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Knight Smart Cart, Operation Manual

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KNIGHT SMART CART OPERATION MANUAL 

SECTION 6 

TROUBLESHOOTING 

39 

 

Battery Charging Troubleshooting

  

 

PROBLEM 

CAUSE 

SOLUTION 

Red LED stays on for 

more than 24 Hrs. 

1. One or more defective or damaged 

cells. 

 
2. Charger has reduced its output 

below the normal level due to a 
DC overload or a DC short. 

 
3. On-board DC systems are drawing 

more current than the charger can 
supply. 

1. Load test the batteries and 

replace as necessary. 

 
2. Remove the source of the 

overload or short. Disconnect 
the charger’s black 
(NEGATIVE) ring terminal from 
the battery. 

 
3. Turn off all DC equipment while 

charging.  ** 

Green LED stays on 

when the battery is 
known to be low. 

1. Faulty or contaminated terminal 

connections. 

 
2. One or more defective or damaged 

cells. 

1. Clean and tighten or repair all 

battery to charger connections. 

 
2. Load test the batteries and 

replace if necessary.  ** 

Neither of the LED’s 

turn on when the AC 
power is applied. 

1. No AC power available at the 

charger. 

 
2. Component failure. 

1. Connect AC power or reset the 

AC breaker on the main panel. 

 
2. Return charger to the 

Manufacturer. 

 

 

**  Please note that you can use the “Power Sonic” cell phone application to check the battery status. 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for Smart Cart

Page 1: ...anual THIS MANUAL CONTAINS IMPORTANT INFORMATION REGARDING INSTALLATION SAFETY MAINTENANCE AND OPERATION OF THE KNIGHT GLOBAL SERVO CART AND SHOULD BE AVAILABLE TO ALL PERSONNEL RESPONSIBLE FOR USING THE CART REV 020 202201 ...

Page 2: ...on sense and judgment when performing the tasks described in this manual If any procedure seems inaccurate incomplete or unsafe please put the equipment in a safe condition and contact Knight Global service department for assistance Knight service department s phone number is 248 375 7962 Throughout this manual there are steps and procedures that if not performed correctly can result in personal i...

Page 3: ...Any Application 13 4 3 Determining the Frequency of Chain Inspections 14 4 3 1 Service Rating Load Criteria 14 4 3 2 Service Class Duty Cycle 14 4 4 Type of Inspections 15 4 4 1 Frequent Inspection Visual 15 4 4 1 1 What to Look for During a Frequent Inspection 15 4 4 2 Periodic Inspection Documented 16 4 4 2 1 Recommendations for Periodic Inspections 16 4 4 2 2 Recommended Record Keeping for Peri...

Page 4: ...TION MANUAL ii TABLE OF CONTENTS 9 KNIGHT S PERFORMANCE WARRANTY 41 10 APPENDIX A USB LOCATION IN SMART CART MANUAL 42 11 APPENDIX B EMENTOOL LITE V1 0 PROGRAMMING SOFTWARE 43 12 APPENDIX C EM 243C JS1 DC MOTOR CONTROLLER 45 ...

Page 5: ...system designer system manufacturer crane or rail manufacturer installer and user to ensure that the installation and associated wiring of the Smart Cart and components are in compliance with ANSI NFPA 70 and all applicable Federal State and Local Codes Hazardous voltages are present in the Smart Cart and components Only properly trained and competent personnel should perform inspections or repair...

Page 6: ...in this manual Therefore always be alert and work safely Follow all applicable Federal State Local or Company policies or regulations Do not overload the Smart Cart this could damage the cart Do not let loads significantly over hang the sides of the platform this could cause the Smart Cart to tip over Lock the wheels when leaving the cart unattended Do not move the Smart Cart with the load in the ...

Page 7: ... weight than the system is rated for If the load weight causes the cart to draw more amps then the programmed current limit the cart will not lift any further until the excess load is removed Downward motion is permitted when overloaded to allow the user to safely set the weight back down on a stable surface Safety Drop Stop SDS Chain All Standard units have a Safety Drop Stop SDS chain included T...

Page 8: ...KNIGHT SMART CART OPERATION MANUAL SECTION 1 SAFETY 4 ...

Page 9: ...t into service the owners and user are advised to examine specific local and or other regulations including ANSI and OSHA regulations that may apply to the use of this product WARNING A falling load can cause injury or death Before installing this cart read the Safety section of this manual Follow all procedures in this section for installation and set up of the Smart Cart Retain all product infor...

Page 10: ... the operator and the lifting device Foot Brake Prevents the cart from moving unintentionally Figure 2 1 This ergonomic lift cart is designed to assist the operator when lifting heavy loads up to 400 lbs The lift assist system consists of a stabilizing cart and a fixture attached to a vertical mast The fixture travels along the rail on the cart s load trolley enabling the system to move vertically...

