wks
CABINET-ASSY-CONTROLLER	MJP5Z7X20	50807-0072	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJPX2AXW1	50999-2922	3	0	Normal Spare	3 wks
SERVOAMP-ASSY,1XC	MJP458Z15	50607-0136	3	1	Critical Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP26Y712	50999-2864	3	0	Normal Spare	3 wks
POWERSUPPLY-ASSY-SERVO	MJP364739	50632-0022	3	1	Critical Spare	3 wks
BOX-ASSY-TEACH	MJPZ8A922	50817-0077L 10	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJPW23WX4	50999-0005	3	0	Normal Spare	3 wks
SERVOAMP-ASSY,1XP	MJPXW8192	50607-0128	3	1	Critical Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJPZ15089	50999-0086	3	0	Normal Spare	3 wks
POWERSUPPLY-ASSY-DC	MJP1X4YZ0	50630-0033	3	1	Critical Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP146Z75	50999-2738	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP3X52WZ	50999-2806	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP12WWY9	50999-0006	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP109X85	50999-2936	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP44209A	50999-2957	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP8AY885	50999-2958	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP67A46X	50999-0185	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP34014A	50999-0622	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP9X1W0Y	50999-2280	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJPZ8033X	50999-0007	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJPYA1739	50999-3001	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP0673Y1	50999-0348	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP5316Z0	50999-2924	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP901W06	50999-0420	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJPXW5ZZ8	50999-0061	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP12YAWX	50999-0044	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP1A0X22	50999-2923	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP6AA332	50999-2925	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP032536	50999-2933	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP6X6112	50999-0062	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJPY9ZY43	50999-0045	3	0	Normal Spare	3 wks
SERVOAMP-ASSY	MJPA1215Z	50607-0129	3	1	Critical Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJP638697	50999-0354	3	0	Normal Spare	3 wks
HARNESS-ASSY-CONTROLLER	MJPAXAA4A	50973-2898	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJPZ59W27	50999-0177	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJPA5Y9W0	50999-0353	3	0	Normal Spare	3 wks
PRINTED CIRCUITBOARD-ASSY	MJPW247XZ	50999-0184	3	0	Normal Spare	3 wks
HARNESS-ASSY-CONTROLLER	MJP294W6A	50977-4118	3	0	Normal Spare	3 wks
HARNESS-ASSY-CONTROLLER	MJP3440WY	50973-2843	3	0	Normal Spare	3 wks
STORAGE MEDIUM	MJP9439WY	60851-0016	3	0	Normal Spare	3 wks
STORAGE MEDIUM	MJP42973A	60851-0003	3	0	Normal Spare	3 wks
STORAGE MEDIUM	MJPY40279	60851-0064	3	0	Normal Spare	3 wks
KEY	MJP5A0XY8	60710-0007	3	1	Critical Spare	6 wks
BATTERY-ASSY	MJP103212	50750-0034	3	1	Critical Spare	4 wks
REDUCTION GEAR-CYCLO,UA80	MJP044AZ3	60216-0035T10	3	1	Critical Spare	16 wks
REDUCTION GEAR-CYCLO,D45	MJP497XX5	60216-0032T10	3	1	Critical Spare	12 wks
