WARNING
This article is intended for certified Pio Super Users who have completed Pio’s Super User course because it requires in-depth knowledge of Pio hardware.
It is dangerous to follow the instructions below if you are not a certified Pio Super User.
Please contact your manager to determine who can perform these steps in your company.
The Pio Robot Swap makes it easy to replace a robot on the grid, even with the system running at all times.
Please find the full step-by-step procedure below for removing a robot from the grid, using the Service Tower.
1. Prepare the pallet with the plywood interface
Locate the plywood interface and straps provided with the replacement robot shipment, and check that the plywood interface is secured to a standard euro pallet.
We recommend adding the new robot to the grid first, to free up the pallet required for shipping back the old robot from the grid.
Place the pallet with the plywood on the floor in front of the Service Tower.
2. Position the Service Tower lift
Ensure the Service Tower lift is at the top level of the grid.
If not, press the “up-arrow” on the Service Tower control panel until the lift stops at the top. A white light on the control panel will illuminate when the lift is at the correct position.
3. Move the robot into the Service Tower
Go to the Service PC and start the Customer Console app. Select the Robot tab, and click the “Remove Robot” icon in the top right corner to start the remove robot procedure.
Enter the robot's number and follow the on-screen instructions to move it into the Service Tower.
Check the robot’s direction and align the pallet accordingly. Robots typically face south in Pio configurations.
4. Lower the lift to the ground level
On the Service Tower control panel, press and hold the “down-arrow” to lower the lift to the ground level.
5. Open the Service Tower hatch
Once the lift is at ground level, press “unlock” on the Service Tower control panel and open the hatch.
6. Activate the robot's track-shift
Set the robot to “offline” mode and short-press the “track-shift” button upwards on the robot control panel to lift the crossing wheels. If all eight wheels are still on the tracks after pressing “track-shift,” adjust by pressing “track-shift” up or down as needed.
Close the side door.
7. Open the robot door
Press “unlock” on the Service Tower control panel and open the robot door at the front of the Service Tower.
8. Prepare the ramp
Lower the Service Tower ramp tracks to the edge of the pallet (without resting on the plywood).
Ensure the pallet is firmly on the ground, and the plywood sheet is securely fastened.
9. Carefully roll the robot onto the pallet
Now gently roll the robot over the ramp and onto the pallet.
NOTE
Avoid damaging the track sensors, and ensure proper alignment.
10. Align the robot on the plywood interface
Position the robot’s body directly over one of the top sheets of the plywood interface, based on its direction.
11. Lock the robot wheels
On the robot control panel, press “track-shift” downwards to ensure all eight wheels are touching and lock into the top sheet of the plywood interface.
NOTE
Confirm all eight wheels are securely locked.
12. Power off the robot
Press the Emergency Stop button at the top cover (R5) or the Power button on the control panel (R5 Pro) to turn the robot off.
13. Remove the robot's top cover
Hold the handgrip at the back of the robot's top cover and pull the cover upwards to open it.
14. Disconnect the batteries
For each battery:
Press and hold the latch lock. Pull the plug upwards (R5) or sideways (R5 Pro) to disconnect the batteries.
15. Replace the top cover
Secure the top cover back onto the robot.
16. Secure the robot with straps
Thread straps underneath the pallet and the robot, aligning with the graphics on the plywood interface.
Tighten the straps as much as possible by hand.
17. Add pallet collars
Place the first pallet collar on top of the pallet, ensuring it sits on the pallet surface (not the plywood).
Stack two additional collars on top of the robot.
Note: Each collar will tighten the straps further.
Related articles
Robot Swap - Adding a robot to the grid using the Service Tower
Service Tower Control panel