Page 11: ...le to the proper location and then retightening the adjustment collars Lift Control The position of the platform or end effector is controlled with either a Right Left analog lever or a digital Up Down pushbutton located on the control handle Breaker The breaker acts as overload over travel protection The breaker will trip if the Smart Cart is used to lift a load that is beyond its capacity The br...

Page 12: ...e to the new handle and mount it to the cart s handle post ii Remove the Control Box s cover iii Press the Blue button located on the left hand side of the battery It will light up iv Press the Analog Lever fully to the Right v Press the Analog Lever fully to the Left vi Allow the Analog Lever to rest in its natural home position without moving it vii The Blue light will flash indicating that the ...

Page 13: ...n cart until the fixture is at a proper height to engage the part by use of the UP DOWN control pendant If necessary engage the foot brake to prevent the cart from moving 2 Ensure that cart has engaged part properly and transfer part to drop off position Note If the foot brake was engaged in step 1 release the brake before moving the cart 3 Use the thumb lever to position part at a proper height f...

Page 14: ...lever right and left Refer to Figure 3 1 Smart Cart Control Configurations Figure 3 1 NUMBER DESCRIPTION 1 Motor Gear Box and Chain Bucket Standard with all Smart Carts 2 Analog Control Handle 3 8 pin cable Standard length pre wired 4 Contorls Enclosure Stadard with all Smart Carts 5 On Off Power Switch for Smart Cart 6 Charge Meter 7 AC Charger Cord 8 Optional Digital Control Handle 1 4 3 6 2 5 7...

Page 15: ...ight lever to move the cart in the upward direction Travel Limits NOTE During operation the cart will ramp down in speed as the travel limits are triggered NOTE The absolute upper and lower travel limits are factory set to the physical limits of the Smart Cart Fault Mode The speed controller board is located under the cover It has a fault LED that designates if a system fault occurs This table sho...

Page 16: ...erson A person who by possession of a recognized degree in an applicable field or certificate of professional standing or who by extensive knowledge training and experience has successfully demonstrated the ability to solve or resolve problems relating to the subject matter at work Designated Person A person selected or assigned by the employer or the employer s representative as being competent t...

Page 17: ... of LIFT Safely in Any Application Don t stack multiple objects on the Smart Cart These are designed to lift one object at a time Do not pull the Smart Cart long distances The cart is designed to be pushed over level ground Do not lift a heavy load onto the Smart Cart ...

Page 18: ...arely to maximum loads Moderate Service Cart and chains normally subjected to moderate loads but fairly frequently to maximum loads Heavy Service Cart and chains normally subjected to loads of heavy magnitude and frequently to maximum loads Very Heavy Service Cart and chains regularly subjected to maximum loads 4 3 2 Service Class Duty Cycle Service Class is determined by the total number of cycle...

Page 19: ...onally the operator should check the system continually during operation to ensure that no malfunctions are occurring such as abnormal noises or binding of the chain 4 4 1 1 What to Look for During a Frequent Inspection Operator should examine the chain throughout its working length to detect any evidence of wear distortion or external damage Equipment should be operated under a load as near as po...

Page 20: ...indicate that disassembly should be done to permit detailed inspection 4 4 2 1 Recommendations for Periodic Inspections Perform the inspection detailed under section 4 4 1 1 What to Look for During a Frequent Inspection of this manual Next the chains should be cleaned for inspection using any cleaning method that will not cause damage Adequate lighting should be provided for the person inspecting ...

Page 21: ...inks number 1 and 13 do not fit onto prongs or have to be forced into selection replace the load chain This length has stretched 2 or more and should be removed from service and replaced with new chain 6 Perform this inspection in multiple sections of the chain working up to the sprocket Figure 4 2 C If Chain Gauge is Not Available Select an unworn un stretched length of the load chain Suspend the...

Page 22: ... damaged the instrument may also not perform accurately 3 Identify the pitch Align the red arrows within the center of the pins on ONE of the OUTER link plates Depending on ease of access one pair of arrows will be more suitable than the others The normal pitch will appear in the Pitch window The number of pins n that the chain is to be measured over will appear in the Measure over pins window 4 S...

Page 23: ...Measure over pins window as previously determined in step 3 6 Read off the Percentage Check the Percentage Wear windows A percentage will appear in 0 25 increments If the chain has elongated by 2 or more the warning window will be filled with red and necessary action must be taken E Lubricating the Servo Arm Roller Chain after replacement After changing the roller chain before a test load is lifte...

