High-bay rack warehouse
Abalioglu, Izmir, Turkey
1 INTRODUCTION
Table of Contents
1
INTRODUCTION ................................................................................................................ 12
1.1
Purpose of the instructions ............................................................................................... 12
1.2
Safety symbols and warnings ............................................................................................ 12
1.3
Applicable Health and Safety Legislation ........................................................................... 14
1.3.1
Basic Health and Safety Procedures .................................................................................. 15
1.3.2
After Servicing .................................................................................................................. 18
1.3.3
Fire Precautions ................................................................................................................ 18
1.3.4
Maintenance .................................................................................................................... 18
1.4
Project Directory ............................................................................................................... 20
2
INSTALLATION DESCRIPTION ............................................................................................ 21
2.1
Basis of design .................................................................................................................. 21
2.2
Purpose of the Installation ................................................................................................ 21
2.3
Applicable Standards ........................................................................................................ 21
2.4
Mechanical equipment ..................................................................................................... 21
2.4.1
Conveyor system .............................................................................................................. 21
2.4.2
Shuttle C501 ..................................................................................................................... 42
2.4.3
Shuttle C401 ..................................................................................................................... 49
2.4.4
Crane ................................................................................................................................ 56
2.5
Electrical equipment ......................................................................................................... 65
2.5.1
Description of the electrical system .................................................................................. 65
2.5.2
Distribution power supply +SB1 ........................................................................................ 65
2.5.3
Conveyor system power supply......................................................................................... 65
2.5.4
Crane and shuttle power supply........................................................................................ 66
2.5.5
Main cabinets ................................................................................................................... 66
2.5.6
Main power consumers .................................................................................................... 68
2.5.7
Control circuits.................................................................................................................. 71
2.5.8
Sensors ............................................................................................................................. 71
2.5.9
Communication ................................................................................................................ 73
3
SAFETY ............................................................................................................................. 74
3.1
General measures ............................................................................................................. 74
3.1.1
Uncontrolled cutout of electrical energy ........................................................................... 74
3.1.2
Vehicles stability ............................................................................................................... 74
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1 INTRODUCTION
3.1.3
Rotating movable parts hazard ......................................................................................... 74
3.1.4
Danger of fire & explosion ................................................................................................ 74
3.1.5
High voltage – touch protection ........................................................................................ 75
3.1.6
Accidental touch of parts under voltage............................................................................ 75
3.1.7
Cable protection against short circuit................................................................................ 75
3.1.8
Overload protection.......................................................................................................... 75
3.1.9
Improper use of switches .................................................................................................. 75
3.2
Safety stop ........................................................................................................................ 76
3.2.1
Emergency stop buttons ................................................................................................... 76
3.2.2
Safety light grid ................................................................................................................. 76
3.2.3
Safety mechanical switches............................................................................................... 76
3.2.4
Door switches ................................................................................................................... 76
3.3
Motion control.................................................................................................................. 77
3.3.1
Conveyor system .............................................................................................................. 77
3.3.2
Shuttles and Cranes .......................................................................................................... 77
3.4
Control system.................................................................................................................. 77
3.4.1
Conveyor system .............................................................................................................. 77
3.4.2
Cranes and shuttles .......................................................................................................... 78
4
INSTALLATION OF THE MACHINE ..................................................................................... 79
4.1
Conveyor system .............................................................................................................. 79
4.1.1
Chain conveyor ................................................................................................................. 79
4.1.2
Roller conveyor 01 ............................................................................................................ 82
4.1.3
Roller conveyor 02 ............................................................................................................ 84
4.1.4
Eccentric lifting table ........................................................................................................ 86
4.1.5
Stopper ............................................................................................................................. 88
4.1.6
Contour check................................................................................................................... 90
4.2
Shuttle C501 ..................................................................................................................... 94
4.2.1
Setting and startup of the machine ................................................................................... 95
4.3
Shuttle C401 ..................................................................................................................... 97
4.3.1
Setting and startup of the machine ................................................................................... 98
4.4
Crane .............................................................................................................................. 100
4.4.1
Transportation and installation ....................................................................................... 100
4.4.2
Stacker crane settings ..................................................................................................... 100
5
OPERATING INSTRUCTIONS AND FAULT FINDING PROCEDURES ................................... 102
5.1
High-bay warehouse layout ............................................................................................. 102
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1 INTRODUCTION
5.1.1
Warehouse layout .......................................................................................................... 102
5.1.2
Designation of warehouse locations ............................................................................... 102
5.1.3
Rack locations ................................................................................................................. 102
5.1.4
Permanently blocked rack locations ................................................................................ 104
5.1.5
Other limitations ............................................................................................................. 104
5.1.6
Transport units ............................................................................................................... 106
5.2
Hierarchy of the system .................................................................................................. 106
5.3
Functions of the system .................................................................................................. 108
5.3.1
Inbound traffic ................................................................................................................ 108
5.3.2
Outbound traffic ............................................................................................................. 108
5.3.3
Warehouse reorganization.............................................................................................. 109
5.3.4
Command execution ....................................................................................................... 109
5.4
Conveyor system ............................................................................................................ 110
5.4.1
Layout............................................................................................................................. 110
5.4.2
Components of conveyor system .................................................................................... 111
5.4.3
Powering the conveyor system cabinets ......................................................................... 111
5.4.4
Modes of operation ........................................................................................................ 112
5.4.5
Operating the conveyor system ...................................................................................... 113
5.5
Cranes ............................................................................................................................ 122
5.5.1
Start-up and shut-down of switching cabinets ................................................................ 122
5.5.2
Emergency Shut-Down.................................................................................................... 122
5.5.3
Regimes of operation ...................................................................................................... 122
5.5.4
Operators’ panel ............................................................................................................. 124
5.5.5
Parameter setting and calibration ................................................................................... 133
5.5.6
Common faults and handling procedures ........................................................................ 136
5.6
Shuttle S401.................................................................................................................... 141
5.6.1
Start-up and shut-down of switching cabinets ................................................................ 141
5.6.2
Emergency Shut-Down.................................................................................................... 141
5.6.3
Regimes and modes of operation.................................................................................... 141
5.6.4
Operators’ panel ............................................................................................................. 143
5.6.5
Parameter setting and calibration ................................................................................... 152
5.6.6
Common faults and handling procedures ........................................................................ 154
5.7
Shuttle S501.................................................................................................................... 158
5.7.1
Start-up and shut-down of switching cabinets ................................................................ 158
5.7.2
Emergency Shut-Down.................................................................................................... 158
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1 INTRODUCTION
5.7.3
Regimes and modes of operation.................................................................................... 158
5.7.4
Operators’ panel ............................................................................................................. 160
5.7.5
Parameter setting and calibration ................................................................................... 169
5.7.6
Common faults and handling procedures ........................................................................ 171
6
MATERIAL FLOW CONTROL SYSTEM I2MFCS .................................................................. 176
6.1
Architecture .................................................................................................................... 176
6.1.1
Database......................................................................................................................... 177
6.1.2
Telegrams module .......................................................................................................... 177
6.1.3
Core module ................................................................................................................... 177
6.1.4
UI module ....................................................................................................................... 178
6.2
Using I2MFCS .................................................................................................................. 178
6.2.1
Starting and stopping the application ............................................................................. 178
6.2.2
Layout............................................................................................................................. 179
6.2.3
Visualization screen ........................................................................................................ 181
6.2.4
Alarms screen ................................................................................................................. 183
6.2.5
Commands screen .......................................................................................................... 184
6.2.6
Transport units screen .................................................................................................... 188
6.2.7
Locations screen ............................................................................................................. 189
6.2.8
Simple commands screen ............................................................................................... 189
6.2.9
Events screen.................................................................................................................. 191
6.2.10
History screens ............................................................................................................... 192
6.2.11
Setting screen ................................................................................................................. 193
6.2.12
Database management ................................................................................................... 194
7
MAINTENANCE ............................................................................................................... 195
7.1
Mechanical maintenance ................................................................................................ 195
7.1.1
Conveyor system ............................................................................................................ 195
7.1.2
Shuttle C501 ................................................................................................................... 214
7.1.3
Shuttle C401 ................................................................................................................... 218
7.1.4
Crane .............................................................................................................................. 221
7.2
Electrical maintenance .................................................................................................... 237
7.2.1
Power rails and current collector .................................................................................... 237
7.2.2
Grouding......................................................................................................................... 238
7.2.3
Switch cabinets ............................................................................................................... 238
7.2.4
Frequency regulators ...................................................................................................... 238
7.2.5
Switching elements ......................................................................................................... 238
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1 INTRODUCTION
7.2.6
Photo-reflective, inductive and magnetic sensors ........................................................... 238
7.2.7
Barcode reader ............................................................................................................... 238
7.2.8
Optical sensors ............................................................................................................... 238
8
SPARE PARTS .................................................................................................................. 239
8.1
Mechanical parts ............................................................................................................ 239
8.1.1
Conveyors system ........................................................................................................... 239
8.1.2
Shuttle C501 ................................................................................................................... 241
8.1.3
Shuttle C401 ................................................................................................................... 241
8.1.4
Crane .............................................................................................................................. 241
8.2
Electrical parts ................................................................................................................ 245
8.2.1
Conveyor system (+SB1 /+SB2) ....................................................................................... 245
8.2.2
Crane .............................................................................................................................. 247
8.2.3
Shuttle C401 ................................................................................................................... 248
8.2.4
Shuttle C501 ................................................................................................................... 249
Table of Figures
Figure 2.1 Main parts of the chain conveyor................................................................................................. 22
Figure 2.2 Driving Station ............................................................................................................................. 23
Figure 2.3 Turning Station .............................................................................................................................23
Figure 2.4 Chain ............................................................................................................................................23
Figure 2.5 Main parts of the roller conveyor .................................................................................................25
Figure 2.6 Driving Station ..............................................................................................................................26
Figure 2.7 Main parts of the roller conveyor .................................................................................................28
Figure 2.8 Driving Station ..............................................................................................................................29
Figure 2.9 Eccentric Lifting Table ...................................................................................................................31
Figure 2.10 Main parts of the eccentric lifting table ......................................................................................32
Figure 2.11 Main parts of the eccentric lifting table ......................................................................................32
Figure 2.12 Lifting device ..............................................................................................................................33
Figure 2.13 Stopper ......................................................................................................................................35
Figure 2.14 Main parts of the stopper ...........................................................................................................36
Figure 2.15 Contour check ............................................................................................................................38
Figure 2.16 Main parts of the weight control ................................................................................................39
Figure 2.17 Main parts of the control of dimensions .....................................................................................40
Figure 2.18 Pallet base control ......................................................................................................................41
Figure 2.19 Main parts of the pallet base control ..........................................................................................41
Figure 2.20 Shuttle with two roller conveyors ...............................................................................................42
Figure 2.21 Main parts of the shuttle C501....................................................................................................43
Figure 2.22 Shuttle frame .............................................................................................................................44
Figure 2.23 Driving set .................................................................................................................................44
Figure 2.24 Driving unit.................................................................................................................................45
Figure 2.25 Hydraulical bumper ....................................................................................................................45
Figure 2.26 Roller conveyor on tilting mechanismus......................................................................................46
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1 INTRODUCTION
Figure 2.27 Tilting mechanismus .................................................................................................................. 46
Figure 2.28 Shuttle with chain conveyor....................................................................................................... 49
Figure 2.29 Main parts of the shuttle C401 ................................................................................................... 50
Figure 2.30 Shuttle frame............................................................................................................................. 51
Figure 2.31 Driving set ................................................................................................................................. 51
Figure 2.32 Driving unit ................................................................................................................................ 52
Figure 2.33 Hydraulical bumper ................................................................................................................... 52
Figure 2.34 Chain conveyor on the shuttle ................................................................................................... 53
Figure 4.1 Chain conveyor ............................................................................................................................ 79
Figure 4.2 Alignment of the chain conveyor ................................................................................................. 80
Figure 4.3 diagonals of the chain conveyor................................................................................................... 80
Figure 4.4 Tensioning of the chain................................................................................................................ 81
Figure 4.5 Guidings for tensioning of the chain ............................................................................................ 81
Figure 4.6 Roller conveyor ........................................................................................................................... 82
Figure 4.7 Alignment of the roller conveyor ................................................................................................. 83
Figure 4.8 Diagonals of the roller conveyor .................................................................................................. 83
Figure 4.9 Roller conveyor ........................................................................................................................... 84
Figure 4.10 Alignment of the roller conveyor ............................................................................................... 85
Figure 4.11 Diagonals of the roller conveyor ................................................................................................ 85
Figure 4.12 Eccentric lifting table ................................................................................................................. 86
Figure 4.13 Alignment of the eccentric lifting table ...................................................................................... 87
Figure 4.14 Adjusting of the lifting mechanismus ......................................................................................... 87
Figure 4.15 Stopper ..................................................................................................................................... 88
Figure 4.16 Alignment of the stopper ........................................................................................................... 89
Figure 4.17 Adjusting of the stopper ............................................................................................................ 89
Figure 4.18 Weight control .......................................................................................................................... 91
Figure 4.19 Control of dimensions................................................................................................................ 92
Figure 4.20 Pallet base control ..................................................................................................................... 93
Figure 4.21 Shuttle with two roller conveyor ................................................................................................ 94
Figure 4.22 Conveyor height leveling............................................................................................................ 95
Figure 4.23 Setting of the guiding wheels ..................................................................................................... 95
Figure 4.24 Leveling of the tilting table ........................................................................................................ 96
Figure 4.25 Shuttle with chain conveyor....................................................................................................... 98
Figure 4.26 Adjusting of the chain conveyor ................................................................................................. 98
Figure 4.27 Control of the guiding wheels .................................................................................................... 99
Figure 5.1 Ground plan of the warehouse. Black boxes represent conveyors, light and dark gray box
represent slot locations in racks ..................................................................................................................103
Figure 5.2 High-bay warehouse: top view with designated locations of racks, transport paths, and vehicles
......................................................................................................................................................................... 105
Figure 5.3 High-Bay warehouse: top view with designated locations of gravitational rack system................105
Figure 5.4 Euro pallet ..................................................................................................................................106
Figure 5.5 Architecture of computer systems in warehouse ........................................................................107
Figure 5.6 Main power cabinet....................................................................................................................111
Figure 5.7 Local and remote mode of operation ..........................................................................................112
Figure 5.8 Cabinet CP001 ............................................................................................................................113
Figure 5.9 Cabinet CP201 ............................................................................................................................113
Figure 5.10 CP001 operator panel main screen ...........................................................................................114
Figure 5.11 Selection of conveyor tables .....................................................................................................115
Figure 5.12 Commands available on main panel ..........................................................................................115
Figure 5.13 Dimension check information ...................................................................................................116
Figure 5.14 Alarm screen ............................................................................................................................117
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Figure 5.15 Settings screen .........................................................................................................................117
Figure 5.16 Login screen .............................................................................................................................118
Figure 5.17 Operator panel on CP501..........................................................................................................118
Figure 5.18 Buttons for operating conveyors...............................................................................................119
Figure 5.19 Operators’ panel .......................................................................................................................124
Figure 5.20 Operators’ panel with physical buttons. ....................................................................................125
Figure 5.21 HMI Screen ...............................................................................................................................126
Figure 5.22 Alarms screen ...........................................................................................................................127
Figure 5.23 Crane regime icons ...................................................................................................................127
Figure 5.24 Crane regime ............................................................................................................................128
Figure 5.25 All mode colors .........................................................................................................................128
Figure 5.26 Crane sensors screen ................................................................................................................129
Figure 5.27 Manual mode crane screen.......................................................................................................130
Figure 5.28 Automatic mode screen ............................................................................................................131
Figure 5.29 Start and cancel buttons ...........................................................................................................132
Figure 5.30 Determining the correct position of the crane regarding the horizontal beam. The spirit level is
lying on the fork..........................................................................................................................................133
Figure 5.31 Operator's panel: the teaching screen ......................................................................................134
Figure 5.32 Accessing the parameter files from SCADA ...............................................................................135
Figure 5.33 Operators panel: parameter adjustment screen........................................................................135
Figure 5.34 Operators’ panel – changing of the material picture. ................................................................139
Figure 5.35 Service screen on operators' panel ...........................................................................................140
Figure 5.36 Operators’ panel .......................................................................................................................143
Figure 5.37 Operators’ panel with physical buttons. ....................................................................................143
Figure 5.38 HMI Screen ...............................................................................................................................144
Figure 5.39 Alarms screen ...........................................................................................................................145
Figure 5.40 Shuttle regime icons .................................................................................................................146
Figure 5.41 Shuttle regime ..........................................................................................................................146
Figure 5.42 All mode colors .........................................................................................................................146
Figure 5.43 Shuttle sensors screen ..............................................................................................................148
Figure 5.44 Manual mode shuttle screen ....................................................................................................149
Figure 5.45 Automatic mode screen ............................................................................................................150
Figure 5.46 Start and cancel buttons ...........................................................................................................150
Figure 5.47 Operator's panel: the teaching screen. .....................................................................................152
Figure 5.48 Accessing the parameter files from operators’ panel ................................................................153
Figure 5.49 Operators panel: parameter adjustment screen........................................................................153
Figure 5.50 Operators’ panel – changing of the material picture .................................................................156
Figure 5.51 Service screen on operators' panel ...........................................................................................157
Figure 5.52 Operators’ panel .......................................................................................................................160
Figure 5.53 Operators’ panel with physical buttons. ....................................................................................160
Figure 5.54 HMI Screen ...............................................................................................................................161
Figure 5.55 Alarms screen ...........................................................................................................................162
Figure 5.56 Shuttle regime icons .................................................................................................................163
Figure 5.57 Shuttle regime ..........................................................................................................................163
Figure 5.58 All mode colors .........................................................................................................................163
Figure 5.59 Shuttle sensors screen ..............................................................................................................165
Figure 5.60 Manual mode shuttle screen ....................................................................................................166
Figure 5.61 Automatic mode screen ............................................................................................................167
Figure 5.62 Start and cancel buttons ...........................................................................................................168
Figure 5.63 Operator's panel: the teaching screen. .....................................................................................169
Figure 5.64 Accessing the parameter files from operators’ panel ................................................................170
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Figure 5.65 Operators panel: parameter adjustment screen .......................................................................170
Figure 5.66 Operators’ panel – changing of the material picture .................................................................174
Figure 5.67 Service screen on operators' panel ...........................................................................................175
Figure 6.1 I2MFCS system architecture .......................................................................................................177
Figure 6.2 I2MFCS services ..........................................................................................................................178
Figure 6.3 I2MFCS UI module ......................................................................................................................179
Figure 6.4 Screen layout..............................................................................................................................179
Figure 6.5 MFCS/WMS context menu..........................................................................................................180
Figure 6.6 Device tiles with context menu ...................................................................................................181
Figure 6.7 Visualization screen ....................................................................................................................182
Figure 6.8 Segment/device context menu ...................................................................................................182
Figure 6.9 Detail info pop-up.......................................................................................................................183
Figure 6.10 Alarms screen ...........................................................................................................................184
Figure 6.11 Working with tables..................................................................................................................185
Figure 6.12 Commands screen ....................................................................................................................186
Figure 6.13 Entering a move command .......................................................................................................187
Figure 6.14 Transport units screen ..............................................................................................................188
Figure 6.15 Locations screen .......................................................................................................................189
Figure 6.16 Simple commands screen with new tile in control panel ...........................................................190
Figure 6.17 Event screen .............................................................................................................................192
Figure 6.18 Movement screen ....................................................................................................................193
Figure 6.19 Setting screen...........................................................................................................................194
Figure 7.1 Driving station ............................................................................................................................196
Figure 7.2 Maintanance parts of the chain conveyor ...................................................................................197
Figure 7.3 Lubrication scheme of the chain conveyor ..................................................................................198
Figure 7.4 Maintanance parts of the roller conveyor ...................................................................................200
Figure 7.5 Lubrication scheme of the roller conveyor ..................................................................................201
Figure 7.6 Maintanance parts of the roller conveyor ...................................................................................203
Figure 7.7 Lubrication scheme of the roller conveyor ..................................................................................204
Figure 7.8 Maintanance parts of the lifting device.......................................................................................206
Figure 7.9 Lubrication scheme of the lifting device ......................................................................................208
Figure 7.10 Maintanance parts of the stopper.............................................................................................210
Figure 7.11 Lubrication scheme of the stopper............................................................................................211
Figure 7.12 Maintanance parts of the weight control ..................................................................................212
Figure 7.13 Maintanance parts of the base control .....................................................................................213
Figure 7.14 Maintanance parts of the driving set ........................................................................................214
Figure 7.15 Maintanance parts of the tilting table .......................................................................................215
Figure 7.16 Other maintanance parts ..........................................................................................................216
Figure 7.17 Lubrication elements of the shuttle ..........................................................................................217
Figure 7.18 Maintanance elements of the driving set ..................................................................................218
Figure 7.19 Other maintanance elements ...................................................................................................219
Figure 7.20 Lubrication scheme of the shuttle .............................................................................................220
Figure 7.21 Bottom carriage........................................................................................................................222
Figure 7.22 Lifting carriage..........................................................................................................................223
Figure 7.23 Upper girder .............................................................................................................................224
Figure 7.24 Wheels on the lifting carriage ...................................................................................................226
Figure 7.25 Lifting unit ................................................................................................................................227
Figure 7.26 Lubrication of the rope with a brush .........................................................................................228
Figure 7.27 Catching device ........................................................................................................................230
Figure 7.28 Speed regulator ........................................................................................................................231
Figure 7.29 Ladder ......................................................................................................................................232
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1 INTRODUCTION
Figure 7.30 Cable chain ...............................................................................................................................233
Figure 7.31 Lubrication scheme ..................................................................................................................235
List of Tables
Table 1.1 Notes and warnings ...................................................................................................................... 13
Table 1.2 Considered regulations and rules Standards.................................................................................. 14
Table 1.3 Contacts table ...............................................................................................................................20
Table 2.1 Main parts of the chain conveyor ...................................................................................................22
Table 2.2 Technical data of the chain conveyor .............................................................................................24
Table 2.3 Technical data of the driving motorgearbox ...................................................................................24
Table 2.4 Main parts of the roller conveyor ...................................................................................................25
Table 2.5 Technical data of the roller conveyor .............................................................................................27
Table 2.6 Technical data of the driving motorgearbox ...................................................................................27
Table 2.7 Main parts of the roller conveyor ...................................................................................................28
Table 2.8 Technical data of the roller conveyor .............................................................................................30
Table 2.9 Technical data of the driving motorgearbox ...................................................................................30
Table 2.10 Technical data of the eccentric lifting table ..................................................................................34
Table 2.11 Technical data of the driving motorgearbox .................................................................................34
Table 2.12 Main parts of the stopper ............................................................................................................36
Table 2.13 Technical data of the stopper.......................................................................................................37
Table 2.14 Technical data of the driving motorgearbox .................................................................................37
Table 2.15 Main parts of the weight control ..................................................................................................39
Table 2.16 Main parts of the control of dimensions.......................................................................................40
Table 2.17 Main parts of the pallet base control ...........................................................................................41
Table 2.18 Main parts of the shuttle C501 .....................................................................................................43
Table 2.19 Technical data of the shuttle ........................................................................................................47
Table 2.20 Technical data of the driving motorgearboxes .............................................................................48
Table 2.21 main parts of the shuttle C401 .....................................................................................................50
Table 2.22 Technical data of the shuttle ........................................................................................................54
Table 2.23 Technical data of the driving motorgearboxes .............................................................................55
Table 2.24 Crane main groups .......................................................................................................................56
Table 2.25 Crane technical data ....................................................................................................................62
Table 5.1 Delivery and dispatch conveyors ..................................................................................................103
Table 5.2 Permanently blocked rack locations .............................................................................................104
Table 5.3 Segments.....................................................................................................................................110
Table 5.4 Buttons and their actions .............................................................................................................126
Table 5.5 Buttons and their actions .............................................................................................................144
Table 5.6 Buttons and their actions .............................................................................................................161
Table 7.1 Maintanance parts of the driving station ....................................................................................196
Table 7.2 Maintanance parts of the chain conveyor ....................................................................................197
Table 7.3 Lubrication plan of the chain conveyor ........................................................................................198
Table 7.4 Maintanance parts of the roller conveyor ....................................................................................200
Table 7.5 Lubrication parts of the roller conveyor .......................................................................................201
Table 7.6 Maintanance parts of the roller conveyor ....................................................................................203
Table 7.7 Lubrication parts of the roller conveyor .......................................................................................204
Table 7.8 Maintanance parts of the lifting device ........................................................................................207
Table 7.9 Lubrication parts of the lifting device ...........................................................................................207
Table 7.10 Maintanance parts of the stopper ..............................................................................................210
Table 7.11 Lubrication parts of the stopper .................................................................................................211
Table 7.12 Maintanance parts of the weight control ...................................................................................212
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Table 7.13 Maintanance parts of the base control ......................................................................................213
Table 7.14 Maintanance parts of the driving set..........................................................................................215
Table 7.15 Maintanance parts of the tilting table ........................................................................................215
Table 7.16 Other maintanance parts ...........................................................................................................216
Table 7.17 Lubrication elements of the shuttle............................................................................................217
Table 7.18 Maintanance elements of the driving set ...................................................................................218
Table 7.19 Other maintanance elements.....................................................................................................219
Table 7.20 Lubrication elements of the shuttle............................................................................................220
Table 7.21 Bottom carriage .........................................................................................................................222
Table 7.22 Lifting carriage ...........................................................................................................................223
Table 7.23 Upper girder ..............................................................................................................................224
Table 7.24 Wheels on the lifting carriage ....................................................................................................225
Table 7.25 Lifting unit .................................................................................................................................227
Table 7.26 Degree of wear ..........................................................................................................................229
Table 7.27 Catching device..........................................................................................................................230
Table 7.28 Speed regulator .........................................................................................................................231
Table 7.29 Ladder .......................................................................................................................................232
Table 7.30 Cable chain ................................................................................................................................233
Table 7.31 Lubrication instructions .............................................................................................................234
Table 7.32 Inspection table .........................................................................................................................236
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1 INTRODUCTION
1 INTRODUCTION
1.1 Purpose of the instructions
These instructions are prepared by the manufacturer.
Instructions clearly define the purpose of the use of the system and contain all data necessary for assuring safe and
correct use of the system.
Information contained herein is intended to professionally qualified persons. Person is professionally qualified if he or
she possesses necessary knowledge (professional knowledge, knowledge about safety and health when using the
equipment, etc.) and competences.
Permanent following and compliance with instructions, norms and standards given by the manufacturer is a guarantee
(warranty) for the safety of personnel and the system, its economical use and long life span.
This manual is to be used by operators in charge of managing the system during its working life.
It is important to keep the manual in a readily accessible place, near the machine and well-known to all the operators in
charge of operating and maintaining the system. The operators and the maintenance staff must be able to quickly find
and consult the manuals and the annexes in any situation.
The manual is an integral part of the sytem safety. Therefore:



It must be kept intact. Immediately request a copy if the manual gets lost or damaged;
It must stay with the system until its destruction (also in case of transportation, sale, lease, etc.);
It must be kept updated and include any changes introduced.
Before performing any operation, it is necessary to read the entire documentation
1.2 Safety symbols and warnings
The purpose of this manual is to enable the building services installation to be operated and maintained in a safe and
efficient manner. It is not a training manual, and it is not a guide for carrying out modifications to the system (transport
vehicle and subsidiary equipment).
Any personnel carrying out work on the system should have suitable levels of training, qualification and competence.
This manual is written with this in mind. If any works are to be carried out on the system, then this manual should be
referred to before work commences. Should the particular issue not be covered by this manual then please refer to the
Installing Contractor, before undertaking such works.
The present manual contains the necessary information for installation, operation, maintenance and cleaning of the
system in its entirety. These instructions are divided in chapters to make reading easier; in order to find a particular
chapter more quickly, use of table of contents is recommended!
Notes or warnings are written in bold and marked with symbols as presented in Error! Reference source not found..
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1 INTRODUCTION
Table 1.1 Notes and warnings
ADVICE
It illustrates useful instructions related to work.
Before use, configuration or maintenance read these instructions carefully!
DANGER
Compliance with the instructions is obligatory. Failure to comply with the instructions may lead
to injuries or death!
WARNING
Warning about a situation, which may arise in life span of the product, or the system and which
can represent potential hazard for personal injury or property damage, environment pollution
and economic losses.
ATTENTION
Warning which must be considered, to avoid serious damages on the machine and personnel.
INFORMATION
Important information!
NOTE:
Some information and illustrations in these instructions can be different from the ones on your machine. This sign
stands for specific information relating exclusively to your machine.
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1 INTRODUCTION
1.3 Applicable Health and Safety Legislation
All personnel involved in the operation and maintenance of the System Reference must comply with relevant
regulations at High-bay rack warehouse Abalioglu, Izmir or the Local Authority guidelines for safe working practices.
During the design and safety management on the transport vehicle the following standards, regulations and rules given
in Table 1.2 have been considered.
Table 1.2 Considered regulations and rules Standards
Standard
Ur. l. RS No. 75/2008
SIST EN ISO 12100-1
SIST EN ISO 12100-2
SIST EN ISO 13857
SIST EN 349
SIST EN ISO 13850
SIST HD 516 S2
SIST EN 953
SIST EN 954-1
SIST EN 981
SIST EN 1037
SIST EN 14121-1
SIST EN 50085-1
SIST EN 50086-1
SIST EN 60204-1
SIST EN 60204-32
SIST-EN-528-2008
Description
Machinery Safety Rules
Machinery safety – Basic notions, general principles of planning – Part 1
Basic terminology, methodology
Machinery safety – Basic notions, general principles of planning – Part 2
Technical principles
Machine safety – Safety distances preventing reach of dangerous areas with upper and
lower limbs
Machinery safety – Least distances preventing contusions on human body parts
Machinery safety – Emergency stop – Principles of planning
Directions for use of low voltage adjusted cables
Machinery safety – Safety devices – General directions for planning and construction of
fixed and movable safety devices
Machinery safety – Parts of command systems
Machinery safety – Systems of visible and audible hazards or notice signals
Machinery safety – prevention of the hazardous switch-on
Machinery safety – Risk assessment – Principles (methodology of evaluation, list of
dangers)
Systems of cable troughs and system of cable tubes for el. installations
Systems of channels for el. installations – Part 1
Machinery safety – Electrical machine equipment – Part 1: General requirements
Machinery safety - Electrical machine equipment – Part 32: Special requirements for
lifting machines
Rail dependent storage and retrieval equipment – Safety requirements
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1 INTRODUCTION
1.3.1 Basic Health and Safety Procedures
The goal of this chapter is to inform the operators and the maintenance technicians about any relevant risks and
dangers and about the general and specific precautions to eliminate or neutralize them.
Only qualified staff can operate the system.
This chapter contains information and instructions relevant to:



situations of danger that might arise during use and maintenance of the system;
protections, guards and safety devices and their correct use;
residual risks and behaviors (general and specific precautions to eliminate or limit them).
The instructions and safety warnings referred to in this manual take into account


the safety of the people responsible for running and maintenance;
the safety and the efficiency of the system.
1.3.1.1 General
Before commencing any task, give careful consideration to



what is or maybe be involved;
the extent of the plant/equipment requiring attention;
how your intended activities may affect others working in the vicinity.
The employer, the manager, and the person in charge of safety must, when assigning duties to workers:



take into account their capability and the condition of their health and safety;
supply the proper individual safety devices;
require each operator to observe the corporate regulations and instructions regarding safety and the use of
the collective or individual protection devices available for them.
The employer shall be responsible for instructing staff regarding:




accident risks,
operator safety devices,
risks produced by noise emissions and
general accident-prevention measures contemplated by European directives and by the legislation of the
country where the system is to be installed.
It is the responsibility of the employer to:




analyze all dangers of the system by assessing the probability of risk based on the functioning methods and the
installation location;
restrict the passage of forklifts;
sensitize and train staff responsible for operations on the work posts and the staff responsible for operating
the system;
apply visual safety signs.
The operator must:



observe the rules and instructions provided by the employer, the manager and the person in charge regarding
collective or individual protection;
correctly use the machinery, equipment, tools, dangerous substances and preparations, means of transport
and handling and any other working equipment in addition to the safety devices;
correctly use the protection devices provided;
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1 INTRODUCTION

immediately inform the employer, manager or person in charge of any deficiency in the safety devices.
All work proposed should only be considered if the plant or the consequences of the operator working on the plant are
carried out in circumstances that are made safe.
An interlock system (similar to Permit-to-Work) should be employed to safeguard the operator and/or any person who
may be affected by the actions of the operator.
Should an accident occur follow the procedures according to the High-bay rack warehouse Abalioglu rules or by the
Local Authority.
Control panel cubicle(s) or distribution boards open for prolonged periods of maintenance must be isolated with
barriers, and clearly visible HAZARD, WARNING, CAUTION or DANGER notices displayed: this a mandatory requirement
irrespective of whether the plant is attended or not.
1.3.1.2 Basic first Aid Principles
The operators should follow the general first aid aims to help an injured person:





Preserve life – This includes the life of the casualty, bystander and rescuer;
Protect the casualty from further harm – Ensure the scene is safe;
Provide pain relief – This could include the use of ice packs or simply applying a sling;
Prevent the injury or illness from becoming worse – Ensure the treatment you provide does not make the
condition worse;
Provide reassurance.
It is important to understand that first aid has its limitations and does not take the place of professional medical
treatment.
If the assistance of medical or nursing personnel will be required immediately send for a doctor or nurse (where they
are employed at the workplace) or an ambulance. When an ambulance is called, arrangements should be made to
direct it to the scene immediately.
For detailed guidance on first aid procedures refer to High-bay rack warehouse Abalioglu or the Local Authority
guidelines for safe working practices.
1.3.1.3 Basic Safety Guide
INFORMATION
The operators and maintenance should NOT consider the following advice to be the SOLE
reference for safety purposes; they are represented merely as reminders of the most basic of
safety considerations.
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1 INTRODUCTION
The operators shall always be aware of the following when accessing the different areas:




limits of their duties;
warnings on the plates on board the system;
procedures of intervention required;
always considering the safety concept on the whole.
Important notes for operators:








Use individual protection means suitable to the risk they have to face. Operators should wear work clothes
(with tight sleeves) and, if necessary, personal protection equipment (gloves, goggles, masks, safety anti-slip
footwear, etc.) in compliance with the legislation and regulations in force in the respective country;
Do not use the system improperly, that is, do not use the system in any manner other than that indicated in
the manual;
When the sytem is operating, do not work near the system wearing chains, bracelets, ties or any other piece of
clothing that might get entangled with the mechanisms. Tie up long hair;
Do not seize with your hands to dangerous areas of movement (rotational or moving);
Make sure that there are no persons in dangerous areas when the machine is started;
During manual operations pay utmost attention to prevent damage to persons or things;
Make sure the floor is regularly cleaned, entering material must be in flawless condition;
Always make sure that safety devices and other means of protection are properly installed.
ATTENTION
Each operator must attend to his/her own safety and health and that of others present in
the working area who might suffer the effects of his/her actions or operations, in
accordance with training and the instructions and resources supplied by the employer!
1.3.1.4 System of keys and Permits-to-work
WARNING
The vehicles in the plant operates automatically. You cannot predict when and where a vehicle
will move.
In the system there are three cranes and two shuttles. In order to prevent injuries of the operators when accessing, the
system of keys should be used. The system of keys consists of a key-lock outside the crane or shuttle area and one keylock on each crane and shuttle. Only one key should be used for manipulation of key-locks. The operator can only
approach a vehicle when he possesses the key. In remote operation (automatic mode) the key is in the key-lock outside
the transport vehicles area. To stop the vehicles movement, the operator has to take the key from the key-lock and
wait for appropriate signal. Only when the vehicles stop, he can access the vehicles area. For local operation of a
vehicle, the operator has to put the key to the key-lock of the selected vehicle. The procedure is further detailed in later
sections.
For maintenance works it is recommended that the Permit-to-Work scheme is introduced by the management. If
correctly operated, the benefits of a Permit-to-Work system can contribute significantly to a safe working environment
and an orderly working regime. The Permit Officer shall only authorize commencement of any maintenance or repair
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1 INTRODUCTION
task upon receipt of the appropriate application for a Permit-to-Work. The Permit Officer is to check and assume
responsibility for placement of all "DANGER", "CAUTION" and/or "LIVE" notices prior to issue of the Permit. When the
work is complete or interrupted the operative shall sign the Permit, acknowledging the work to be complete or
interrupted. Only when all Permits pertaining to the plant/equipment on which work has been carried out are returned
to the Permit Officer will the plant/equipment should be returned to normal operation.
1.3.2 After Servicing



No system can be re-energized until it has been certified as tested and safe to operate.
Checks should be made to ensure that any control panels, switch panels, distribution boards, etc., that have
been accessed are properly closed up and secured.
Checks should be made to ensure that plant has been isolated prior to switching supplies back on to prevent
shocks to the electrical system.
1.3.3 Fire Precautions
The system shall operate exclusively indoors, protected from the weather, where there is no danger of explosion or fire
because it is not made of flameproof materials.
The following regular and routine checks should be carried out to ensure that they are always capable of functioning
correctly. Report any defects or issues to the System Management.






