German Bionic CRAY X Debuts A New Exoskeleton Instruction Manual

German Bionic CRAY X Debuts A New Exoskeleton

Product Information

The product is called CRAY X and is manufactured by German Bionic. It is a device that comes with an instruction manual. The manual is a copy of the original German version, dated as of 18.01.2023. For any inquiries or support, you can contact German Bionic via email at info@germanbionic.com or call +49 (0) 821 907 497 80. Additional information can be found on their website at www.germanbionic.com or www.germanbionic.io.

Product Usage Instructions

1. Introduction
   The introduction section provides an overview of the manual and includes the purpose of the manual, warranty information, and warning notices.

2. Safety
   The safety section contains important information regarding the safe use of the product. It is crucial to read and understand this section before operating the device.

3. Device Description
   This section provides a description of the CRAY X device and its type label.

4. Unpacking
   Instructions on how to unpack the device are provided in this section.

5. Transport
   Guidelines for transporting the device safely are included in this section.

6. Operation
   This section covers the general operation of the device. It includes instructions on how to don and fasten the device.

7. Decommissioning/Storage
   Instructions on how to decommission and store the device properly are provided in this section.

8. Disposal
   Guidelines for the proper disposal of the device are included in this section.

9. Maintenance
   This section outlines the maintenance schedule and provides instructions for the annual maintenance of the device.

10. Faults and Malfunctions
    Information on identifying and troubleshooting faults and malfunctions is provided in this section.

11. Specifications
    The specifications section lists detailed technical specifications of the CRAY X device.

INTRODUCTION

IMPORTANT
To ensure the safe operation of the Cray X, it is essential to read this manual. Keep this manual in a safe place.

For more information, please refer to the online version of the instruction manual at www.germanbionic.io. You will receive the login details for the website separately.

Purpose
The German Bionic Cray X exoskeleton is a human-machine system that combines human intelligence with machine power. It supports or amplifies the wearer’s movements in an active-assistive capacity, thus minimizing the risk of occupational accidents and injuries due to excessive strain. The German Bionic Cray X was specially designed for the manual lifting of heavy goods and tools and to reduce associated compression forces in the lower back. The German Bionic Cray X exoskeleton connects to the internet via WLAN or LTE (IoT capable). Anonymized device data are continuously collected during use and can be accessed via www.germanbionic.io.

Warranty for devices included in the scope of delivery

Scope of delivery:

• Cray X exoskeleton
• Makita 40V battery [BL4025]
• Opt: Makita charger for 1 battery
• Instruction manual

The devices included in the scope of delivery each have a 12-month warranty that covers material and functional damage provided that their use complies with that described in the enclosed or online instruction manual. The exact scope of delivery is indicated on the delivery note.

Warning and information notices contained in the instruction manual

• DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
• IMPORTANT Describes a potentially harmful situation which, if not avoided, may result in damage, malfunction and/or failure of the exoskeleton.
• NOTICE Additional information on how to operate the product.
• The symbol is used to represent operating steps.
• The general graphical symbols under ISO 3864-2: 2004-10 also apply.

SAFETY

Intended use

• The Cray X is primarily intended for industrial use.
• The specifications detailed in “Ambient conditions” and “Specifications” must be observed.
• The efficient and safe operation of the Cray X requires appropriate transport, unpacking and set-up, as well as qualified handling and proper maintenance.
• Legal accident prevention regulations and other generally accepted safety or occupational health rules must be observed.
• All repair work must be carried out by the German Bionic customer service.
• Any interventions and modifications, such as opening the covers or any manipulations that might affect the safety technology and functionality of the Cray X must carried out by German Bionic.
• Only original accessories and spare parts may be used, as only they guarantee the safe and malfunction-free operation of the Cray X.

Improper use
Any use other than that described in section 2.1 is considered improper and will void all liability and warranty claims against the manufacturer.

Operating conditions

The following operating conditions must be observed when using the Cray X:

• The Cray X is intended for industrial use.
• The specifications detailed in “Ambient conditions” and “Specifications” must be observed.
• Ambient operating temperature: 0 °C to 40 °C
• Ambient operating humidity: max. 70%
• Protect from direct sunlight
• Minimum room width for using the Cray X: 113.5 cm
• Observe minimum height requirement for safe setup
• Protect from extreme weather conditions (heavy rain, hail, snow, storm) in accordance with the IP54 standard.
• Use only up to max. 6500 feet above sea level
• Do not use in salty air.