Page 24: ...y 5 7 9 11 or 13 links as appropriate exceeds that of the unused chain by 2 Figure 4 3 4 4 2 2 Recommended Record Keeping for Periodic Inspections Adequate records as a part of periodic inspection are essential for the proper use of calibrated chains The chain record should include a complete description and identification of the new chain the date and results of each inspection the date and resul...

Page 25: ...r gear oil Knight recommends using Demag Chain Grease P N 665 009 44 Ensure that oil is applied to all roller chain links and rollers Refer to Figure 4 4 Chain Lubrication P N 665 009 44 If Demag Chain Grease is not available SAE 50 to 90 EP oil or equivalent may be used Substitute a dry lubricant for use in dusty environments Lubricate hook and safety latch pivot points with same lubricant used o...

Page 26: ...n good general working order Repair or replace any broken or missing parts Cycle the Smart Cart and listen for any abnormal noises grinding etc If any abnormal noises are evident an inspection of the Smart Cart must be performed Inspect how the chain feeds through the Smart Cart If any binding is evident clean and lubricate the chain Refer to section 4 4 2 Periodic Inspection Documented If the pro...

Page 27: ...s should be taken by qualified maintenance personnel Electrical Maintenance To be performed by qualified electrical personnel only ITEM FREQUENCY MAINTENANCE Control Handles Weekly Check for function Replace if needed Valves Timers and Switches Weekly Check during an operation cycle to ensure the sequence is operating at optimum efficiency Wiring Monthly Check for broken loose missing and worn wir...

Page 28: ...e of any contamination Daily Inspect pads and latch for wear or damage Welds Monthly Inspect welds and ensure that they are intact no cracks or broken spots Wiring Monthly Ensure that wiring is intact and not cut or frayed Lubricate Chain Quarterly Inspect and lubricate chain when dry Manual Slides and Bearings Semi annually Lubricate with Mobil MOBILUX EP 1 641282 00 grease or equivalent Chain El...

Page 29: ... Ensure that all labels are intact and legible Replace as necessary Refer to Figure 4 5 Figure 4 5 If any of the labels or warning tags listed above are missing contact Knight Global at 248 377 4950 to order replacements On Off and Cable Tags Enclosure Label Knight and Warning Labels ...

Page 30: ...slack the chain Step 3 Turn the cart s power OFF and ensure that the cart is unplugged Step 4 Remove both chains from the chain nest The bottom bolt releases the Safety Drop Stop SDS chain and the top bolt releases the Load chain A 4mm allen wrench will be required to accomplish this Refer to Figure 4 7 Figure 4 7 Step 5 Remove the bottom bolt and the SDS chain first and then remove the top bolt a...

Page 31: ... 12 Press the down button Step 13 Stop the movement of the chains when the yellow interface chain links have moved through the gear box and are at an acceptable height to reattach the cart s trolley Step 14 Lubricate both the load and the Safety Drop Stop SDS chains per section 4 4 3 Chain Lubrication Step 15 Reinstall both chains into each of their correct chain buckets Step 16 Reinstall the chai...

Page 32: ...er and have NO twists in them when they are installed into the chain nest Refer to Figure 4 11 Figure 4 11 Step 23 First the last link of the load chain is installed into the top slot of the chain nest The chain must be kept parallel with no twists The bolt is installed in front of the last link of the load chain and into the chain nest Refer to Figure 4 12 Figure 4 12 Step 24 Next the last link o...

Page 33: ...4 MAINTENANCE 29 Step 25 Reinstall the large O ring into the groove located on the chain nest Refer to Figure 4 12 Step 26 Move the small O ring down so it is just above the top of the chain nest Step 27 The cart may now be repowered and tested ...

Page 34: ...e weight is set down on the supporting surface Step 2 Using the Down button to slack the chain Step 3 Turn the cart s power OFF and ensure that the cart is unplugged Step 4 Remove both chains from the chain nest The bottom bolt releases the Safety Drop Stop SDS chain and the top bolt releases the Load chain A 4mm allen wrench will be required to accomplish this Refer to Figure 4 14 Figure 4 14 Fig...

Page 35: ...ove the 1 one M5 retainer bolt that secures both chain buckets to the mast Refer to Figure 4 15 Figure 4 15 Step 7 Remove both chain buckets from the mast Step 8 Remove both chains from their individual chain buckets Step 9 Remove both of the end stop assemblies from the each of the old load and Safety Drop Stop SDS chains Step 10 Using the chain installation tool locate the load chain pocket open...

Page 36: ...s per section 4 4 3 Chain Lubrication Step 16 Reinstall both chains into each of their correct chain buckets Step 17 Reinstall the chain buckets back to the mast Step 18 The SDS chain needs to be cut to the correct length so it has slack in it when the load chain is properly connected Step 19 Ensure that both chains are parallel with no twists from the gear box down to their respective ends Step 2...