Ensure that all fire-fighting equipment Is fully tested and operational at all times.
Ensure that fire-fighting equipment is suitable for use on electrical systems.
Ensure emergency lock-stop buttons are clearly labelled;
Ensure all doors to the system are kept shut;
Ensure hand fire appliances are kept in their proper locations and regularly checked by the Civil Defense or
manufacturers;
Ensure the correct extinguishers are available for dealing with the likely types of fires in the areas covered by
them. (For any information and advice in this respect consult the local Civil Defense).
In the vicinity of the operating area a fire extinguishing system is recommended. For electrical devices use Dry Powder
(class A, B, C) or CO2 Gas (A – limited, B).
If you discover a fire, you must get everyone out as quickly as possible and call the Civil Defense. However, you may
discover a fire in its very early stages and think that you can deal with it yourself. The first thing that you should
remember is that fire spreads very quickly. Even a small contained fire can quickly spread, producing smoke and fumes
which can kill in seconds. If you are in any doubt do not tackle the fire, no matter how small. You can put yourself at risk
by fighting the fire.
1.3.4 Maintenance
All maintenance procedures are described in these instructions. Do not perform maintenance or other operations not
provided in these instructions.
Consistent compliance with these instructions is the condition for safe use of the machine and its long life span.
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1 INTRODUCTION
INFORMATION
Only professionally qualified and authorized personnel may use and maintain the machine
after thorough reading and understanding of these instructions!
Notes for maintenance in addition to the notes for operators given in section Basic Safety Guide:














Before working with any system that can cause potential harm always ensure that you are aware of local
emergency procedures and the locations of emergency equipment.
Ensure that all the require documentation has been submitted and approved before commencing works.
It is the responsibility of each individual to ensure that, via the application of plain "common sense" and the
mandatory safety regulations, each task is carried out safely.
Always allow the system to roll to a stop naturally. Never attempt to shorten the time by holding system parts.
Carry out maintenance operations with the system switched-off.
Always assume every circuit is 'live' until it has been checked with a voltmeter, or similar approved means:
check your instruments with a known 'live' source before using them for testing.
Never touch two sides of a circuit simultaneously, whether it is alive or dead.
Whenever work is to be carried out on a vehicle or equipment all electrical isolators should be locked off and
all fuses covering the item should be removed as an added safeguard. Indicate at main panel that work is being
carried out on particular plant. Lock off electrical supplies where possible and retain the key(s).
Turn off the master switch and lock it with a padlock before operating on the electrical board, the junction
box, cables and any other electrical component of the system. The fact of being impossible for unauthorized
persons to remove the lock will allow carrying out the relevant operations in safety.
Do not use metal rules or measuring tapes when working on or near live equipment.
Always use tools with hand grips adequately insulated against the voltage of the circuit being worked on.
Do not lubricate when the moving parts are in motion.
Always remove guards, access panels and other safety devices immediately the work in hand is completed.
When maintenance or repair work is either interrupted or complete then it is the responsibility of the engineer
or individual in charge to ensure that the plant is left in a safe condition.
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1 INTRODUCTION
1.4 Project Directory
Table 1.3 gives all relevant information for the project.
Table 1.3 Contacts table
Role
Organization Name & Address
Contact Details
Mechanical
design
Iskra impuls Kranj d.o.o
Zasavska 43g
4000 Kranj
Electrical
design
Iskra impuls Kranj d.o.o
Zasavska 43g
4000 Kranj
PLC
programming
Iskra impuls Kranj d.o.o
Zasavska 43g
4000 Kranj
tel.: +386 4 20 10 210
fax: +386 4 20 10 211
email: support@iskraimpuls.si
web: www.iskraimpuls.si
tel.: +386 4 20 10 210
fax: +386 4 20 10 211
email: support@iskraimpuls.si
web: www.iskraimpuls.si
tel.: +386 4 20 10 210
fax: +386 4 20 10 211
email: support@iskraimpuls.si
web: www.iskraimpuls.si
tel.:
fax:
email:
web:
tel.:
fax:
email:
web:
tel.:
fax:
email:
web:
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2 INSTALLATION DESCRIPTION
2 INSTALLATION DESCRIPTION
2.1 Basis of design
System has design that allow it to achieve maximum operational safety. Condition for safe and reliable operation of the
system is its faultlessness, which can be achieved and maintained by systematic execution of prescribed inspections and
professional maintenance.
2.2 Purpose of the Installation
System is intended for transport loads. The conveyor system transfers pallets to and from the vehicles in the
warehouse. High-bay warehouse comprises of three aisles. In each aisle, there is an automatic storage retrieval
machine (crane) with one deck. For conveying the transport unit to and from the warehouse, there are also some
supporting conveyor tables and two shuttle cars.
2.3 Applicable Standards
During the design and safety management on the system, the standards, regulations and rules, given in Chapter 1.3,
Table 1.2Error! Reference source not found., have been considered
2.4 Mechanical equipment
2.4.1 Conveyor system
2.4.1.1
2.4.1.1.1
Chain conveyor
Technical description
Chain conveyor is used for transport of paletts. Pallet is traveling in longitudinal direction of the conveyor. Chain
conveyor can work as independent unit or can be built in another working unit.
Dimensions of the pallet is 1200mm x 800mm
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2 INSTALLATION DESCRIPTION
Table 2.1 Main parts of the chain conveyor
Pos.
Name
1
Longitudinal beam
2
Drive station
3
Turning station
4
Chain
5
Chain guiding
1
3
4
5
2
Figure 2.1 Main parts of the chain conveyor
Chain conveyors components are screwed together. Longitudinal beam consists steel tube and two turning
station screwed on it. Both longitudinal beams are connected with distance beams.
On the bottom side, there is drive station mounted. Both chains are guided with standard chain guiding.
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2 INSTALLATION DESCRIPTION
Longitudinal beam is made of rectangural tube. Chain guidings are conected to them.
Driving station is assembled of driving shaft, housing units with bearings, driving and turning sprockets and
motorgearbox. Driving sprockets and gearbox are connected to the shaft with clamping devices.
Figure 2.2 Driving Station
Turning station where turning sprockets are mounted is
fixed at the end of longitudinal beam. From the outher side,
there is a protection cover.
Figure 2.3 Turning Station
Chain runs over turning sprockets of the driving station and both turning stations and over the tensioning
sprocket of the driving station which allowes us to make proper tension of the chain.
Chain is supported with standard plastic chain guiding
Figure 2.4 Chain
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2 INSTALLATION DESCRIPTION
Table 2.2 Technical data of the chain conveyor
Type of the chain conveyor:
Capacity
10 kN
Dimensions
Length
different lengths
Width
1140 mm
Distance between chains
1060 mm
Chain ISO 12-B2 with straight lamels
Speed:
Conveyor speed ( vz )
0,2 m/s
Other data:
Control voltage:
24 V DC
Voltage / frequency:
3x400V / 50 Hz
Table 2.3 Technical data of the driving motorgearbox
Chain conveyor drive:
Type
K89-LE160MF4EF-L150NHA-IN
Output torque
565
Nm
Motor revolutions
1.440
r.p.m.
Gearbox revolutions
184
r.p.m.
Ratio
7,97
Voltage
400
V
Power
11
kW
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2 INSTALLATION DESCRIPTION
2.4.1.2
2.4.1.2.1
Roller conveyor 01
Technical description
Driven roller conveyor is used for transport of paletts. Pallet is traveling in longitudinal direction of the roller conveyor.
Roller convyor can work as independent unit or can be built in another working unit.
Dimensions of the pallet is 1200mm x 800mm
Table 2.4 Main parts of the roller conveyor
4
Pos.
Name
1
Longitudinal beam
2
Cover
3
Driving station
4
Drive
5
Roller
6
Driving belt
7
Driven belt
2
3
1
Figure 2.5 Main parts of the roller conveyor
4
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6
7
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2 INSTALLATION DESCRIPTION
Roller conveyors components are screwed together. Rollers are mounted between 2 longitudinal beams.
Longitudinal beams are protected with covers. Driving station is mounted on one of the longitudinal beams.
Timing belts are used for movement transfer. Driving timing belts drives two nearest rollers, all other rollers
are conected with another driven timing belts.
Longitudinal beam is made of C profile with holes rollers which are 200mm apart. Rollers are conected to the
beam with screws.
Rollers are standard purchased elements. Diameter of the rollers is 88,9mm. There are 2 sealed bearings inside
of the roller and double timing sprocket on one end of the roller.
Driving station is assembly with motorgearbox, driving timing bar sprocket which is connected with Taper Lock
bush, and driving timing belt. Tension in the driving timing belt can be adjusted by vertical adjustment of the
Motorgearbox.
Figure 2.6 Driving Station
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2 INSTALLATION DESCRIPTION
Table 2.5 Technical data of the roller conveyor
Type of the roller conveyor:
01
Capacity
2x10 kN
Dimensions
Length
different lengths
Width
975 mm
Distance between rollers
200 mm
Roller 5170-STKV 88,9x2,9-B20-IGM12x20-EBL=AL=965
Diameter of roller
88,9 mm
Speed:
Conveyor speed ( vz )
0,2 m/s
Other data:
Control voltage
24 V DC
Voltage / frequency
3x400V / 50 Hz
Table 2.6 Technical data of the driving motorgearbox
Roller conveyor drive:
Type
BF39-LE80MD4E-L16N
Output torque
79
Nm
Motor revolutions
1.440
r.p.m.
Gearbox revolutions
66
r.p.m.
Ratio
21,9
Voltage
3x400
V
Power
0,55
kW
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2 INSTALLATION DESCRIPTION
2.4.1.3
Roller conveyor 02
2.4.1.3.1
Technical description
Driven roller conveyor is used for transport of paletts. Pallet is traveling in longitudinal direction of the roller conveyor.
Roller conveyor can work as independent unit or can be built in another working unit.
Dimensions of the pallet is 1200mm x 800mm
Table 2.7 Main parts of the roller conveyor
5
2
Pos.
Name
1
Longitudinal beam
2
Cover
3
Drive station
4
Drive motorgearbox
5
Roller
6
Driving belt
7
Driven belt
7
1
4
6
3
Figure 2.7 Main parts of the roller conveyor
Roller conveyors components are screwed together. Rollers are mounted between 2 longitudinal beams.
Longitudinal beams are protected with covers. Driving station is mounted on one of the longitudinal beams.
Timing belts are used for movement transfer. Driving timing belts drives two nearest rollers, all other rollers
are conected with another driven timing belts.
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2 INSTALLATION DESCRIPTION
Longitudinal beam is made of C profile with holes rollers which are 200mm apart. Rollers are conected to the
beam with screws.
Rollers are standard purchased elements. Diameter of the rollers is 88,9mm. There are 2 sealed bearings inside
of the roller and double timing sprocket on one end of the roller.
Driving station is assembly with motorgearbox, driving timing bar sprocket which is connected with Taper Lock
bush, and driving timing belt. Tension in the driving timing belt can be adjusted by vertical adjustment of the
Motorgearbox.
Figure 2.8 Driving Station
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2 INSTALLATION DESCRIPTION
Table 2.8 Technical data of the roller conveyor
Type of the roller conveyor:
01
Capacity
2x10 kN
Dimensions
Length
different lengths
Width
975 mm
Distance between rollers
200 mm
Roller 5170-STKV 88,9x2,9-B20-IGM12x20-EBL=AL=965
Diameter of roller
88,9 mm
Speed:
Conveyor speed ( vz )
0,2 m/s
Other data:
Control voltage:
24 V DC
Voltage / frequency
3x400V / 50 Hz
Table 2.9 Technical data of the driving motorgearbox
Roller conveyor drive:
Type
BF39-LE80MD4E-L16N
Output torque
79
Nm
Motor revolutions
1.440
r.p.m.
Gearbox revolutions
66
r.p.m.
Ratio
21,9
Voltage
3x400
V
Power
0,55
kW
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2 INSTALLATION DESCRIPTION
2.4.1.4
2.4.1.4.1
Eccentric lifting table
Technical description
Eccentric lifting table which has a roller conveyor on board is situaded in the middle of chain conveyor. Eccentic lifting
table is used for lifting and lowering the roller conveyor. In upper position, the roller conveyor is abowe the chain
conveyor and in bottom position ther is opposite situation. That enables to take over the pallet from roller conveyor to
the chain conveyor and opposite. Movement of the pallet on the roller conveyor an on the chain conveyor is
perpndicular.
Dimensions of the pallet is 1200mm x 800mm
Figure 2.9 Eccentric Lifting Table
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2 INSTALLATION DESCRIPTION
Figure 2.10 Main parts of the eccentric lifting table
Pos.
Name
1
Bottom frame
2
Upper frame
3
Lifting device
2
3
1
Figure 2.11 Main parts of the eccentric lifting table
Bottom frame is welded part made of rectangural tubs and plates.It has 4 leveling which enables us to level the
device.
Upper frame is welded part made of rectangural tubs and plates. It is adjusted for fixing the roller conveyor.
Lifting device. Lifting is done with eccentric. Device consist motorgearbox, driving shaft and two shafts with
eccentric arms, driving sprocket and chain, housing units with bearings and holders fort he upper frame.
With turning of the eccentric arms for 90 degrees, lifting or lowering is enabled.
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2 INSTALLATION DESCRIPTION
Figure 2.12 Lifting device
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2 INSTALLATION DESCRIPTION
Table 2.10 Technical data of the eccentric lifting table
Type of the lifting table:
eccentric
Capacity
10 kN
Dimensions
Length
1040 mm
Width
870 mm
Lifting height
40 mm
Speed:
Lifting speed ( vy )
0,01 m/s
Other data:
Control voltage
24 V DC
Voltage / frequency
3x400V / 50 Hz
Table 2.11 Technical data of the driving motorgearbox
Eccentric lifting table drive:
Type
K79-LE90SG4E-L16N
Output torque
820
Nm
Motor revolutions
1.425
r.p.m.
Gearbox revolutions
17
r.p.m.
Ratio
81,47
Voltage
400
V
Power
1,1
kW
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2.4.1.5
2.4.1.5.1
Stopper
Technical description
Stopper is used for stopping and alignement of the pallets at desired situation.
Movable part of stopper is lifting and lowering and stops the pallet when it is in upper position or pallet pass over
when it is in bottom position.
Lifting movement is inclined so that it does not scratch the pallet during movement.
Figure 2.13 Stopper
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2 INSTALLATION DESCRIPTION
Table 2.12 Main parts of the stopper
Pos.
Name
1
Bottom frame
2
Guiding frame
3
Movable part
4
Motorgearbox
3
4
2
1
Figure 2.14 Main parts of the stopper
Bottom frame is anchored to the ground. Position of the bottom frame and those complete stopper can be
adjusted.
Guiding frame is atatched to the bottom frame. It consists linear guiding profiles..
Movable part. Is stopping the pallet. The shape is different if it stops the pallets comming paralel or
perpendicural on the roller conveyor.
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2 INSTALLATION DESCRIPTION
Table 2.13 Technical data of the stopper
Type of the lifting table:
eccentric
Capacity
10 kN
Dimensions
Lifting height
40 mm
Speed:
Lifting speed ( vy )
0,1 m/s
Other data:
Control voltage
24 V DC
Voltage / frequency
3x400V / 50 Hz
Table 2.14 Technical data of the driving motorgearbox
Eccentric lifting table drive:
Type
DF39-LA63MF4-L4N
Output torque
200
Nm
Motor revolutions
1.350
r.p.m.
Gearbox revolutions
13
r.p.m.
Ratio
100,44
Voltage
400
V
Power
0,18
kW
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2.4.1.6
2.4.1.6.1
Contour check
Technical description
Contour check consists weight control, control of dimensions of the load and pallet base control.
Figure 2.15 Contour check
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2 INSTALLATION DESCRIPTION
2.4.1.6.2
Weight control
Weight control is checking that the load is not exceeded. It is usually integrated in the contour check assembly.
Table 2.15 Main parts of the weight control
1
Pos.
Name
1
Base frame
2
Guiding set
3
Weighting set
2
3
Figure 2.16 Main parts of the weight control
Base frame in anchored to the ground. Conveyor is attached from the upper side.
Guiding set is anchored to the floor and it prevents damages of weighting sensors due to horizontal forces.
Weighting set is enabling leveling of the device and takes care that load is equally distributed on all 4
weighting sensors.
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2 INSTALLATION DESCRIPTION
2.4.1.6.3
Control of dimensions
Control of dimensions is used for checking that load dimensions are not exceeded.
Table 2.16 Main parts of the control of dimensions
Pos.
Name
1
Frame
2
Height control
3
Width control
4
Length control
3
2
1
4
Figure 2.17 Main parts of the control of dimensions
Frame is assembled pou of standard aluminium profiles.
Height control. Sensor and reflector is used for the control of height.
Width control. Two sensor and reflectors are used for the control of width.
Length control. Measuring light grid and two sensors are used for control of length.
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2 INSTALLATION DESCRIPTION
2.4.1.6.4
Pallet base control
Pallet base control is checking empty area of the pallet where the pickup forks are reaching. It is usually integrated in
the contour check assembly.
Figure 2.18 Pallet base control
Table 2.17 Main parts of the pallet base control
Pos.
Name
1
Base frame
2
Guiding wheels
3
Flags
4
Supporting wheels
5
Sensors
Figure 2.19 Main parts of the pallet base control
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2 INSTALLATION DESCRIPTION
Base frame in anchored to the ground. It enables leveling of the device.
Guiding wheels lead the pallet when it passes through.
Flags are set in the way so that pallet which has no damages does not hit the flag when it pases throught.
Damaged pallet moves the flag and in that way activating the sensor.
Supporting wheels support the pallet when it passes through.
2.4.2 Shuttle C501
2.4.2.1 Technical description
Shuttle with two roller conveyors with inclination on board is transporting pallets longitudinal along the warehouse
from the input place till the output place. It stops automatically at the desired position where the symmetry of the
roller conveyors of the shuttle are aligned with the symmetry of the input or output conveyors.
Dimensions of the pallet is 1200mm x 800mm
Shuttle is running on the longitudinal rails (standard IPE profiles). Running and guiding wheels are made of Vulkolan.
Driving motorgearbox is connected on two of the running wheels with cardan shafts.
Figure 2.20 Shuttle with two roller conveyors
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2 INSTALLATION DESCRIPTION
Figure 2.21 Main parts of the shuttle C501
Table 2.18 Main parts of the shuttle C501
Pos.
Name
1
Shuttle Frame
2
Driving wheel set with guiding wheels
5
Driving wheel set
6
Driven wheel set
7
Driven wheel set with guiding wheels
8
Control cabinet
9
Current collector
10
End switches
12
Roller conveyor with inclination
13
Roller conveyor with inclination
14
Driving motorgearbox
15
Hydraulical buffer
16
Kardan Shaft
Shuttle frame is made out of steel plates and standard tubes with machined connecting surfaces for connection with
other shuttle components.
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2 INSTALLATION DESCRIPTION
Figure 2.22 Shuttle frame
Driving set is assembled from driving shaft, running wheel, housing units with bearings and frame. Running and guiding
wheels are made of vulkolan. Guiding wheels are set on eccentric shafts which allows adjustment of the wheels.
Figure 2.23 Driving set
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2 INSTALLATION DESCRIPTION
Driving unit is asemmbled of motorgearbox and 2 kardan shafts whish are connected to the shafts of driving
wheels.Gearbox is fixed directly to the shuttle frame.
Figure 2.24 Driving unit
Hydraulical bumpers (one on each side) are fixed to the shuttle frame. They prevent damages of the shuttle elements in
case of failure when shuttle runs over the end limits.
Figure 2.25 Hydraulical bumper
There are two roller conveyors with tilting mechanismus on board. Roller conveyor is described in the Chapter 2.4.1.3
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Figure 2.26 Roller conveyor on tilting mechanismus
Roller conveyor carrier is monted on rotating bearings. Tilting is enabled with eccentrical mounted shaft mounded on
the tilting motorgearbox. By turning of the eccentric shaft, tilting table is moved upwards or downwards together with
roller conveyor thus enabling inclination of the roller conveyor.
Figure 2.27 Tilting mechanismus
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Table 2.19 Technical data of the shuttle
Type Shuttle with two roller conveyor:
Capacity
2x10 kN
Rail profile
IPE 180
Shuttle dimensions
Height
2.207 mm
Height with load
2.725 mm
Distance between wheels
3.650 mm
Overall length
4.392 mm
Width
1.300 mm
Distance between rails
1.050 mm
Diameter of the running wheels
350 mm
Diameter of the guiding wheels
150 mm
Speed:
Shuttle speed ( vx )
2,50 m/s
Conveyor speed ( vz )
0,2 m/s
Acceleration:
Shuttle acceleration ( ax )
1,00 m/s2
Other data:
Control voltage
24 V DC
Voltage / frequency
3x400V / 50 Hz
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Table 2.20 Technical data of the driving motorgearboxes
Shuttle drive:
Type
K89-LE160MF4EF-L150NHA-IN
Output torque
565
Nm
Motor revolutions
1.440
r.p.m.
Gearbox revolutions
184
r.p.m.
Ratio
7,97
Voltage
400
V
Power
11
kW
Roller conveyor drive:
Type
BF39-LE80MD4E-L16N
Output torque
79
Nm
Motor revolutions
1.440
r.p.m.
Gearbox revolutions
66
r.p.m.
Ratio
21,9
Voltage
3x400
V
Power
0,55
kW
Tilting table drive:
Type
FDF39-LA71MH4-L8N-IN
Output torque
190
Nm
Motor revolutions
1.440
r.p.m.
Gearbox revolutions
19
r.p.m.
Ratio
73,93
Voltage
3x400
V
Power
0,37
kW
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2.4.3 Shuttle C401
2.4.3.1 Technical description
Shuttle with chain conveyor on board is transporting pallets transverse across the warehouse from the input place till
the output place. It stops automatically at the desired position where the symmetry of the chain conveyor of the
shuttle is aligned with the symmetry of the input or output conveyor.
Dimensions of the pallet is 1200mm x 800mm
Shuttle is running on the longitudinal rails (standard IPE profiles). Running and guiding wheels are made of Vulkolan.
Driving motorgearbox is connected on two of the running wheels with cardan shafts.
Figure 2.28 Shuttle with chain conveyor
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2 INSTALLATION DESCRIPTION
Figure 2.29 Main parts of the shuttle C401
Table 2.21 main parts of the shuttle C401
Pos.
Name
1
Shuttle Frame
4
Driving wheel set
5
Driving wheel set with guiding wheels
6
Driven wheel set with guiding wheels
7
Driven wheel set
8
Control cabinet
10
Current collector
11
End switches
12
Barcode reader
15
Chain conveyor
16
Driving motorgearbox
17
Kardan Shaft
18
Hydraulical buffer
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2 INSTALLATION DESCRIPTION
Shuttle frame is made out of steel plates and standard tubes with machined connecting surfaces for connection with
other shuttle components.
Figure 2.30 Shuttle frame
Driving set is assembled from driving shaft, running wheel, housing units with bearings and frame. Running and guiding
wheels are made of vulkolan. Guiding wheels are set on eccentric shafts which allows adjustment of the wheels.
Figure 2.31 Driving set
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2 INSTALLATION DESCRIPTION
Driving unit is asemmbled of motorgearbox and 2 kardan shafts whish are connected to the shafts of driving wheels.
Gearbox is fixed directly to the shuttle frame.
Figure 2.32 Driving unit
Hydraulical bumbpers (one on each side) are fixed to the shttle frame. They prevent damages of the shuttle elements in
case of failure when shuttle runs over the end limits.
Figure 2.33 Hydraulical bumper
Chain conveyor is mounted on the shuttle with adjustable legs which allows us to level the conveyor.
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2 INSTALLATION DESCRIPTION
Figure 2.34 Chain conveyor on the shuttle
Chain conveyor is described in the Chapter 2.4.1.1
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Table 2.22 Technical data of the shuttle
Type Shuttle with chain conveyor:
Capacity
10 kN
Rail profile
IPE 180
Shuttle dimensions
Height
2.207 mm
Height with load
2.725 mm
Histance between wheels
2.500 mm
Overall length
2.842 mm
Width
1.300 mm
Distance between rails
1.050 mm
Diameter of the running wheels
350 mm
Diameter of the guiding wheels
150 mm
Speed:
Shuttle speed ( vx )
2,50 m/s
Conveyor speed ( vz )
0,2 m/s
Acceleration:
Shuttle acceleration ( ax )
1,80 m/s2
Drugi podatki:
Control voltage
24 V DC
Voltage / frequency
3x400V / 50 Hz
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Table 2.23 Technical data of the driving motorgearboxes
Shuttle drive:
Type
K89-LE160MF4EF-L150NHA-IN
Output torque
565
Nm
Motor revolutions
1.440
r.p.m.
Gearbox revolutions
184
r.p.m.
Ratio
7,97
Voltage
400
V
Power
11
kW
Chain conveyor drive:
Type
FZADS49-LE90SG4E-L16N
Output torque
160
Nm
Motor revolutions
1.440
r.p.m.
Gearbox revolutions
65
r.p.m.
Ratio
21,77
Voltage
3x400
V
Power
1,1
kW
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2 INSTALLATION DESCRIPTION
2.4.4 Crane
Stacker crane is intended for storing pallets into rack shelves.
2.4.4.1 Main parts of the stacker crane
Main parts of the stacker crane are seen in drawing No. 1157-02-0000):
Table 2.24 Crane main groups
Pos.
Name of assembly
Drawing No.
1
Bottom carriage
1157210
2
Column
1157214
3
Ladder
1157217
4
Lifting carriage
1157218
5
Wheels on lifting carriage
710094
6
Catching device
712001
7
Upper girder
1157221
8
Maintenance platform
1157222
9
Lifting unit
1157224
10
Lifting unit platform
1157225
11
Cable chain
1157227
12
Speed regulator
1157228
13
Joint Bottom carriage- Column
819017
14
Bumper
836025
15
Lifting carriage platform
1157229
16
Control cabinet platform
1157230
17
Y Positioning
1157231
18
Switches in X direction
1157232
19
Assembly accessories
738013
20
Data transmission
1157233
21
Switches on lifting carriage
1157234
22
Switches in Y direction
1157236
23
Connection box
1157237
24
Collector bracket
1157239
25
Power bus bar
1157241
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2.4.4.1.1
Pos. 1: Bottom carriage
On the crane, there are two sets of wheels, one driving set and one free set.
The framework of the bottom carriage is a box shaped profile welded from sheet metals with treated surfaces for fixing
running and leading wheels and for connecting the column of the crane with bottom carriage.
On the wheel set, a running wheel with barrel bearings and the diameter of 400mm is mounted. On the driving wheel
set, there is also an electrically powered furnished drive with momentum lever. Driving force of the crane is transferred
from the drive over shaft and momentum ring to the running wheel. Entire set of leading and running wheels is
designed for simple and quick maintenance. Bearings of running wheels and leading wheels have to be lubricated
regularly.
2.4.4.1.2
Pos. 2: Column
The column is composed of lower and upper part and screwed together with the pre-stressed screws. Column is made
of rigid, welled full-wall (box shaped) sheet metals with a diaphragm built in. The column is connected with the bottom
girder with the pre-stressed screws.
Along the column, a 140x40mm leading rail in accordance with DIN 174 is fixed with HV screws. The leading rail serves
for vertical leading of the lifting carriage. On the other side, a 50x40mm (DIN 174) leading rail is fixed along the column.
This rail is used for a horizontal balance of the lifting carriage and it is fixed to the column with the HV screws. In the
middle of the column, front side the catching rail is fixed along the column. The catching rail is type T 90.75.16
according to DIN 15311.
On the column backside, a plate for a lifting unit is welled. On one column side, a ladder is fixed stretching from the
floor to the top of the crane. Ladder can be used for intervention access to any height of the lifting carriage and onto
the upper maintenance landing.
2.4.4.1.3
Pos. 3: Ladder
Aluminum ladder is fixed on one side of the column. It enables access to the lifting carriage in any position and access
to servicing landing on the top of the crane. In the middle of the ladder, a safety rope is fixed. A safety carriage for
preventing possible falls in depth runs along this rope.
ATTENTION
2.4.4.1.4
It is mandatory to use safety belt, while climbing on the ladder!
Pos. 4, 5, 6: Lifting carriage
Lifting carriage has rigid framework, welded of sheet metals. On the carriage, guiding wheels are installed, for leading
the carriage along the column. These wheels allow the carriage to be aligned to all directions. Guiding wheels, which
run along the leading rail and which lead the carriage in transversal direction of the passage are type KEHT 90PP brand
H&T and are adjustable over eccentric wheel axles. Guiding wheels running along front and back head surface of the
leading rail and which lead the lifting carriage in longitudinal passage direction are made of metal. They are adjustable
over eccentric wheel axles and have a lubrication nipple built-in.
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Lifting carriage is protected against falling with an automatic holding mechanism for the case of the lifting rope
breakdown or failure of the electromotor drive. On the lifting carriage, a grip jaw is fixed. The jaw is connected to a
speed regulator with a steel rope. If the rate of descent of the lifting carriage is exceeded, the speed regulator activates
the grip jaw, which blocks the lifting carriage movement along the steel leads. In order to unblock the jaw (after the
repair), perform a manual intervention, and manually direct the lifting drive up with low speed. Unblocked brake is
immediately functional.
On the lifting carriage arm, double deep telescopic forks are screwed with eight M16 bolts. The forks have two motors,
brand SEW. One motor drives forks to the first depth and the other motor drives forks to the second depth.
2.4.4.1.5
Pos. 7: Upper grider
Upper girder has a box-shaped profile welded from sheet metals with treated surfaces for fixing upper leading wheels
and rope wheels. On the upper girder, pulleys with diameters of 630mm and crane upper guiding wheels are situated.
2.4.4.1.6
Pos. 8: Maintenance platform
On the top of the column, a service landing is screwed enabling maintenance and replacement of the upper guiding
wheels or interventions on the pulleys.
ATTENTION
2.4.4.1.7
It is mandatory to use safety belt, while climbing on the ladder!
Pos. 9 and 10: Lifting unit
Lifting unit is made of one steel rope, led over pulleys on to the upper girder, to the lifting carriage, where it is fixed.
The steel rope is driven from the electromotor drive with one drum. The rope drum is made of steel tube and has right
thread. The electromotor drive is fixed on the steel plate on the backside of the column. There is a maintenance
platform under the lifting unit. It enables visibility of the rope during entire working time, and makes visual inspection
easier.
2.4.4.1.8
Pos. 11: Cable chain
Cable chain, which is attached to the lifting carriage and fixed on the middle of the column, runs along the entire
column height and it is guided with the channels over the whole traveling length. The cable chain type is 27i.12.200.0
brand IGUS. The cables in the cable chain are used for the connection between the lifting carriage and the control
cabinet.
2.4.4.1.9
Pos. 12: Speed regulator
Mechanism of the speed regulator is built-in the lifting carriage and connected over steel ropes to the speed regulator.
If the descending rate of the lifting carriage is exceeded, speed regulator activates grip jaws over the steel rope and the
mechanism. The jaws hold special leads on the column (safety brake rail) and stop descending. Mechanism is
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2.4.4.1.15 Pos. 18: Switches in X direction
A bracket with a limit switch type 3SE5 112-OCH01, brand SIEMENS and with two magnetic switches type BN 310-2rz,
brand SCHMERSAL, is screwed to the bottom girder. The limit switch controls the end position (before the impact with
the bumper) of the stacker crane. The position of the magnet, that initiates the magnetic switch, is determined, so that
the crane impacts the hydraulic bumper with 70% of his maximum speed. Each side of the corridor has its own magnet
and its own magnet switch. The magnets are placed on the c-profiles and they can be adjusted for about +/- 500mm.
2.4.4.1.16 Pos. 19: Assembly accessories
The assembly accessories were used during the crane installation. The buyer should keep one set of these accessories
for a possible disassembly purpose.
2.4.4.1.17 Pos. 20: Data transmission
The optical data transmission device that is on the crane is placed on an adjustable bracket that is screwed under the
lifting unit platform. The stationary optical data transmission device is placed on a stand at the end of each corridor.
The type of the data transmission device is ISD 400, brand SICK.
2.4.4.1.18 Pos. 21: Switches on lifting carriage
Each lifting carriage has a frame made of aluminium profiles. On these profiles, different sensors are attached. There
are also three brackets, made of bended sheet metal. They are placed along the forks and used to carry some additional
sensors and holders with reflectors. These brackets are strong enough to hold one person and they cover the free space
between the emergency control cabinet and the telescopic forks. The stacker crane has next controls on the lifting
carriage:

Forks occupied control, sensor type is WL23 2P2430, with reflector type PL40A, brand SICK

Load alignment control left, sensor type is WL23 2P2430, with reflector type PL40A, brand SICK

Load alignment control right, sensor type is WL23 2P2430, with reflector type PL40A, brand SICK

Place occupied control left depth-2, sensor type is DS50-P1122, brand SICK

Place occupied control right depth-2, sensor type is DS50-P1122, brand SICK

Place occupied control left depth-1, sensor type is WTB27-3P2461, brand SICK

Place occupied control right depth-1, sensor type is WTB27-3P2461, brand SICK
2.4.4.1.19 Pos. 22: Switches in Y direction
On the bracket of leading wheels on lifting carriage, a bracket for switches in Y direction is fixed. Bracket holds two
Schmersal BN310_2rz magnetic switches and a Siemens 3SE5 114-0CH01-1AC5 limit switch. Two C profiles are mounted
at the bottom and two at the top of the column. Both top and bottom have a magnet and a limit switch bracket, each
of them can be individually adjusted +/-400mm.
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2.4.4.1.20 Pos. 23: Connection box
Terminal box is placed on the backside of the column, just near the lifting unit motor. It is easy to access from the lifting
unit maintenance platform. In the terminal box the cables that are coming from the main control cabinet and the cables
that are coming from the cable chain are connected.
2.4.4.1.21 Pos. 24: Collector bracket
The collector arm holds the collectors that are sliding in to the power bus bar. On the same time the collector arm holds
the barcode reader type OLM 100, brand SICK, which is used for x positioning of the stacker crane.
DANGER
Before beginning any intervention on to the power bus bar, main switches must be in position
»O«.
Check the voltage in the power rails before intervention.
Intervention is allowed only to professionally qualified people.
2.4.4.1.22 Pos. 25: Power busbar
The power bus bar is type VKS 10, brand VAHLE. It is supported with the holding profiles type VPT 10, brand VAHLE. The
holding profiles are screwed to the shelving uprights and at the end of the corridor they are supported by the selfstanding brackets that are anchored to the bottom concrete. Along the entire length of the power bus bar, a strip with
printed barcode is glued at the top of the holding profiles and it is read by the barcode reader type OLM 100, brand
SICK that is screwed on to the collector arm.
DANGER
Before beginning any intervention on to the power bus bar, main switches must be in position
»O«.
Check the voltage in the power rails before intervention.
Intervention is allowed only to professionally qualified people.
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Table 2.25 Crane technical data
Type of crane:
Stacker crane
PAŞA 800kg x 18,96m
Weight of crane
≈ 11.550 kg
Load capacity:
Load
800
kg
Construction:
Rail
S41
Upper leading
U-180
Light passage width
1.500
mm
Rail eccentricity
250
mm
Height
18.886
mm
Length
4.743
mm
Wheel base
3.850
mm
Width
1.388
mm
Running wheel diam.
400
mm
Leading wheel diam.
110
mm
Upper wheel diam.
150
mm
Crane dimensions:
Lift drive:
Gear (1x)
Speed
Accelerations / declines
K189-LES180ZLJ4EF-L260/145MH-IN
-brand
SIEMENS
- nominal power
22
kW
- motor torque
143,41
Nm
- motor revolutions
1465
min-1
- motor frequency
50
Hz
- gear ratio
74,35
- nominal voltage
400
V
- brake momentum
145
Nm
- brake voltage
400
V
- installation shape
M4A
-automatic mode
36
m/min
- manual mode
0,25
m/min
- automatic mode
0,50
m/s2
- manual mode
0,25
m/s
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Driving unit:
Gear (1x)
Speeds
Accelerations / declines
KAS129-LES180MM4EF-L260/100MHA-IN
-brand
SIEMENS
- nominal power
18,5
kW
- motor torque
120,6
Nm
- motor revolutions
1465
min-1
- motor frequency
50
Hz
- gear ratio
11,8
- nominal voltage
400
V
- brake momentum
100
Nm
- brake voltage
400
V
- installation shape
M3A
- automatic mode
180
m/min
- manual mode
1,0
m/min
- automatic mode
0,5
m/s2
- semi-automatic mode
0,3
m/s2
- manual mode
0,3
m/s2
Telescopic forks:
Gear (2x)
R27 DRS80M4BE2HRTF
-brand
SEW
- nominal power
1,1
kW
- motor torque
7,5
Nm
- motor revolutions
1408
min-1
- motor frequency
50
Hz
- withdrawal momentum
76
Nm
- withdrawal revolutions
139
min-1
- gear ratio
10,13
- nominal voltage
400
V
- brake momentum
14
Nm
- brake voltage
400
V
- installation shape
M3
Load capacity
800
Kg
L max:
1200
mm
B max:
800
mm
Loading:
Pallet
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2 INSTALLATION DESCRIPTION
H max:
1800
mm
Operating mode:
Remote
Automatic
Semi-automatic
Local
Semi-automatic
Manual
Other data:
Control voltage
24
V
Drive voltage
400 / 50
V/Hz
Start-up power
37
kW
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2.5 Electrical equipment
2.5.1 Description of the electrical system
The power supply of the system is implemented by distribution cabinet and later for vehicles by enclosed rail system.
The system has its own control system based on Simatic S7-1500 for conveyor system and Simotion D425 for shuttles
and cranes (vehicles). Communication is based on Profinet protocol. Motors for conveyor system are frequency
regulated or driven over contactor. Motors for vehicles are controlled via Simotion control system and are also
frequency regulated.
Besides power and control system there are numerous sensors used to run the system correctly and to avoid dangerous
situations.
We can sum majority of the electrical equipment in the following groups:






Distribution power supply cabinet
Enclosed conductor bars and current takers for vehicles power supply
Main cabinets with belonging power, control and switching devices also with HMI
Small cabinets with belonging power, control and switch devices
External equipment – sensors, motors, signalization equipment (beacon lights, horn), lights, smaller
enclosures, cables
Communication equipment
2.5.2 Distribution power supply +SB1
Main power supply for the system is distributed from supplier and connected to electrical cabinet +SB1. Electrical
cabinet +SB1 is distribution cabinet from where conveyor system, shuttles and cranes are supplied. Cabinet is divided
on seven main circuit breakers:







+SB1-2Q1: circuit breaker for crane 01
+SB1-3Q1: circuit breaker for crane 02
+SB1-4Q1: circuit breaker for crane 03
+SB1-5Q1: circuit breaker for conveyor system
+SB1-6Q1: circuit breaker for 24VDC supply for conveyor system
+SB1-7Q1: circuit breaker for shuttle 01
+SB1-8Q1: circuit breaker for shuttle 02
2.5.3 Conveyor system power supply
The power supply for conveyor system is implemented from electrical cabinet +SB1 which is further transmitted to the
cabinet +SB2. +SB1-5Q1 circuit breaker enables or disables the power for the frequency drives and motors, while +SB16Q1 circuit breaker enables or disables the control power.
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2.5.4 Crane and shuttle power supply
2.5.4.1 Crane
The power supply for crane is implemented from electrical cabinet +SB1 to enclosed rail system that consists of 6-pole
(5+PE) conductor copper strip (bars) 100A. Two current collectors are placed on the vehicle frame and provides power
supply to the machine which is further transmitted to the cabinet +L01 to the main rotary switch. This switch and +SB1(2Q1,3Q1 and 4Q1) circuit breaker enables or disables the power for the frequency supply modules, frequency drives
(motor modules) and motors.
INFORMATION
The control circuits 230 VAC and 24 VDC are not affected by the main rotary switch.
2.5.4.2 Shuttle
The power supply shuttle is implemented from electrical cabinet +SB1 to enclosed rail system that consists of 6-pole
(5+PE) conductor copper strip (bars) 60A. Two current collectors are placed on the vehicle frame and provides power
supply to the machine which is further transmitted to the cabinet +L01 to the main rotary switch. This switch and +SB1(7Q1 and 8Q1) circuit breaker enables or disables the power for the frequency supply modules, frequency drives (motor
modules) and motors.
INFORMATION
The control circuits 230 VAC and 24 VDC are not affected by the main rotary switch.
2.5.5 Main cabinets
2.5.5.1 Conveyor system
2.5.5.1.1
+SB2 Main cabinet
Main cabinet +SB2 consists of two cabinets and it is standing beside +SB1. It contains all executive and safety
components of the electrical equipment which controls conveyor system. From this cabinet all freguency regulated
motors and motors driven over contactor are controlled. It also includes control system Simatic S7-1500 for conveyor
system. Communication is based via Profinet communication protocol.
2.5.5.1.2
+CP301
Small cabinet +CP301 is connected with main cabinet +SB2. It is cabinet with only control voltage and contains
decentralized peripheral module (ET200MP) on which are connected special safety peripheral modules SDI and nonsaftey DI/DO modules. All sensors, safety grids, buttons, stop buttons, safety door locking switches and signaling lights
in that area are connected to the modules, respectively to the ET200MP module. Module is connected to main cabinet
+SB2 via Profinet communication. Frequency driven motors and motor driven over contactor are controlled from the
main cabinet +SB2, where regulators and contactors are located.
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2 INSTALLATION DESCRIPTION
2.5.5.1.3 +CP502
Small cabinet +CP502 is connected with main cabinet +SB2. It is cabinet with only control voltage where power is
directed to 24VDC by power supply unit. It contains decentralized peripheral module (ET200MP) on which are
connected special safety peripheral modules SDI and non-saftey DI/DO modules. All sensors, safety grids, buttons, stop
buttons, safety door locking switches and signaling lights in that area are connected to the modules, respectively to the
ET200MP module. Module is connected to main cabinet +SB2 via Profinet communication. Frequency driven motors
and motor driven over contactor are controlled from the main cabinet +SB2, where regulators and contactors are
located. In front of the cabinet operating touch panel is mounted.
All cabinets (+SB2, +CP301 and +CP502) are equipped with lighting which turns on when the doors are opened. Aircondition with filters are used for eliminating excessive heat.
All components in the cabinets are marked with fixed labels, which are not to be removed when a component is
replaced. Terminals for connecting cables are situated in the lower part of the cabinets. Cable entries to the cabinets
are at the bottom. All connections in the cabinets are accomplished with flexible conductors of a proper cross section,
proper color and insulation. All cable ends are terminated with suitable cable terminators. End of each conductor is
labelled with marking rings with a clamp label, marking which clamp the conductor is connected to.
2.5.5.2 Cranes
2.5.5.2.1
+L01 Main cabinet
Main cabinet +L01 is fixed on the column on the back side of the crane. All executive and safety components of the
electrical equipment and the controlling computer which control the machine are located in the main cabinet. The
cabinet is equipped with lighting, which turns on when the doors are opened. Fan units with filter are used for
conveying excessive heat.
All components in the cabinet are marked with fixed labels, which are not to be removed when a component is
replaced. Terminals for connecting cables are situated in the lower part of the cabinet. Most of the cable enters the
switch cabinet from the bottom hatch. Several smaller cables go through cable glands on upper surface. All connections
in the cabinet are accomplished with flexible conductors of a proper cross section and proper color insulation. All cable
ends are terminated with suitable cable terminators. End of each conductor is labeled with marking rings with a clamp
label, marking which clamp the conductor is connected to.
Main rotary switch on +L01 is placed on the left side cabinet door, emergency stop button is placed on the right side
cabinet door.
2.5.5.2.2 +L02 Small cabinet
+L02 is smaller cabinet on the lifting carriage which is connected with the main cabinet using high flexible cables in a
power chain. Decentralized peripheral module (ET200MP) is connected to the +L01 main cabinet via Profinet
communication. All sensors on the table (lifting carriage) are connected to the DI/DO/AI modules, respectively to the
ET200MP module. Frequency driven motors on the lifting carriage are controlled from the main cabinet where the
regulators are located.
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2 INSTALLATION DESCRIPTION
2.5.5.2.3 +L03 Touch panel
Touch panel is located in the lifting cabin. It is used for operating the crane
2.5.5.3 Shuttles
2.5.5.3.1 +L01 Main cabinet
Main cabinet +L01 is fixed on the vehicle. All executive and safety components of the electrical equipment and the
controlling computer which control the machine are located in the main cabinet. The cabinet is equipped with lighting,
which turns on when the doors are opened. Fan units with filter are used for conveying excessive heat.
All components in the cabinet are marked with fixed labels, which are not to be removed when a component is
replaced. Terminals for connecting cables are situated in the lower part of the cabinet. Most of the cable enters the
switch cabinet from the bottom hatch. Several smaller cables go through cable glands on upper surface. All connections
in the cabinet are accomplished with flexible conductors of a proper cross section and proper color insulation. All cable
ends are terminated with suitable cable terminators. End of each conductor is labeled with marking rings with a clamp
label, marking which clamp the conductor is connected to.
Main rotary switch on +L01 is placed on the left side cabinet door, emergency stop button is placed on the right side
cabinet door.
2.5.6 Main power consumers
2.5.6.1
Conveyors system
2.5.6.1.1
Drives
Conveyors system includes drives for:





Chain conveyor
Roller conveyor
Lifting table
Vertical adjustment
Excenter lifting
Motors are frequency regulated or driven over contactor. For frequency regulated motors Sinamics G120C frequency
converters are used. They are located and powered in main cabinet +SB2.
2.5.6.1.2
230VAC power circuit
230VAC source it is located in main cabinet +SB2 and it is used for:



Cabinet lights
Power sockets
Fan units for heating
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2 INSTALLATION DESCRIPTION
2.5.6.2 Crane
2.5.6.2.1
Drives
TRAVEL DRIVE
Crane is driven in the X-axis direction with one motor powered by one Sinamics motor module that moves machine
along the isle. Motor module it is located and powered in main cabinet +L01.
HOIST DRIVE
One motor lifts the carriage platform driving one steel rope cable drum along Y-axis. Motor is powered by one Sinamics
motor module that moves machine along the isle. Motor module it is located and powered in main cabinet +L01.
LIFTING CARRIAGE (PLATFORM) MOTORS
Lifting carriage is comprises 2 motors with forks. Each motor is for one fork depth. First motor is for single depth and
second motor is for double depth. Motors are powered by one Sinamics double motor module that moves forks in
single or double deep racks to get the pallet. Motor module it is located and powered in main cabinet +L01. Motors are
powered with flexible cables placed in the plastic chain.
2.5.6.2.2
230VAC power circuit
230VAC source it is located in main cabinet +L01 and on the machine construction, powered from small cabinet +L02:


Cabinet lights, power sockets and fan units for heating are located in +L01
Reflector, rotating beacon and horn are located in +L02
2.5.6.3 Shuttle C401
2.5.6.3.1
Drives
TRAVEL DRIVE
Shuttle is driven in the X-axis direction with one motor powered by one Sinamics motor module that moves machine
along the isle. Motor module it is located and powered in main cabinet +L01.
ROLLER DECK PLATFORM
There are two roller deck platforms, located on the shuttle, each with one motor. Motors are powered by one Sinamics
double motor module. Motor module it is located and powered in main cabinet +L01.
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2 INSTALLATION DESCRIPTION
HOIST DRIVE
On each roller deck platform motor for hoist is located. Motors are powered by one Sinamics double motor module.
Motor module it is located and powered in main cabinet +L01.
2.5.6.3.2
230VAC power circuit
230VAC source it is located in main cabinet +L01 and it is used for:





Cabinet lights
Power sockets
Fan units for heating
Rotating beacon
Horn
2.5.6.4 Shuttle C501
2.5.6.4.1
Drives
TRAVEL DRIVE
Shuttle is driven in the X-axis direction with one motor powered by one Sinamics motor module that moves machine
along the isle. Motor module it is located and powered in main cabinet +L01.
CONVEYOR DECK PLATFORM
Conveyor deck platform is located on the shuttle. Conveyor motor is powered by one Sinamics motor module. Motor
module it is located and powered in main cabinet +L01.
2.5.6.4.2
230VAC power circuit
230VAC source it is located in main cabinet +L01 and it is used for:





Cabinet lights
Power sockets
Fan units for heating
Rotating beacon
Horn
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2 INSTALLATION DESCRIPTION
2.5.7 Control circuits
2.5.7.1
Conveyor system
In main cabinet +SB2 power is directed to 24VDC by power supply unit. Control voltage circuits supplies:








PLC
ET modules
Switch
Optical communication for vehicles
Frequency converters control
Sensor devices
Signaling lights
Panel
2.5.7.2
Cranes
In main cabinet +L01 power is directed to 24VDC by power supply unit. Control voltage circuits supplies:





Simotion module D425 and TM15 terminal module
Smart line module
Sensor module SMC30
Optical communication
Sensor devices
Since small cabinet +L02 doesn’t have its own 24 VDC power supply, it is provided from +L01 via power chain. It
supplies ET200MP control module with belonging DI/DO modules, sensors on lifting carriage and signaling lights and
panel in enclosure +L03.
2.5.7.3
Shuttles
In main cabinet +L01 power is directed to 24VDC by power supply unit. Control voltage circuits supplies:





Simotion module D425 and TM15 terminal module
Smart line module
Sensor module SMC30
Optical communication
Sensor devices
2.5.8 Sensors
Sensors with functions are very important for the system functionality.
2.5.8.1
2.5.8.1.1
Conveyor system
Safety sensors
Sensors installed in the safety circuits have function to trigger the safety PLC which is located in main cabinet +SB2.
Their intention is to stop movable parts in case of danger. Safety signals are connected to the special safety input
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2 INSTALLATION DESCRIPTION
modules connected to the ET200MP, which further transmits signals to the safety PLC. There are several types of safety
sensors installed in conveyor system:



Safety light grid: To prevent people to enter danger area
Safety doors switch: To prevent vehicle movement in case of enter the protected area
Mechanical safety switch: Prevent further movement of the machine
2.5.8.1.2
Sensors for normal operation
Sensors that are used for normal operating conditions:




Optical reflective sensors: For occupancy, gap control, slow an stop position
Barcode reader: For scanning barcode type on the pallet
Proximity sensors: For position detection of lifting table, vertical adjustment and excenter lifting conveyors
Light grids: For detection of the pallet dimensions.
2.5.8.2
Cranes
2.5.8.2.1
Safety sensors
Sensors installed in the safety circuits have function to bring the machine to a safe state. When safety circuit is
interrupted 24VDC from motor modules is taken away which cause safe stopping the moving motors and other
movable parts:





Rope brake up sensor and sensor for catching device: In case of lifting carriage drop
Safety doors switch: To prevent vehicle movement in case of enter the protected area
Mechanical safety switch: Prevent further movement of the machine
Load cells: Weight control
Cabin safety door switch: To prevent movement of the machine in case opened cabin doors
2.5.8.2.2
Sensors for normal operation
Sensors that are used for normal operating conditions:



Optical reflective sensors: For occupancy, gap control and forks depth
Optical sensors: For linear positioning in x and y direction via 2D barcode type
Magnetic sensors: For slowing down vehicle before safety end position is reached
2.5.8.3
Shuttles
2.5.8.3.1
Safety sensors
Sensors installed in the safety circuits have function to bring the machine to a safe state. When safety circuit is
interrupted 24VDC from motor modules is taken away which cause safe stopping the moving motors and other
movable parts:


Safety doors switch: To prevent vehicle movement in case of enter the protected area
Mechanical safety switch: Prevent further movement of the machine
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2 INSTALLATION DESCRIPTION
2.5.8.3.2
Sensors for normal operation
Sensors that are used for normal operating conditions:



Optical reflective sensors: For occupancy, gap control and forks depth
Optical sensors: For linear positioning in x direction via 2D barcode type
Magnetic sensors: For slowing down vehicle before safety end position is reached
2.5.9 Communication
Communication with the system and external world is implemented:


Frequency regulated motors in conveyor system are implemented through Profinet communication connected
to PLC in main cabinet +SB2.
Cranes and shuttles are implemented through SICK ISD400 optical data transmission. One unit is on the vehicle
connected to Simotion D425, second unit is placed parallel on construction and connected to PLC in main
cabinet +SB2
System communication is used for the data communication with other (higher level) devices (MFC).
For decentralized periphery units and the operator panels (HMI) Profinet connection it is used..
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3 SAFETY
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3 SAFETY
3.1.5 High voltage – touch protection
Technical measure for protection against electric shock (direct and indirect touch)
Automatic power supply switch-off is implemented by connecting exposed parts of the device to a protective conductor
and by equalizing main potentials. Protective conductors are in yellow-green color. All protective conductors must be
connected to a special collector in the distribution cabinet, which is connected to the protective ground
Protective devices for over-current protection (fuses, switches, etc.) execute automatic defect current cutout.
Disconnection device, which is built in the installation or in parts of the installation, must automatically uncouple power
supply to the part of installation, which is protected by this device
Protection against electric shock must be verified with measurements after the installation and also later during regular
inspections and periodic measurements
Usage of a SELV (Safety Extra Low Voltage) of 24 V is used as an additional protective measure.
3.1.6 Accidental touch of parts under voltage
Protection is implemented by applying a proper choice of equipment installed in the system and in the corresponding
distribution cabinets, which have to be properly closed and with access allowed only to the authorized personnel.
Cables are placed in protective tubes and properly located to prevent mechanical damages.
In the distribution cabinets, non-insulated parts must be covered with an insulating material (connecting terminals,
switches, etc.).
3.1.7 Cable protection against short circuit
Protection against dangerous short-circuit currents is performed with suitable circuit protection in all distribution
cabinets.
3.1.8 Overload protection
Protection against current overloading is ensured by correct choice of conductor cross sections regarding allowed
current loadings and proper choice of installation fuses, bimetal relays or thermal circuit breakers.
3.1.9 Improper use of switches
All switches in the system are marked with label plates to prevent confusion if approached carefully and with normal
level of caution.
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3 SAFETY
3.2 Safety stop
3.2.1 Emergency stop buttons
In case of danger emergency stop button must be activated. Emergency stop button immediately stops movable parts
of the system to prevent danger.
Emergency stop buttons are located:




On small cabinets all over the conveyor system
On small cabinets by the door of vehicles
On main cabinets on cranes and shuttles
In crane cabin
INFORMATION
Every emergency stop button does not stop the whole system. See Heading 5
3.2.2 Safety light grid
Located on conveyor system to prevent entering the hazardous area. Any interruption of the safety light grid
immediately stops the vehicle.
3.2.3 Safety mechanical switches
Located on vehicles to prevent further movement of the machine. Switches can be bypassed by the key on vehicle. If
the bypass function is activated the vehicle can work in hand mode.
3.2.4 Door switches
Located on the door by the vehicles rail. Their function is to prevent vehicle movement in case of enter the protected
area.
INFORMATION
There is no option to bypass Emergency stop push-buttons, as well as door switches. Only limit
switches bypassing is possible.
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3 SAFETY
3.3 Motion control
3.3.1 Conveyor system
For conveyor system the Sinamics G120C frequency drives are used. It comprised control and power unit in one
module. They communicates with PLC by Profinet.
3.3.2 Shuttles and Cranes
For cranes and shuttles Sinamics S120 frequency drives are used. The SINAMICS comprised of two parts – the control
unit and the motor modules. The control unit SIMOTION D425 serves for motion control as well as a programmable
logical controller (PLC). Motor modules are connected with control unit by DRIVE CLIQ interface. Motor modules are
supplied with Smart line module which supplies the power through DC link.
For position control of vehicles is used barcode positioning system. End positions are detected by mechanical limit
switches, connected into the safety circuit. Before the end position is reached, a magnetic sensor reduces the speed of
the vehicle.
Vehicles are positioned to the warehouse place based on the readings of the incremental encoder for the gantry and
hoist (only for cranes) drive. Forks (only for cranes) are positioned into the rack on the readings of the absolute
encoder.
3.4 Control system
3.4.1 Conveyor system
The Simatic S7-1500 (CPU 1515F-2 PN) takes the role of the PLC for the conveyor system. All decentralized peripheral
modules in small cabinets are connected to PLC by Profinet.
The applicative software on the conveyor system controller enables autonomous operation.
The controller tasks are:












communication to the higher-level system (task management, status reports, alarm reports),
task execution in automatic mode,
execution of simple movements in manual and backup (service) mode,
control of device state and safe stop in case of error,
control of functions of conveyor system equipment,
control of frequency regulators,
communication with the user (HMI),
coordination of take-off and delivery to the connected systems,
control of load presence and position,
checking site occupation,
diagnostic of errors and generation of alarm messages,
immediate stop in case of abnormal states or events.
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3 SAFETY
3.4.2 Cranes and shuttles
The SINAMICS D425 takes the role of the PLC for vehicles. ET200MP decentralized peripheral module which is used on
cranes for additional I/Os is connected to D425 by Profinet.
The applicative software on the vehicles controllers enables autonomous operation.
The controller tasks are:













communication to the higher-level system (task management, status reports, alarm reports),
task execution in automatic mode,
execution of simple movements in manual and backup (service) mode,
control of device state and safe stop in case of error,
control of functions of vehicles equipment,
control of frequency regulators,
communication with the user (HMI),
coordination of take-off and delivery to the connected systems,
control of load presence and position,
checking site occupation,
checking vehicles speed,
diagnostic of errors and generation of alarm messages,
immediate stop in case of abnormal states or events.
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4 INSTALLATION OF THE MACHINE
4 INSTALLATION OF THE MACHINE
4.1 Conveyor system
4.1.1 Chain conveyor
Handling during lifting a cargo is allowed only to qualified personal!
DANGER
While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
DANGER
For lifting of all types of equipment:
- use car lift with suitable load capacity!
- handle slowly and carefully, without any oscillation;
- set the machine onto intended, prepared place.
DANGER
MACHINE SHOULD ONLY BE UNLOADED, TRANSPORTED AND INSTALLED BY A RELEVANT
SERVICE!
Figure 4.1 Chain conveyor
4 INSTALLATION OF THE MACHINE
Setting and startup of the machine
After installation or some serious maintenance work, conveyor must be checked:
1. Height¸and leveling of the conveyor must be adjusted by means of screwing the levelling legs
in order to reach desired height. For levelling, water scale should be used.
2. Alignment of the conveyor with transport line
Figure 4.2 Alignment of the chain conveyor
Transport load must run straight through hole line of conveyors. To ensure that, each conveyor in line must be aligned.
3. Adjusment of the rectangularity of the conveyor.
In case that there is some inclination of the conveyor and load is not traveling in a straight line, alignment must
be carried out.




check diagonals of the conveyor
lose fixing bolts of the distance beams
adjust conveyor frame in the way that diagonals are the same
fix bolts of the distance beams
Figure 4.3 diagonals of the chain conveyor
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4 INSTALLATION OF THE MACHINE
4. Tensioning of the chains.
1
Figure 4.4 Tensioning of the chain
Chain can be tensioned by screwing the tensioning nut (1) on the driving station. In case there is no more space for
tensioning, chain needs to be shortened!
4.1.1.1 Guidings for the tensioning
Hold the chain in the middle and pull up. Relationship between lifted height H and whole length L should be max, 1:100
H:L ~ 1:100
L
H
Figure 4.5 Guidings for tensioning of the chain
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4 INSTALLATION OF THE MACHINE
5. Check oil level in the gearboxes and check all bolts.
Before startup, conveyor complete conveyor if every parts are fixed, check smootnes of running of all moving parts.
After startup, shuttle should run for 20 min. Carry out sound control of the bearings and gearbox and check oil sealing
on the drives.
4.1.2 Roller conveyor 01
Handling during lifting a cargo is allowed only to qualified personal!
DANGER
While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
DANGER
For lifting of all types of equipment:
- use car lift with suitable load capacity!
- handle slowly and carefully, without any oscillation;
- set the machine onto intended, prepared place.
DANGER
MACHINE SHOULD ONLY BE UNLOADED, TRANSPORTED AND INSTALLED BY A RELEVANT
SERVICE!
Figure 4.6 Roller conveyor
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4.1.2.1 Settings and startup of the machine
After installation or some serious maintenance work, conveyor must be checked:
1. Heightand leveling of the conveyor must be adjusted by means of screwing the levelling legs
in order to reach desired height. For levelling, water scale should be used.
2. Alignment of the conveyor with transport line
Figure 4.7 Alignment of the roller conveyor
Transport load must run straight through hole line of conveyors. To ensure that, each conveyor in line must be aligned.
3. Adjusment of the rectangularity of the conveyor.
In case that there is some inclination of the rollers and load is not traveling in a straight line, alignment must be
carried out.
check diagonals of the conveyor
lose fixing bolts of the rollers
adjust conveyor frame in the way that diagonals are the same
fix bolts or rollers
Figure 4.8 Diagonals of the roller conveyor
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4. Check oil level in the gearboxes and check all bolts.
Before startup, conveyor complete conveyor if every parts are fixed, check smootnes of running of all moving parts.
After startup, shuttle should run for 20 min. Carry out sound control of the rollers and gearbox and check oil sealing on
the drives.
4.1.3 Roller conveyor 02
Handling during lifting a cargo is allowed only to qualified personal!
DANGER
While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
DANGER
For lifting of all types of equipment:
- use car lift with suitable load capacity!
- handle slowly and carefully, without any oscillation;
- set the machine onto intended, prepared place.
DANGER
MACHINE SHOULD ONLY BE UNLOADED, TRANSPORTED AND INSTALLED BY A RELEVANT
SERVICE!
Figure 4.9 Roller conveyor
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Setting and startup of the machine
After installation or some serious maintenance work, conveyor must be checked:
1. Heightand leveling of the conveyor must be adjusted by means of screwing the levelling legs
in order to reach desired height. For levelling, water scale should be used.
2. Alignment of the conveyor with transport line
Figure 4.10 Alignment of the roller conveyor
Transport load must run straight through hole line of conveyors. To ensure that, each conveyor in line must be aligned.
3. Adjusment of the rectangularity of the conveyor.
In case that there is some inclination of the rollers and load is not traveling in a straight line, alignment must be
carried out.




check diagonals of the conveyor
lose fixing bolts of the rollers
adjust conveyor frame in the way that diagonals are the same
fix bolts or rollers
Figure 4.11 Diagonals of the roller conveyor
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4. Check oil level in the gearboxes and check all bolts.
Before startup, conveyor complete conveyor if every parts are fixed, check smootnes of running of all moving parts.
After startup, shuttle should run for 20 min. Carry out sound control of the rollers and gearbox and check oil sealing on
the drives.
4.1.4 Eccentric lifting table
Handling during lifting a cargo is allowed only to qualified personal!
DANGER
While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
DANGER
For lifting of all types of equipment:
- use car lift with suitable load capacity!
- handle slowly and carefully, without any oscillation;
- set the machine onto intended, prepared place.
DANGER
MACHINE SHOULD ONLY BE UNLOADED, TRANSPORTED AND INSTALLED BY A RELEVANT
SERVICE!
Figure 4.12 Eccentric lifting table
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Setting and startup of the machine
After installation or some serious maintenance work, conveyor must be checked:
1. Perpendiqural run of the pallet from chain to roller conveyor
Check if the lines of onveying the pallet of chainand roller conveyor are perpendicural.
Figure 4.13 Alignment of the eccentric lifting table
2.
Control of the correct tension of the driving chain (1). Tension of the driving chain can be adjusted with moving
of the gearbox holding plate together with gearbox.
2
1
3
Figure 4.14 Adjusting of the lifting mechanismus
3.
Paralel running of the front and back eccentric arms. This can be achieved with shorthening or lengthening of
the arms (2)
4. Adjusting of the turning the limiter
With setting of the bolt (3), turning angle can be limited in both directions
5.
Check oil level in the gearboxes and check all bolts.
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Before startup, complete device must be checked if every parts are fixed, check smootnes of running of all moving
parts. After startup, device should run for 10 min. Carry out sound control of the bearings and gearbox and check oil
sealing on the drives.
4.1.5 Stopper
Handling during lifting a cargo is allowed only to qualified personal!
DANGER
While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
DANGER
For lifting of all types of equipment:
- use car lift with suitable load capacity!
- handle slowly and carefully, without any oscillation;
- set the machine onto intended, prepared place.
DANGER
MACHINE SHOULD ONLY BE UNLOADED, TRANSPORTED AND INSTALLED BY A RELEVANT
SERVICE!
Figure 4.15 Stopper
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4.1.5.1 Setting and startup of the machine
After installation or some serious maintenance work, conveyor must be checked:
1. Perpendiqural run of the pallet from chain to roller conveyor
Check if the lines of conveying the pallet of chain and roller conveyor are perpendicural. Also check paralelity of the
stopper.
Figure 4.16 Alignment of the stopper
2. Control of the correct height of the stopper. The height can be adjusted by shortening of the arm (1).
1
Figure 4.17 Adjusting of the stopper
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3. Check oil level in the gearboxes and check all bolts.
Before startup, complete device must be checked if every parts are fixed, check smootnes of running of all moving
parts. After startup, device should run for 10 min. Carry out sound control of the bearings and gearbox and check oil
sealing on the drives.
4.1.6 Contour check
Handling during lifting a cargo is allowed only to qualified personal!
DANGER
While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
DANGER
For lifting of all types of equipment:
- use car lift with suitable load capacity!
- handle slowly and carefully, without any oscillation;
- set the machine onto intended, prepared place.
DANGER
MACHINE SHOULD ONLY BE UNLOADED, TRANSPORTED AND INSTALLED BY A RELEVANT
SERVICE!
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4.1.6.1 Setting and startup of the machine
After installation or some serious maintenance work, device must be checked
4.1.6.1.1
Weight control
2
1
Figure 4.18 Weight control
1.
Fine leveling of the device. Use nuts 1.
2.
Fine leveling of the guiding set. Use nuts 2.
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4.1.6.1.2
Control of dimensions
Adjust all sensors and reflectors to desired position.
Figure 4.19 Control of dimensions
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4.1.6.1.3
Pallet base control
3
2
1
Figure 4.20 Pallet base control
3.
Fine adjusting of the pallet base control. Use the nuts 1.
4.
Fine adjusting of the guiding wheels. Use bolts 2.
5.
Fine adjusting of the flags. Use bolts 3.
6.
Set sensors.
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4.2 Shuttle C501
Handling during lifting a cargo is allowed only to qualified personal!
DANGER
While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
DANGER
For lifting of all types of equipment:
- use car lift with suitable load capacity!
- handle slowly and carefully, without any oscillation;
- set the machine onto intended, prepared place.
DANGER
MACHINE SHOULD ONLY BE UNLOADED, TRANSPORTED AND INSTALLED BY A RELEVANT
SERVICE!
Figure 4.21 Shuttle with two roller conveyor
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4.2.1 Setting and startup of the machine
After installation or some serious maintenance work, some elemets of the shuttle must be adjusted:
1.
Height and levelling of the conveyor must be checked (measure X – distance between upper side of the rail
profiles and upper side of the roller).
Conveyor must be levelled by adjusting of the levelling nuts (1) in order to reach desired height and alignment
with pickup conveyor. For levelling, water scale should be used
X
1
Figure 4.22 Conveyor height leveling
2.
Control of running of the driving wheels and setting of the guiding wheels
1
2
Figure 4.23 Setting of the guiding wheels
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Shuttle must run straight without causing side forces on the guiding wheels. This must be ensured by alignment of the
running wheel sets and with setting of the guiding wheels.
Guiding whels are mounted on the eccentric shafts which enables us to set the clearance between guiding wheels and
the guiding surface of the rail. Each guiding wheel must have 0,5 mm of the clearance.
Optimal running of the shuttle is achieved when contact with rail is exchangeing between inner (2) and outher (1)
guiding wheel. If only one of the guiding wheels is in contact all the time, that means that shuttle is inclined and it shoul
be aligned again.
3.
Adjusment and levelling of the tilting table.
In orer to level conveyor (set up the inclination) following procedure must be carried out:




Turn (with drive) the eccentric shaft in upper position
Remove circlip and pin (1)
Screw or unscrew rod end (2) and adjust length of the arm
Sset back circlip and pin (1)
1
2
Figure 4.24 Leveling of the tilting table
4.
Control of the roller conveyors is described in the chapter of the roller conveyor.
5.
Functional control of the sensors and switches
6.
General control
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Check lubrication of the bearings, oil level in the gearboxes and all bolts.
Before startup, check complete shuttle if every parts are fixed, check smootnes of running of all moving parts.
After startup, shuttle should run for 20 min. Carry out sound control of the bearings and gearboxes and check oil sealing
on the drives.
4.3 Shuttle C401
Handling during lifting a cargo is allowed only to qualified personal!
DANGER
While loading or unloading avoid strokes. Dwelling under lifted cargo is strictly forbidden!
DANGER
For lifting of all types of equipment:
- use car lift with suitable load capacity!
- handle slowly and carefully, without any oscillation;
- set the machine onto intended, prepared place.
DANGER
MACHINE SHOULD ONLY BE UNLOADED, TRANSPORTED AND INSTALLED BY A RELEVANT
SERVICE!
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Figure 4.25 Shuttle with chain conveyor
4.3.1 Setting and startup of the machine
After installation or some serious maintenance work, some elements of the shuttle must be adjusted:
1.
Height and levelling of the conveyor must be checked (measure X – distance between upper side of the rail
profiles and upper side of the chain).
Conveyor must be levelled by adjusting of the levelling nuts (1) in order to reach desired height and alignment
with pickup conveyor. For levelling, water scale should be used.
Figure 4.26 Adjusting of the chain conveyor
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2.
Control of running of the driving wheels and setting of the guiding wheels
1
2
Figure 4.27 Control of the guiding wheels
Shuttle must run straight without causing side forces on the guiding wheels. This must be ensured by alignment of the
running wheel sets and with setting of the guiding wheels.
Guiding whels are mounted on the eccentric shafts which enables us to set the clearance between guiding wheels and
the guiding surface of the rail. Each guiding wheel must have 0,5 mm of the clearance.
Optimal running of the shuttle is achieved when contact with rail is exchangeing between inner (2) and outher (1)
guiding wheel. If only one of the guiding wheels is in contact all the time, that means that shuttle is inclined and it shoul
be aligned again.
3.
Control of the Chain conveyor is described in the chapter of the chain conveyor.
4.
Functional control of the sensors and switches
5.
General control
Check lubrication of the bearings, oil level in the gearboxes and all bolts.
Before startup, check complete shuttle if every parts are fixed, check smootnes of running of all moving parts.
After startup, shuttle should run for 20 min. Carry out sound control of the bearings and gearboxes and check oil sealing
on the drives.
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4.4 Crane
4.4.1 Transportation and installation
Handling during lifting a machine is allowed only to qualified personal!
Stacker crane is designed to operate indoors.
ATTENTION
Stacker crane should only be unloaded, transported and installed by a relevant service!
DANGER
While loading or unloading, avoid strokes. Dwelling under lifted cargo is strictly forbidden!
DANGER
For lifting of all types of equipment:
- use car lift with suitable load capacity;
- handle slowly and carefully, without any oscillation;
- set the machine onto intended, prepared place.
INFORMATION
For lifting, transportation or carriage use suitable bores, grooves or transport ears, designed for
such purposes.
4.4.2 Stacker crane settings
4.4.2.1 Column
After the crane installation, first the column must be adjusted to the vertical position. The adjustment can be done with
the eccentric axles of the upper guiding wheels. Each axle is eccentric for 5,5mm. Normally the crane is delivered with
the open eccentrics and after the installation one wheel is in contact with the upper guiding rail and the other wheel is
free. Turn the axle of the wheel that is in contact with the guiding rail with the wrench size 36 so long until the column
is not in the vertical position. When the column is in vertical position turn the axle of the free wheel until you reach a
gap of 1mm between the wheel and upper guiding rail. Now tighten both axles with clamping devices. Tightening
torque is 41 Nm.
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4.4.2.2 Bottom carriage
Bottom carriage has four guiding wheels. The wheels have eccentric axles and they run on both railhead sides.
Normally the bottom carriage is delivered with the open eccentrics. Before machine startup, the gap between the
railhead and the guiding wheel on all four wheels should be adjusted on 0,5mm. After the machine startup, the running
of the four guiding wheels must be checked again. If during the crane horizontal movement on one crane side, only one
wheel is turning and on the other crane side only the wheel that is on opposite railhead side turns, then the bottom
carriage is not parallel to the rail axis. By turning the wheel eccentric axles, the parallelism can be achieved.
4.4.2.3 Lifting carriage
Lifting carriage has two main wheels (230mm), eight side wheels (90 – KEHT90 PP) and two wheels for the
stabilization (100 – NUTR45100). The bottom wheel (230) runs on the front side of guiding profile (40x120) that runs
along the entire column length. The upper wheel runs (230) on backside of the same guiding profile. Both wheels have
eccentric axles and are always in contact with the guiding profile. With turning eccentric axles of these two wheels, the
level of the lifting carriage in the crane driving direction can be adjusted. Side wheels are placed in pair on a balance.
They have eccentric axles. With turning of these eccentric axles, the level of the lifting carriage in the forks movement
direction can be adjusted. On one side, a pair of wheels should be in contact with the guiding profile and the opposite
pair of wheels should have 0,3mm gap to the guiding profile on the column. A pair of stabilization wheels (100 –
NUTR45100) is running on the guide 40x50, which runs along the entire column length. Both wheels axles are eccentric
and with turning of these axles, the gap between the forks front side and rack can be adjusted.
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5 OPERATING INSTRUCTIONS AND FAULT FINDING PROCEDURES
5.1 High-bay warehouse layout
High-bay warehouse comprises of three aisles. On each side of an aisle are double deep racks with 60 horizontal
locations and 8 vertical locations. Racks in the warehouse have 5752 (3 x 2 x 60 x 8 x 2 - 8) slots for storing transport
units. On the output of the warehouse there is a gravitational rack system capable of storing 192 (24 x 8) transport
units.
Automated machines are taking care of storing and retrieving of the goods. In each aisle, there is a crane (automatic
storage retrieval machine, ASRS) with one deck. For conveying the transport unit to and from the warehouse, there are
also some supporting conveyor tables and two shuttle cars.
5.1.1 Warehouse layout
5.1.2 Designation of warehouse locations
There are three types of locations in the system:
1.
2.
3.
rack locations,
conveyor locations (conveyor tables), and
crane and shuttle locations (decks).
5.1.3 Rack locations
Rack locations in high-bay warehouse are denoted as
W:rr:xx:y:z ,
where




rr is a rack index:
xx is horizontal index:
y is vertical index:
z is depth index:
11, 12, 21, 22, 31, 32, (52)
01 … 60, (01 … 24)
1 … 8, (1)
1 … 2, (1 … 6).
Values in parenthesis are given for gravitational rack system.
High-bay warehouse comprises of up to 1920 pallet locations per crane. Racks (rr) are always denoted with two-digit
number, where first digit represent the aisle number while the last digit is 1 for the racks on the left and 2 for the racks
on the right, when observing the system from the conveyor side. The pallet storage and retrieval operations are
performed by three stacker cranes, numbered by their aisles from 1 to 3. Aisle numbering as well as the rack denoting
is shown in Figure 5.1.
In the horizontal direction there are 60 locations, numbered consecutively from 1 to 60, starting at the conveyor side.
There are 8 locations in vertical direction. Slots with vertical index 1 are in the lowest position. In the direction of forks
movement, racks closer to an aisle have index 1, while the farthest location has index 2. Each rack window can store
two pallets.
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Figure 5.1 Ground plan of the warehouse. Black boxes represent conveyors, light and dark gray box represent slot locations in racks
5.1.3.1 Conveyor locations
Conveyor locations (tables) are denoted as
Tfsn ,
where



f is a functional group:
s is a subgroup:
n is a conveyor number: 0 … 4.
0 … 3,
0 … 2,
Conveyors in the system are graphically presented in Figure 5.2.
Vehicles (cranes and shuttles) pick pallets from delivery conveyors and drop them to dispatch conveyors as given in
Table 5.1Error! Reference source not found..
Table 5.1 Delivery and dispatch conveyors
Crane/shuttle
Delivery conveyors
Dispatch conveyors
1
T112
T121
2
T212
T221
3
T312
T321, T322
4
T012, T122, T222
T211, T311, T021
5
T023, T024, T321, T322
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5.1.3.2 Deck locations on vehicles
Deck locations on vehicles (cranes and shuttles) are denoted as
Cv0n ,
where


v is the vehicle number:
n is deck number:
1 … 4, (5),
1, (1 … 2).
Values in parenthesis are given for shuttle 5, which has two decks.
Some examples of warehouse location designations are given Figure 5.2 and Figure 5.3. For crane 1, the designated rack
locations are at level 1, for crane 2 at level 3, and for crane 3 at level 5.
5.1.4 Permanently blocked rack locations
Conveyor lines are physically occupying some rack locations (see Figure 5.2 and Figure 5.3). Therefore, some rack
locations do not exist and cannot be used for storage. Table 5.2 lists non-existing rack locations, which should be
permanently blocked.
Table 5.2 Permanently blocked rack locations
Permanently blocked rack locations
Reason
W:32:47:1:1 – W:32:47:1:2
Space is occupied by conveyors 321 and 322
W:32:48:1:1 – W:32:48:1:2
Space is occupied by conveyors 321 and 322
W:32:49:1:1 – W:32:49:1:2
Space is occupied by conveyors 321 and 322
W:32:50:1:1 – W:32:50:1:2
Space is occupied by conveyors 321 and 322
5.1.5 Other limitations
Conveyor T023 cannot be reached with deck C502 of Shuttle 5.
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Figure 5.2 High-bay warehouse: top view with designated locations of racks, transport paths, and vehicles
Figure 5.3 High-Bay warehouse: top view with designated locations of gravitational rack system
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5.1.6 Transport units
A transport unit is a standard euro pallet of size 800 mm x 1200 mm (Figure 5.4). Goods to be stored in the warehouse
must be placed on a pallet in such a way that



there is no overhang,
pallet with goods is up to 1800 mm high, and
weight of goods, including a pallet, does not exceed 800 kg.
Format of transport unit barcodes Is PNNNNNNNNN, where character P stands for pallet and NNNNNNNNN presents a
number in range 000000001 – 999999999.
Figure 5.4 Euro pallet
5.2 Hierarchy of the system
The automated warehouse consists of eight sub-systems (
Figure 5.5):





3 x programmable logic controller (PLC) for cranes,
2 x programmable logic controller (PLC) for shuttles
1 x programmable logic controller (PLC) for the conveyor system,
material flow and control system (MFCS) with supervisory control and data acquisition (SCADA) functionality,
and
warehouse management system (WMS).
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WMS
(SAP)
MFCS &
SCADA
Crane1
PLC
Crane 2
PLC
Crane 3
PLC
Shuttle 4
PLC
Shuttle 5
PLC
Conveyors
PLC
Figure 5.5 Architecture of computer systems in warehouse
The vehicles and the conveyor system are fully automated and computer guided. The automation is carried out on
several levels. Sensors, frequency converters, etc. represent the low automation level. These are controlled by the PLC
located either in the electrical cabinet of a vehicle or in the electrical cabinet of the conveyor system. PLCs processes
the input data and command the vehicles and conveyors in order to perform simple commands.
Supervisory control and data acquisition (SCADA) system takes values from PLCs in order to show to an operator the
current status of the system. In also performs logging of some interesting quantities.
Movements of the vehicles and conveyors are performed according to the commands received from MFCS. The main
task of MFCS is to brake the complex commands, received from WMS, to the simple commands, which can be executed
by PLCs. MFCS has to execute the commands received from WMS in such a way to finish the commands as soon as
possible (rearrangement of commands, parallel commands …).
WMS takes care of warehouse organization and business logic. It initiates automatic movements in the warehouse. The
picture of the warehouse (which locations are occupied; which transport unit is stored there) should be handled by
WMS. The optimal placement of goods in the warehouse is very important for efficient movements of transport units
and goods. WMS should also strive to achieve high availability of the system by distributing the similar product to
different aisles. The placement of the goods is done solely by WMS.
The communication between PLCs is implemented by Profinet protocol, while PLCs and MFCS communicate by TCP/IP
telegrams. The communication between MFCS and WMS is performed via web services.
The important IP addresses are:







MFCS: 192.168.20.233,
Conveyor PLC: 192.168.10.203,
Crane 1: 192.168.10.10,
Crane 2: 192.168.10.20,
Crane 3: 192.168.10.30,
Crane 4: 192.168.10.40,
Crane 5: 192.168.10.50.
Gateway for all devices is set to 192.168.10.1. Devices communicate with MFC system via ports 2001 and 2002.
The network equipment in the system should be configured to allow network traffic between these devices on the
given ports.
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5.3 Functions of the system
5.3.1 Inbound traffic
To store a transport unit to the system the following operations must be done:
1.
2.
3.
4.
5.
6.
7.
Operators must manually put a transport unit to the conveyor table T001.
The transport unit is then conveyed to T002. During the movement its barcode is read and physical quantities
are measured.
On conveyor T002 the entry of a new transport unit is reported to WMS.
On this stage MFCS will perform a task on its own or wait for WMS task:
a. If there is something wrong with the transport unit (no barcode, some dimension is not compliant
with the requirements, etc.) MFCS will report the fault to WMS and on its own send the transport unit
to T005 via T004.
b. For transport units, which are ready for storing, WMS should provide the final position in the
warehouse W:##:##:#:#, where # represents a number. WMS should also make appropriate
reservations to prevent dead-lock situations.
When the command is received, the transport unit continues in in the following way:
a. For racks W:1#:##:#:# transport units follow conveyors T002, T110, T111, and T112 where they are
picked by crane 1 (deck C101).
b. For all other racks transport units follow conveyors T010, T011, and T012, where they are picked by
shuttle 4 (deck C401).
In case that the transport unit goes to racks W:2#:##:#:#, shuttle 4 (deck C401) deposits it to conveyor T211
from where it continues to T212. For racks W:3#:##:#;#, the transport unit is dropped to conveyor T311 and
then conveyed to T312. Transport unit on conveyor T212 is then picked by crane 2 (deck C201) and transport
unit on conveyor T312 by crane 3 (deck C301). In case that a transport unit goes directly to W:52:##:0:1, it is
dropped to conveyor T021.
A crane stores a transport unit to required slot in a rack.
5.3.2 Outbound traffic
To retrieve a transport unit from the warehouse, the following operations must be done:
1.
2.
3.
4.
5.
6.
7.
WMS should first give a command to move a transport unit from a slot in high-bay warehouse to a slot in
gravitational rack.
Crane picks a transport unit from the slot in the warehouse and drops it to the appropriate conveyor: from
W:1#:##:#:# to T121, from W:2#:##:#:# to T221, and from W:3#:##:#:# to T321 or T322.
Transport units from T121 and T221 are further conveyed to T122 and T222, respectively.
A transport unit from T122 or T222 is transferred to shuttle 4.
Shuttle 4 deposits a transport unit from its deck C401 to T021.
Based on the commands and optimization performed on MFCS, transport units are further conveyed to T023
or T024 via T022.
Transport units on conveyors T023 and T024 as well as transport units on conveyors T321 and T322 can be
simultaneously picked by shuttle 5 on decks C501 and C502 and finally dropped to the gravitational rack
W:52:##:0:1
It is also possible to directly move a transport unit from input to W:52:##:0:1. In this case steps 1-4 and 5b of inbound
traffic must be completed first, and are then followed by steps 5 – 7 of outbound traffic.
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5.3.3 Warehouse reorganization
To access the transport units in depth 2 or for optimization of the warehouse it is also possible to move transport units
between slots in the same aisle – the designation of slots should not differ in the first two symbols. For example,
repositioning of a transport unit from slot W:22:22:2:2 to slot W:21:21:2:1 is possible, but from slot W:22:22:2:2 to slot
W:12:12:1:2 is not.
Additionally, it is possible to automatically move transport units from slots W:1#:##:#:# to slots W:2#:##:#:# or
W:3#:##:#:# and from slots W:2#:##:#:# to slots W:3#:##:#:#.
Movements of transport units from slots W:2#:##:#:# to slots W:1#:##:#:# or from slots W:3#:##:#:# to slots
W:1#:##:#:# or W:2#:##:#:# can only be made in two phases by generating two WMS commands:


with the first command they should be send to the gravitational rack and
after reentry on the input line (entry notification on T002) to the final destination.
5.3.4 Command execution
Tasks, given by WMS, are executed by conveyors and the vehicles. The tasks on conveyor lines depend on transport
units, which are there. The order of execution is thus irrelevant.
The order of task execution is important only on vehicles. Here MFCS will execute commands based on priority, WMSID
and vehicle performance:


When a vehicle gives a transport unit to a conveyor line or to a rack slot, it can immediately start with
execution of the next command.
When a vehicle finishes the current operation, it will first start executing the feasible commands with the
highest level of priority. If there are many commands with the same priority level, the commands will be
executed in such a way to optimize the vehicle movements.
It can happen that a task fails due to poor handling, a rack slot empty, a rack slot full, a conveyor full, etc. In such
situations command on MFCS should be canceled and then new command from MFCS or WMS issued.
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5.4 Conveyor system
5.4.1 Layout
The conveyor system transfers pallets to and from the vehicles in the warehouse. It is divided to segments to allow for
fluent operation. A segment is a group of conveyor tables. The conveyor tables, as schematically presented in Error!
Reference source not found., are grouped in segments according to Table 5.3.
Table 5.3 Segments
Segment
Conveyor tables in segment
Description
T00
T001, T002
Pallet entry
T03
T004, T005
Error lane
T01
T010, T011, T012
Input to shuttle C401
(transport units to cranes C201 and C301)
T11
T003, T110, T111, T112
Input to crane 1
T12
T121, T122
Output from crane 1
T21
T211, T212
Input to crane 2
T22
T221, T222
Output from crane 2
T31
T311, T312
Input to crane 3
T32
T321, T322
Output from crane 3
T02
T021, T022, T023, T024
Output from 4
(transport units from canes 1 and 2)
The pallet entry is where the pallets enter the automatic warehouse. When a new pallet is placed on conveyor T001, it
starts moving to T002. During this move, the pallet dimensions and weight are checked. If the measurements are within
the specified tolerances, the pallet continues towards one of the vehicles, otherwise it is rejected and sent to the error
lane (T004 and T005).
On successful dimension check, a pallet can continue to:




racks W:1#:##:#:# via segment T11, and crane 1 (C101),
racks W:2#:##:#:# via segment T01, shuttle 4, segment T21, and crane 2 (C201),
racks W:3#:##:#:# via segment T01, shuttle 4, segment T31, and crane 3 (C301),
directly to output via segment T01, shuttle 4, segment T02, shuttle 5.
From the warehouse, the pallet can be sent to the output in the following ways:



from W:1#:##:#:# via crane 1 (C101), segment T12, shuttle 4, segment T02, shuttle 5,
from W:2#:##:#:# via crane 2 (C201), segment T22, shuttle 4, segment T02, shuttle 5,
from W:3#:##:#:# via crane 3 (C301), segment T32, shuttle 5.
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5.4.2 Components of conveyor system
5.4.2.1 Roller / chain conveyor
A conveyor is a device that transports a pallet. A motor that drives the conveyor is controlled directly or via frequency
inverter. Each conveyor is equipped with a photocell that detects a pallet presence.
5.4.2.2 Lifting unit
A lifting unit is used to transfer a pallet from a roller conveyor to a chain conveyor or vice versa. This is achieved by
raising or lowering the roller conveyor. The motor that drives the lifting unit is controller directly. Each lifting unit is
equipped with two inductive sensors that detect when the lifting unit is in the raised or lowered position.
5.4.2.3 Aligner
An aligner is used where a pallet needs to be aligned before it can travel further. This is done by rising the aligner in a
pallet travel path direction. The motor that drives the aligner is controlled directly. An aligner is equipped with two
inductive sensors that detect when the aligner is in the upper or lower position.
5.4.3 Powering the conveyor system cabinets
The start-up procedure is as follows

Turn the switch +SB1-1Q1 on the main power cabinet (Figure 5.6) to positon ON.
To shut-down the conveyor system

Turn the switch +SB1-1Q1 on the main power cabinet to positon OFF.
Figure 5.6 Main power cabinet
When the main power cabinet is switched on, the whole conveyor system is also powered.
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5.4.3.1
Emergency Shut-Down
Emergency shut-down of the conveyor system may be activated through:

E-stop safety buttons on cabinets CP001, CP101, CP201, CP301, CP401, CP501, or CP502.
When all E-stop safety buttons are pulled out, it is possible to reset the system and start the movement again.
The safety relay uses two channel safety system. In cases when the emergency stop condition is lost only for very short
time period (pressing and quickly releasing mushroom safety button, quickly opening and closing a door, …) it may
happen that only one channel is lost and the safety contactor cannot be reset. Remedy is to press the E-stop button and
only release it after a few seconds.
5.4.4 Modes of operation
Each segment of conveyor system can be set to one of the operating modes:


local and
remote,
designated with pictograms in Figure 5.7. The mode of operation is valid for all conveyor tables in the segment.
In local mode the system operates by manually pressing the corresponding buttons on operators’ panel or buttons,
while in automatic mode, MFC system sends corresponding commands.
Figure 5.7 Local and remote mode of operation
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5.4.5 Operating the conveyor system
The conveyor system can be operated via two operator panels located on cabinets CP001 (Figure 5.8) and CP501, and
with physical buttons located on cabinets CP101, CP201 (Figure 5.9), CP301, and CP321.
Figure 5.8 Cabinet CP001
Figure 5.9 Cabinet CP201
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5.4.5.1 Main screen
The operator panel (Figure 5.8) shows the visualisation of the conveyor system and allows for the user interaction. On
the main screen (Figure 5.10) the operator can see the state of the conveyor system, where conveyor tables are shown
with most important sensor status as well as current action - an arrow shows the current direction of movement.
A box around the conveyor tables represents a segment. The status of segment is represented with the color as follows:





blinking red – alarm,
black – local,
yellow – remote inactive,
green – remote active (change from remote inactive requested by MFC system),
orange – remote active, finishing the last task before switching to local.
Figure 5.10 CP001 operator panel main screen
5.4.5.1.1
Changing the mode of operation
To change the mode of operation, the operator has to press the pictogram (Figure 5.7), usually located in the top left
corner of a segment.
MFC system can operate with a segment only when it is in remote mode of operation. When in remote mode, the
operator cannot control a segment. All the movements of conveyors, lifting tables, and aligners are performed
automatically.
5.4.5.1.2
Working with panel in local mode
To work manually with a selected segment, it must be first put to local mode. When segment in local mode, the user
has to select the conveyor tables which he wants to manipulate. The box near a table can be empty, which means it is
not selected, or can display a checkmark, which means it is selected for operation (Figure 5.11, top left). The status can
be changed by pressing a box on the screen.
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Figure 5.11 Selection of conveyor tables
At the same time, an operator can select more than one unit. It is even not necessary that units are included in the
same segment. All units with checkmarks will move simultaneously. To trigger a movement, the operator has to keep
pressed an appropriate button (Figure 5.12):
F1: to move away from a panel,
F2: to move towards a panel,
F3: to move right,
F4: to move left,
F5: to lover lifting table or aligner,
F6: to raise lifting table or aligner.
Figure 5.12 Commands available on main panel
5.4.5.1.3
Dimension and weight control
When dimension check fails, a pallet is conveyed from table T002 over table T004 to table T005. When on table T005, a
dimension check screen pops-up (Figure 5.13), which shows why a pallet was rejected. Possible reasons are:
load overhangs pallet at front (active icon 1),
load overhangs pallet at back (2),
load too wide on left side (3),
load too wide on right side (4),
pallet bottom does not allow for fork manipulation on cranes (5),
pallet too high (6),
barcode not read (7),
overweight (8), and
rejected by upper level system, MFC (when no other icon isactive).
When operators takes a pallet from T005, the statuses are cleared.
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6
1
3
2
4
8
5
7
Figure 5.13 Dimension check information
Information about a pallet on conveyor table T005 can also be displayed by pressing F7 button (Figure 5.12).
5.4.5.1.4
Alarm handling
When an alarm appears, the corresponding segment goes to alarm state. Besides, alarm icon above F10 button (Figure
5.12) starts to blink.
By pressing F10 button, an alarm screen (Figure 5.14) opens with detailed information about the active errors.
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Figure 5.14 Alarm screen
To reset an alarm, the operator must first remove the reason for it, and then press F10 button (when on the alarm
screen) or press a reset button on a cabinet.
Possible alarms, accompanied with possible causes and remedy are given in a separate chapter.
5.4.5.1.5
Settings
From the settings screen the operator can:
enter the IP address of the MFC system (192.168.1.118 in Figure 5.15),
reset the MFC communication by pressing top left icon in Figure 5.15, and
clear the communication queue between PLC and MFC system by pressing top right icon in Figure 5.15.
Figure 5.15 Settings screen
5.4.5.1.6
Permissions
Some functions of the main panel are only available with elevated user permissions. When an operator requests such a
function, for example access to the settings screen, the login screen (Figure 5.16) pops-up.
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Figure 5.16 Login screen
To elevate permisions a user must enter:
user: yag
password: yag
After entering the correct user and password, an operator must request the required function again.
5.4.5.2 Panel on cabinet CP501
Operator is advised to use panel on cabinet when manually intervening on segments T31 and T02. Functions of the
panel are the same as those of the main panel, but limited to segments T31 and T02.



user can put a segment to local or remote mode,
do manual movements in local mode,
check and reset alarms.
Figure 5.17 Operator panel on CP501
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5.4.5.3 Buttons on cabinets CP101, CP201, CP301, CP302
Conveyors next to cranes can be operated also with controls available on cabinets CP101, CP201, CP301, and CP321.
In all cases the segment is composed of two conveyors. To operate in local mode:


an operator must first switch a segment in local mode; in Figure 5.18 one has to put the switch to the right
position,
then, by pressing buttons with conveyor designation, the conveyor starts to move in predetermined direction.
To go back to remote mode, an operator has to turn the switch back to the left position.
Figure 5.18 Buttons for operating conveyors
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5.4.5.4 Common faults and handling procedures
No
Alarm description
Remedy
1
MFC mismatch (segment s)
MFC sent segment s to the error state
2
Tfsn material missmatch
Sensor and data information on conveyor Tfsn differ
3
Tfsn running too long conveyor
Tfsn motors for rollers or chain are running too long. There must be some
problem with sensors or improper material handling. Check the positions of
pallets in the warehouse and on MFC and adapt accordingly.
4
Tfsn running too long hoist
Tfsn hoist motor (lifting table, aligner) is running too long. Check the position
of sensors.
5
Tfsn limit switch
Tfsn limit switch is crossed. Adjust the positon of switches used in normal
operation.
6
Tfsn not ready (xxQ1, yyF1)
Tfsn motor is not ready. Check the listed elements (motor protections, fuses,
frequency inverter).
7
MFC queue full
There is no communication between conveyor system and MFC. MFC can be
down, or connection is lost. Cehck cabling.
8
TCP IP chanel fault
Connection between MFC and conveyor system is lost. MFC can be down,
check cabling.
9
Phase alignment
There is a problem in power supply. Check all three phases.
10
c101 main switch (2Q1)
Crane 1 (C101) is switched off. Switch it on.
11
c201 main switch (3Q1)
Crane 2 (C201) is switched off. Switch it on.
12
c301 main switch (4Q1)
Crane 3 (C301) is switched off. Switch it on.
13
c401 main switch (7Q1)
Shuttle 4 (C401) is switched off. Switch it on.
14
c501 main switch (8Q1)
Shuttle 5 (C501, C502) is switched off. Switch it on.
15
Conveyor main switch (5Q1)
Conveyor main switch is off. Switch it on.
16
Conveyor 24V (6Q1)
Protection 6Q1 tripped. Remove the reason and set it back.
17
Main cabinet ventilation (13F2)
Fuse 13F2 tripped. Remove the reason and set it back.
18
Sensors 24V (14F4)
Fuse 14F4 tripped. Remove the reason and set it back.
19
Frequency regulator 24V (14F5)
Fuse 14F5 tripped. Remove the reason and set it back.
20
Cp502 fuse, main cabinet (15F2)
Fuse 15F2 tripped. Remove the reason and set it back.
21
Cp502 24V fuse (124F4)
Fuse 124F4 tripped. Remove the reason and set it back.
22
Cp502 ventilation (125F1)
Fuse 125F1 tripped. Remove the reason and set it back.
23
(Segments T00, T01, T03, T11, T12)
stop button CP001
Stop button is pressed. When there is no danger, release it and reset the
system.
24
(Segments T00, T01, T03) safety
contactor out (12k1)
Stop button is pressed. When there is no danger, release it and reset the
system.
25
(Segments T11, T12) stop button
Stop button is pressed. When there is no danger, release it and reset the
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CP101
system.
26
(Segments T11, T12) safety
contactor out (12k2)
Stop button is pressed. When there is no danger, release it and reset the
system.
27
(Segments T21, T22) stop button
CP201
Stop button is pressed. When there is no danger, release it and reset the
system.
28
(Segments T02, T21, T22, T31) stop
button CP501
Stop button is pressed. When there is no danger, release it and reset the
system.
29
(Segments T21, T22) safety
contactor out (12k3)
Stop button is pressed. When there is no danger, release it and reset the
system.
30
(Segment T31) stop button CP301
Stop button is pressed. When there is no danger, release it and reset the
system.
31
(Segment T31) safety contactor out
(12k4)
Stop button is pressed. When there is no danger, release it and reset the
system.
32
(Segment T32) stop button CP321
Stop button is pressed. When there is no danger, release it and reset the
system.
33
(Segment T32) safety contactor out
(12k6)
Stop button is pressed. When there is no danger, release it and reset the
system.
34
(Segment T02) safety contactor out
(12k5)
Stop button is pressed. When there is no danger, release it and reset the
system.
35
(Segment T02) safety contactor out
(12k5)
Stop button is pressed. When there is no danger, release it and reset the
system.
36
ET200 CP301 unreachable
There is no Profinet communication with ET200 module in CP301. Check if
there is power supply, check cabling.
37
ET200 CP502 unreachable
There is no Profinet communication with ET200 module in CP502. Check if
there is power supply, check cabling.
38
CLV620 unreachable
There is no Profinet communication with barcode reader CLV620. Check if
there is power supply, check cabling.
39
Frequency regulator Tsfn
unreachable
There is no Profinet communication with frequency inverter for table Tsfn.
Check if it has power supply, check cabling.
40
Crane x unreachable
There is no Profinet communication with Crane x. Check if it is powered on.
Check the cabling, optical communication.
41
Shuttle x unreachable
There is no Profinet communication with Shuttle x. Check if it is powered on.
Check the cabling, optical communication.
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5.5 Cranes
5.5.1 Start-up and shut-down of switching cabinets
The start-up procedure of the crane is as follows.


Turn the switch +SB1-2Q1 (Crane 1), +SB1-3Q1 (Crane 2), +SB1-4Q1 (Crane 3) on the main power cabinet to
position ON.
Turn the switch +L01-402Q1 on the crane main cabinet +L01 to position ON.
Shut-down procedure for the crane is executed in reversed order.


Turn the switch +L01-402Q1 on the crane main cabinet +L01 to position OFF.
Turn the switch +SB1-2Q1 (Crane 1), +SB1-3Q1 (Crane 2), +SB1-4Q1 (Crane 3) on the main power cabinet to
position OFF.
5.5.2 Emergency Shut-Down
Emergency shut-down may be activated through:





Safety switches, which limit the crane’s movement area: travelling (408S1), hoisting (427S1), the speed
regulator switch (408S2) and the catching jaws (427S2).
Mushroom safety button on main cabinet (409S1).
Operators’ cabin doors on the lifting carriage (428S1, 428S2).
Doors for accessing the crane area from conveyor side or opposite side.
Light grids.
When all mushroom safety buttons are pulled out and all safety switches deactivated, it is possible to reset the system
and start the movement again.
When operator accesses the crane, he needs to open a door to the aisle first and afterwards he also opens a door to
the cabin. The faults on the crane can be reset and crane locally operated only when the safety is re-established. To
do this, the operator must press the reset button to reset faults.
Movement is in exceptional situations possible also when the safety switches are activated. Safety override is only
possible in manual mode. In this case, the operator must turn the key for overriding the limit switches to position 1.
5.5.3 Regimes of operation
The crane distinguishes between operation regimes:




Local regime:
o Manual mode
o Semi-automatic mode
Remote regime:
o Automatic mode
Auto finish mode,
No regime.
5 OPERATING INSTRUCTIONS AND FAULT FINDING PROCEDURES
Local regime is used, when operator needs to control crane from operator’s cabin or when access to crane aisle is
needed to disable in attentional automatic crane movement. When crane is in local regime it can operate only in
manual or semi-automatic mode from the panel.
Remote regime is crane operating regime, when crane is controlled remotely by MFCS.
In manual mode, all movements of the crane and the lifting carriage are made by pressing the respective buttons on
the operators’ panel. In semi-automatic mode, a crane itself performs a simple operation that consists of a movement
to the selected location, loading of a material from that location, or the depositing of material to it. Manual or Semiautomatic mode can be selected from the operators’ panel and are enabled only in local regime.
The control regime is signaled on the operators’ panel and on MFCS PC.
The regime of operation is set by position of key-locks located:


on each aisle entrance on small enclosure, and
on the operators’ panel in the cabin on the lifting carriage (CRANE - +L02).
Key on the small enclosure can be set to LOCAL, REMOTE or AUTO FINISH position.
Key on the lifting carriage can be set to LOCAL or REMOTE position.
The local regime is enabled only when the key-locks are set in the following ways:

small enclosure key to LOCAL, and CRANE key to LOCAL
The remote regime is enabled only when key-locks are set as follows:

small enclosure key to REMOTE, and CRANE key to REMOTE
When crane is operating in REMOTE regime, AUTO FINISH regime can be enabled with changing key position from
REMOTE to AUTO FINISH. In AUTO FINISH regime, crane will finish current task and then stop. Crane will not start
executing next task to allow entrance to crane aisle. Always wait to crane finishes current to, otherwise automatic reset
could not be possible and manual intervention will be needed. When crane is stopped, key can be turned to LOCAL
position.
In all other key positions crane is in state NO-REGIME and cannot move.
Safety is regulated through system of two pairs of keys. Each pair consists of a key for a key-lock and a key for the door
lock.
Before approaching a crane, the operator should:




Switch key to AUTO FINISH on small enclosure and wait till crane finishes current task.
Led light for operation on small enclosure should be off, in case that led light is on or blinking, operator
should wait that crane finishes the current task.
When crane is stopped, carry the pair of keys, open the door to aisle, enter the aisle, and close the door.
By using the pair of keys turn the key-lock on the lifting carriage cabinet to LOCAL position.
Now the crane is in LOCAL regime and after resetting the faults, it can be operated from the operators’ panel.
When leaving a crane, the operator should:
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



Remove a pair of keys from the key-lock on crane cabinet; this is only possible when the key-lock is switched
to REMOTE position.
Leave the crane and close the door to the aisle.
Put the pair of keys to the key lock in small enclosure and switch it to REMOTE position.
After resetting the faults, the system can be operated from MFCS.
In automatic mode, the crane is completely autonomous, and its movements are unpredictable.
5.5.4 Operators’ panel
Operators’ panel is in the operators’ cabin as shown in Figure 5.19. Close to Simatic panel there is a button for resetting
the faults, and two key-locks: the first is used to set the mode of the crane, while the other is used to override the
safety functions.
Figure 5.19 Operators’ panel
5.5.4.1 Physical buttons
The operators’ panel has eight physical buttons. Close to operators’ panel is the safety stop button that can be used in
case of emergency stop is needed. If the button is pressed, the crane will brake on emergency ramp, this can cause
undesirable effects and should only be used in case of an emergency.
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Figure 5.20 Operators’ panel with physical buttons.
5.5.4.2 HMI
The main screen, manual screens and automatic screen share the status values shown in Figure 5.21. They represent:



Physical position is given as a numbered value, presenting coordinates in millimetres: Crane’s horizontal and
vertical position and forks single deep and double deep position.
Distance to the nearest logical position (slot in a rack, conveyor) given in millimetres.
Nearest logical position (slot in a rack, conveyor) designated with four indices giving the logical coordinate.
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Figure 5.21 HMI Screen
5.5.4.2.1
Buttons
There are six buttons on top of the main screen as shown in Table 5.4. With pressing button operator change screen or
execute an action.
Table 5.4 Buttons and their actions
Button
Action
Opens the crane manual operation screen, for a detailed description check Chapter 5.5.4.4.1
Opens the semi-automatic operation screen, for a detailed description check Chapter
5.5.4.4.2
Opens the crane sensor screen, for a detailed description check Chapter 5.5.4.35.5.4.3.
Opens the alarm screen on which we display all the alarms, as shown Figure 5.22. If an alarm
is present the button flashes red.
If a user is not logged in the login popup widow appears and prompts the user for the
username and password. If a user is logged in the button shows the advanced menu form
which the operator can edit crane parameters.
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Toggles between the Turkish and English language.
Figure 5.22 Alarms screen
5.5.4.2.2
Crane regime - controlling partner
The first icon represents crane regime, on the icon is seen which device can control the crane. There are three different
icons of which two are used for displaying the controlling partner, as shown in the Figure 5.23.
Figure 5.23 Crane regime icons
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Crane regimes icons:
No regime selected. This symbol is used to show that there is no clear controlling partner. This is
achieved when keys aren’t in appropriate positions. Crane movement is not possible.
Crane is in local regime and can be controlled via the operator’s panel.
Crane is in remote regime and is controlled by the MFCS.
Figure 5.24 Crane regime
5.5.4.2.3
Crane mode
Crane mode is displayed via assorted buttons background colours as shown in Figure 5.25.
Figure 5.25 All mode colors
Colour meaning:
1.
2.
3.
4.
5.
5.5.4.3
Cyan represents that the crane is in manual mode.
Red represents that the crane as the safety override key switch active.
Blue represents that the crane is automatic mode.
Green represents that the crane is operating automatically.
Turquoise represents that the crane is in automatic finish mode.
Sensors
The sensors screen contains overview of crane sensors. Each sensor is represented by a circle accompanied with the
electrical plan identifier for that specific sensor. If the sensor is inactive, it is presented as a grey circle. If the sensor is
active, it is presented as a green circle. Next to the selected device there are two output fields that are visible only if the
crane is occupied. The first one displays which device is occupied and the second displays the barcode.
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5.5.4.3.1
Crane
Figure 5.26 Crane sensors screen
If the crane is occupied, field with palette barcode number is displayed.
The functionality of the sensors is as follows (electrical plan identifier: description):