REDUCTION GEAR-CYCLO,UA45	MJPA26Y35	60216-0038T10	3	1	Critical Spare	12 wks
MOTOR-ASSY-ELECTRIC,5KW	MJP5Z7144	50601-0131	3	1	Critical Spare	11 wks
HARNESS-ASSY-MACH INE	MJP3A8WX7	50975-5484	3	0	Normal Spare	11 wks
MOTOR-ASSY-ELECTRIC,2KW	MJP6W0747	50601-0130	3	1	Critical Spare	12 wks
GREASE,MULTEMP FZ	MJPA3A8YZ	60499-1053	3	1	Critical Spare	4 wks
PRINTED CIRCUITBOARD-ASSY	MJP7Y4X08	50999-0422	3	0	Normal Spare	6 wks
PRINTED CIRCUITBOARD-ASSY	MJP1Y6364	50999-2939	3	0	Normal Spare	3 wks
GEAR-ASSY,SPARE PARTS-SET	MJPXYAZX1	50210-0086	3	1	Critical Spare	9 wks
GEAR-ASSY,SPARE PARTS-SET	MJP899XA9	50210-0094	3	1	Critical Spare	9 wks
GREASE,MULTEMP FZ	MJP3901Y4	60499-1062	3	1	Critical Spare	3 wks
GREASE,DAPHNEGREASEMP#3	MJP1X0YWW	60499-0059	3	1	Critical Spare	4 wks
GEAR-ASSY,SPARE PARTS-SET	MJPYZAY45	50210-0091	3	1	Critical Spare	10 wks
HARNESS-ASSY-MACH INE	MJP686131	50975-5485	3	0	Normal Spare	4 wks
PRINTED CIRCUITBOARD-ASSY	MJPWX9A36	50999-2883	3	0	Normal Spare	20 Days
GASKET.LIQUID #1206D	MJPAXW695	60347-0009	3	1	Critical Spare	4 wks
FAN,MOTOR	MJPX602Y9	60376-0052	3	1	Critical Spare	4 wks
SEAL,OIL	MJP146A0X	60341-0317	3	1	Critical Spare	10 wks
HARNESS-ASSY-MACH INE	MJPYW905A	50975-5804	3	0	Normal Spare	40 Days
RING-O	MJP6021Y9	60340-1024	3	1	Critical Spare	4 wks
RING-O	MJPZ8XA54	60340-1109	3	1	Critical Spare	4 wks
RING-O,AS568 267	MJPY4970Z	60340-1282	3	1	Critical Spare	4 wks
xtray 120 x 60	MJP70Y4Z3	0711-2300	108	1	Normal Spare	1 wks
xtray 220 x 60	MJP328346	0721-2300	67	1	Normal Spare	1 wks
x1 fitting/black zinc	MJP16XX12	2701	450	1	Normal Spare	1 wks
x3 angled fitting / black plated	MJP319Z77	2703	20	1	Normal Spare	1 wks
x5 joining fitting (20 pcs) incl. bolt & nut / black zinc	MJPZ68119	2705	18	1	Normal Spare	1 wks
x15 bracket 10	MJP011ZZZ	2715-120	170	1	Normal Spare	1 wks
x15 bracket 220	MJP5X321Y	2715-220	123	1	Normal Spare	1 wks
TL50 Pro Select with IO-Link Tower Light; 4 Lighted Segments with Audible	MJP751136	TL50PS4AKQ	23	2	Critical Spare	3 wks
Mounting bracket	MJP507X04	SMB30A	23	2	Normal Spare	2 wks
Q-CABLE PVC STRAIGHT 4P 5M	MJP678562	0ECAB00045	2	1	Normal Spare	2 wks
RECEPTACLE 4P MALE STRAIGHT 1 M	MJP0031Z2	0ECAB00145	2	1	Normal Spare	2 wks
Q-CABLE PVC 90D 4P 5M WKC	MJP6X07Z4	0ECAB00213	2	1	Normal Spare	2 wks
SICK PHOTO REFLECTOR ROUND 84MM TOTAL OD	MJPY49W32	0ECAP00073	2	1	Normal Spare	2 wks
SICK PROX INDUCTIVE M12 10-30VDC PNP	MJP52ZY54	0ECAP00143	2	1	Normal Spare	2 wks
LIMIT SWITCH SAFETY WITH CRANK ROLLERCO	MJP7A0944	0ECAP00214	2	1	Normal Spare	2 wks
PROX INDUCTIVE ANALOG IFM EFECTOR	MJP045069	0ECAP00423	2	1	Normal Spare	2 wks
SICK PHOTO RETRO M12 10-30VDC SENSING R	MJPWX50A8	0ECAP00715	2	1	Critical Spare	2 wks
SICK PHOTO DIFFUSE BACK. SUPP. CABLE 2M	MJPW6Z422	0ECAP00852	2	1	Normal Spare	2 wks
PHOTO DIFFUSE M12 10-30VDC WITH TIMER S	MJP3YW42Z	0ECAP00853	2	1	Normal Spare	2 wks
ACDRV 1HP 120VAC 1PH POWERFLEX 525 FRAM	MJP1W3476	0EDRV00361	2	1	Critical Spare	2 wks
FUSE GMA 2A 250VAC GMA2 BUS	MJPXWZ9Y9	0EFUS00041	2	1	Consumable	2 wks
FUSE GMA 5A 125VAC	MJP2A303Z	0EFUS00042	2	1	Consumable	2 wks
FUSE GMA 15A 125V GMA1	MJPX9WZ63	0EFUS00105	2	1	Consumable	2 wks
FUSE GMA TYPE 5A 250VAC SLOW BLOW	MJP346331	0EFUS00408	2	1	Consumable	2 wks
