Abalioglu - Kullanım - Klavuzu - ING PDF

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
GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 2/251
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

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
5.6.3 Regimes and modes of operation.................................................................................... 141
5.6.4 Operators panel ............................................................................................................. 143
5.7 Shuttle S501.................................................................................................................... 158

1 INTRODUCTION
5.7.3 Regimes and modes of operation.................................................................................... 158

5.7.4 Operators panel ............................................................................................................. 160
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

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

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
1 INTRODUCTION
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 5.40 Shuttle regime icons .................................................................................................................146
Figure 5.41 Shuttle regime ..........................................................................................................................146
Figure 5.43 Shuttle sensors screen ..............................................................................................................148
Figure 5.44 Manual mode shuttle screen ....................................................................................................149
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 5.56 Shuttle regime icons .................................................................................................................163
Figure 5.57 Shuttle regime ..........................................................................................................................163
Figure 5.59 Shuttle sensors screen ..............................................................................................................165
Figure 5.60 Manual mode shuttle screen ....................................................................................................166
Figure 5.63 Operator's panel: the teaching screen. .....................................................................................169
Figure 5.64 Accessing the parameter files from operators panel ................................................................170
1 INTRODUCTION
Figure 5.65 Operators panel: parameter adjustment screen .......................................................................170

Figure 5.66 Operators panel changing of the material picture .................................................................174
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 6.11 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
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 2.7 Main parts of the roller conveyor ...................................................................................................28
Table 2.8 Technical data of the roller conveyor .............................................................................................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 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
1 INTRODUCTION
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

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..

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.

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 Description
Ur. l. RS No. 75/2008 Machinery Safety Rules
SIST EN ISO 12100-1 Machinery safety Basic notions, general principles of planning Part 1
Basic terminology, methodology
SIST EN ISO 12100-2 Machinery safety Basic notions, general principles of planning Part 2
Technical principles
SIST EN ISO 13857 Machine safety Safety distances preventing reach of dangerous areas with upper and
lower limbs
SIST EN 349 Machinery safety Least distances preventing contusions on human body parts
SIST EN ISO 13850 Machinery safety Emergency stop Principles of planning
SIST HD 516 S2 Directions for use of low voltage adjusted cables
SIST EN 953 Machinery safety Safety devices General directions for planning and construction of
fixed and movable safety devices
SIST EN 954-1 Machinery safety Parts of command systems
SIST EN 981 Machinery safety Systems of visible and audible hazards or notice signals
SIST EN 1037 Machinery safety prevention of the hazardous switch-on
SIST EN 14121-1 Machinery safety Risk assessment Principles (methodology of evaluation, list of
dangers)
SIST EN 50085-1 Systems of cable troughs and system of cable tubes for el. installations
SIST EN 50086-1 Systems of channels for el. installations Part 1
SIST EN 60204-1 Machinery safety Electrical machine equipment Part 1: General requirements
SIST EN 60204-32 Machinery safety - Electrical machine equipment Part 32: Special requirements for
lifting machines
SIST-EN-528-2008 Rail dependent storage and retrieval equipment Safety requirements

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;

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.

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 key-
lock 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

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.

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.

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 Iskra impuls Kranj d.o.o tel.: +386 4 20 10 210

design Zasavska 43g fax: +386 4 20 10 211
4000 Kranj email: support@iskraimpuls.si
web: www.iskraimpuls.si
Electrical Iskra impuls Kranj d.o.o tel.: +386 4 20 10 210
design Zasavska 43g fax: +386 4 20 10 211
PLC Iskra impuls Kranj d.o.o tel.: +386 4 20 10 210
programming Zasavska 43g fax: +386 4 20 10 211
tel.:
fax:
email:
web:
tel.:
fax:
email:
web:
tel.:
fax:
email:
web:

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 Chain conveyor
2.4.1.1.1 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

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.

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

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

2.4.1.2 Roller conveyor 01
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.
Table 2.4 Main parts of the roller conveyor
Pos. Name
1 Longitudinal beam
2 Cover
3 Driving station
4 Drive
5 Roller
6 Driving belt
7 Driven belt
4 2 3 1
Figure 2.5 Main parts of the roller conveyor
4 3 6 7

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.

Table 2.5 Technical data of the roller conveyor
Type of the roller conveyor: 01
Capacity 2x10 kN
Dimensions
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:
Other data:
Control voltage 24 V DC
Voltage / frequency 3x400V / 50 Hz
Roller conveyor drive:

Type BF39-LE80MD4E-L16N
Output torque 79 Nm
Ratio 21,9
Voltage 3x400 V
Power 0,55 kW

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.
Table 2.7 Main parts of the roller conveyor
Pos. Name
1 Longitudinal beam
2 Cover
3 Drive station
4 Drive motorgearbox
5 Roller
6 Driving belt
7 Driven belt
5 2 1 7 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.