408S1: the mechanical limit switch for horizontal movement - gantry,
410S1, 410S2: magnet switch slow for horizontal movement – gantry,
427S1: the mechanical limit switch for vertical movement - hoist,
432S1, 432S2, magnet switch slow for vertical movement - hoist
427S2: the mechanical safety switch for triggering the activation of catching jaws,
408S2: the mechanical safety switch for triggering the loosen rope of the speed regulator,
410S3: the mechanical switch for triggering the over-speed of the lifting carriage,
435B1, 435B2: optical sensors for checking the clearance between crane and rack,
435B3, 435B4: optical sensors for checking the forks middle position.
433B1, 433B2: rack occupied – first depth
434B1, 434B2, rack occupied – second depth
5.5.4.4 Mode
If the crane is controlled via MFCS, it operates in the automatic mode, where command come from the MFCS.
If the crane is controlled via the operators’ panel as explained in the Chapter 5.5.4.2, then the operator can set control
mode by clicking the button
for local mode, or button
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5.5.4.4.1
Manual
First button activates the manual control of the crane. Operator can control crane movement from that screen. Arrows
above physical buttons represent the direction of movement.
F1 – Fast speed movement, must be pressed with other action button F1...F7.
F2, F3 – Horizontal movement of crane – gantry (F2 – forward, F3 - backward).
F4, F5 – Vertical movement of crane – hoist (F4 – up, F5 - down).
F6, F7 – Forks movement (F6 – toward rack cn2, F7 – toward rack cn1).
With button above keys F6 and F7 you can select which forks can be moved. If you want to move one type of fork
(single deep, double deep), other should be on the middle position. Otherwise fork motion is blocked.
Figure 5.27 Manual mode crane screen
Manual movement is possible while a fault is present.
Incautious manipulation with the crane in manual mode can cause serious injuries to the equipment and rack
construction.
When a limit switch is activated, the crane can only be operated by overriding the safety functions. This is achieved by
turning the limit switch override key and then resetting the faults. When the limit switches are overridden, the crane
can be operated only at slow speed. The activation of the safety override key switch is also signalized as explained in
Chapter 5.5.4.2.3.
The manipulation with overridden safety functions must be performed very cautiously, due to disabled safety
devices.
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5.5.4.4.2
Semi-automatic
Button
activates the semi-automatic mode, where the operator inputs the desired action and location in the five
input fields. When the start button is pressed the crane start executing requested task.
Figure 5.28 Automatic mode screen
Input fields:
1.
2.
3.
4.
5.
Command, where the operator selects the desired action from a drop-down list. There are four options:
a. - - - - – which symbolizes no action is selected
b. Move – which symbolizes that the crane will move to the selected location.
c. Pick - which symbolizes that the crane will move to the selected location and collect the material at
that location.
d. Drop - which symbolizes that the crane will move to the selected location and deposit the material at
that location.
Rack, were the entered number is a combination of the crane name and rack identifier (cn1 for left rack, and
cn2 for right rack, where cn is crane number from 1 to 3).
Travel, were the entered number represents the desired horizontal location, for the crane (from 1 to 60).
Hoist, were the entered number represents the desired vertical location, for the crane (from 1 to 8).
Depth, were the entered number represents the depth of the fork (from 1 to 2).
After all the fields are entered and selected, the start button must be pressed which triggers the execution of the
entered task. The execution of the task can be stopped at any time with pressing the cancel button.
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Start button.
Cancel button.
Figure 5.29 Start and cancel buttons
The active order is displayed in the current task output fields. The last field is the state machine status which represents
the current step of the step machine (used troubleshooting).
The state machine field shows the current operation of the crane. It is given in terms of two-digit numbers with the
following meaning:
o
o
o
o
00 … 01: initialization of a command,
30 … 31: movement to the target location,
70 … 74: pick or drop procedure,
90 … 99: material movement and other finalization steps.
When switching from the manual to the semi-automatic mode the crane is not yet operating automatically, which is
signalized via colour as defined in the Chapter 0. To start the automatic operation, the start button must be pressed. If
the operation was successfully finished and regime not changed, then automatic operation can be continued (is not
reset).
Each time the automatic operation is stared after reset or regime change, an audible warning is issued via the horn.
In case of an alarm during semi-automatic movement, the crane stops all actions (automatic operation is lost). After
reset of the faults, the crane continues to execute the command from its current state.
If the operator wishes to cancel the current task, the cancel button must be pressed.
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5.5.5 Parameter setting and calibration
5.5.5.1 Usernames and passwords
To access the calibration and parameter setting screens on operators’ panel, the user must specify the username and
password. The following are configured:

username: yag, password: yag
5.5.5.2 Fine tuning of slot and conveyor positions
The physical coordinates of each slot in a rack are calculated from the mechanical drawings of the racks. Since there are
slight deviations of the physical rack regarding to the drawings, fine adjustment of slot positions is possible. During the
commissioning of the system the slot positions were already fine-tuned. In case of problems with some of the positions,
its offset with respect to the calculated position can be specified.
The offset for the hoist must be set in such a way, that the distance between the top of fork and the top of the rack
beam is 85 mm when the crane approached the location with GOTO command. See Figure 5.30 for details.
Offset of the travel must be set in such a way, that distance between fork and closest vertical beam of rack construction
is XX mm.
Figure 5.30 Determining the correct position of the crane regarding the horizontal beam. The spirit level is lying on the fork
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5.5.5.2.1
Changing offsets using the operators’ panel
On the offset screen, shown in Figure 5.31, first enter the location in form of three-index value (rack, travel and hoist)
and then press the Read button. Current travel and hoist offsets in millimeters appear in grey fields.
In accordance to the current values write the new values to the white fields bellow. When pleased with the setting,
press the Write button to apply the new values.
Even if you decide to change only one value, both values must be specified!
Figure 5.31 Operator's panel: the teaching screen
5.5.5.2.2
Parameter handling on operators’ panel
The parameter screen on operator’s panel enables users to save the parameter settings of the crane to the file on the
CF card. This is done by entering the file name in form of 6-digit number, for example by entering month, day and year
information, e.g. mmddyy. In the Error! Reference source not found. the number 190617 is entered to represent
19.6.2017. Afterwards the save button can be pressed.
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Figure 5.32 Accessing the parameter files from SCADA
5.5.5.3 Adjustment of velocity, acceleration and offset parameters on operators’ panel
Parameters for velocity, acceleration, crane offset and scale can be adjusted on operators’ panel parameter screen.
Velocity and acceleration can be adjusted for automatic and manual mode of crane operation. With offset parameter
rack slots and transport locations are changed for same constant offset. This can be useful in case of changing bar code
tape or position of an absolute encoder.
Figure 5.33 Operators panel: parameter adjustment screen
Absolute encoders for hoist are referenced from parameter adjustment screen by pressing corresponding button.
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5.5.6 Common faults and handling procedures
No.
Alarm description
Remedy
1
Fuse control 230 VAC, +L01-403F1...403F3
Check the elements in the electrical cabinet.
2
Fuse control 24 VDC, +L01-404F1...404F9
3
Limit switch travel, +L01-408S1
4
Limit switch speed governor hoist - rope; +L01-408S2
5
E-STOP push button main cabinet, +L01-409S1
Check the elements in the electrical cabinet.
The crane travelled over the limit switch.
Override safety and in manual mode put the
crane back to the working area. Check for
reasons.
Check the switch and the status of the speed
regulator rope.
Release the stop button on the cabinet.
6
E-STOP over rail , +L01-409K1
7
Limit switch speed governor hoist - overspeed; +L01410S3
8
Protection travel and hoist brakes, +L01-420Q1
Close aisle door or release the stop button on
outside cabinets.
Visually check the status of the crane,
especially the lifting carriage ant the ropes.
Repair the damage. When everything is OK,
release the switch.
Check the elements in the electrical cabinet.
9
Protection travel and hoist fan motors, +L01-420Q2
Check the elements in the electrical cabinet.
10
Protection forks back brake, +L01-421Q1
Check the elements in the electrical cabinet.
11
Protection forks front brake, +L01-422Q1
Check the elements in the electrical cabinet.
12
Limit switch hoist, +L02-427S1
13
Limit switch catching device - jaws, +L02-427S2
14
Cabin door open - to main cabinet, +L02-428S1
The crane travelled over the limit switch.
Override safety and in manual mode put the
crane back to the working area. Check for
reasons.
Visually check the crane, particularly the status
of the lifting carriage and ropes. Repair the
damage. When everything is OK, override
safety and in manual mode release the catching
jaws by moving the lifting carriage upwards.
Close the door.
15
Cabin door open - to deck (forks), +L02-428S2
Close the door.
16
E-STOP push button control panel, +L02-428S3
Release the stop button on the cabinet.
17
No clearance between crane and left rack, +L02-43515
18
No clearance between crane and left rack, +L02-43515
19
Axis error: travel
20
Axis error: hoist
21
Axis error: forks SD
22
Axis error: forks DD
Remove the pallet or material (plastic foil) that
was triggered in the gap between the crane and
a rack.
Remove the pallet or material (plastic foil) that
was triggered in the gap between the crane and
a rack.
Error on corresponding drive. See TO and DO
drive messages for details. Make sure that
crane can move freely.
Error on corresponding drive. See TO and DO
drive messages for details. Make sure that
crane can move freely.
Error on corresponding drive. See TO and DO
drive messages for details. Make sure that
crane can move freely.
Error on corresponding drive. See TO and DO
drive messages for details. Make sure that
crane can move freely.
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24
Travel motor running too long, +EXT-418M1
25
Hoist motor running too long, +EXT-416M1
26
Forks SD motor running too long, +EXT-421M1
27
Forks DD motor running too long, +EXT-422M1
28
Communication error with transport system PLC
(receive direction)
29
30
Communication error with transport system PLC (send
direction)
Communication error with MFCS (receive direction)
31
Communication error with MFCS (send direction)
MFCS is not responding.
32
40
Enormous value of absolute encoder or magnet
switches - travel
Erroneous value of absolute encoder or magnet
switches - hoist
Automatic start not possible: wrong location
Check absolute encoder value and both magnet
switches.
Check absolute encoder value and both magnet
switches.
Check entered location.
41
Automatic start not possible: crane occupied
42
Automatic start not possible: crane is empty
Pickup is not possible if there is already a pallet
on the crane.
Drop is not possible if crane is empty.
43
Barcode mismatch
44
Underweight
45
Overweight
46
No clearance between crane and rack 1
47
No clearance between crane and rack 2
48
Material picture differs from sensor
49
Material movement not successful
50
Transport system conveyor not ready
51
MFCS error
52
Automatic start not possible: fork not in the middle
53
Sagging of Axis hoist
54
Crane out of working area (travel)
55
Crane out of working area (hoist)
34
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Something is blocking the movement. Check for
reasons.
Something is blocking the movement. Check for
reasons.
Something is blocking the movement. Check for
reasons.
Something is blocking the movement. Check for
reasons.
The conveyor PLC is not responding.
- Switch on the electrical cabinet.
- Check communication cables and optical link.
- Reset communication through SCADA system.
Same as above.
MFCS is not responding.
MFCS has issued a command for a pallet which
is not on crane.
Check the load, remove it if it is too heavy.
Calibrate the load sensor.
Check the load, remove it if it is too heavy.
Calibrate the load sensor.
Remove the pallet or material (plastic foil) that
was triggered in the gap between the crane and
a rack.
Remove the pallet or material (plastic foil) that
was triggered in the gap between the crane and
a rack.
The material picture occupancy and the sensor
436B1 state differ.
The crane has performed movement, but the
status of occupancy sensor has not changed.
Check the situation.
Check if transport system is without alarms and
in automatic mode.
MFCS has requested the crane to raise an error.
Usually due to the too long pickup/deposit
operation on conveyors.
Place both forks manually to middle position
and check both sensors 435B3 and 435B4.
Hoist brake malfunction, check hoist motor
brake.
Software limit switch was triggered. Move the
crane back to the working area.
Software limit switch was triggered. Move the
crane back to the working area.
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56
Crane out of working area (fork SD)
57
Crane out of working area (fork DD)
60
71
Deposit to rack not possible - location occupied (side=1,
depth=1)
Deposit to rack not possible - location occupied (side=1,
depth=2)
Deposit to rack not possible - location occupied (side=2,
depth=1)
Deposit to rack not possible - location occupied (side=2,
depth=2)
Pick from rack not possible - location empty (side=1,
depth=1)
Pick from rack not possible - location empty (side=1,
depth=2)
Pick from rack not possible - location empty (side=2,
depth=1)
Pick from rack not possible - location empty (side=2,
depth=2)
Pick from rack not possible - depth 1 occupied (side=1,
depth=2)
Pick from rack not possible - depth 1 occupied (side=2,
depth=2)
E-STOP push button, CP101
Software limit switch was triggered. Move the
crane back to the working area.
Software limit switch was triggered. Move the
crane back to the working area.
Rack location is occupied, or sensor is not
working properly – 433B1.
Rack location is occupied, or sensor is not
working properly – 434B1.
Rack location is occupied, or sensor is not
working properly – 433B2.
Rack location is occupied, or sensor is not
working properly – 434B2.
Rack location is empty, or sensor is not working
properly – 433B1.
Rack location is empty, or sensor is not working
properly – 434B1.
Rack location is empty, or sensor is not working
properly – 433B2.
Rack location is empty, or sensor is not working
properly – 434B2.
Rack location of first depth is occupied, or
sensor is not working properly – 434B1.
Rack location of first depth is occupied, or
sensor is not working properly – 434B2.
Release stop button on the cabinet.
72
Door to C101 open
Close the door at aisle entry.
73
Light grid - MLG, T10
74
Light grid - MLG, T110
75
E-STOP push button, CP401
Check light grid, remove any obstacles and
reset error.
Check light grid, remove any obstacles and
reset error.
Release stop button on the cabinet.
61
62
63
64
65
66
67
68
69
115
Service M required
116
Service 3M required
117
Service 6M required
118
Service 12M required
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Maintenance of crane is required. After
maintenance is done, confirmation on
operator’s panel is needed.
Maintenance of crane is required. After
maintenance is done, confirmation on
operator’s panel is needed.
Maintenance of crane is required. After
maintenance is done, confirmation on
operator’s panel is needed.
Maintenance of crane is required. After
maintenance is done, confirmation on
operator’s panel is needed.
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5.5.6.1 Material movement
In many situations, when the pallet movement is not successfully performed by crane, the manual intervention is
required.
Before starting the manual intervention, it is mostly advised to check the status of a pallet in the MFCS. With manual
operation place the pallet on the position shown in MFCS.
If, for some reason, the operator decides, to manually complete the unfinished command, the material picture on the
crane as well as on the MFCS system must be fixed to reflect the current situation. If the operator has unloaded a pallet
from the crane, he should delete its material picture on the crane, or, if he has loaded the pallet onto the crane, he
should enter the correct barcode.
The material picture can be changed via the operators’ panel.
5.5.6.1.1
Changing the material picture via operators’ panel
Go to the service screen and click on “material” icon. The screen shown in Figure 5.34 appears. The barcode of the
pallet on the deck is shown. Value 0 means that there is no material picture on the deck.
Figure 5.34 Operators’ panel – changing of the material picture.


If pallet is loaded in the manual mode to crane deck, enter its barcode in the “New barcode” field and tap
button on the right side of entry field. If there is no pallet on the lifting carriage, the new barcode will not be
accepted.
If crane deck is empty and you want to delete material picture, enter 0 in the “New barcode field” to clear the
material picture. If there is a pallet on the lifting carriage, the material picture cannot be deleted (sensor
436B1).
5.5.6.2 Service screen
Service screen on operators’ panel can be accessed only if user is logged in with username and password.
Service screen is accessed by pressing service button in upper
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Figure 5.35 Service screen on operators' panel
Service and maintenance of the crane is requested if remaining days or remaining operating hours for each service
elapsed. If service is needed, warning is triggered on MFCS system. Crane can still operate although service warning is
present. Service warning can be reset only on operators’ panel on “Service” screen by pressing reset
service separately.
for each
Reset button can be pressed only if service is done according to scheduled maintenance plan!
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5.6 Shuttle S401
5.6.1 Start-up and shut-down of switching cabinets
The start-up procedure of the shuttle is as follows.


Turn the switch +SB1-7Q1 on the main power cabinet to position ON.
Turn the switch +L01-202Q1 on the shuttle main cabinet +L01 to position ON.
Shut-down procedure for the shuttle is executed in reversed order.


Turn the switch +L01-202Q1 on the shuttle main cabinet +L01 to position OFF.
Turn the switch +SB1-7Q1 on the main power cabinet to position OFF.
5.6.2 Emergency Shut-Down
Emergency shut-down may be activated through:




Safety switches, which limit the shuttle’s movement area: travelling (208S1).
Mushroom safety button on main cabinet.
Doors for accessing the shuttle area from both ends of aisle.
Light grids.
When all mushroom safety buttons are pulled out and all safety switches deactivated, it is possible to reset the system
and start the movement again.
When operator accesses the shuttle, he needs to open a door to access the aisle. The faults on the shuttle can be
reset and machine locally operated only when the safety is re-established. To do this, the operator must press the
reset button to reset faults.
Movement is in exceptional situations possible also when the safety switches are activated. Safety override is only
possible in manual mode. In this case, the operator must turn the key for overriding the limit switches to position 1.
5.6.3 Regimes and modes of operation
The shuttle distinguishes between operation regimes:




Local regime:
o Manual mode
o Semi-automatic mode
Remote regime:
o Automatic mode
Auto finish mode,
No regime.
Local regime is used, when operator needs to control shuttle from operator’s panel or when access to aisle is needed to
disable inattentional automatic shuttle movement. When shuttle is in local regime it can operate only in manual or
semi-automatic mode from the panel.
Remote regime is normal operating regime, when machine is controlled remotely by MFCS.
In manual mode, all movements of the machine are made by pressing the respective buttons on the operators’ panel.
In semi-automatic mode, a machine itself performs a simple operation that consists of a movement to the selected
5 OPERATING INSTRUCTIONS AND FAULT FINDING PROCEDURES
location, loading of a material from that location, or the depositing of material to it. Manual or Semi-automatic mode
can be selected from the operators’ panel and are enabled only in local regime.
The control regime is signaled on the operators’ panel and on MFCS PC.
The regime of operation is set by position of key-locks located:


on each aisle entrance on aisle entrance enclosure, and
on the operators’ panel in the shuttle cabinet +L01.
Key on the aisle entrance enclosure can be set to LOCAL, REMOTE or AUTO FINISH position.
Key on the shuttle can be set to LOCAL or REMOTE position.
The local regime is enabled only when the key-locks are set in the following ways:

aisle entrance enclosure key to LOCAL, and shuttle key to LOCAL
The remote regime is enabled only when key-locks are set as follows:

aisle entrance enclosure key to REMOTE, and shuttle key to REMOTE
When shuttle is operating in REMOTE regime, AUTO FINISH regime can be enabled with changing key position from
REMOTE to AUTO FINISH. In AUTO FINISH regime, shuttle will finish current task and then stop. Shuttle will not start
executing next task to allow entrance to shuttle aisle. Always wait to shuttle finishes current task, otherwise automatic
reset could not be possible and manual intervention will be needed. When shuttle is stopped, key can be turned to
LOCAL position.
In all other key positions shuttle is in state NO-REGIME and cannot move.
Safety is regulated through system of two pairs of keys. Each pair consists of a key for a key-lock and a key for the door
lock.
Before approaching a shuttle, the operator should:




Switch key to AUTO FINISH on aisle entrance enclosure and wait till shuttle finishes current task.
Led light for operation on aisle entrance enclosure should be off, in case that led light is on or blinking,
operator should wait that shuttle finishes the current task.
When shuttle is stopped, carry the pair of keys, open the door to aisle, enter the aisle, and close the door.
By using the pair of keys turn the key-lock on the shuttle cabinet to LOCAL position.
Now the shuttle is in LOCAL regime and after resetting the faults, it can be operated from the operators’ panel.
When leaving a shuttle, the operator should:




Remove a pair of keys from the key-lock on shuttle cabinet; this is only possible when the key-lock is
switched to REMOTE position.
Leave the shuttle and close the aisle door.
Put the pair of keys to the key lock in aisle entrance enclosure and switch it to REMOTE position.
After resetting the faults, the system can be operated from MFCS.
In automatic mode, the shuttle is completely autonomous, and its movements are unpredictable.
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5.6.4 Operators’ panel
Operators’ panel is in the operators’ cabin as shown in Figure 5.36. Close to Simatic panel there is a button for resetting
the faults, and two key-locks: one is used to set the mode of the shuttle, while the other is used to override the safety
functions.
Figure 5.36 Operators’ panel
5.6.4.1 Physical buttons
The operators’ panel has eight physical buttons. Close to operators’ panel is the safety stop button that can be used in
case of emergency stop is needed. If the button is pressed, the shuttle will brake on emergency ramp, this can cause
undesirable effects and should only be used in case of an emergency.
Figure 5.37 Operators’ panel with physical buttons.
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5.6.4.2 HMI
The main screen, manual screens and automatic screen share the status values shown in Figure 5.38. They represent:



Physical position is given as a numbered value, presenting coordinates in millimetres: Shuttle’s horizontal
position.
Distance to the nearest logical position (slot in a rack, conveyor) given in millimetres.
Nearest logical position (conveyor) designated with index giving the logical coordinate.
Figure 5.38 HMI Screen
5.6.4.2.1
Buttons
There are six buttons on top of the main screen as shown in Table 5.5. With pressing button operator change screen or
execute an action.
Table 5.5 Buttons and their actions
Button
Action
Opens the shuttle manual operation screen, for a detailed description check Chapter
5.6.4.4.1
Opens the semi-automatic operation screen, for a detailed description check Chapter
5.6.4.4.2
Opens the shuttle sensor screen, for a detailed description check Chapter 5.6.4.3.
Opens the alarm screen on which we display all the alarms, as shown Figure 5.39. If an alarm
is present, the button flashes red.
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If a user is not logged in the login popup widow appears and prompts the user for the
username and password. If a user is logged in the button shows the advanced menu form
which the operator can edit shuttle parameters.
Toggles between the Turkish and English language.
Figure 5.39 Alarms screen
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5.6.4.2.2
Shuttle regime - controlling partner
The first icon represents shuttle regime, on the icon is seen which device can control the shuttle. There are three
different icons of which two are used for displaying the controlling partner, as shown in the Figure 5.40.
Figure 5.40 Shuttle regime icons
Shuttle regimes icons:
No regime selected. This symbol is used to show that there is no clear controlling partner. This is
achieved when keys aren’t in appropriate positions. Shuttle movement is not possible.
Shuttle is in local regime and can be controlled via the operator’s panel.
Shuttle is in remote regime and is controlled by the MFCS.
Figure 5.41 Shuttle regime
5.6.4.2.3
Shuttle mode
Shuttle mode is displayed via assorted buttons background colours as shown in Figure 5.42.
Figure 5.42 All mode colors
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Colour meaning:
1.
2.
3.
4.
5.
5.6.4.3
Cyan represents that the shuttle is in manual mode.
Red represents that the shuttle as the safety override key switch active.
Blue represents that the shuttle is automatic mode.
Green represents that the shuttle is operating automatically.
Turquoise represents that the shuttle is in automatic finish mode.
Sensors
The sensors screen contains overview of shuttle sensors. Each sensor is represented by a circle accompanied with the
electrical plan identifier for that specific sensor. If the sensor is inactive, it is presented as a grey circle. If the sensor is
active, it is presented as a green circle or red if it’s safety related.
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5.6.4.3.1
Shuttle
Figure 5.43 Shuttle sensors screen
If the shuttle is occupied, field with palette barcode number is displayed.
The functionality of the sensors is as follows (electrical plan identifier: description):






208S1: the mechanical limit switch for horizontal movement - gantry,
210S1, 210S2: magnet switch slow for horizontal movement – gantry,
334B1, 334B2: optical sensors for checking the clearance between shuttle and rack,
234B1: conveyor slow on deck
234B2: conveyor stop on deck
234B3: satellite path free
5.6.4.4 Mode
If the shuttle is controlled via MFCS, it operates in the automatic mode, where command come from the MFCS.
If the shuttle is controlled via the operators’ panel as explained in the Chapter 5.6.4.2.2, then the operator can set
control mode by clicking the button
5.6.4.4.1
for local mode, or button
for semi-automatic mode.
Manual
First button activates the manual control of the shuttle. Operator can control shuttle movement from that screen.
Arrows above physical buttons represent the direction of movement.
F1 - Fast speed movement, must be pressed with other action button F1...F7.
F2, F3 - Horizontal movement of shuttle – gantry (F2 – forward, F3 - backward).
F6, F7 - Conveyor movement (F6 – forward, F7 – backward).
F8 - Reset faults.
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Figure 5.44 Manual mode shuttle screen
Manual movement is possible while a fault is present.
Incautious manipulation with the shuttle in manual mode can cause serious injuries to the equipment and rack
construction.
When a limit switch is activated, the shuttle can only be operated by overriding the safety functions. This is achieved by
turning the limit switch override key and then resetting the faults. When the limit switches are overridden, the shuttle
can be operated only at slow speed. The activation of the safety override key switch is also signalized as explained in
Chapter 5.6.4.2.3.
The manipulation with overridden safety functions must be performed very cautiously, due to disabled safety
devices.
5.6.4.4.2
Semi-automatic
Button
activates the semi-automatic mode, where the operator inputs the desired action and location in the input
fields. When the start button is pressed the shuttle starts executing requested task.
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Figure 5.45 Automatic mode screen
Input fields:
6.
7.
Command, where the operator selects the desired action from a drop-down list:
a. - - - - – which symbolizes no action is selected
b. Move – which symbolizes that the shuttle will move to the selected location.
c. Pick - which symbolizes that the shuttle will move to the selected location and collect the material at
that location.
d. Drop - which symbolizes that the shuttle will move to the selected location and deposit the material
at that location.
Travel, were the entered number represents the desired horizontal location – conveyor number.
After all the fields are entered and selected, the start button must be pressed which triggers the execution of the
entered task. The execution of the task can be stopped at any time with pressing the cancel button.
Figure 5.46 Start and cancel buttons
The active order is displayed in the current task output fields. The last field is the state machine status which represents
the current step of the step machine (used troubleshooting).
The state machine field shows the current operation of the shuttle. It is given in terms of four-digit number “ssdd” with
the following meaning:
ss - Shuttle state machine:
o
o
o
o
00 … 01: initialization of a command,
30 … 31: movement to the target location,
40 … 41: deck pick or drop procedure,
90 … 99: alarm or other finalization steps.
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dd – Deck state machine for each deck independently:
o
o
o
0: initialization of a command,
70 … 72: conveyor movement,
90 … 95: material movement and other finalization steps.
When switching from the manual to the semi-automatic mode the shuttle is not yet operating automatically, which is
signalized via colour as defined in the Chapter 5.6.4.2.3. To start the automatic operation, the start button must be
pressed. If the operation was successfully finished and regime not changed, then automatic operation can be continued
(is not reset).
Each time the automatic operation is started after reset or regime change, an audible warning is issued via the horn.
In case of an alarm during semi-automatic movement, the shuttle stops all actions (automatic operation is lost). After
reset of the faults, the shuttle continues to execute the command from its current state.
If the operator wishes to cancel the current task, the cancel button must be pressed.
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5.6.5 Parameter setting and calibration
5.6.5.1 Usernames and passwords
To access the calibration and parameter setting screens on operators’ panel, the user must specify the username and
password. The following are configured:

username: yag, password: yag
5.6.5.2 Fine tuning of slot and conveyor positions
The physical coordinates of each conveyor are calculated from the mechanical drawings. Since there are slight
deviations of the physical rack regarding to the drawings, fine adjustment of positions is possible. During the
commissioning of the system the slot positions were already fine-tuned. In case of problems with some of the positions,
its offset with respect to the calculated position can be specified.
Offset of the travel must be set in such a way, that conveyor is properly aligned to transport conveyor.
5.6.5.2.1
Changing offsets using the operators’ panel
On the offset screen, shown in Figure 5.47, first enter the location in form of one-index value (travel index) and then
press the Read button. Current travel offset in millimeters appear in grey fields.
In accordance to the current values write the new values to the white fields bellow. When pleased with the setting,
press the Write button to apply the new values.
Figure 5.47 Operator's panel: the teaching screen.
5.6.5.2.2
Parameter handling on operators’ panel
The parameter screen on operator’s panel enables users to save the parameter settings of the shuttle to the file on the
CF card. This is done by entering the file name in form of 6-digit number, for example by entering month, day and year
information, e.g. mmddyy. In the Figure 5.48 the number 180617 is entered to represent 18.6.2017. Afterwards the
save button can be pressed.
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Figure 5.48 Accessing the parameter files from operators’ panel
5.6.5.3 Adjustment of velocity, acceleration and offset parameters on operators’ panel
Parameters for velocity, acceleration and shuttle can be adjusted on operators’ panel parameter screen. Velocity and
acceleration can be adjusted for automatic and manual mode of shuttle operation. With offset parameter rack slots and
transport conveyor locations are changed for same constant offset. This can be useful in case of changing bar code tape
or absolute encoder position.
Figure 5.49 Operators panel: parameter adjustment screen
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5.6.6 Common faults and handling procedures
No.
Alarm description
1 Fuse control 230 VAC, +L01-203F1, 203F3
2 Fuse control 24 VDC, +L01-204F1...204F8
3 Limit switch travel, +L01-208S1
E-STOP push button, +L01-211A1
Protection travel fan motor, +L01-220Q2
Check the elements in the electrical cabinet.
Protection conveyor brake, +L01-221Q1
Check the elements in the electrical cabinet.
Error on corresponding drive. See TO and DO drive
messages for details. Make sure that crane can move
freely.
Error on corresponding drive. See TO and DO drive
messages for details. Make sure that crane can move
freely.
Something is blocking the movement. Check for
reasons.
Something is blocking the movement. Check for
reasons.
The conveyor PLC is not responding.
- Switch on the electrical cabinet.
- Check communication cables and optical link.
- Reset communication through SCADA system.
The conveyor PLC is not responding.
- Switch on the electrical cabinet.
- Check communication cables and optical link.
- Reset communication through SCADA system.
MFCS is not responding.
Axis error: travel
9 Axis error: conveyor C401
11 Travel motor running too long, +EXT-218M1
12 Conveyor C401 motor running too long, +EXT-221M1
13 Communication error with transport system PLC (receive
direction)
14 Communication error with transport system PLC (send
direction)
15 Communication error with MFCS (receive direction)
16 Communication error with MFCS (send direction)
17 Enormous value of absolute encoder or magnet switches 18
19
20
21
22
Check the elements in the electrical cabinet.
Check the elements in the electrical cabinet.
Satellite travelled over the limit switch. Override
safety and in manual mode put the crane back to the
working area. Check for reasons.
Close aisle door or release the stop button on
outside cabinets.
Release the stop button on the cabinet.
4 E-STOP over rail - doors, +L01-209K1
5
6
7
8
Remedy
MFCS is not responding.
Material mismatch: place C401
Check absolute encoder value and both magnet
switches.
Software limit switch was triggered. Move satellite
back to the working area.
Deck material occupancy differ from sensor state.
Automatic start not possible: bad target
Check entered location.
Automatic start not possible: deck is empty
Drop is not possible if satellite is empty.
Automatic start not possible: deck is occupied
Pick is not possible if there is already a pallet on the
deck.
The machine has performed movement, but the
status of occupancy sensor has not changed. Check
the situation.
Check if transport system is without alarms and in
automatic mode.
Check if transport system is without alarms and in
automatic mode.
Remove obstacle and check sensor on transport
system.
Remove obstacle and check sensor on transport
travel
Shuttle travel out of range
23 Material movement not successful
24 Transport system conveyor not ready - pick
25 Transport system conveyor not ready - deposit
65 No clearance between shuttle and transporter 12
66 No clearance between shuttle and transporter 122
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5 OPERATING INSTRUCTIONS AND FAULT FINDING PROCEDURES
system.
67 No clearance between shuttle and transporter 211
E-STOP push button, CP101
Remove obstacle and check sensor on transport
system.
Remove obstacle and check sensor on transport
system.
Remove obstacle and check sensor on transport
system.
Remove obstacle and check sensor on transport
system.
Remove the pallet or material (plastic foil) that was
jammed in the gap between the shuttle and
conveyors.
Release the stop button on the cabinet.
E-STOP push button, CP201
Release the stop button on the cabinet.
E-STOP push button, CP301
Release the stop button on the cabinet.
E-STOP push button, CP401
Release the stop button on the cabinet.
Door to shuttle open
Close door.
Door to C101 open
Close door.
Door to C201 open
Close door.
Door to C301 open
Close door.
Light grid - MLG, T10
Check light grid, remove any obstacles and reset
error.
Check light grid, remove any obstacles and reset
error.
Check light grid, remove any obstacles and reset
error.
MFCS has issued a command for a pallet which is not
on crane.
MFCS has requested the crane to raise an error.
Usually due to the too long pickup/deposit operation
on conveyors.
MFCS has requested the crane to raise an error.
68 No clearance between shuttle and transporter 222
69 No clearance between shuttle and transporter 311
70 No clearance between shuttle and transporter 21
71 No clearance between shuttle and conveyors - path not
clear
72
73
74
75
79
80
81
82
83
84 Light grid - MLG, T110
85 Light grid - MLG, T21
90 Barcode mismatch: deck
91 MFCS: unknown error
92 MFCS: synchronization failure
115 Service M required
116 Service 3M required
117 Service 6M required
118 Service 12M required
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Maintenance of crane is required. After maintenance
is done, confirmation on operator’s panel is needed.
Maintenance of crane is required. After maintenance
is done, confirmation on operator’s panel is needed.
Maintenance of crane is required. After maintenance
is done, confirmation on operator’s panel is needed.
Maintenance of crane is required. After maintenance
is done, confirmation on operator’s panel is needed.
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5.6.6.1 Material movement
In many situations, when the pallet movement is not successfully performed by shuttle, the manual intervention is
required.
Before starting the manual intervention, it is mostly advised to check the status of a pallet in the MFCS. With manual
operation place the pallet on the position shown in MFCS.
If, for some reason, the operator decides, to manually complete the unfinished command, the material picture on the
shuttle as well as on the MFCS system must be fixed to reflect the current situation. If the operator has unloaded a
pallet from the shuttle, he should delete its material picture on the shuttle, or, if he has loaded the pallet onto the
shuttle, he should enter the correct barcode.
The material picture can be changed via the operators’ panel.
5.6.6.1.1
Changing the material picture via operators’ panel
Go to the service screen and click on “material” icon. The screen shown in Figure 5.50 appears. The barcode of the
pallet on the deck is shown. Value 0 means that there is no material picture on the deck.
Figure 5.50 Operators’ panel – changing of the material picture


If pallet is loaded in the manual mode to shuttle deck, enter its barcode in the “New” field and tap button on
the right side of entry field. If there is no pallet on the lifting carriage, the new barcode will not be accepted.
If shuttle deck is empty and you want to delete material picture, enter 0 in the “New” field to clear the
material picture. If there is a pallet on the lifting carriage, the material picture cannot be deleted.
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5.6.6.2 Service screen
Service screen on operators’ panel can be accessed only if user is logged in with username and password.
Service screen is accessed by pressing service button in
upper icon row.
Figure 5.51 Service screen on operators' panel
Service and maintenance of the shuttle is requested if remaining days or remaining operating hours for each service
elapsed. If service is needed, warning is triggered on MFCS. Shuttle can still operate although service warning is
present. Service warning can be reset only on operators’ panel on “Service” screen by pressing reset
service separately.
for each
Reset button can be pressed only if service is done according to scheduled maintenance plan!
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5.7 Shuttle S501
5.7.1 Start-up and shut-down of switching cabinets
The start-up procedure of the shuttle is as follows.


Turn the switch +SB1-8Q1 on the main power cabinet to position ON.
Turn the switch +L01-302Q1 on the shuttle main cabinet +L01 to position ON.
Shut-down procedure for the shuttle is executed in reversed order.