Responsibility of the operator
The instructions in the manual must be observed in full and without restrictions. In addition to the safety information and instructions provided in this manual, the operator is responsible for:

• Compliance with local legal regulations, such as accident prevention, general safety and applicable environmental protection regulations.
• Compliance with inspection and maintenance deadlines
• The operational safety of the Cray X
• Briefing and training of operating personnel

User requirements

• The Cray X may only be operated by physically able, healthy and authorized users. Users must be sufficiently familiarized with the safety features and have been informed about possible hazards by the operator.
• Persons under the age of 18 and individuals who are not fully trained are prohibited from operating the Cray X and performing maintenance work on the device.
• Suitable for body heights of 1.55–1.95 m.
• Pregnant women may not operate the Cray X.
• Persons who are under the influence of alcohol, medication or other drugs that impair response time may not operate the Cray X.
• Users are strongly advised not to wear objects (e.g. necklaces) that can get caught or cause skin irritation.

Safety features
Both leg connections of the Cray X are equipped with mechanical end stops that limit the angle of rotation of the connections around the drive axis to 180°. Limiting the extension of the leg connections protects the wearer from the risk of injury during use of the Cray X.

What to do in case of emergency
WARNING Malfunctions or improper use of the Cray X cause a risk of injury due to uncontrolled movements of the Cray X.

Activate the emergency stop

1. Press the emergency stop switch. “Emergency stop activated” appears on the display. The Cray X turns off the electric motors and the support function. The leg linkages can still be moved with the user’s own muscle power.
2. Eliminate the source of hazard.

Release the emergency stop

1. Release the emergency stop by turning clockwise.
2. Reset the emergency stop by pressing the On/Off button. Follow the instructions on the display.

FCC statement

Federal Communications Commission (FCC) statement

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense.

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that might cause undesired operation.

WARNING:
Changes or modifications not expressly approved by German Bionic could void the user’s authority to operate the equipment.

Industry Canada Statement
This device complies with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: (1) This device may not interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

ISED Canada ICES-003 Compliance Label
CAN ICES-3 (B)/NMB-3(B)

RF Exposure Guidance
In order to comply with FCC / ISED RF Exposure requirements, this device must be installed to provide at least 50 mm separation from the human body at all times.

DEVICE DESCRIPTION

Cray X

1. Upper chest strap linkage via telescopic rails with safety bolts
2. Back padding
3. Support structure with battery holder
4. Push/turn knob
5. Electric motors
6. Display
7. No-slip strap
8. Chest strap with buckle
9. Hip belt with storage pockets
10. Front leg connection
11. Type label
12. On/off button
13. Emergency stop button
14. Rear leg connection

Type label
The identifying information for the Cray X (serial number, model name, etc.) are indicated on the type label. The type label is located on the support structure.

UNPACKING

• NOTICE Keep the carton and packing material for storage and subsequent transport.
• Carefully remove the packing material and carefully take the components of the scope of delivery out of the carton.

TRANSPORT

NOTICE Keep the carton and packing material for storage and subsequent transport.

1. Remove the battery from the Cray X.
2. Use packaging material to protect the Cray X from sliding around in the box.
3. Carefully place the components of the scope of delivery in the box.
4. Secure the packed Cray X before transport and protect it from strong impact and other destructive forces.
5. Also, follow the instructions on the box.

OPERATION

• WARNING The straps and leg connections can catch on objects → fall and draw-in hazard. Make sure there is enough space (see “2.3 Operating conditions”) and stow all loose ends in the space provided (see online instruction manual “Putting on the Cray X”).
• CAUTION Residual risk: Skin abrasions/risk of falling during use
• The Cray X must be properly fastened (see online instruction manual).
• CAUTION Unexpected movements if operating modes are mixed up → risk of stumbling. Check the current mode on the display before every use and switch modes if necessary.
• CAUTION Unusual movements when climbing a ladder → risk of falling.
• Do not climb ladders with the Cray X.
• CAUTION Incorrect positioning of the straps → tension in the neck and back.
• Follow the instructions in the online instruction manual “Putting on the Cray X”.
• CAUTION Body contact with the Cray X → Skin irritaUon. Allergic reactions may occur. The following materials were used in the Cray X:
  • Cover: PA12
  • Support structure: Carbon fibre-reinforced plastic (CFRP)
  • Display cover: Polycarbonate (PC).
  • Avoid direct skin contact in case of allergy.
  • Wear long-sleeved outerwear and long pants.
• CAUTION Leaving the battery in the Cray X when not in use → risk from uncontrolled motor movements. Remove the battery from the device after use.
• Follow the battery manufacturer’s storage instructions.
• IMPORTANT Excessive humidity, dusty environment → electric motor damage. Pay attention to the ambient conditions.
• IMPORTANT This device is not suitable for use in residential environments and may not provide adequate radio reception in these surroundings.
• NOTICE Do not remove the battery from the Cray X until the device has properly shut down.
• NOTICE For optimal comfort, the support structure is adapted to the wearer’s body and personal requirements using adjustable straps (see online instruction manual “Putting on the Cray X”).
• NOTICE If the straps are too loose during use of the exoskeleton or it is uncomfortable to wear, check that the Cray X has been fitted correctly and tighten the straps if necessary.
• NOTICE Special care is required when climbing stairs.