Page 37: ...st be kept parallel with no twists The bolt is installed in front of the last link of the load chain and into the chain nest Refer to Figure 4 20 Figure 4 20 Step 25 Next the last link of the SDS chain is installed into the bottom slot of the chain nest The chain must be kept parallel with no twists The bolt is installed through the last link of the SDS and into the chain nest Step 26 Reinstall th...

Page 38: ...m battery are 1 Power down the Smart Cart 2 Set the foot brake 3 Plug the charger into a wall outlet 4 Observe the charging LED When it turns green the battery is fully charged Refer to Figure 5 1 The batteries charge can also be monitored via the phone application See section 5 B Lithium Ion Battery 5 See the charging curve on the next page Refer to Figure 5 2 Figure 5 1 Window located on front s...

Page 39: ...500 has a phone application named Power Sonic that will allow you to monitor its charge The phone application will allow you to choose between any battery in any of the Knight Smart Carts you own The phone application lists the State of Charge SOC of your battery the batteries temperature and its cycle life Refer to Figure 5 3 Figure 5 3 ...

Page 40: ...ng 3 Input Logic for Limit inputs 1 PNP 1 PNP 4 Maximum Speed Forward 100 Fixture moves Up 100 Fixture moves Down 5 Maximum Speed Reverse 100 Fixture moves Down 100 Fixture moves Up 6 Current Limit Forward 100 Fixture moves Up 100 Fixture moves Down 7 Current Limit Reverse 100 Fixture moves Down 100 Fixture moves Up 8 Current Trip 1 Enabled 1 Enabled 9 Not Used 10 Fault Output Combinations 1 Multi...

Page 41: ...ault Number Fault Signal from Controller LED Flashing Frequency 1 Power On One blink 2 Current Limit Fault Led is lit solid 3 Current Trip Fault Blinks fast with no pauses 4 Zero Current Trip Fault Long blink and a short pause 5 Overvoltage Fault Blinks fast 4 four times and a long pause 6 Overheat Fault Short blink and a long pause 7 Timeout Fault Blinks fast 3 three times and then a long blink 8...

Page 42: ... the charging light is ON Damaged pendent or cable Replace damaged pendent or cable Electrical fault Contact Knight Global Service Dept 248 377 4950 Weight overloaded Remove excess weight from fixture Smart Cart is slow to raise or will not raise to the top Batteries are discharged Recharge the batteries A Fault may exist with the motor switch Contact Knight Global Service Dept 248 377 4950 Smart ...

Page 43: ... the charger s black NEGATIVE ring terminal from the battery 3 Turn off all DC equipment while charging Green LED stays on when the battery is known to be low 1 Faulty or contaminated terminal connections 2 One or more defective or damaged cells 1 Clean and tighten or repair all battery to charger connections 2 Load test the batteries and replace if necessary Neither of the LED s turn on when the ...

Page 44: ...RT Knight Smart Carts contain various materials which at the end of the service life must be disposed of or recycled where appropriate in accordance with local statutory regulations Decommissioning WARNING Knight Smart Carts must be decommissioned by qualified personnel Ensure there is not a load on the cart Remove power from cart Remove cart from rail or support structure If desired Knight Global...

Page 45: ...e defective Any field modification made to Knight Products or Systems without the written authorization by Knight Global shall void Knight s warranty obligation Any purchased components not manufactured by Knight Global and their specific individual warranties are not covered Paint defects scratches and marring from shipping are also excluded on all Knight Global products and products not manufact...

Page 46: ...aste of natural resources Knight has migrated to a complete set of controls documentation in electronic format that is located on a USB drive This USB drive is created for each Knight Smart Cart order and is placed in the inside of the front cover of the Knight Smart Cart Technical Manual binder which ships with each job Please refer to Figure 1 below Knight Smart Cart Technical Manual and USB Dri...

Page 47: ...KNIGHT SMART CART OPERATION MANUAL APPENDIX B PROGRAMMING SOFTWARE 43 11 APPENDIX B EMenTool Lite v1 0 Programming Software ...

Page 48: ...KNIGHT SMART CART OPERATION MANUAL APPENDIX B PROGRAMMING SOFTWARE 44 ...

Page 49: ...KNIGHT SMART CART OPERATION MANUAL APPENDIX C DC MOTOR CONTROLLER 45 12 APPENDIX C EM 243C JS1 DC MOTOR CONTROLLER ...

Page 50: ...KNIGHT SMART CART OPERATION MANUAL APPENDIX C DC MOTOR CONTROLLER 46 ...

Page 51: ...326 Phone 248 377 4950 Fax 248 377 2135 For additional copies of the literature contact salesorders knightglobal com For technical questions contact servos knightglobal com For service related requests contact service knightglobal com www knightglobal com ...

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