Turn the switch +L01-302Q1 on the shuttle main cabinet +L01 to position OFF.
Turn the switch +SB1-8Q1 on the main power cabinet to position OFF.
5.7.2 Emergency Shut-Down
Emergency shut-down may be activated through:




Safety switches, which limit the shuttle’s movement area: travelling (308S1).
Mushroom safety button on main cabinet.
Doors for accessing the shuttle area from both ends of aisle.
Light grids.
When all mushroom safety buttons are pulled out and all safety switches deactivated, it is possible to reset the system
and start the movement again.
When operator accesses the shuttle, he needs to open a door to access the aisle. The faults on the shuttle can be
reset and machine locally operated only when the safety is re-established. To do this, the operator must press the
reset button to reset faults.
Movement is in exceptional situations possible also when the safety switches are activated. Safety override is only
possible in manual mode. In this case, the operator must turn the key for overriding the limit switches to position 1.
5.7.3 Regimes and modes of operation
The shuttle distinguishes between operation regimes:




Local regime:
o Manual mode
o Semi-automatic mode
Remote regime:
o Automatic mode
Auto finish mode,
No regime.
Local regime is used, when operator needs to control shuttle from operator’s panel or when access to aisle is needed to
disable inattentional automatic shuttle movement. When shuttle is in local regime it can operate only in manual or
semi-automatic mode from the panel.
Remote regime is normal operating regime, when machine is controlled remotely by MFCS.
5 OPERATING INSTRUCTIONS AND FAULT FINDING PROCEDURES
In manual mode, all movements of the machine are made by pressing the respective buttons on the operators’ panel.
In semi-automatic mode, a machine itself performs a simple operation that consists of a movement to the selected
location, loading of a material from that location, or the depositing of material to it. Manual or Semi-automatic mode
can be selected from the operators’ panel and are enabled only in local regime.
The control regime is signaled on the operators’ panel and on MFCS PC.
The regime of operation is set by position of key-locks located:


on each aisle entrance on aisle entrance enclosure, and
on the operators’ panel in the shuttle cabinet +L01.
Key on the aisle entrance enclosure can be set to LOCAL, REMOTE or AUTO FINISH position.
Key on the shuttle can be set to LOCAL or REMOTE position.
The local regime is enabled only when the key-locks are set in the following ways:

aisle entrance enclosure key to LOCAL, and shuttle key to LOCAL
The remote regime is enabled only when key-locks are set as follows:

aisle entrance enclosure key to REMOTE, and shuttle key to REMOTE
When shuttle is operating in REMOTE regime, AUTO FINISH regime can be enabled with changing key position from
REMOTE to AUTO FINISH. In AUTO FINISH regime, shuttle will finish current task and then stop. Shuttle will not start
executing next task to allow entrance to shuttle aisle. Always wait to shuttle finishes current task, otherwise automatic
reset could not be possible and manual intervention will be needed. When shuttle is stopped, key can be turned to
LOCAL position.
In all other key positions shuttle is in state NO-REGIME and cannot move.
Safety is regulated through system of two pairs of keys. Each pair consists of a key for a key-lock and a key for the door
lock.
Before approaching a shuttle, the operator should:




Switch key to AUTO FINISH on aisle entrance enclosure and wait till shuttle finishes current task.
Led light for operation on aisle entrance enclosure should be off, in case that led light is on or blinking,
operator should wait that shuttle finishes the current task.
When shuttle is stopped, carry the pair of keys, open the door to aisle, enter the aisle, and close the door.
By using the pair of keys turn the key-lock on the shuttle cabinet to LOCAL position.
Now the shuttle is in LOCAL regime and after resetting the faults, it can be operated from the operators’ panel.
When leaving a shuttle, the operator should:




Remove a pair of keys from the key-lock on shuttle cabinet; this is only possible when the key-lock is
switched to REMOTE position.
Leave the shuttle and close the aisle door.
Put the pair of keys to the key lock in aisle entrance enclosure and switch it to REMOTE position.
After resetting the faults, the system can be operated from MFCS.
In automatic mode, the shuttle is completely autonomous, and its movements are unpredictable.
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5.7.4 Operators’ panel
Operators’ panel is in the operators’ cabin as shown in Figure 5.52Error! Reference source not found.. Close to Simatic
panel there is a button for resetting the faults, and two key-locks: one is used to set the mode of the shuttle, while the
other is used to override the safety functions.
Figure 5.52 Operators’ panel
5.7.4.1 Physical buttons
The operators’ panel has eight physical buttons. Close to operators’ panel is the safety stop button that can be used in
case of emergency stop is needed. If the button is pressed, the shuttle will brake on emergency ramp, this can cause
undesirable effects and should only be used in case of an emergency.
Figure 5.53 Operators’ panel with physical buttons.
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5.7.4.2 HMI
The main screen, manual screens and automatic screen share the status values shown in Figure 5.54. They represent:



Physical position is given as a numbered value, presenting coordinates in millimetres: Shuttle’s horizontal
position and inclination position for both decks.
Distance to the nearest logical position (slot in a rack, conveyor) given in millimetres.
Nearest logical position (slot in a rack, conveyor) designated with two indices giving the logical coordinate
Figure 5.54 HMI Screen
5.7.4.2.1
Buttons
There are six buttons on top of the main screen as shown in Table 5.6. With pressing button operator change screen or
execute an action.
Table 5.6 Buttons and their actions
Button
Action
Opens the shuttle manual operation screen, for a detailed description check Chapter
5.7.4.4.1
Opens the semi-automatic operation screen, for a detailed description check Chapter
5.7.4.4.2
Opens the shuttle sensor screen, for a detailed description check Chapter 5.7.4.3
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Opens the alarm screen on which we display all the alarms, as shown Figure 5.55. If an alarm
is present, the button flashes red.
If a user is not logged in the login popup widow appears and prompts the user for the
username and password. If a user is logged in the button shows the advanced menu form
which the operator can edit shuttle parameters.
Toggles between the Turkish and English language.
Figure 5.55 Alarms screen
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5.7.4.2.2
Shuttle regime - controlling partner
The first icon represents shuttle regime, on the icon is seen which device can control the shuttle. There are three
different icons of which two are used for displaying the controlling partner, as shown in the Figure 5.56.
Figure 5.56 Shuttle regime icons
Shuttle regimes icons:
No regime selected. This symbol is used to show that there is no clear controlling partner. This is
achieved when keys aren’t in appropriate positions. Shuttle movement is not possible.
Shuttle is in local regime and can be controlled via the operator’s panel.
Shuttle is in remote regime and is controlled by the MFCS.
Figure 5.57 Shuttle regime
5.7.4.2.3
Shuttle mode
Shuttle mode is displayed via assorted buttons background colours as shown in Figure 5.58.
Figure 5.58 All mode colors
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Colour meaning:
1.
2.
3.
4.
5.
5.7.4.3
Cyan represents that the shuttle is in manual mode.
Red represents that the shuttle as the safety override key switch active.
Blue represents that the shuttle is automatic mode.
Green represents that the shuttle is operating automatically.
Turquoise represents that the shuttle is in automatic finish mode.
Sensors
The sensors screen contains overview of shuttle sensors. Each sensor is represented by a circle accompanied with the
electrical plan identifier for that specific sensor. If the sensor is inactive, it is presented as a grey circle. If the sensor is
active, it is presented as a green circle or red if it’s safety related.
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5.7.4.3.1
Shuttle
Figure 5.59 Shuttle sensors screen
If the shuttle is occupied, field with palette barcode number is displayed.
The functionality of the sensors is as follows (electrical plan identifier: description):











308S1: the mechanical limit switch for horizontal movement - gantry,
310S1, 310S2: magnet switch slow for horizontal movement – gantry,
334B1, 334B2: optical sensors for checking the clearance between shuttle and rack,
336B1: rack occupied on deck S501
336B3: rack occupied on deck S502
334B1: conveyor slow deck S501
334B3: conveyor slow deck S502
334B2: conveyor stop deck S501
334B4: conveyor stop deck S502
325B1: inclination reference sensor on deck S501
325B2: inclination reference sensor on deck S502
5.7.4.4 Mode
If the shuttle is controlled via MFCS, it operates in the automatic mode, where command come from the MFCS.
If the shuttle is controlled via the operators’ panel as explained in the Chapter 5.7.4.2.2, then the operator can set
control mode by clicking the button
for local mode, or button
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5.7.4.4.1
Manual
First button activates the manual control of the shuttle. Operator can control shuttle movement from that screen.
Arrows above physical buttons represent the direction of movement.
F1 - Fast speed movement, must be pressed with other action button F1...F7.
F2, F3 - Horizontal movement of shuttle – gantry (F2 – forward, F3 - backward).
F4, F5 - Inclination movement (F4 – up, F5 - down).
F6, F7 - Conveyor movement (F6 – forward - toward dynamic rack, F7 – backward).
F8 - Reset faults.
With button above keys F4 to F7 – “Deck 501/502” you select which deck is controlled.
Figure 5.60 Manual mode shuttle screen
Manual movement is possible while a fault is present.
Incautious manipulation with the shuttle in manual mode can cause serious injuries to the equipment and rack
construction.
When a limit switch is activated, the shuttle can only be operated by overriding the safety functions. This is achieved by
turning the limit switch override key and then resetting the faults. When the limit switches are overridden, the shuttle
can be operated only at slow speed. The activation of the safety override key switch is also signalized as explained in
Chapter 5.7.4.2.3.
The manipulation with overridden safety functions must be performed very cautiously, due to disabled safety
devices.
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5.7.4.4.2
Semi-automatic
Button
activates the semi-automatic mode, where the operator inputs the desired action and location in the input
fields. When the start button is pressed the shuttle starts executing requested task.
Figure 5.61 Automatic mode screen
Input fields:
8.
Command, where the operator selects the desired action from a drop-down list. There are three options for
each deck:
a. - - - - – which symbolizes no action is selected
b. Move – which symbolizes that the shuttle will move to the selected location.
c. Pick - which symbolizes that the shuttle will move to the selected location and collect the material at
that location.
d. Drop - which symbolizes that the shuttle will move to the selected location and deposit the material
at that location.
9. Rack, were the entered 52 for dynamic rack or 0 for conveyors.
10. Travel, were the entered number represents the desired horizontal location in dynamic rack or index in
dynamic rack construction.
After all the fields are entered and selected, the start button must be pressed which triggers the execution of the
entered task. The execution of the task can be stopped at any time with pressing the cancel button.
Shuttle can pick from two conveyors simultaneously.
Shuttle can drop in rack construction simultaneously if rack slots are close to each other.
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Start button.
Cancel button.
Figure 5.62 Start and cancel buttons
The active order is displayed in the current task output fields. The last field is the state machine status which represents
the current step of the step machine (used troubleshooting).
The state machine field shows the current operation of the shuttle. It is given in terms of six-digit numbers with the
following meaning ssd1d1d2d2.
ss - Shuttle state machine:
o
o
o
o
o
00 … 01: initialization of a command,
10 … 12: deck inclination referencing,
30 … 31: movement to the target location,
40 … 41: deck pick or drop procedure,
90 … 99: alarm or other finalization steps.
dd – Deck state machine for each deck independently:
o
o
o
o
o
0: initialization of a command,
60 … 61: inclination movement down,
70 … 72: conveyor movement,
80 … 81: inclination movement horizontal position,
90 … 95: material movement and other finalization steps.
When switching from the manual to the semi-automatic mode the shuttle is not yet operating automatically, which is
signalized via colour as defined in the Chapter 5.7.4.2.3. To start the automatic operation, the start button must be
pressed. If the operation was successfully finished and regime not changed, then automatic operation can be continued
(is not reset).
Each time the automatic operation is started after reset or regime change, an audible warning is issued via the horn.
In case of an alarm during semi-automatic movement, the shuttle stops all actions (automatic operation is lost). After
reset of the faults, the shuttle continues to execute the command from its current state.
If the operator wishes to cancel the current task, the cancel button must be pressed.
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5.7.5 Parameter setting and calibration
5.7.5.1 Usernames and passwords
To access the calibration and parameter setting screens on operators’ panel, the user must specify the username and
password. The following are configured:

username: yag, password: yag
5.7.5.2 Fine tuning of slot and conveyor positions
The physical coordinates of each conveyor and rack are calculated from the mechanical drawings of the racks. Since
there are slight deviations of the physical rack regarding to the drawings, fine adjustment of slot positions is possible.
During the commissioning of the system the slot positions were already fine-tuned. In case of problems with some of
the positions, its offset with respect to the calculated position can be specified.
Offset of the travel must be set in such a way, that conveyor is properly aligned to rack construction or transport
conveyor.
5.7.5.2.1
Changing offsets using the operators’ panel
On the offset screen, shown in Figure 5.63, first enter the location in form of two-index value (rack and travel index)
and then press the Read button. Current travel offset in millimeters appear in grey fields.
In accordance to the current values write the new values to the white fields bellow. When pleased with the setting,
press the Write button to apply the new values.
Figure 5.63 Operator's panel: the teaching screen.
5.7.5.2.2
Parameter handling on operators’ panel
The parameter screen on operator’s panel enables users to save the parameter settings of the shuttle to the file on the
CF card. This is done by entering the file name in form of 6-digit number, for example by entering month, day and year
information, e.g. mmddyy. In the Figure 5.64 the number 190617 is entered to represent 19.6.2017. Afterwards the
save button can be pressed.
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Figure 5.64 Accessing the parameter files from operators’ panel
5.7.5.3 Adjustment of velocity, acceleration and offset parameters on operators’ panel
Parameters for velocity, acceleration and shuttle can be adjusted on operators’ panel parameter screen. Velocity and
acceleration can be adjusted for automatic and manual mode of shuttle operation. With offset parameter rack slots and
transport conveyor locations are changed for same constant offset. This can be useful in case of changing bar code tape
or absolute encoder position.
Figure 5.65 Operators panel: parameter adjustment screen
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5.7.6 Common faults and handling procedures
No.
Alarm description
Remedy
1
Fuse control 230 VAC, +L01-303F1, 303F2
Check the elements in the electrical cabinet.
2
Fuse control 24 VDC, +L01-304F2...304F8
3
Limit switch travel, +L01-308S1
4
E-STOP over rail - doors, +L01-309K1
5
E-STOP push button, +L01-309S1
Check the elements in the electrical cabinet.
Satellite travelled over the limit switch. Override
safety and in manual mode put the crane back to
the working area. Check for reasons.
Close aisle door or release the stop button on
outside cabinets.
Release the stop button on the cabinet.
6
Protection travel fan motor, +L01-320Q2
Check the elements in the electrical cabinet.
7
Protection conveyor brake - C501, +L01-321Q1
Check the elements in the electrical cabinet.
8
Protection inclination brake - C501, +L01-322Q1
Check the elements in the electrical cabinet.
9
Protection conveyor brake - C502, +L01-324Q1
Check the elements in the electrical cabinet.
10
Protection inclination brake - C502, +L01-325Q1
Check the elements in the electrical cabinet.
11
13
No clearance between trolley and left rack, +L01334B5
No clearance between trolley and right rack, +L01334B6
Axis error: travel
14
Axis error: inclination C501
15
Axis error: inclination C502
16
Axis error: conveyor C501
17
Axis error: conveyor C502
19
Travel motor running too long, +EXT-318M1
20
Inclination C501 motor running too long, +EXT322M1
Inclination C502 motor running too long, +EXT325M1
Conveyor C501 motor running too long, +EXT321M1
Conveyor C502 motor running too long, +EXT324M1
Communication error with transport system PLC
(receive direction)
Remove the pallet or material (plastic foil) that was
jammed in the gap between the shuttle and a rack.
Remove the pallet or material (plastic foil) that was
jammed in the gap between the shuttle and a rack.
Error on corresponding drive. See TO and DO drive
messages for details. Make sure that crane can
move freely.
Error on corresponding drive. See TO and DO drive
messages for details. Make sure that crane can
move freely.
Error on corresponding drive. See TO and DO drive
messages for details. Make sure that crane can
move freely.
Error on corresponding drive. See TO and DO drive
messages for details. Make sure that crane can
move freely.
Error on corresponding drive. See TO and DO drive
messages for details. Make sure that crane can
move freely.
Something is blocking the movement. Check for
reasons.
Something is blocking the movement. Check for
reasons.
Something is blocking the movement. Check for
reasons.
Something is blocking the movement. Check for
reasons.
Something is blocking the movement. Check for
reasons.
The conveyor PLC is not responding.
- Switch on the electrical cabinet.
- Check communication cables and optical link.
- Reset communication through SCADA system.
The conveyor PLC is not responding.
- Switch on the electrical cabinet.
- Check communication cables and optical link.
12
21
22
23
24
25
Communication error with transport system PLC
(send direction)
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- Reset communication through SCADA system.
26
Communication error with MFCS (receive direction)
MFCS is not responding.
27
Communication error with MFCS (send direction)
MFCS is not responding.
28
29
Enormous value of absolute encoder or magnet
switches - travel
Trolley travel out of range
30
Material mismatch: place C501
Check absolute encoder value and both magnet
switches.
Software limit switch was triggered. Move satellite
back to the working area.
Deck material occupancy differ from sensor state.
31
Material mismatch: place C502
Deck material occupancy differ from sensor state.
32
Inclination referencing for too long - C501
Check inductive referencing sensor.
33
Inclination referencing for too long - C502
Check inductive referencing sensor.
34
Protection travel motor brake, +L01-320Q1
Check the elements in the electrical cabinet.
41
Automatic start not possible: bad target
Check entered location.
42
Automatic start not possible: deck is empty - C501
Drop is not possible if satellite is empty.
43
Automatic start not possible: deck is empty - C502
Drop is not possible if satellite is empty.
44
46
Automatic start NOT possible: deck is occupied C501
Automatic start NOT possible: deck is occupied C502
Material movement not successful - C501
47
Material movement not successful - C502
48
Transport system conveyor NOT ready - pick C501
49
Transport system conveyor NOT ready - pick C502
50
Transport system conveyor NOT ready - drop C501
51
Transport system conveyor NOT ready - drop C502
52
Light grid - MLG, T21
53
Light grid - MLG, T321
54
Light grid - MLG, T322
55
Inclination not alligned: C501
56
Inclination not alligned: C502
58
Deposit not allowed, rack occupied: C501
59
Deposit not allowed, rack occupied: C502
62
Door opened, CP501
Pick is not possible if there is already a pallet on the
deck.
Pick is not possible if there is already a pallet on the
deck.
The machine has performed movement, but the
status of occupancy sensor has not changed. Check
the situation.
The machine has performed movement, but the
status of occupancy sensor has not changed. Check
the situation.
Check if transport system is without alarms and in
automatic mode.
Check if transport system is without alarms and in
automatic mode.
Check if transport system is without alarms and in
automatic mode.
Check if transport system is without alarms and in
automatic mode.
Check light grid, remove any obstacles and reset
error.
Check light grid, remove any obstacles and reset
error.
Check light grid, remove any obstacles and reset
error.
Check that deck is in horizontal position and
properly homed.
Check that deck is in horizontal position and
properly homed.
Dynamic rack is occupied, or sensor is not adjusted
properly.
Dynamic rack is occupied, or sensor is not adjusted
properly.
Close door.
63
Door opened, CP502
Close door.
64
No clearance between shuttle and T023
Remove obstacle and check sensor on transport
system.
45
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65
No clearance between shuttle and T024
66
No clearance between shuttle and T321
67
No clearance between shuttle and T322
68
111
No clearance between shuttle and rack 52, place X =
1..5
No clearance between shuttle and rack 52, place X =
6..12
No clearance between shuttle and rack 52, place X =
13..19
No clearance between shuttle and rack 52, place X =
20..24
Barcode mismatch: deck C501
112
Barcode mismatch: deck C502
113
MFCS: unknown error
114
MFCS: synchronization failure
115
Service M required
116
Service 3M required
117
Service 6M required
118
Service 12M required
69
70
71
Remove obstacle and check sensor on transport
system.
Remove obstacle and check sensor on transport
system.
Remove obstacle and check sensor on transport
system.
Remove obstacle and check sensor on transport
system.
Remove obstacle and check sensor on transport
system.
Remove obstacle and check sensor on transport
system.
Remove obstacle and check sensor on transport
system.
MFCS has issued a command for a pallet which is
not on crane.
MFCS has issued a command for a pallet which is
not on crane.
MFCS has requested the crane to raise an error.
Usually due to the too long pickup/deposit
operation on conveyors.
MFCS has requested the crane to raise an error.
Maintenance of crane is required. After
maintenance is done, confirmation on operator’s
panel is needed.
Maintenance of crane is required. After
maintenance is done, confirmation on operator’s
panel is needed.
Maintenance of crane is required. After
maintenance is done, confirmation on operator’s
panel is needed.
Maintenance of crane is required. After
maintenance is done, confirmation on operator’s
panel is needed.
5.7.6.1 Material movement
In many situations, when the pallet movement is not successfully performed by shuttle, the manual intervention is
required.
Before starting the manual intervention, it is mostly advised to check the status of a pallet in the MFCS. With manual
operation place the pallet on the position shown in MFCS.
If, for some reason, the operator decides, to manually complete the unfinished command, the material picture on the
shuttle as well as on the MFCS system must be fixed to reflect the current situation. If the operator has unloaded a
pallet from the shuttle, he should delete its material picture on the shuttle, or, if he has loaded the pallet onto the
shuttle, he should enter the correct barcode.
The material picture can be changed via the operators’ panel.
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5.7.6.1.1
Changing the material picture via operators’ panel
Go to the service screen and click on “material” icon. The screen shown in Figure 5.66 appears. The barcode of the
pallet on the deck is shown. Value 0 means that there is no material picture on the deck.
Figure 5.66 Operators’ panel – changing of the material picture


If pallet is loaded in the manual mode to shuttle deck, enter its barcode in the “New” field and tap button on
the right side of entry field. If there is no pallet on the lifting carriage, the new barcode will not be accepted.
If shuttle deck is empty and you want to delete material picture, enter 0 in the “New” field to clear the
material picture. If there is a pallet on the lifting carriage, the material picture cannot be deleted.
5.7.6.2 Service screen
Service screen on operators’ panel can be accessed only if user is logged in with username and password.
Service screen is accessed by pressing service button in upper
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Figure 5.67 Service screen on operators' panel
Service and maintenance of the shuttle is requested if remaining days or remaining operating hours for each service
elapsed. If service is needed, warning is triggered on MFCS. Shuttle can still operate although service warning is
present. Service warning can be reset only on operators’ panel on “Service” screen by pressing reset
service separately.
for each
Reset button can be pressed only if service is done according to scheduled maintenance plan!
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6 MATERIAL FLOW CONTROL SYSTEM I2MFCS
Material Flow Control System I2MFCS is a software tool that allows you to control and monitor the flow of material to
and from the warehouse. To do this, it must communicate with superior system like warehouse management system,
and orchestrate subordinate transport devices like conveyors and vehicles to complete the requested orders in a smart
and efficient way.
Basic unit of I2MFCS system is a transport unit (usually a pallet). I2MFCS does not care about the loading unit stored on
a transport unit.
In normal operation, I2MFCS gets orders or complex commands for transport of transport units from superior system.
Based on the system setup it tries to find the optimal way to move the transport unit from source to destination. To do
so, it must break a complex commands to a number of simple commands, and send them to adequate transport
devices in proper sequence. Transport devices try to perform the requested movements and reply to I2MFCS
accordingly. Based on the response from transport devices I2MFCS promptly informs superior system about command
execution.
In case of superior system malfunction or some special requirement, the system enables manual typing of complex as
well as simple commands.
All the above process is promptly visualized on the user interface in terms of tables and graphics. Real-time visualization
enables an operator to easily monitor the system and react appropriately in case of a need.
In event of system malfunction, a problematic device is highlighted and the reason for the malfunction is displayed as a
text message to allow an operator for quickly intervention with appropriate corrective measures.
6.1 Architecture
The software has modular architecture and is designed using modern concepts. As presented in Error! Reference
source not found., it consists of:




Database, to store all important information like commands, positions of transport units, configuration of
devices and locations,
Telegrams module for communicating with PLCs via TCPIP telegrams,
Core application, which includes all business logic, and
User interface module through which a user can interact with the system.
6 MATERIAL FLOW CONTROL SYSTEM I2MFCS
UI
Database
CORE
PLC
PLC
Telegram
UI
PLC
PLC
PLC
PLC
Figure 6.1 I2MFCS system architecture
6.1.1 Database
Microsoft SQL Express or Microsoft SQL server system can be used for manipulation of tables and records in a database.
The configuration of the database is performed during the commissioning by running SQL script.
6.1.2 Telegrams module
Telegrams module is implemented as Windows service and runs in the background on (preferably) server-type
Windows installation. It takes care of communicating with programmable logic controllers on one side and core
application on the other side. For communication with PLCs it uses a proprietary TCPIP protocol, which allows for
robust communication, and for communication with core module it uses WCF framework.
6.1.3 Core module
The Core module is also implemented as Windows service and runs in the background on (preferably) server-type
Windows installation. It is not necessary to run it on the same machine as Telegrams module. The module
communicates with superior system via web services, with Telegrams module via proprietary TCPIP protocol, with User
interface via WCF framework, and with database using SQL calls.
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Based on the current system state, it selects commands and coordinates its execution among transport devices like
conveyors, shuttle-cars, and stacker-cranes. From the received feedback it refreshes representation of the system in
the internal memory, database, and reports statuses to the superior system.
6.1.4 UI module
User interface module or UI module allows a user to monitor and control the warehouse system. It offers simple and
intuitive user interface, which allows for efficient operation of the warehouse. From UI module, a user can monitor and
control the behavior of the whole warehouse system.






At any time a user can check the real-time visualization od system with shown positions of transport devices,
transport units, crucial sensors, and all other vital information.
UI module provides visual and textual alarm messaging to enable a user for quick responseFrom UI module it is also possible to change the behavior of the system, enter new commands or change their
priority.
A user can check the position of a transport unit in the warehouse.
UI enables user to reconfigure the availability of slots in the warehouse.
A user can browse a database for past events.
User interface module runs as a stand-alone Windows desktop application. It is possible to run many client applications
simultaneously, which connect to the Core service installed on any machine in the network. A client application gets the
current data directly from the core module or from the database.
6.2 Using I2MFCS
6.2.1 Starting and stopping the application
6.2.1.1 Services
Services, running on server, should be configured to start automatically when server starts (Figure 6.2). I2MFCS CORE
service must be started in the name of an user who has permissions to access database, I2MFCS Telegrams service can
be started with Local System permissions.
Figure 6.2 I2MFCS services
6.2.1.2 Starting and closing UI module
To start UI module, a user has to double click i2MFC icon on the desktop (Error! Reference source not found.).
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6 MATERIAL FLOW CONTROL SYSTEM I2MFCS
Figure 6.3 I2MFCS UI module
To exit the UI module, an operator has to press cross in the top right corner (Figure 6.3).
6.2.2 Layout
Main screen in Figure 6.4 consists of main area, surrounded by the control panel on top, the status line at the bottom,
and the application menu on left side.
Figure 6.4 Screen layout
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6 MATERIAL FLOW CONTROL SYSTEM I2MFCS
6.2.2.1 Main area
On main area the user gets all available information. Its content depends on the item, selected in application menu.
6.2.2.2 Control panel
Control panel consists of several live tiles with included semaphores, which give an operator a quick and informative
overview of the system state. Each tile represents one important component of the warehouse system.
6.2.2.2.1
Tile MFCS/WMS
MFCS/WMS tile is used to change the mode of operation. When MFCS is selected and written inside the tile, only
manually entered commands are sent to execution. When WMS is selected, only commands received from WMS are
send to execution.
The semaphore above the tile shows weather the tile is active (green) or inactive (gray). Command are executed only
when the tile is active. Tile becomes inactive in case of some critical errors, or when user manually changes its state.
To change the mode, operator has to right-click the tile and from the context menu (Figure 6.5) select:




Execute WMS commands to switch to WMS mode,
Execute MFCS commands to switch to MFCS mode,
Start to enable execution of new commands,
Stop to stop execution of new commands.
Left-click on tile is equivalent to selecting Start from the context menu.
When a user does not have enough permissions, some context menu items may be inactive.
Figure 6.5 MFCS/WMS context menu
6.2.2.2.2
Device tiles
A device tile can represent one (vehicles) or many devices (conveyors). From the tile, we can observe device status and
perform some basic control.
Possible semaphore statuses are:





light blue: device offline,
black: device in local mode,
red: device in alarm,
yellow: device in remote automatic mode, inactive,
green: device in remote automatic mode, active.
From the device context menu (Figure 6.6) one can select:
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6 MATERIAL FLOW CONTROL SYSTEM I2MFCS




Reset to acknowledge active alarms,
Auto on to put a device from remote automatic inactive to active mode,
Auto off to put a device rom remote automatic active mode to inactive mode,
Refresh place data to get data about transport units on decks from corresponding programmable logic
controllers.
Figure 6.6 Device tiles with context menu
When a fault occurs device goes to alarm state (red). When fault is reset, or when a device mode of operation changes
from local to remote, device goes to remote automatic inactive mode (yellow). By selecting Auto on, device goes to
remote automatic active mode, where it is able to fetch and execute commands.
Left-click on tile is equivalent to selecting Reset from the context menu.
When a user does not have enough permissions, some context menu items may be inactive.
6.2.2.3 Status line
Status line at the bottom (Figure 6.4) displays the current user together with current date and time.
6.2.2.4 Application menu
By clicking on an item in application menu (Figure 6.4) a corresponding content appears in main area. For example,
when clicking on Visualization, a screen with real-time graphics appears, as in Figure 6.4. Currently selected item is
highlighted.
When a user does not have enough permissions, some application menu items may be inactive.
In next sections, application menu screens will be presented in detail in order of their appearance.
6.2.3 Visualization screen
Visualization screen shows a real-time schematic representation of the vital devices in the system (Figure 6.7). Its
graphics is prepared in such a way, to reflect the real-world setup.
Light blue graphics presents auxiliary equipment as racks and rails.
A segment or a vehicle is surrounded by a box, which changes its color according to its state. The box moves around a
display to make the visualization more realistic.
A segment or a vehicle box includes individual decks, displayed as rounded gray squares. Each deck has a nametag,
which corresponds to the mechanical drawings. Small circles outside the top left corner of the square represent some
vital sensors:


on top is the status of deck occupancy sensor,
second signals middle fork position in case of cranes.
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When a deck is occupied with a transport unit, the square becomes black with a wider border and has transport unit ID
written inside, like in place T002 in Figure 6.7.
Figure 6.7 Visualization screen
A box, representing conveyor system segment (a group of conveyors) or vehicle (shuttle or crane), is changes its color
according to the status of a segment/vehicle. The color-coding is the same as for tiles in the control panel:





light blue: offline,
black: local mode,
red: in alarm,
yellow: remote automatic inactive,
green: remote automatic active.
A user can control a device through a context menu, which appears after right-click on a device (Figure 6.8).
Figure 6.8 Segment/device context menu
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The meaning of the context menu commands:








Reset: acknowledges active alarms,
Auto on: changes device mode from remote automatic inactive to remote automatic active,
Auto off: changes device mode from remote automatic active to remote automatic inactive,
Home: issues a command to move a device to home position,
Maintenance on: informs WMS that a devices will be blocked for longer time due to malfunction or service,
Maintenance off: informs WMS that a device is again available for operation,
Refresh place data: gets current transport unit information from programmable logic controller,
Set time: synchronizes real-time clock of programmable logic controller with I2MFCS time.
By hovering a mouse pointer over a device some additional information is pop-up. The contents differs from device to
device. Example in Figure 6.9 shows a device mode, currently performed operation (state machine), positions given in
terms of rack locations (logical) and in millimeters (physical). For each deck it also displays transport unit on it (TU), and
a task it executes (execute) and a task which is about to execute (buffer). It also shows some vital sensor information.
Figure 6.9 Detail info pop-up
6.2.4 Alarms screen
Alarms screen displays information about currently active alarms. If the system is running error-free, the table is empty.
Error! Reference source not found. shows an example of alarm screen with some active alarms. The table includes the
following information:





Time when an alarm has arrived,
Unit which send an alarm,
Alarm ID
Alarm status, which can be active, acknowledged, or removed, and
Alarm description.
By pressing the reset button on the right of the table, request to acknowledge alarms is sent to all devices in the
system. Successfully acknowledged alarms are then removed from the screen.
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Figure 6.10 Alarms screen
6.2.5 Commands screen
Commands screen (Figure 6.11 ) is one of the most important screens. On this screen, an operator can check the status
of commands, and manage them. Main screen area is split to three parts:



Commands table at top-left,
Detailed simple commands table at bottom-left, and
Control desk on the right side.
6.2.5.1 Tables
6.2.5.1.1
Description
Commands table shows information about commands. It displays:



WMS ID: has a value greater than 0, if a command was received from WMS, and 0, if command was issued
from MFCS,
MFCS ID: each command gets its unique MFCS ID.
Task: explains the purpose of a command. It can be
o Material commands (create, move, delete),
o Segment commands (reset, auto on, auto off),
o Other commands (cancel of an existing command),
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6 MATERIAL FLOW CONTROL SYSTEM I2MFCS









TU: shows information about transport unit involved in a command (for material commands),
Source: position of a transport unit before command start (form material commands),
Target: target position of a transport unit at command completion (for material commands),
Segment: conveyor segment or vehicle name (for segment commands),
Cancel: MFCS ID of a command to be canceled (for job commands),
Priority: commands with higher number will be executed earlier,
Info: some text description of a command,
Status: shows the status of a command. It can be:
o Not active when a command is waiting for execution,
o Active when a command is in execution,
o Finished when a command is completed, and
o Canceled when WMS or a user has canceled it.
Time: a time when a command entered a system.
On Detailed simple commands screen one can observe how the selected complex command splits to a number of
simple commands. All simple commands share common MFCS ID, but have different IDs. This IDs can be also observed
in Visualization screen. Task column displays a simple command in descriptive way. Status can be:




Not active, when a simple command is waiting for execution,
Written, when a simple command is send to PLC for execution,
In PLC, when it is executing in PLC, and
Finished, when it is completed.
6.2.5.1.2
Working with tables
When a user selects a command, its details display on the control desk.
By clicking on a column header, command sort ascending or descending with respect to the information stored in this
column.
Many command headers possess a filter icon. By clicking on it, an input field appears to which a user can enter a text
required in displayed records. In Error! Reference source not found. text W:11 was entered to Target column to display
only commands, which have target location in rack W:11.
Figure 6.11 Working with tables
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6 MATERIAL FLOW CONTROL SYSTEM I2MFCS
Figure 6.12 Commands screen
6.2.5.2 Entering commands
There are several command available on control desk on the right.
6.2.5.2.1
Refresh
Majority of tables in the application are not refreshed automatically. A user has to press the refresh button to update
the screen with latest values of database records.
6.2.5.2.2
CMD TU
By pressing CMD TU button, a user can enter a command, which involves transport unit operation. The command can
be:




Material move: to move a transport unit from source to destination,
Material delete: to delete a transport unit at source,
Material create: to create a transport unit at source,
Material info: only available from WMS to inform about the current status of a warehouse location.
Commands require additional parameters like:



TU: designation of a transport unit,
Source: current TU location,
Target: final TU location,
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

Info: any text,
Priority: higher number increases the priority.
When entering a command (Figure 6.13), the user interface helps user to fill the fields. If something is wrong or missing,
a warning is displayed. Some fields are interconnected, for example TU designation and source location. If user enters
source location, he can press small B button, and application will automatically fill in the transport unit ID. Similarly, by
pressing L button, source location is filled-in based on the entered transport unit information. When all fields are
correctly filled-up, the user should press the confirm button, to send the command to execution. Anytime during he can
also change his mind and cancel the operation.
Figure 6.13 Entering a move command
6.2.5.2.3
CMD Segment
By pressing CMD Segment button, a user can enter a command, which involves operation on conveyor segments or
vehicles. He can select among commands:





Segment info: refreshes information about the segment,
Segment on: to put segment to remote automatic active mode,
Segment off: to put segment to remote automatic inactive mode,
Segment reset: to acknowledge error on a segment in question,
Segment homing: to move a vehicle to predetermined service location.
For segment information, a user can enter exact segment designation, for example T00, T01, or vehicle name, for
example C1, C2. To address all segment at once, he can use an asterisk symbol (*).
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6.2.5.2.4
Restart and Delete
To restart or delete an existing command, a user must first select it. The command in question displays on control desk.
Now he can request to restart it, or delete it by pressing the corresponding button. To confirm the operation, an
operator must press Confirm button.
Additionally, in case of deletion, an operator must specify the reason, which can be:





PLC: for a problem on PLC level,
MFCS: a reason related to MFCS operation,
Operator: some reason related to business logic,
Location empty: when a slot from which a transport unit should be retrieved is empty,
Location full: when a slot to which a transport unit should be stored, is occupied.
It is important to enter the correct reason; otherwise, the system can retry the same command again and again.
6.2.6 Transport units screen
Transport units screen (Figure 6.14) holds information about position of transport units in the warehouse.
Figure 6.14 Transport units screen
From the control desk, a user can delete the selected transport unit, or create a new one on desired location. By using
move command, a transport unit can be booked to another location by issuing corresponding delete and create
command.
With the move command, the transport unit does not change its physical location; it only updates its location in the
database.
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6.2.7 Locations screen
Locations screen (Figure 6.15) serves for managing warehouse locations. The table lists all available locations in the
warehouse. A user can block a location, if it is broken or currently inaccessible. The reservation system is not used in
the Abalioglu warehouse. Locations are allotted to two classes: 1 is used for normal locations, which can hold only one
transport unit at the same time, and 999 for locations in gravitational warehouse, which can hold many transport units
at once.
Figure 6.15 Locations screen
6.2.8 Simple commands screen
For testing purposes, or for solving some strange situation in the warehouse, it might be better to enter simple
commands. Devices (conveyors, vehicles) are able to understand and directly execute them.
6.2.8.1 Switching between commands and simple commands mode
When on simple commands screen (Figure 6.16), a new tile Commands/Simple commands appear in the control panel.
By right-click we can select to:


Execute commands or
Execute simple commands only.
In normal operation, the new tile displays Commands. In this mode the Simple command table shows current status of
simple commands.
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When an operator wants to operate the devices by issuing simple commands, he must first change the mode of
operation in control panel to MFCS (left tile) and to Simple commands (the new tile). Now the execution of simple
commands, which MFCS generates from complex commands, stops.
Figure 6.16 Simple commands screen with new tile in control panel
6.2.8.2 Entering new commands
From the control desk on the right, we can enter many different simple commands:
6.2.8.2.1
Cmd conveyor simple commands
Move: to move a transport unit from source to target location; both locations are on conveyor system,
Create: to create a transport unit on desired source location,
Delete: to delete a transport unit from desired location,
6.2.8.2.2
Cmd vehicle simple commands
Move: to move a vehicle to a given location,
Pick: to pick a transport unit from a given location,
Drop: to drop a transport unit to a given location,
Delete: to delete a transport unit from a vehicle deck,
Create: to create a transport unit on a vehicle deck,
Cancel: to cancel current simple command performed by a vehicle.
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6 MATERIAL FLOW CONTROL SYSTEM I2MFCS
6.2.8.2.3
Segment commands simple commands
Reset: tries to acknowledge alarms on a segment or a vehicle,
Info: requires information update for a segment or a vehicle,
Segment on: puts a segment/vehicle to remote automatic active mode,
Segment off: puts a segment/vehicle to remote automatic inactive mode.
6.2.8.2.4
Restart and delete simple commands
On one hand an inactive command can be repeated by selecting Restart button. On the other hand, a command can be
canceled by selecting Delete button. Each operation must be Confirmed before it goes to execution.
6.2.9 Events screen
Events screen in Figure 6.17 serves merely as detailed log of I2MFCS operation. It is useful in case of problems. The
records include:




Time stamp,
Severity description (Event, warning, error, exception),
Type (module that logged the information), and
Description in plain English only.
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6 MATERIAL FLOW CONTROL SYSTEM I2MFCS
Figure 6.17 Event screen
6.2.10 History screens
By using history screens, user can browse the database for past events. There are many history screens:





Alarms screen hold information of all alarms that appeared in the past,
Movements screen gives detailed information about transport unit movement in the warehouse,
Commands screen lists all complex commands,
Simple commands screen lists all simple commands, and
Events screen presents all events that appeared in the past.
Each history screen includes simple filter above the table as for example Movements screen in Figure 6.18. User must
enter start and end date to display a time interval of his interest. On some screens, it is also possible to put filter on
some other columns. For example, in Movements screen one can select specific location and observe the flow of
transport units over it, or give a transport unit data, to check its movements in the warehouse.
The filter is applied when user presses the Refresh button. For records present in table, a user can use sorting and
additional filtering from column headers.
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Figure 6.18 Movement screen
6.2.11 Setting screen
Setting screen displayed in Figure 6.19 servers for



changing user,
changing the application language, and
managing the database.
6.2.11.1 User management
Application starts with a user with very low permission level.
By entering the right user and password, another user can be logged in the system. User logging is mainly used to
elevate permission level to use some advanced functions of the system. When elevated permission are not needed
anymore, the user should be logged out.
There are three default users:



user: User, password: yag, with minimal permissions,
user: Operator, password: 0p3rat0r, with some additional permission, and
user: Admin, password: I2MFCSr00t.
Additional users with password and desired permission levels can be entered directly into the database.
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6 MATERIAL FLOW CONTROL SYSTEM I2MFCS
6.2.11.2 Change language
Application language can be changed on-the-fly by clicking on Other language button.
6.2.12 Database management
With years, the database increases. When it reaches its limits (currently set to 6 GB) it is necessary to compact it.
The database can be compacted manually by using SQL commands directly by Microsoft SQL server tools, or
automatically by pressing Reduce database button. The latter, deletes the least important records to get additional 1
GB of space.
Before compacting, make complete backup of the database. This operation is only allowed for IT specialists!
Figure 6.19 Setting screen
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7 MAINTENANCE
7.1 Mechanical maintenance
7.1.1 Conveyor system
7.1.1.1 Chain conveyor
7.1.1.1.1
Inspection
Daily inspection
Make visual control that transport load runs straight through hole line of conveyors.
Monthly and quarterly inspection must include:





general visual and functional control
control of the tension of the chains
oil level control and leakage control of the gearboxes
check straight running of the transported load.
carry out sound control of the bearings and gearboxes.
Annual inspection must include:





carry out monthly inspection in more precisely manner
if necessary, disassembled some elements in order to carry out cleaning, lubrication and control. Especially all
rollers and belts must be checked.
general maintenance of the gearboxes should be carried out by the specialist
check all bolts
clean up the whole machine and repaire colour if there are some damages
General inspection
In case that some serious maintenance of the equipement was carried out (maintenance, setting up bigger number of
components at the same time) general inspection must be carried out.




carry out inspection in very precise manner
maintanance management must decide for the general inspection intervals but it should be done at least every
5 years
general inspection must be done if there were some serious damages and repairement of the equiepement
complete functional test must be carry out after general inspection was done
7 MAINTENANCE
7.1.1.1.2

Maintenance
Driving station
2
1
4
3
Figure 7.1 Driving station
Table 7.1 Maintanance parts of the driving station
Working hours/ months
Pos.
1
Name
motorgearbox
2.000 / 6
4.000 / 12
2
Housing unit with
bearing
1.000 / 3
3
Driving sprocket
2.000 / 6
2.000 / 6
4
Clamping device
2.000 / 6
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
 To be checked
- to be maintained
 oil level control
smoothnes by
running
cleaning of the
cooling ribs
control of the brake
clearance
-oil changing
 breakdown
wear out
-lubrication
 breakdown
wear out
 attachment
Chapter
Instructions
read SIEMENS
replace
replace
Aralub SKA 00
replace
replace
replace
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7 MAINTENANCE

Other parts
1
2
3
4
Figure 7.2 Maintanance parts of the chain conveyor
Table 7.2 Maintanance parts of the chain conveyor
Working hours/ months
Pos.
1
Name
Bearing
2.000 / 6
2
Sprocket
2.000 / 6
3
Chain
1.000 / 3
4
Chain guiding
1.000 / 3
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
 To be checked
- to be maintained






breakdown
wear out
breakdown
wear out
breakdown
wear out


breakdown
wear out
Instructions
replace
replace
Chapter
replace
replace
replace
replace
replace
replace
197/251
7 MAINTENANCE
7.1.1.1.3
Lubrication plan
Table 7.3 Lubrication plan of the chain conveyor
Pos.
Name
1
Motorgearboxes
2
3
Chain
Housing unit with bearings

Lubrication interval
(days)
according to SIEMENS
documentation
90
90
Lubricator
WKS special
FOR LPD-2
Aralub SKA
00
Quantity of
lubricator
til lubricator
comes out
Way of
lubrication
Sprey
with hand tool
Lubrication scheme
3
1
2
Figure 7.3 Lubrication scheme of the chain conveyor
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7 MAINTENANCE
7.1.1.2 Roller conveyor 01
7.1.1.2.1
Inspection
Daily inspection
Make visual control that transport load runs straight through hole line of conveyors.
Monthly and quarterly inspection must include:




general visual and functional control
oil level control and leakage control of the gearboxes
check straight running of the transported load.
carry out sound control of the rollers and gearboxes.
Annual inspection must include:





carry out monthly inspection in more precisely manner
if necessary, disassembled some elements in order to carry out cleaning, lubrication and control. Especially all
rollers and belts must be checked.
general maintenance of the gearboxes should be carried out by the specialist
check all bolts
clean up the whole machine and repaire colour if there are some damages
General inspection
In case that some serious maintenance of the equipement was carried out (maintenance, setting up bigger number of
components at the same time) general inspection must be carried out.




carry out inspection in very precise manner
maintanance management must decide for the general inspection intervals but it should be done at least every
5 years
general inspection must be done if there were some serious damages and repairement of the equiepement
complete functional test must be carry out after general inspection was done
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7 MAINTENANCE
7.1.1.2.2
ATTENTION
Maintenance
Danger of falling.
-Never stand on the rollers of the conveyor.
Figure 7.4 Maintanance parts of the roller conveyor
Table 7.4 Maintanance parts of the roller conveyor
Working hours/ months
Pos.
1
Name
motorgearbox
2.000 / 6
4.000 / 12
2
Timing sprocket
1.000 / 3
3
Taper Lock bush
4.000 / 12
4
Driving timing belt
2.000 / 6
5
Driven timing belt
2.000 / 6
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
 To be checked
- to be maintained
oil level
control
smoothnes by
running
cleaning of the
cooling ribs
control of the
brake clearance
- oil changing
 breakdown
 wear out
 attachment





breakdown
wear out
breakdown
wear out
Instructions
read SIEMENS
Chapter
13
replace
replace
replace
replace
replace
replace
replace
200/251
7 MAINTENANCE
6
Roller
4.000 / 12


7.1.1.2.3
breakdown of
bearings
wear out
replace
replace
Lubrication plan
Table 7.5 Lubrication parts of the roller conveyor
Pos.
Name
Lubrication interval (days)
1
Motorgearboxes
according to SIEMENS
documentation

Lubricator
Quantity of
lubricator
Way of
lubrication
Lubrication scheme
1
Figure 7.5 Lubrication scheme of the roller conveyor
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7 MAINTENANCE
7.1.1.3 Roller conveyor 02
7.1.1.3.1
Inspection
Daily inspection
Make visual control that transport load runs straight through hole line of conveyors.
Monthly and quarterly inspection must include:




general visual and functional control
oil level control and leakage control of the gearboxes
check straight running of the transported load.
carry out sound control of the rollers and gearboxes.
Annual inspection must include:





carry out monthly inspection in more precisely manner
if necessary, disassembled some elements in order to carry out cleaning, lubrication and control. Especially all
rollers and belts must be checked.
general maintenance of the gearboxes should be carried out by the specialist
check all bolts
clean up the whole machine and repair colour if there are some damages
General inspection
In case that some serious maintenance of the equipment was carried out (maintenance, setting up bigger number of
components at the same time) general inspection must be carried out.




carry out inspection in very precise manner
maintenance management must decide for the general inspection intervals but it should be done at least
every 5 years
general inspection must be done if there were some serious damages and repairement of the equipment
complete functional test must be carry out after general inspection was done
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7 MAINTENANCE
7.1.1.3.2
ATTENTION
Maintenance
Danger of falling.
-Never stand on the rollers of the conveyor.
Figure 7.6 Maintanance parts of the roller conveyor
Table 7.6 Maintanance parts of the roller conveyor
Working hours/ months
Pos.
1
Name
motorgearbox
2.000 / 6
4.000 / 12
2
Timing sprocket
1.000 / 3
3
Taper Lock bush
4.000 / 12
4
Driving timing belt
2.000 / 6
5
Driven timing belt
2.000 / 6
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
 To be checked
- to be maintained
 oil level control
smoothnes by
running
cleaning of the
cooling ribs
control of the brake
clearance
- oil changing
 breakdown
 wear out
 attachment



breakdown
wear out
breakdown
Instructions
read SIEMENS
Chapter
13
replace
replace
replace
replace
replace
replace
203/251
7 MAINTENANCE
6
Roller
4.000 / 12



7.1.1.3.3
wear out
breakdown of
bearings
wear out
replace
replace
replace
Lubrication plan
Table 7.7 Lubrication parts of the roller conveyor
Pos.
Name
Lubrication interval (days)
1
Motorgearboxes
according to SIEMENS
documentation

Lubricator
Quantity of
lubricator
Way of
lubrication
Lubrication scheme
1
Figure 7.7 Lubrication scheme of the roller conveyor
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7 MAINTENANCE
7.1.1.4 Eccentric lifting table
7.1.1.4.1
Inspection
Daily inspection
Make visual control that the lines of conveying the pallet of chainand roller conveyor are perpendicural. Also check that
pallet is not inclined during lifting.
Monthly and quarterly inspection must include:





general visual and functional control
control of the tension of the driving chain
oil level control and leakage control of the gearboxes
check straight running of the transported load.
carry out sound control of the bearings and gearboxes.
Annual inspection must include:





carry out monthly inspection in more precisely manner
if necessary, disassembled some elements in order to carry out cleaning, lubrication and control. Especially all
rollers and belts must be checked.
general maintenance of the gearboxes should be carried out by the specialist
check all bolts
clean up the whole machine and repaire colour if there are some damages
General inspection
In case that some serious maintenance of the equipement was carried out (maintenance, setting up bigger number of
components at the same time) general inspection must be carried out.




carry out inspection in very precise manner
maintanance management must decide for the general inspection intervals but it should be done at least every
5 years
general inspection must be done if there were some serious damages and repairement of the equiepement
complete functional test must be carry out after general inspection was done
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7 MAINTENANCE
7.1.1.4.2
Maintenance
Lifting device

1
2
4
6
3
5
7
Figure 7.8 Maintanance parts of the lifting device
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7 MAINTENANCE
Table 7.8 Maintanance parts of the lifting device
Working hours/ months
Pos.
1
Name
motorgearbox
2.000 / 6
4.000 / 12
2
Gliding bearing
2.000 / 6
3
Clamping device
2.000 / 6
4
Driving sprocket
2.000 / 6
5
Driven sprocket
2.000 / 6
6
Driving chain
1.000 / 3
7
Housing unit with
bearing
2.000 / 6
7.1.1.4.3
 To be checked
- to be maintained
 oil level control
smoothnes by
running
cleaning of the
cooling ribs
control of the brake
clearance
- oil changing
 breakdown
 wear out
 attachment
 breakdown
 wear out
 breakdown
 wear out
 breakdown
 wear out
-lubrication
 breakdown
 wear out
-lubrication
Instructions
read SIEMENS
Chapter
replace
replace
replace
replace
replace
replace
replace
replace
replace
WKS special
replace
replace
-Aralub SKA 00
Lubrication plan
Table 7.9 Lubrication parts of the lifting device
Pos.
Name
Lubrication interval (days)
1
Motorgearboxes
2
3
Chain
Housing unit with bearings
according to SIEMENS
documentation
90
90
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
Lubricator
WKS special
FOR LPD-2
Aralub SKA
00
Quantity of
lubricator
til lubricator
comes out
Way of
lubrication
Sprey
with hand tool
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7 MAINTENANCE

Lubrication scheme
3
1
2
Figure 7.9 Lubrication scheme of the lifting device
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7 MAINTENANCE
7.1.1.5 Stopper
7.1.1.5.1
Inspection
Daily inspection
Make visual control that the lines of conveying the pallet of chainand roller conveyor are perpendicural. Also check
paralelity of the stopper.
Monthly and quarterly inspection must include:




general visual and functional control
control of the guiding linear profiles and trolleys
oil level control and leakage control of the gearboxes
carry out sound control of the bearings and gearboxes.
Annual inspection must include:





carry out monthly inspection in more precisely manner
if necessary, disassembled some elements in order to carry out cleaning, lubrication and control. Especially all
rollers and belts must be checked.
general maintenance of the gearboxes should be carried out by the specialist
check all bolts
clean up the whole machine and repaire colour if there are some damages
General inspection
In case that some serious maintenance of the equipement was carried out (maintenance, setting up bigger number of
components at the same time) general inspection must be carried out.




carry out inspection in very precise manner
maintanance management must decide for the general inspection intervals but it should be done at least every
5 years
general inspection must be done if there were some serious damages and repairement of the equiepement
complete functional test must be carry out after general inspection was done
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.1.5.2
Maintenance
3
2
1
Figure 7.10 Maintanance parts of the stopper
Table 7.10 Maintanance parts of the stopper
Working hours/ months
Pos.
1
Name
motorgearbox
2.000 / 6
4.000 / 12
2
Linear guiding
2.000 / 6
3
Trolley
2.000 / 6
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
 To be checked
- to be maintained
 oil level control
smoothnes by
running
cleaning of the
cooling ribs
control of the brake
clearance
- oil changing
 breakdown
 wear out
 breakdown
 wear out
-lubricate
Instructions
read SIEMENS
Chapter
replace
replace
replace
replace
-Aralub SKA 00
210/251
7 MAINTENANCE
7.1.1.5.3
Lubrication plan
Table 7.11 Lubrication parts of the stopper
Pos.
Name
Lubrication interval (days)
1
Motorgearboxes
2
Trolley
according to SIEMENS
documentation
90

Lubricator
Quantity of
lubricator
Way of
lubrication
FOR LPD-2
Aralub SKA
00
til lubricator
comes out
with hand tool
Lubrication scheme
2
1
Figure 7.11 Lubrication scheme of the stopper
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.1.6
Contour check
7.1.1.6.1
Maintenance

Weight control
1
Figure 7.12 Maintanance parts of the weight control
Table 7.12 Maintanance parts of the weight control
Working hours/ months
Pos.
1
Name
Weighting cells
1.000 / 3
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
 To be checked
- to be maintained
 breakdown
Instructions
replace
Chapter
212/251
7 MAINTENANCE

Pallet base control
1
2
Figure 7.13 Maintanance parts of the base control
Table 7.13 Maintanance parts of the base control
Working hours/ months
Pos.
1
Name
Supporting wheels
2.000 / 6
2
Guiding wheels
2.000 / 6
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
 To be checked
- to be maintained
 breakdown
 wear out
 breakdown
 wear out
Instructions
replace
replace
replace
replace
Chapter
213/251
7 MAINTENANCE
7.1.2 Shuttle C501
7.1.2.1 Maintenance
ATTENTION

Danger of moving of the machine.
-Never change all 4 wheels at the same time. Ensure that Machine is secured if some lifting of
the machine will be carry out.
Driving set
Figure 7.14 Maintanance parts of the driving set
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7 MAINTENANCE
Table 7.14 Maintanance parts of the driving set
Working hours/ months
Pos.
1
Name
motorgearbox
 To be checked
- to be maintained
 oil level control
smoothnes by
running
cleaning of the
cooling ribs
control of the brake
clearance
- oil changing
 breakdown
 wear out
 breakdown
 wear out
-lubrication
 breakdown
 wear out
 breakdown
 wear out
2.000 / 6
4.000 / 4
2
Driving wheel
1.000 / 3
3
Housing unit with
bearing
1.000 / 3
4
Guiding wheel
2.000 / 6
1.000 / 3
5
Brush
1.000 / 3

Instructions
read SIEMENS
Chapter
13
replace
replace
replace
replace
-Aralub SKA 00
replace
replace
replace
replace
Tilting table
2
1
3
Figure 7.15 Maintanance parts of the tilting table
Table 7.15 Maintanance parts of the tilting table
Working hours/ months
Pos.
1
Name
motorgearbox
2.000 / 6
4.000 / 4
2
rod end
2.000 / 6
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
 To be checked
- to be maintained
 oil level control
smoothnes by
running
cleaning of the
cooling ribs
control of the brake
clearance
- oil changing
 breakdown
 wear out
Instructions
read SIEMENS
Chapter
13
replace
replace
215/251
7 MAINTENANCE
3
gliding bearing

1.000 / 3

replace
wear out
Other elements
1
2
Figure 7.16 Other maintanance parts
Table 7.16 Other maintanance parts
Working hours/ months
Pos.
1
Name
Buffer
4.000 / 12
2
Current collector
1.000 / 3
7.1.2.1.1
 To be checked
- to be maintained
 breakdown
Instructions
read LEBEN
 wear out
-fixing
replace
-tighten fixing bolts
Chapter
13
Roller conveyor
Maintenance of the roller conveyor is described in the Chapter 7.1.1.3
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.2.2 Lubrication plan
Table 7.17 Lubrication elements of the shuttle
Pos.
Name
1
Motorgearboxes
2
Housing units with bearings
3
Roller conveyor

Lubrication interval
(days)
according to SIEMENS
documentation
90
Lubricator
Quantity of
lubricator
Way of
lubrication
FOR LPD-2
Aralub SKA
00
till lubrication
come out
with hand
lubrication tool
according to instructions
for roller conveyor
Lubrication scheme
1
2
2
3
1
Figure 7.17 Lubrication elements of the shuttle
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.3 Shuttle C401
7.1.3.1 Maintenance
ATTENTION

Danger of moving of the machine.
-Never change all 4 wheels at the same time. Ensure that Machine is secured if some lifting of
the machine will be carry out.
Driving set
Figure 7.18 Maintanance elements of the driving set
Table 7.18 Maintanance elements of the driving set
Working hours/ months
Pos.
1
Name
motorgearbox
2.000 / 6
4.000 / 4
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
 To be checked
- to be maintained
 oil level control
smoothnes by
running
cleaning of the
cooling ribs
control of the brake
clearance
- oil changing
Instructions
read SIEMENS
Chapter
13
218/251
7 MAINTENANCE
2
Driving wheel
1.000 / 3
3
Housing unit with
bearing
1.000 / 3
4
Guiding wheel
2.000 / 6
1.000 / 3
5
Brush
1.000 / 3

 breakdown
 wear out
 breakdown
 wear out
-lubrication
 breakdown
 wear out
 breakdown
 wear out
replace
replace
replace
replace
-Aralub SKA 00
replace
replace
replace
replace
Other elements
2
1
Figure 7.19 Other maintanance elements
Table 7.19 Other maintanance elements
Working hours/ months
Pos.
1
Name
Buffer
4.000 / 12
2
Current collector
1.000 / 3
7.1.3.1.1
 To be checked
- to be maintained
 breakdown
Instructions
read LEBEN
 wear out
-fixing
replace
-tighten fixing bolts
Chapter
13
Chain conveyor
Maintanance of the chain conveyor is described in the Chapter 7.1.1.1
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.3.2 Lubrication plan
Table 7.20 Lubrication elements of the shuttle
Pos.
Name
1
Motorgearboxes
2
Housing units with bearings
3
Chain conveyor

Lubrication interval
(days)
according to SIEMENS
documentation
90
Lubricator
Quantity of
lubricator
Way of
lubrication
FOR LPD-2
Aralub SKA
00
till lubrication
come out
with hand
lubrication tool
according to instructions
for chain conveyor
Lubrication scheme
1
2
2
3
Figure 7.20 Lubrication scheme of the shuttle
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.4 Crane
ATTENTION

Driving unit
ATTENTION

Before replacing the running wheel, bearings, the ride gear, or the free drive wheel set, lift the
framework of the crane for approximately 5mm by using an auxiliary lifting device. This
unloads the wheel set and enables unscrewing and replacement or elimination of faults.
Upper leading wheels
ATTENTION

Before any interference on the lifting unit, put the lifting carriage onto shock absorbers
situated on the bottom carrier.
Danger of the crane tipping over
Never change all upper leading wheels at the same time.
Lifting carriage
Guiding wheels of the lifting carriage have to be replaced in case of damaged bearings or when it becomes impossible
to eliminate the air slot by adjusting screws. After replacement of wheels, readjust the air slot.
For servicing the lifting carriage (in case when works have to be done from the lower side of the lifting carriage), two
supporting pillars must be provided. Lowering the lifting carriage on the pillars prevents uncontrolled descending of the
carriage.
ATTENTION
Do not lubricate the crane rail!
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.4.1 Bottom carriage
Table 7.21 Bottom carriage
Pos.
Name
6
Wheel
19
Motor a with
conical reduction
gear
20
21
Two row cylinder
bearing
Working
hours
4.600
2.000
2.300
3.000
Leading wheel
1.200
22
Locking device
4.600
 To be checked
- to be maintained
 damage
 wear
 oil level
 travel ease
 cleaning cooling ways
 test brake shoes, test working air
slot, change oil
Chapter
Replace wheel
Read SIEMENS
instruction, call
SIEMENS service
16
≤10 mm replace
0,3<“air slot“<1,2
Replace bearing
 damage
 wear
- lubricate






Instructions
damage
wearing out
travel ease
noise at run
fixing
tightening momentum
Lubricate with Aralub
SKA or Multitop
Leading wheel
change
Lubricate
Clamp set
replace
22
22
20
20
6
6
19
Figure 7.21 Bottom carriage
21
21
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.4.2 Lifting carriage
Table 7.22 Lifting carriage
Pos.
Name
6
Telescopic forks
Working
hours
3.000
7
Load pin
4.600
 To be checked
- to be maintained
 damage
 travel ease
 noise at run
 wear
- lubricate
 damage
 function
Instructions
Chapter
Read EUROFORK
manual
16
Read TECSIS manual
16
7
6
Figure 7.22 Lifting carriage
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
223/251
7 MAINTENANCE
7.1.4.3 Upper girder
Table 7.23 Upper girder
Pos.
Name
9
Leading wheel
Working
hours
4.600
10
Shrink disc
4.600
11
Pulley
4.600
 To be checked
- to be maintained
 damage
 travel ease
 noise at run
 wear
 fixing
 tightening momentum
 damage
 wear
 firm fixing
- no need for maintenance
Instructions
Chapter
Leading wheel
replace
Clamp set
replace
Replace pulley
11
9
10
Figure 7.23 Upper girder
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.4.4 Wheels on the lifting carriage
Table 7.24 Wheels on the lifting carriage
Pos.
Name
3
Wheel Φ230x36
Working
hours
1.200
4
Wheel Φ230x30
1.200
19
Guiding wheel
1.200
20
Guiding wheel
with axle
1.200
16
Shrink disc
4.600
17
Shrink disc
4.600
18
Shrink disc
4.600
21
Bearing
27
DU Bush
1.200
 To be checked
- to be maintained
 wear
 damage
 travel ease
 noise at run
- lubricate
 damage
 travel ease
 noise at run
- lubricate
 wear
 damage
 travel ease
 noise at run
- lubricate
 wear
 damage
 travel ease
 noise at run
- lubricate
 fixing
 tightening momentum
 fixing
 tightening momentum
 fixing
 tightening momentum
 damage
 wear
- lubricate
 damage
 wear
- lubricate
 wear
28
DU Washer
1.200
 wear
3.000
22
Bearing
3.000
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
Instructions
Chapter
Leading wheel
replace
Aralub SKA 00 or
Multitop
Leading wheel replace
Aralub SKA 00 or
Multitop
Leading wheel
replace
Aralub SKA 00 or
Multitop
Leading wheel
replace
Aralub SKA 00 or
Multitop
Clamp set
replace
Clamp set
replace
Clamp set
replace
Replace bearing
Lubricate with Aralub
SKA or Multitop
Replace bearing
Lubricate with Aralub
SKA or Multitop
Sliding washer
replace
Sliding bearing
replace
225/251
7 MAINTENANCE
4
16
19
21
18
19
20
27
28
20
3
17
27
28
22
Figure 7.24 Wheels on the lifting carriage
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.4.5 Lifting unit
Table 7.25 Lifting unit
Pos.
Name
1
Rope drum
Working
hours
4.600
9
Steel rope
2.300
11
Motor with conical
reduction gear
2.000
Instructions
 To be checked
- to be maintained
 damage
 leading profile worn out
 damage
 appearance of excessive wear
Chapter
Replace rope drum
Replace rope
Daily inspection of its
look!!!
Read SEW instruction,
call SEW service
oil level
Travel ease
cleaning of cooling ways
test brake shoes
– test working air slot
 change oil




16
 10 mm replace
0,3<“air slot“<1,2
11
9
1
Figure 7.25 Lifting unit
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.4.6 Maintenance of steel ropes
7.1.4.6.1
Lubrication of steel ropes
Lubricants:
Lifting rope – almost every grease can be used.
According to DIN 15020, the steel ropes of the lifting unit must be »regularly maintained, where the maintenance
procedure depends on the type of the lifting device, its use and the type of rope «.
Regular maintenance can considerably prolong life period of the rope.
Built-in DIEPA steel rope is soaked with a special highly resistant lubricant and anti-corrosion protective material. If dry
areas appear on the rope surface due to any reason the rope must be obligatory lubricated. Regular lubrication has a
very positive influence on life span of the rope.
Most frequently, the rope is lubricated with a brush or with a rag. When lubricated with a rag, the use of protective
gloves is obligatory.
ATTENTION
Hazard of damages with damaged and projecting parts or rope
Figure 7.26 Lubrication of the rope with a brush
ATTENTION
Almost all suitable oils and lubricants are allowed for lubricating the steel rope.
Lubricants almost do not penetrate in the interior of the rope therefore avoid excessive
lubrication. Excessive lubricant remains on the outer side of the rope and makes recognition of
damages and signs of wear difficult.
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.4.6.2
Removal of damaged wires
If damaged wires that could damage adjacent ropes at rope transition over the rope wheels are detected at inspection,
such damaged ends of wires have to be removed immediately. Never cut them off with pliers.
The best way of remediation is to bend such wire in different directions until the wire breaks somewhere near the rope.
Such parts of the rope must be marked and inspected in shorter time intervals.
7.1.4.6.3
Inspection of rope wear
During operation, the rope is exposed to permanent wearing. Therefore, it should be inspected in regular time
intervals.
A number of visible damages of the wires can disclose the wear level of ropes and the time when a rope needs to be
replaced. The rope must be inspected (possibly in the area of biggest folding) on two different distances.
Number of damaged wires in outer braided wires, and time when the replacement of rope is necessary, depends on
rope construction and class of the device operation.

Steel rope:
Construction of rope: Bright steel rope- right/left coiled; 1770N/mm2
DIEPA X43 – cross-knitted
Rope diameter:
 = 22mm
Operational class:
4m
Number of bearing wires in outer braided wires is 152.
Table 7.26 Degree of wear
Measurement distance
Degree of wear
(number of damaged wires)
6 x d = 132 mm
13
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
30 x d = 660 mm
26
229/251
7 MAINTENANCE
7.1.4.7 Catching device
Table 7.27 Catching device
Pos.
Name
15
Catching device
Working
hours
4.600
 To be checked
- to be maintained
 function
 air slot
 grip jaws wear
Instructions
Chapter
Read THYSSEN manual
16
Figure 7.27 Catching device
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
230/251
7 MAINTENANCE
7.1.4.8 Speed regulator
Table 7.28 Speed regulator
Pos.
Name
9
Speed governor
Working
hours
4.600
10
Rope wheel
4.600
11
Steel rope
1.000
 To be checked
- to be maintained
 function
-
 damage
 wear
 travel ease
 suitability of furnishing
 damage
 appearance of excessive wear
set (to strain)
Instructions
Chapter
Replace speed
governor
Replace rope wheel
16
Replace steel rope
10
11
9
Figure 7.28 Speed regulator
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
231/251
7 MAINTENANCE
7.1.4.9 Ladder
Table 7.29 Ladder
Pos.
Name
Working hours
8-11
Protection against
fall
Verify at each
use!!!
DANGER OF
DEATH
12
Steel rope
 To be checked
- to be maintained
 function
 damage


4.600
-
damage
appearance
excessive wear
set (to strain)
Instructions
Chapter
Replace protection
against fall
16
Replace steel rope
of
12
11
10
8
9
Figure 7.29 Ladder
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
232/251
7 MAINTENANCE
7.1.4.10 Cable chain
Table 7.30 Cable chain
Pos.
Name
19
Cable chain
Working
hours
4.600
 To be checked
- to be maintained
 function
 damage
 torsion
Instructions
Chapter
Replace cable chain in
full length or only
damaged links
19
Figure 7.30 Cable chain
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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7 MAINTENANCE
7.1.4.11 Instructions for lubrication
1.
2.
3.
4.
5.
First condition for reliable operation of the stacker crane is careful execution of all prescribed inspections,
professional lubrication and maintenance.
A register with all characteristic data about the crane is enclosed to the instructions. The investor arranges
control book for maintenance and lubrication of the crane. Both books must be on the crane, or in the
technical department, or in workshop.
Before the lubrication and maintenance (or any other work on the crane), conditions, cited in suitable
directions for safe use of stacker cranes, must be fulfilled. Lubrication should be done in accordance with the
lubrication scheme, where theoretical terms are given. Individual parts must be lubricated more frequently
according to the opinion of the responsible maintainer at regular examinations. Every regular or extraordinary
lubrication need to be recorded in the control book.
Use only prescribed or equivalent lubricants, namely:
 Oil INA EPOL 310, FAM REDOL 8610
 Oil INA POLAR K 68, SHELL OMALA 220
 Consistent grease FOR LPD or INA LIS-3
 WIPPERMANN WKS-Special
Maintain electrical motors and driving gears according to manufacturer's instructions.
NOTE:
Manufacturer’s instructions must be strictly followed during the maintenance and lubrication of the reduction gears
and electrical motors! At lubrication of the catching device, braking surfaces must remain dry.
Table 7.31 Lubrication instructions
Type of lubricant
Quantity of
lubricant
Lubrication
method
Bearings of running and leading
wheels
Lubrication
frequency
(days)
According to
the SIEMENS
manual
90 or as
necessary
Aralub SKA 00 or
Multitop
3
Leading wheels on the lifting
carriage
90 or as
necessary
Aralub SKA 00 or
Multitop
Until grease
starts to get
out
Until grease
starts to get
out
4
Rope of lifting unit
30 or as
necessary
Shell Malleus GL or
other suitable
lubricant
With a manual
lubrication
device
With a manual
lubrication
device
With a brush
5
Telescopic forks
Upon
manufacturer's
instructions
Pos.
Name
1
Electro-motor driving gears
2
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7 MAINTENANCE
7.1.4.12 Lubrication scheme
4
1
3
5
1
2
2
Figure 7.31 Lubrication scheme
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7 MAINTENANCE
7.1.4.13 Control sheet
ATTENTION
The control sheet is intended for machine inspections. For the user inspections, described in
the table, are obligatory. See manufacturer's equipment documentation enclosed to the
instructions for use (appendix, item 16).
Table 7.32 Inspection table
Type of inspection
Daily
Type of
activity
Functionality
inspection
Daily
Functionality
inspection
Daily
Cleaning
Daily
Examination
of wear
Weekly
Subject of
Inspection
-entire
machine
-safety
devices
safety devices
Realisation
method
Visual
Performer
Notice
Operator
before
machine
starts
Visual
Operator
before
machine
starts
after
machine
stops
- entire
machine
-safety
devices
Lifting rope
Visual
Maintainer
Cleaning
Rail
Visual
Maintainer
Every three
months
SERVICE
ENTIRE
MACHINE
Annually
SERVICE
overloading
device
Operator
Test
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
Instructions
before
machine
starts
before
machine
starts
MANUFACTU
RER or
REPAIRER
MANUFACTU
RER or
REPAIRER
236/251
7 MAINTENANCE
7.2 Electrical maintenance
Safe and reliable operation of all equipment in the warehouse can be achieved with regular and professional
maintenance of the equipment. Damaged elements have to be replaced with new ones. Special attention should be
devoted to switching elements and elements that are constantly or occasionally exposed to vibrations (connectors,
clamps, switches, motors, sensors, etc.).
INFORMATION
In the beginning of the year, a term plan of maintenance needs to be made. It is necessary to
lead a diary of maintenance works for all interventions and maintenance works.
For regular maintenance of the system, electro-maintainer is needed. Maintainer must have required professional
electrical education for maintenance and servicing of automatic devices.
Maintainer must:

Have complete electrical documentation of the warehouse and all necessary tools for electrical maintenance

Be acquainted in details with the system

Be acquainted with all operating modes

Be acquainted with all safety systems in the warehouse
DANGER
In case that units which require parameter setting or software changes are replaced, this must
be performed by a qualified person!
7.2.1 Power rails and current collector
Little maintenance is required at normal environment and operating conditions.

Regular inspection every six months for any external damage.

Visual inspection every four weeks; note any expansions of the conductors and burns.

Remove carbon brush dust, particularly from isolating sections.

Check for abrasion of the carbon brushes as well as firm sealing of all contact screws and cable connections.