The Cray X provides the following functions:

• Active, electric motor-powered support for the wearer
  • Power transmission through leg connections and a chest strap
  • Supporting torque depending on movement speed and selected settings
• Provision of anonymized movement data via the German Bionic IO platform

Donning/Fastening

• NOTICE Users who are familiar with the Cray X can preadjust the length of relevant straps (shoulder, pelvis, legs).
• NOTICE It is very important to ensure that the hip belt is optimally positioned, as it carries most of the total load. Care should be taken to ensure that the axis of rotation of the motor is aligned with that of the hip joint.

DECOMMISSIONING/STORAGE

NOTICE Leaving the battery in the Cray X when not in use → risk from uncontrolled motor movements. Always remove the battery of the Cray X for storage. Also follow the instructions of the battery manufacturer.

Decommissioning
NOTICE Follow the manufacturer’s instructions for decommissioning the battery.

1. Remove the battery from the holder (see online instruction manual).
2. Store the Cray X in a clean, dry and flat place (refer to the specifications for storage).

Storage

• NOTICE Keep the carton and packing material for storage and subsequent transport.
• NOTICE Follow the storage instructions in the Cray X specifications.
• NOTICE Follow the manufacturer’s instructions for storing the battery.

1. Carefully place all the components of the scope of delivery in the box.
2. Secure the contents with the packing material.
3. Close the carton.
4. Store the carton in a dry and safe place.

DISPOSAL
According to the European Directive 2012/19/EU, waste electrical and electronic equipment must be collected separately and recycled in an environmentally friendly manner. For the disposal of the rechargeable battery, also follow the enclosed Makita manual. Old devices must not be disposed of in the municipal waste.

MAINTENANCE

For maintenance of operational safety, the prescribed deadlines for inspection, cleaning and maintenance work must be observed.

NOTICE
Please refer to the complete maintenance and washing instructions provided in the online manual.

Maintenance schedule

Annual maintenance
The Cray X is sent to the manufacturer for annual maintenance. Maintenance can also be carried out on-site if previously arranged with a service employee from German Bionic.

1. Arrange an annual maintenance visit with German Bionic.
2. Prepare the Cray X for transport (see “TRANSPORT”).
3. Close the carton and send it to the manufacturer.

Annual maintenance by qualified technicians from the manufacturer includes:

• Comprehensive wear check of electronics and electric motors
• Comprehensive wear check of all belts and straps with their fastening systems
• Function test

FAULTS AND MALFUNCTIONS

Faults

emergency stop. Follow
vated” appears on the| switch was triggered.| further instructions.
display.| |
“Motors switched off”| The motors have over-| The motors will remain switched off for two minutes
appears on the display.| heated and have there-

fore been switched off

| to allow the temperature to go down and then turn

on again automatically.

| to cool down.|
“Motor error” appears| An error has occurred| Press the push/turn knob to confirm the error. The
on the display.| in the motor system.| Cray X needs to be recalibrated.
“Battery low” appears| The battery charge has| Switch off the Cray X , remove the battery, and charge it
on the display.| dropped below 10%.| and insert a fully charged battery (see online instruc-
| | tion manual).
“Error/restart required| Restarting the motor| The Cray X must be switched off and restarted.
[…]” appears on the

display.

| did not solve the problem.|

Malfunctions

SPECIFICATIONS

German Bionic Systems GmbH.

SCAN ME
FOR THE ONLINE MANUAL

References

• Welcome! - Onicio Leal
• German Bionic | Smart Wearable Tools for Workplace Safety · German Bionic
• German Bionic IO

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