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.

Table 2.8 Technical data of the roller conveyor
Type of the roller conveyor: 01
Capacity 2x10 kN
Dimensions
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:
Other data:
Control voltage: 24 V DC

Output torque 79 Nm
Ratio 21,9
Voltage 3x400 V
Power 0,55 kW

2.4.1.4 Eccentric lifting table
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.
Figure 2.9 Eccentric Lifting Table

Figure 2.10 Main parts of the eccentric lifting table
Pos. Name
1 Bottom frame
2 Upper frame
3 Lifting device
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.

Figure 2.12 Lifting device

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:
Eccentric lifting table drive:

Type K79-LE90SG4E-L16N
Ratio 81,47
Voltage 400 V
Power 1,1 kW

2.4.1.5 Stopper
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

Table 2.12 Main parts of the stopper
Pos. Name
1 Bottom frame
2 Guiding frame
3 Movable part
4 Motorgearbox
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.

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:
Eccentric lifting table drive:

Type DF39-LA63MF4-L4N
Ratio 100,44
Voltage 400 V
Power 0,18 kW

2.4.1.6 Contour check
Contour check consists weight control, control of dimensions of the load and pallet base control.
Figure 2.15 Contour check

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
Pos. Name
1 Base frame
2 Guiding set
3 Weighting set
1 2
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.

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
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.

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

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.
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

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.

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

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

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

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
Acceleration:
Shuttle acceleration ( ax ) 1,00 m/s2
Other data:

Table 2.20 Technical data of the driving motorgearboxes
Shuttle drive:
Ratio 7,97
Voltage 400 V
Power 11 kW
Output torque 79 Nm
Ratio 21,9
Voltage 3x400 V
Power 0,55 kW
Tilting table drive:
Type FDF39-LA71MH4-L8N-IN
Ratio 73,93
Voltage 3x400 V
Power 0,37 kW

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.
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

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

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

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.

Figure 2.34 Chain conveyor on the shuttle
Chain conveyor is described in the Chapter 2.4.1.1

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
Acceleration:
Shuttle acceleration ( ax ) 1,80 m/s2
Drugi podatki:

Table 2.23 Technical data of the driving motorgearboxes
Shuttle drive:
Ratio 7,97
Voltage 400 V
Power 11 kW
Chain conveyor drive:
Type FZADS49-LE90SG4E-L16N
Ratio 21,77
Voltage 3x400 V
Power 1,1 kW

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

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 It is mandatory to use safety belt, while climbing on the ladder!
2.4.4.1.4 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.

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 It is mandatory to use safety belt, while climbing on the ladder!
2.4.4.1.7 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


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.

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 self-
standing 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.

Table 2.25 Crane technical data
Type of crane:
Stacker crane PAA 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
Crane dimensions:
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
Lift drive:
Gear (1x) 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
Speed -automatic mode 36 m/min

- manual mode 0,25 m/min
Accelerations / declines - automatic mode 0,50 m/s2
2
- manual mode 0,25 m/s

Driving unit:
Gear (1x) KAS129-LES180MM4EF-L260/100MHA-IN

-brand SIEMENS
- nominal power 18,5 kW
- gear ratio 11,8
- installation shape M3A
Speeds - automatic mode 180 m/min
- manual mode 1,0 m/min
Accelerations / declines - 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
- withdrawal momentum 76 Nm
- withdrawal revolutions 139 min-1
- gear ratio 10,13
- installation shape M3
Load capacity 800 Kg
Loading:
Pallet
L max: 1200 mm
B max: 800 mm

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

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

+SB1-5Q1: 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 +SB1-
6Q1 circuit breaker enables or disables the control power.

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 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.

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. Air-
condition 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.

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

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.
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
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.

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.
230VAC source it is located in main cabinet +L01 and it is used for:
Cabinet lights
Power sockets
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
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.
230VAC source it is located in main cabinet +L01 and it is used for:
Cabinet lights
Power sockets
Rotating beacon
Horn

2.5.7 Control circuits

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 doesnt 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.
2.5.8.1.1 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

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
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
Load cells: Weight control
Cabin safety door switch: To prevent movement of the machine in case opened cabin doors
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
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:

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..

3 SAFETY

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.

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.