HEAT WIRE 20GA NI/CHROME 200 FT LG (Bulk Roll)	MJPY24026	0EHEA00006	2	1	Consumable	2 wks
MTR 230/460V 1HP 56C PREMIUM EFF	MJP649W38	0EMTR00123	2	1	Critical Spare	2 wks
MTR 1HP 143TC 1800RPM HIGH EFF BALDORV	MJPW231ZX	0EMTR00211	2	1	Critical Spare	2 wks
POWER SUPPLY 2.5AMPS 24V 60W INPUT 90-	MJP55Z9YX	0EPWR00480	2	1	Critical Spare	2 wks
RELAY TERMINAL COIL : 24VDC RATING : 5A	MJPZ68Z23	0ERLY00107	2	1	Normal Spare	2 wks
CONTACTOR COIL : 24VDC / 70mA RATING :	MJP6222Y0	0ERLY00110	2	1	Normal Spare	2 wks
HEAD RELAY TERMINAL COIL : 24	MJP887W16	0ERLY00167	2	1	Normal Spare	2 wks
RELAY HEAD COIL 4PDT IDEC 24VDC RAT	MJP8A5YZ7	0ERLY00210	2	1	Normal Spare	2 wks
RELAY TIMER COIL : 24-240VAC 24-48VAC/DC	MJPY510Y2	0ERLY00346	2	1	Normal Spare	2 wks
800F CAGE CLAMP BASE 3 WITH CONTACT 1NO	MJPZ5YYZ9	0ESWT00581	2	1	Normal Spare	2 wks
800F CAGE CLAMP BASE (3) WITH CONTACT 1N	MJPXZAYW2	0ESWT00582	2	1	Normal Spare	2 wks
800F CAGE CLAMP CONTACT 1NO	MJPA56305	0ESWT00583	2	1	Normal Spare	2 wks
800F CAGE CLAMP CONTACT 1NC	MJP92X745	0ESWT00584	2	1	Normal Spare	2 wks
BEARING FLANGED UCFK204-12 3 BOLTS GRE	MJP9185ZA	0MBRG00002	2	1	Normal Spare	2 wks
BALL BEARING SB204-12 (S/S 1/4-28)3/4 B	MJP94679X	0MBRG00015	4	2	Consumable	2 wks
HOUSING PFL4Z(47M2-Z) DRAWING:	MJPY55915	0MBRG00055	2	1	Normal Spare	2 wks
WHEEL FLAT BELT FENNER FA	MJP555A42	0MBRG00060	2	1	Normal Spare	2 wks
BELT TIMING 187L050 137900	MJP1A8942	0MCHN00046	2	1	Normal Spare	2 wks
BELT TIMING 225L050 137903	MJP81264X	0MCHN00047	2	1	Normal Spare	2 wks
LATCH (LEFT) DUAL STAGE 8-240-L-54	MJP06WWX2	0MHDW00098	2	1	Normal Spare	2 wks
LATCH (RIGHT) DUAL STAGE 8-240-R-54	MJP51YW4Z	0MHDW00099	2	1	Normal Spare	2 wks
SPRING ZC 1/2 OD X 3/8 ID X 2 LG F	MJP11AX89	0MHDW00119	2	1	Normal Spare	2 wks
SMC CYLINDER 3/4" BORE 2" STROKE NCDM	MJP6XA66Y	0MPNU00212	2	1	Critical Spare	2 wks
SMC CYLINDER 3/4" BORE 4" STROKE NCMC	MJPX47689	0MPNU00213	2	1	Critical Spare	2 wks
SMC DOUBLE ACTING CYLINDER 3/4"BORE 3 ST	MJP343648	0MPNU00913	2	1	critical Spare	2 wks
SMC REED SWITCH D-A93L 3M CABLE	MJP82X1XW	0MPNU01950	2	1	Critical Spare	2 wks
SMC CYL. 2PO BORE X 12PO STROKE AJUSTAB	MJPWWZW01	0MPNU02431	2	1	Critical Spare	2 wks
REDUCER E17, 40:1, 56C, LR WINS	MJP104850	0MRED00111	2	1	Normal Spare	2 wks
REDUCER E26, 20:1, 145TC, LR WINSMITH	MJP8W1YZ6	0MRED00143	2	1	Normal Spare	2 wks
CARRIAGE GATE LATCH STUD 3/8-16 X 1 3/4	MJP86434Z	5MHDW00043	2	1	Normal Spare	2 wks
HEAVY DUTY TORSION SPRING LH	MJPA94W16	5MHDW00108	2	1	Normal Spare	2 wks
HEAVY DUTY TORSION SPRING RH	MJP03A529	5MHDW00109	2	1	Normal Spare	2 wks
20 CARRIAGE CAM IDLER ROLLER ASS'Y	MJP6A8580	6MROL00261	2	1	Normal Spare	2 wks
URETHANE INSERT JAW DURO 45 ORANGEOTHE	MJP507247	7MCLA00079	2	1	Normal Spare	2 wks
Ubiquiti Networks UNVR UniFi Protect NVR	MJPW28ZW9	UNVR4	2	1	Critical Spare	3 wks
1080p Network Camera	MJP8575Z3	UVC-G3-FLEX	70	5	Critical Spare	3 wks
Skyhawk 4TB Surveillance Hard SATA 6Gb/s 64MB Cache 3.5-Inch Internal Drive	MJP01317W	ST4000VX007	8	2	Critical Spare	3 wks
24-Port Gigabit Ethernet High-Power PoE+ Unmanaged Switch (300W)	MJP48X63X	GS524PP	1	1	Normal Spare	1 wks
Vision assembly Mujin) PhoXi 3D Scanner XL Gen2	MJPX9A529	3S-SBXL-67CBC	16	1	Normal Spare	8 wks	5 years