Carbon brushes must be replaced sufficiently early so that the holders of the carbon brushes will not contact
the outside edges of the joint splice caps.
The current collectors must be checked every two months or in accordance with operational requirements.
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7 MAINTENANCE
7.2.2 Grouding
All joints of the metallic construction with grounding of the building must be examined. We also recommend an annual
inspection of the operation of safety devices for electrical shock protection.
7.2.3 Switch cabinets
Filters of the fan and filter units must be checked monthly and replaced if dirty. In regular time intervals (every month),
it is necessary to check and tighten all screw joints and check plug connection.
7.2.4 Frequency regulators
Regulator must be maintained in accordance with appended technical documentation. Every six months all screw joints
on frequency regulators have to be tightened. Filters must be replaced if they are dirty.
7.2.5 Switching elements
Inspection is performed every six months. All connections must be tightened and contact elements checked. If contact
elements are over burned or contact pressure is too low, replace the elements.
7.2.6 Photo-reflective, inductive and magnetic sensors
During the periodic 3-month checks, it is necessary to wipe up sensors with a dry rag, check fixation of sensors,
condition of connectors and other connections in the connection cabinets and in the main cabinet.
7.2.7 Barcode reader
During the periodic 3-month checks, it is necessary to wipe up external lens surfaces with a dry rag.
7.2.8 Optical sensors
During the periodic 3-month checks, it is necessary to wipe up external lens surfaces. To clean the optics cover:

Use a clean and soft rag to remove dust from the optics cover.

Wipe the window for light output on the optics cover with a clean and damp cloth.
Check fixation of sensors, condition of connectors and other connections in the connection cabinets and in the main
cabinet.
ATTENTION
Do not use aggressive cleaning agents. Do not use abrasive cleaning agents.
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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8 SPARE PARTS
8.1 Mechanical parts
8.1.1 Conveyors system
8.1.1.1 Chain conveyor
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
Driving shaft
600.1060.0000-01-04
GP
2
1
Axis of tensioning sprocket
600.0000.0000-03-02
GP
3
1
Axis 1
600.0000.0000-02-02
GP
4
1
Axis 2
600.0000.0000-05-01
GP
5
1
Sprocket (12B-2); z=13
600.0000.0000-02-01
GP
6
1
Sprocket (12B-2); z=15
600.0000.0000-01-03
GP
7
1
Motorgearbox
FZADS49…
SIEMENS
8
2
Bearing
3004-B-2RSR-TVH
INA - FAG
9
2
Housing unit with bearing
PCJ30-N
INA - FAG
10
2
Clamping device
KTR206 30x55
KTR
11
2
Chain 12 B-2 (straight lamels)
DIN 8187; 12-B2; 20 links.+conn.link
Type 3
Wippermann
8.1.1.2 Roller conveyor 01
Pos.
Name
Plan, standard
Manufacturer
1
Timing belt Poly Chain GT-2
8MGT-896-21
GATES
2
Timing belt Poly Chain GT-2
8MGT-896-21
GATES
3
Roller
5170-STKV89x2,9-B20-IGM12x20; L=EBL=965
KRAUS
4
Timing Sprocket
8M-30S-21 3F
ULMER
5
Taper-Lock Bush
Taper Lock 1210-030
ULMER
6
Motorgearbox
BF39-LE80MB4-L4/5N
SIEMENS
8.1.1.3 Roller conveyor 02
Pos.
Name
Plan, standard
Manufacturer
1
Timing belt Poly Chain GT-2
8MGT-896-21
GATES
2
Timing belt Poly Chain GT-2
8MGT-896-21
GATES
3
Roller
5170-STKV89x2,9-B20-IGM12x20; L=EBL=965
KRAUS
4
Timing Sprocket
8M-30S-21 3F
ULMER
8 SPARE PARTS
5
Taper-Lock Bush
Taper Lock 1210-030
ULMER
6
Motorgearbox
BF39-LE80MB4-L4/5N
SIEMENS
8.1.1.4 Eccentric lifting table
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
Sprocket (12B-1); z=15
1157.700.01.02.014
2
1
Sprocket (12B-1); z=26
1157.700.01.02.013
3
1
Driving shaft
1157.700.01.02.001
4
1
Arm 1
1157.700.01.02.002
5
1
Arm 2
1157.700.01.02.003
6
1
Arm 3
1157.700.01.02.004
7
1
Arm 4
1157.700.01.02.005
10
1
Housing unit with bearing
PASEY 40-N
INA
14
1
Motorgearbox
K79-LE90SG4E-L8/10N
SIEMENS
16
2
Clamping device
KTR 201 040x065
KTR
17
1
Chain 12 B-1
DIN 8187; 12-B1; li.+1 con. li. Typ 3
Wippermann
8.1.1.5 Stopper
Pos.
Number
Name
Plan, standard
Manufacturer
14
1
Motorgearbox
DF39-LA63MF4-L4/2N
SIEMENS
16
2
Trolley
LAH25BNZ
NSK
8.1.1.6 Contour check – weight control
Pos.
Name
Plan, standard
Manufacturer
1
WEIGHTING CELLS
7MH5113-3PD00/7MH41304AE11/7MH5713-4AA00
SIWAREX
8.1.1.7 Contour check – pallet base control
Pos.
Name
Plan, standard
Manufacturer
1
Vulkolan Wheel
HTH 82x100
BLICKLE
2
Vulkolan Wheel
FSTH 125x25-15K
BLICKLE
3
Flag
1157.100.10.04.005
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8 SPARE PARTS
8.1.2 Shuttle C501
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
Driving shaft
1157.401.01.006
Iskra Impuls
2
2
Driving wheel
vk H 350x80x745
Vulkoprin
3
2
Guiding wheel
vk L 150x35x315
Vulkoprin
4
2
Housing unit with bearing
PMEY 45
INA_FAG
5
1
Cardan shaft
0.109.301
ELBE
6
1
Motorgearbox
K89-LE160MF4EF-L150-100NHA-IN
SIEMENS
7
1
Motorgearbox
FDF39-LA71MH4-L8N-IN
SIEMENS
8
2
Brush
PP 90
MINK
9
4
Gliding bearing
EGF252165-E40
INA_FAG
8.1.3 Shuttle C401
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
Driving shaft
1157.401.01.006
Iskra Impuls
2
2
Driving wheel
vk H 350x80x745
Vulkoprin
3
2
Guiding wheel
vk L 150x35x315
Vulkoprin
4
2
Housing unit with bearing
PMEY 45
INA_FAG
5
1
Cardan shaft
0.109.301
ELBE
6
1
Motorgearbox
K89-LE160MF4EF-L150-100NHA-IN
SIEMENS
7
2
Brush
PP 90
MINK
8.1.4 Crane
8.1.4.1 Table of crane spare parts
8.1.4.1.1
Bottom carriage
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
SHAFT Φ110
700165
ISKRA IMPULS
2
1
WHEEL
700023
ISKRA IMPULS
3
2
HOUSING - 1
700167
ISKRA IMPULS
4
2
HOUSING- 2
700168
ISKRA IMPULS
5
1
ELECTRICAL MOTOR WITH
CONICAL REDUCTION GEAR
SIEMENS
6
2
BEARING
KAS129-LES180MM4EF-L260/100MHAIN; Mounting position: M3A; P=18,5kW;
S1=100%; n=124min-1; I=11,80;
23218-E1-XL-TVPB
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FAG
241/251
8 SPARE PARTS
7
2
8
1
9
2
10
2
SEAL RING A105X140X12
DIN 3760
11
1
SEAL RING A90X110X12
DIN 3760
8.1.4.1.2
GUIDING WHEEL WITH AXLE
Φ110
SHRINK DISC
13
KEHT 110PP
H&T
KTR 201-110x155
CLAMPEX
NO. 741020
PHOENIX
Wheels on lifting carriage
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
AXLE
710006
ÜCGE
2
2
AXLE 80X183
710007
ÜCGE
3
1
AXLE 50X160
710008
ÜCGE
4
1
AXLE 70X87
710009
ÜCGE
5
1
SPACER SLEEVE - 1
710013
ÜCGE
6
1
SPACER SLEEVE - 1
710014
ÜCGE
7
1
RUNNING WHEEL
NTUR 45100
FAG
8
2
GUIDING WHEEL WITH AXLE
KEHT 90 PP
H&T
9
1
BEARING
NUP 213E.TVP2
FAG
10
1
BEARING
NNF5010C.2LS.V
FAG
11
4
WASHER
EGW62-E40
INA
12
2
BUSH
EGB6030-E40
INA
13
1
SEALRING- NILOSRING
6213 AV
NILOS
14
1
SEALRING A75X100X10
DIN 3760
15
2
CIRCLIP 80X2,5
DIN 471
16
2
CIRCLIP 60X2
DIN 471
8.1.4.1.3
0X142
Upper girder
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
UPPER WHEEL AXLE
722005
ÜCGE
2
1
PULLEY AXLE
722006
ÜCGE
3
1
SAFETY RING
722007
ÜCGE
4
1
SPACER RING
722031
ÜCGE
5
2
vk LF 150/40/325
VULKOPRIN
6
2
POLYURETHANE WHEEL
Φ150X40
PULLEY 630
A 009.63.16
CAH
7
1
SHRINK DISC
KTR 400 - 45x75
CLAMPEX
8
2
CIRCLIP 25X1,2
DIN 471
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8 SPARE PARTS
8.1.4.1.4
Lifting unit
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
ELECTRICAL MOTOR WITH
CONICAL REDUCTION GEAR
K189 LES180ZLJ4EF-L260/145MH-IN
Mounting position M4A; P=22kW;
S1=100%; n=20min-1 ;I=74,35;
SIEMENS
2
1
DIEPA
left coiled, cross-knitted, soaked, stressfree, greased; strength class:
2
1770N/mm ; L=40m; Rope ends: 1x
protected, 1x pressed thimble NG22
with bore 55D10.
8.1.4.1.5
Cable chain
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
CABLE CHAIN
CABLE CHAIN TYPE: 27i.12.200.0
10 LINKS
IGUS
8.1.4.1.6
Speed regulator
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
SPEED GOVERNOR
Code: 8024206300 DX/L
PFB
2
1
PULLEY 280
A009.28.07
CAH
3
1
STEEL ROPE 6
Steel rope 6; Type: A106; Execution:
right handed, strength class: galvanized;
1770N/mm2; L=37,5m; Rope ends:
protected;
DIEPA
8.1.4.1.7
Lifting carriage platform
Pos.
Number
Name
Plan, standard
Manufacturer
1
1
HINGE WITH A SWITCH
TESZ 110/30
ELAN
2
1
HINGE
TESZ/S/30
ELAN
3
2
DUAL BALL CATCH
NO. 263-9010
DIRAK
8.1.4.1.8
Control cabinet platform
Pos.
Number
Name
Plan, standard
Manufacturer
1
2
SPIRAL SPRING DOOR HINGE
NO. 0
FRIDAVO
2
2
DUAL BALL CATCH
NO. 263-9010
DIRAK
4
4
RUBBER WASHER Φ75X25
ART. NO. 781100
PHOENIX
5
4
ART. NO. 741020
PHOENIX
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8 SPARE PARTS
8.1.4.2 Table of forks spare parts
Pos.
Number
Name
Code
Priority
Manufacturer
028
2
LOWER CHAIN TAKEUP PIN FOR VARIANT
M3.S1749
A
EUROFORK
029
2
LOWER CHAIN TAKEUP WHEEL
M3.S1750
A
EUROFORK
032
2
FLEYER CHAIN LOWER ATTACHMENT
MS1765
A
EUROFORK
035
4
FLEYER CHAIN PIN
MS1736
A
EUROFORK
036
2
FLEYER CHAIN PIN UPPER ATTACHMENT
MS1737
A
EUROFORK
044
18
PIN FOR NUTR17-X
20.5433.44
A
EUROFORK
046
4
TAKEUP WHEEL SPACER
M3.S1759
A
EUROFORK
050
18
WHEEL KRV32PP
MS1767
A
EUROFORK
053
24
WHEEL KRV22PP
MS1758
A
EUROFORK
054
24
PIN FOR WHEEL KRV22PP
MS1724
A
EUROFORK
055
72
SHIM
MS1727
A
EUROFORK
056
2
TAKEUP WHEEL COVER
M3.S1753
A
EUROFORK
060
4
ANTI-SLIDE STRIPS 175x1200 Sp.1
Scg002-175x1200
A
EUROFORK
075
4
REFLECTOR DG-K DIMOND GRANEED 16x40
Sc1001-16x40
A
EUROFORK
01N
6
BEARING 6207 2RS1
Sca017
A
EUROFORK
02N
18
WHEEL NUTR17-X
Sci011
A
EUROFORK
03N
81
BEARING 6005 2RS1
Sca007
A
EUROFORK
04N
4
BEARING NUP-304ECP
Sca036
A
EUROFORK
05N
2
SENSOR WL8-P2231
WL8-P2231
A
EUROFORK
08N
6
P=3/4"x7/16" S. CHAIN L.=2667,00
Scd004.2667.00
A
EUROFORK
09N
6
COUPLING P=3/4"x7/16" S.
Scc004
A
EUROFORK
10N
6
FLEYER CHAIN FL122 2x2 L.= 2076,45
Scd007.2076.45
A
EUROFORK
037
2
UPPER GROUP TAKEUP WHEEL
UCW000
A
EUROFORK
03N
6
P=1/2"x5/16" D. CHAIN L.=787,40
Scd001.0787.40
A
EUROFORK
04N
6
COUPLING P=1/2"x5/16" D.
Scc001
A
EUROFORK
05N
1
GEAR MOTOR SEW R27DRS80M4BE2HRTF
A
EUROFORK
08N
2
A
EUROFORK
09N
2
ENCODER COUPLING ECOFLEX BKL/003 Ø10 Ø10
ENCODER PROFINET AFM60A-S4NB018X12
R27DRS80M4BE2
HRTF
SCTR154
A
EUROFORK
10N
6
P=1/2"x5/16" D. CHAIN L.=736,60
AFM60AS4NB018X12
Scd001.0736.60
A
EUROFORK
Complete EUROFORK spare part list (priority B and C) is available as a separate document (TR030S8039a.pdf) which is
part of the forks documentation.
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
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8 SPARE PARTS
8.2 Electrical parts
8.2.1 Conveyor system (+SB1 /+SB2)
8.2.1.1 Wearing parts
Poz.
Number
Description
Type
Manufacturer
1
1
Filter fan 700/770 m3/h, 230 V, 50/60Hz
3244100
RITTAL
8.2.1.2 Spare parts category A
Poz.
Number
Description
Type
Manufacturer
1
1
S7-1500, PS 25W 24V DC
6ES7505-0KA00-0AB0
Siemens
2
1
CPU 1515F-2 PN
6ES7515-2FM01-0AB0
Siemens
3
1
SIMATIC S7-1500, weighing module
7MH4980-1AA01
Siemens
4
1
ET 200MP, F-DI 16X24VDC
6ES7526-1BH00-0AB0
Siemens
5
1
DI 32X24VDC HF
6ES7521-1BL00-0AB0
Siemens
6
1
DQ 16X24VDC/0.5A ST
6ES7522-1BH00-0AB0
Siemens
7
1
SITOP PSU300S 40A STABILIZED POWER SUPPLY
6EP1437-2BA20
Siemens
8
1
SITOP PSU300S 20 A STABILIZED POWER SUPPLY
6EP1436-2BA10
Siemens
9
1
SCALANCE XB005
6GK5005-0BA00-1AA3
Siemens
10
1
SCALANCE X108 switch
6GK5108-0BA00-2AA3
Siemens
11
1
SINAMICS G120C
6SL3210-1KE11-8AF1
Siemens
12
1
SINAMICS G120C
6SL3210-1KE13-2AF1
Siemens
13
1
SINAMICS BRAKING RESISTOR R=370OHM
6SL3201-0BE14-3AA0
Siemens
14
2
Sinamics line reactor
6SL3203-0CE13-2AA0
Siemens
15
2
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-1AA15
Siemens
16
2
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-1DA15
Siemens
17
1
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-0GA15
Siemens
18
1
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-1FA15
Siemens
19
1
CONTACTOR, AC-3, 11KW/400V, 1NO+1NC, DC 24V
3RT2026-1BB40
Siemens
20
1
CONTACTOR, AC-3, 7.5KW/400V, 1NO+1NC, DC 24V
3RT2025-1BB40
Siemens
21
1
CONTACTOR, AC-3, 5.5KW/400V, 1NO+1NC, DC 24V
3RT2024-1BB40
Siemens
22
1
CIRCUIT BREAKER 3VA2, 500A
3VA2450-5JP32-0AA0
Siemens
23
1
CIRCUIT BREAKER 3VA1, 100A
3VA1010-3ED32-0AA0
Siemens
24
1
CIRCUIT BREAKER 3VA1, 63A
3VA1063-3ED32-0AA0
Siemens
25
1
KTP1200 BASIC
6AV2123-2MB03-0AX0
Siemens
26
1
KTP700 BASIC
6AV2123-2GB03-0AX0
Siemens
27
1
SIWAREX WL 280 LOAD CELL
7MH5113-3PD00
Siemens
28
10m
IE FC TP STANDARD CABLE, GP 2X2 (PROFINET TYP A)
6XV1840-2AH10
Siemens
29
5
Photoelectric retro-reflective sensor
GL10-P4554
SICK
30
5
Reflector
PL40A
SICK
31
1
Ultrasonic sensor
UM30-214111
SICK
32
1
Photoelectric retro-reflective sensor
WL9G-3P2432
SICK
33
2
Proximity sensors
IME18-08NPSZC0S
SICK
34
5
Photoelectric sensors
GTB10-P4214
SICK
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
245/251
8 SPARE PARTS
35
1
Light beam
M20Z-02550A122
SICK
36
1
Bar code scanners
CLV620-0120
SICK
37
1
Light grid
MLG5-1750F511
SICK
38
1
Optical data transmission, infrared sender
ISD400-7212
SICK
39
5
Female connector, M12 straight, 5m
DOL-1204-G05M
SICK
8.2.1.3 Spare parts category B
Poz.
Number
Description
Type
Manufacturer
1
1
AUXILIARY SWITCH 1NC+1NO
5ST3010
Siemens
2
1
CIRCUIT BREAKER 400V 10KA, 3-POLE, C, 3A, D=70MM
5SY4303-7
Siemens
3
1
CIRCUIT BREAKER 400V 10KA, 3-POLE, C, 16A, D=70MM
5SY4316-7
Siemens
4
1
CONTACTOR RELAY, 2NO+2NC DC 24V
3RH2122-1BB40
Siemens
5
1
MAIN SWITCH 100A/690V 400V/37KW
3LD2766-1GP51
Siemens
6
1
MAIN SWITCH 63A/690V 400V/22KW
3LD2565-1GP51
Siemens
7
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 2A, D=70MM
5SY4102-7
Siemens
8
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 16A, D=70MM
5SY4116-7
Siemens
9
1
CIRCUIT BREAKER 400V 10KA, 3-POLE, C, 13A, D=70MM
5SY4313-7
Siemens
10
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 3A, D=70MM
5SY4103-7
Siemens
11
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, B, 10A, D=70MM
5SY4110-6
Siemens
12
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 8A, D=70MM
5SY4108-7
Siemens
13
2
CIRCUIT BREAKER 400V 10KA, 2-POLE, C, 2A, D=70MM
5SY4202-7
Siemens
14
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 6A, D=70MM
5SY4106-7
Siemens
15
1
CIRCUIT BREAKER 400V 10KA, 3-POLE, C, 6A, D=70MM
5SY4306-7
Siemens
16
4
CONTACTOR, AC-3, 3KW/400V, 1NC, DC 24V
3RT2015-1BB42
Siemens
17
1
Monitoring relay
3UG4513-1BR20
Siemens
18
1
SIGNALING COLUMN, LIGHT ELEMENT, GREEN
8WD4220-5AC
Siemens
19
1
SIGNALING COLUMN, LIGHT ELEMENT, RED
8WD4220-5AB
Siemens
20
1
SIGNALING COLUMN, LIGHT ELEMENT, CLEAR
8WD4220-5AE
Siemens
21
3
CONTACTOR, AC-3, 3KW/400V, 1NO, DC 24V
3RT2015-1BB41
Siemens
22
1
ACTUATOR-/INDICATOR COMPONENT WITH INTEGRATED LED
3SB3400-1PD
Siemens
23
2
ACTUATOR-/INDICATOR COMPONENT WITH INTEGRATED LED
3SB3400-1PE
Siemens
24
1
LASTIC ROUND INDICATOR: WITH HOLDER CLEAR
3SB3001-6AA70
Siemens
25
1
KEY-OPER.SWITCH, 3 POSITIONS
3SB3000-4PD21-Z Y02 Z =
Siemens
SSG14
26
1
22MM PLASTIC ROUND ACTUATOR:
3SB3001-0AA51
Siemens
27
1
22MM PLASTIC ROUND ACTUATOR:
3SB3001-0AA71
Siemens
28
1
Selectors witch, 2 switching positions
3SB32 01-2KA11
Siemens
29
1
KEY-OPER.SWITCH, 3 POSITIONS
3SB3000-4PD21-Z Y02 Z =
Siemens
SSG15
30
1
KEY-OPER.SWITCH, 3 POSITIONS
3SB3000-4PD21-Z Y02 Z =
Siemens
SSG11
31
1
KEY-OPER.SWITCH, 3 POSITIONS
3SB3000-4PD21-Z Y02 Z =
Siemens
SSG12
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
246/251
8 SPARE PARTS
32
1
KEY-OPER.SWITCH, 3 POSITIONS
3SB3000-4PD21-Z Y02 Z =
Siemens
SSG13
8.2.2 Crane
8.2.2.1 Wearing parts
Poz.
Number
Description
Type
Manufacturer
1
1
Filter fan 700/770 m3/h, 230 V, 50/60Hz
3244100
RITTAL
8.2.2.2 Spare parts category A
Poz.
Number
Description
Type
Manufacturer
1
1
SIMOTION DRIVE-BASED CONTROL UNIT D425-2 DP/PN
6AU1425-2AD00-0AA0
Siemens
2
1
SINAMICS TERMINAL MODULE TM15
6SL3055-0AA00-3FA0
Siemens
3
1
SINAMICS S120 REACTOR_LINE_3AC_380-480V_28A
6SL3000-0CE23-6AA0
Siemens
4
1
SINAMICS S120 Smart line module
6SL3130-6TE23-6AA3
Siemens
5
1
SINAMICS LINE/MOTOR MODULES INTERNAL AIR COOLING
6SL3162-1AF00-0AA1
Siemens
6
1
SINAMICS S120 SINGLE MOMO 30A D-TYPE
6SL3120-1TE23-0AD0
Siemens
7
1
SINAMICS S120 DOUBLE MOMO 3A/3A D-TYPE
6SL3120-2TE13-0AD0
Siemens
8
1
SITOP PSU300S 20 A STABILIZED POWER SUPPLY
6EP1436-2BA10
Siemens
9
1
IM 155-5 PN ST
6ES7155-5AA00-0AB0
Siemens
10
1
DI 32X24VDC HF
6ES7521-1BL00-0AB0
Siemens
11
1
DQ 16X24VDC/0.5A ST
6ES7522-1BH00-0AB0
Siemens
12
1
AI 8XU/I/RTD/TC ST
6ES7531-7KF00-0AB0
Siemens
13
1
SINAMICS DRIVE-CLIQ CABLE IP20/IP20 LENGTH: 0.60 M
6SL3060-4AU00-0AA0
Siemens
14
1
SINAMICS S120 SENSOR MODULE SMC30
6SL3055-0AA00-5CA2
Siemens
15
1
LV HRC FUSE LINK GL/GG WITH NON-INSULATED GRIP LUGS
3NA3824
Siemens
16
1
KTP700 BASIC
6AV2123-2GB03-0AX0
Siemens
17
1
Electro-mechanical safety switches
3SE5112-0LH01
Siemens
18
1
Electro-mechanical safety switches
3SE5112-0LE01
Siemens
19
1
Magnetic switch
BN310-2RZ-5M
Schmersal
20
1
Magnet
BN34
Schmersal
21
1
Hinge safety switch
TESZ1102
Schmersal
22
1
Linear measurement sensors
OLM100-1201
SICK
23
1
Optical data transmission, red sender
ISD400-7211
SICK
24
1
Photoelectric proximity sensor
WTB27-3P2461
SICK
25
1
Distance sensor
DS50-P1112
SICK
26
1
Photoelectric retro-reflective sensor
WL23-2P2430P02
SICK
27
1
Reflector
PL40A
SICK
28
1
Cable chain
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
247/251
8 SPARE PARTS
8.2.2.3 Spare parts category B
Poz.
Number
Description
Type
Manufacturer
1
1
AUXILIARY SWITCH 1NC+1NO
5ST3010
Siemens
2
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 10A, D=70MM
5SY4110-7
Siemens
3
1
CIRCUIT BREAKER 400V 10KA, 3-POLE, C, 6A, D=70MM
5SY4306-7
Siemens
4
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, B, 6A, D=70MM
5SY4106-6
Siemens
5
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 6A, D=70MM
5SY4106-7
Siemens
6
1
CIRCUIT BREAKER 230V 10KA, 1+N-POLE, C, 4A, D=70MM
5SY4504-7
Siemens
7
1
CONTACTOR RELAY, 2NO+2NC DC 24V
3RH2122-1BB40
Siemens
8
1
CONTACTOR RELAY, 3NO+1NC AC 230V, 50/60 HZ,
3RH2131-1AP00
Siemens
9
1
CONTACTOR, AC-3, 3KW/400V, 1NO, DC 24V
3RT2015-1BB41
Siemens
10
1
Relay Module
LZS:RT4A4L24
Siemens
11
1
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-0GA15
Siemens
12
1
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-1AA15
Siemens
13
1
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-0BA15
Siemens
14
1
Main / Emergency stop switch 37kW/100A
3LD2714-0TK53
Siemens
15
1
Selectors witch, 2 switching positions
3SU1100-2BF60-1MA0
Siemens
16
1
M. STOP MUSHROOM PUSHBUTTON, 22MM, ROUND, PLASTIC,
3SU1000-1HB20-0AA0
Siemens
17
1
ACTUATOR-/INDICATOR COMPONENT CONTACT BLOCK 1NC
3SU1400-1AA10-1CA0
Siemens
18
1
ACTUATOR-/INDICATOR COMPONENT CONTACT BLOCK 1NO
3SU1400-1AA10-1BA0
Siemens
19
1
KEY-OPER.SWITCH, 2 POSITIONS
3SU1000-5BF21-0AA0-Z
Siemens
20
1
KEY-OPER.SWITCH, 2 POSITIONS
Y01 Y01:SSG11
3SU1000-5BF21-0AA0-Z
Siemens
21
1
KEY-OPER.SWITCH, 2 POSITIONS
Y01 Y01:SSG12
3SU1000-5BF21-0AA0-Z
Siemens
22
1
CES KEY-OPER.SWITCH, 2 POSITIONS O-I LATCHING
Y01 Y01:SSG13
3SU1000-5BF01-0AA0
Siemens
23
1
LLUMINATED PUSHBUTTON PLASTIC, BLUE
3SU1001-0AB50-0AA0
Siemens
24
1
INDICATOR LIGHT PLASTIC, RED
3SU1102-6AA20-1AA0
Siemens
8.2.3 Shuttle C401
8.2.3.1 Wearing parts
Poz.
Number
Description
Type
1
1
Filter fan 700/770 m3/h, 230 V, 50/60Hz
3244100
Manufacturer
RITTAL
8.2.3.2 Spare parts category A
Poz.
Number
Description
Type
1
1
SIMOTION DRIVE-BASED CONTROL UNIT D425-2 DP/PN
6AU1425-2AD00-0AA0
Siemens
2
1
SINAMICS TERMINAL MODULE TM15
6SL3055-0AA00-3FA0
Siemens
3
1
SINAMICS LINE REACTOR FOR 16 KW SMART LINE MODULE
6SL3000-0CE21-6AA0
Siemens
4
1
SINAMICS S120 SMART LINE MODULE 16kW
6SL3130-6TE21-6AA4
Siemens
5
1
SINAMICS S120 SINGLE MOMO 18A D-TYPE
6SL3120-1TE21-8AD0
Siemens
6
1
SINAMICS S120 SINGLE MOMO 3A D-TYPE
6SL3120-1TE13-0AD0
Siemens
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
Manufacturer
248/251
8 SPARE PARTS
7
1
SITOP PSU300S 20 A STABILIZED POWER SUPPLY
6EP1436-2BA10
Siemens
8
1
SINAMICS DRIVE-CLIQ CABLE IP20/IP20 LENGTH: 0.60 M
6SL3060-4AU00-0AA0
Siemens
9
1
SINAMICS S120 SENSOR MODULE SMC30
6SL3055-0AA00-5CA2
Siemens
10
1
KTP700 BASIC
6AV2123-2GB03-0AX0
Siemens
11
1
Electro-mechanical safety switches
3SE5112-0LH01
Siemens
12
1
Optical data transmission, red sender
ISD400-7211
SICK
13
1
Linear measurement sensors
OLM100-1201
SICK
14
1
Photoelectric retro-reflective sensor
GL10-P4554
SICK
15
1
Reflector
PL40A
SICK
16
1
Magnetic switch
BN310-2RZ-5M
Schmersal
17
1
Magnet
BN34
Schmersal
18
1
Cable chain
Manufacturer
8.2.3.3 Spare parts category B
Poz.
Number
Description
Type
1
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 10A, D=70MM
5SY4110-7
Siemens
2
1
CIRCUIT BREAKER 400V 10KA, 3-POLE, C, 6A, D=70MM
5SY4306-7
Siemens
3
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, B, 6A, D=70MM
5SY4106-6
Siemens
4
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 6A, D=70MM
5SY4106-7
Siemens
5
1
CIRCUIT BREAKER 230V 10KA, 1+N-POLE, C, 4A, D=70MM
5SY4504-7
Siemens
6
1
CONTACTOR RELAY, 2NO+2NC DC 24V
3RH2122-1BB40
Siemens
7
1
CONTACTOR RELAY, 3NO+1NC AC 230V, 50/60 HZ,
3RH2131-1AP00
Siemens
8
1
CONTACTOR, AC-3, 3KW/400V, 1NO, DC 24V
3RT2015-1BB41
Siemens
9
1
Relay Module
LZS:RT4A4L24
Siemens
10
1
Main / Emergency stop switch 22kW/63A
3LD2514-0TK53
Siemens
11
1
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-0GA15
Siemens
12
1
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-0BA15
Siemens
13
1
BLUE ILLUMINATED PUSHBUTTON
3SU1152-0AB50-1BA0
Siemens
14
1
EM. STOP MUSHROOM PUSHBUTTON
3SU1000-1HB20-0AA0
Siemens
15
1
ACTUATOR-/INDICATOR COMPONENT CONTACT BLOCK 1NC
3SU1400-1AA10-1CA0
Siemens
16
1
ACTUATOR-/INDICATOR COMPONENT CONTACT BLOCK 1NO
3SU1400-1AA10-1BA0
Siemens
17
1
KEY-OPER.SWITCH, 2 POSITIONS
Siemens
18
1
ACTUATOR-/INDICATOR COMPONENT CONTACT BLOCK 2NO
3SU1000-5BF21-0AA0-Z
Y01 Y01:SSG14
3SU1400-1AA10-1BA0
19
1
CES KEY-OPER.SWITCH, 2 POSITIONS O-I LATCHING
3SU1000-5BF01-0AA0
Siemens
20
1
RED INDICATOR LIGHT WITH CONCENTRIC RINGS
3SU1102-6AA20-1AA0
Siemens
Siemens
8.2.4 Shuttle C501
8.2.4.1 Wearing parts
Poz.
Number
Description
Type
Manufacturer
1
1
Filter fan 700/770 m3/h, 230 V, 50/60Hz
3244100
RITTAL
8.2.4.2 Spare parts category A
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
249/251
8 SPARE PARTS
Poz.
Number
Description
Type
Manufacturer
1
1
SIMOTION DRIVE-BASED CONTROL UNIT D425-2 DP/PN
6AU1425-2AD00-
Siemens
2
1
SINAMICS TERMINAL MODULE TM15
6SL3055-0AA00-3FA0
Siemens
3
1
SINAMICS LINE REACTOR FOR 16 KW SMART LINE MODULE
6SL3000-0CE21-6AA0
Siemens
4
1
SINAMICS S120 SMART LINE MODULE 16kW
6SL3130-6TE21-6AA4
Siemens
5
1
SINAMICS S120 SINGLE MOMO 18A D-TYPE
6SL3120-1TE21-8AD0
Siemens
6
1
SINAMICS S120 DOUBLE MOMO 3A/3A D-TYPE
6SL3120-2TE13-0AD0
Siemens
7
1
SINAMICS S120 SINGLE MOMO 3A D-TYPE
6SL3120-1TE13-0AD0
Siemens
8
1
SINAMICS S120 DOUBLE MOTOR MODULE 3A/3A
6SL3120-2TE13-0AA4
Siemens
9
1
SITOP PSU300S 20 A STABILIZED POWER SUPPLY
6EP1436-2BA10
Siemens
10
1
SINAMICS DRIVE-CLIQ CABLE IP20/IP20 LENGTH: 0.60 M
6SL3060-4AU00-0AA0
Siemens
11
1
SINAMICS S120 SENSOR MODULE SMC30
6SL3055-0AA00-5CA2
Siemens
12
1
KTP700 BASIC
Siemens
13
1
Electro-mechanical safety switches
6AV2123-2GB030AX0
3SE5112-0LH01
14
1
Optical data transmission, red sender
ISD400-7211
SICK
15
1
Proximity sensors
IME18-08NPSZC0S
SICK
16
1
Linear measurement sensors
OLM100-1201
SICK
17
1
Photoelectric retro-reflective sensor
GL10-P4554
SICK
18
1
Reflector
PL40A
SICK
19
1
Distance sensor
DT35-B15251
SICK
20
1
Magnetic switch
BN310-2RZ-5M
Schmersal
21
1
Magnet
BN34
Schmersal
22
1
Cable chain
Manufacturer
Siemens
8.2.4.3 Spare parts category B
Poz.
Number
Description
Type
1
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 10A, D=70MM
5SY4110-7
Siemens
2
1
CIRCUIT BREAKER 400V 10KA, 3-POLE, C, 6A, D=70MM
5SY4306-7
Siemens
3
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, B, 6A, D=70MM
5SY4106-6
Siemens
4
1
CIRCUIT BREAKER 230/400V 10KA, 1-POLE, C, 6A, D=70MM
5SY4106-7
Siemens
5
1
CIRCUIT BREAKER 230V 10KA, 1+N-POLE, C, 4A, D=70MM
5SY4504-7
Siemens
6
1
CONTACTOR RELAY, 2NO+2NC DC 24V
3RH2122-1BB40
Siemens
7
1
CONTACTOR RELAY, 3NO+1NC AC 230V, 50/60 HZ,
3RH2131-1AP00
Siemens
8
1
CONTACTOR, AC-3, 3KW/400V, 1NO, DC 24V
3RT2015-1BB41
Siemens
9
1
Relay Module
LZS:RT4A4L24
Siemens
10
1
Main / Emergency stop switch 22kW/63A
3LD2514-0TK53
Siemens
11
1
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-0GA15
Siemens
12
1
CIRCUIT-BREAKER SZ S00, FOR MOTOR PROTECTION, CLASS 10
3RV2011-0BA15
Siemens
13
1
BLUE ILLUMINATED PUSHBUTTON
3SU1152-0AB50-1BA0
Siemens
14
1
EM. STOP MUSHROOM PUSHBUTTON
3SU1000-1HB20-0AA0
Siemens
15
1
ACTUATOR-/INDICATOR COMPONENT CONTACT BLOCK 1NC
3SU1400-1AA10-1CA0
Siemens
16
1
ACTUATOR-/INDICATOR COMPONENT CONTACT BLOCK 1NO
3SU1400-1AA10-1BA0
Siemens
KEY-OPER.SWITCH, 2 POSITIONS
3SU1000-5BF21-0AA0-Z
Y01 Y01:SSG15
Siemens
17
1
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
250/251
8 SPARE PARTS
18
1
ACTUATOR-/INDICATOR COMPONENT CONTACT BLOCK 2NO
3SU1400-1AA10-1BA0
Siemens
19
1
CES KEY-OPER.SWITCH, 2 POSITIONS O-I LATCHING
3SU1000-5BF01-0AA0
Siemens
20
1
RED INDICATOR LIGHT WITH CONCENTRIC RINGS
3SU1102-6AA20-1AA0
Siemens
ÜÇGE DRS DEPO RAF SİSTEMLERİ Kestel/Bursa/TURKEY
251/251