3 SAFETY
3.3 Motion control

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

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.

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.

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

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 4.2 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

4. Tensioning of the chains.
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
Figure 4.5 Guidings for tensioning of the chain

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



SERVICE!
Figure 4.6 Roller conveyor

4.1.2.1 Settings and startup of the machine

Figure 4.7 Alignment of the roller 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.

lose fixing bolts of the rollers
fix bolts or rollers
Figure 4.8 Diagonals of the roller conveyor

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



SERVICE!
Figure 4.9 Roller conveyor

Figure 4.10 Alignment of the roller 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.

lose fixing bolts of the rollers
fix bolts or rollers
Figure 4.11 Diagonals of the roller conveyor

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



SERVICE!
Figure 4.12 Eccentric lifting table

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.
3
2 1
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

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


SERVICE!
Figure 4.15 Stopper

4.1.5.1 Setting and startup of the machine

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).
Figure 4.17 Adjusting of the stopper

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



SERVICE!

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.

4.1.6.1.2 Control of dimensions
Adjust all sensors and reflectors to desired position.
Figure 4.19 Control of dimensions

4.1.6.1.3 Pallet base control
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.

4.2 Shuttle C501



SERVICE!
Figure 4.21 Shuttle with two roller conveyor

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
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

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)
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

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



SERVICE!

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

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.

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!

- use car lift with suitable load capacity;
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.

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.

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. rack locations,
2. conveyor locations (conveyor tables), and
3. 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: 11, 12, 21, 22, 31, 32, (52)

xx is horizontal index: 01 60, (01 24)
y is vertical index: 1 8, (1)
z is depth index: 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.

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: 0 3,
s is a subgroup: 0 2,
n is a conveyor number: 0 4.
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

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: 1 4, (5),

n is deck number: 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
5.1.5 Other limitations

Conveyor T023 cannot be reached with deck C502 of Shuttle 5.

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

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).

WMS
(SAP)
MFCS &
SCADA
Crane1 Crane 2 Crane 3 Shuttle 4 Shuttle 5 Conveyors

PLC PLC PLC PLC PLC 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.

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. Operators must manually put a transport unit to the conveyor table T001.
2. The transport unit is then conveyed to T002. During the movement its barcode is read and physical quantities
are measured.
3. On conveyor T002 the entry of a new transport unit is reported to WMS.
4. 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.
5. 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).
6. 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.
7. 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. WMS should first give a command to move a transport unit from a slot in high-bay warehouse to a slot in
gravitational rack.
2. 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.
3. Transport units from T121 and T221 are further conveyed to T122 and T222, respectively.
4. A transport unit from T122 or T222 is transferred to shuttle 4.
5. Shuttle 4 deposits a transport unit from its deck C401 to T021.
6. Based on the commands and optimization performed on MFCS, transport units are further conveyed to T023
or T024 via T022.
7. 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.

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.

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
T31 T311, T312 Input to 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.

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.

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

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

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.

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.

3 2 4
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.

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.

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

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

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.
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 is pressed. When there is no danger, release it and reset the
stop button CP001 system.
24 (Segments T00, T01, T03) safety Stop button is pressed. When there is no danger, release it and reset the
contactor out (12k1) system.
25 (Segments T11, T12) stop button Stop button is pressed. When there is no danger, release it and reset the

CP101 system.
26 (Segments T11, T12) safety Stop button is pressed. When there is no danger, release it and reset the
27 (Segments T21, T22) stop button Stop button is pressed. When there is no danger, release it and reset the
CP201 system.
28 (Segments T02, T21, T22, T31) stop Stop button is pressed. When there is no danger, release it and reset the
button CP501 system.
29 (Segments T21, T22) safety Stop button is pressed. When there is no danger, release it and reset the
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 Stop button is pressed. When there is no danger, release it and reset the
(12k4) system.
32 (Segment T32) stop button CP321 Stop button is pressed. When there is no danger, release it and reset the
system.
(12k6) system.
(12k5) system.
(12k5) 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
38 CLV620 unreachable There is no Profinet communication with barcode reader CLV620. Check if
39 Frequency regulator Tsfn There is no Profinet communication with frequency inverter for table Tsfn.
unreachable 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.

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 cranes 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.
Local regime is used, when operator needs to control crane from operators 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 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 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:

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.

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: Cranes 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.

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.

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

Crane regimes icons:
No regime selected. This symbol is used to show that there is no clear controlling partner. This is
achieved when keys arent in appropriate positions. Crane movement is not possible.
Crane is in local regime and can be controlled via the operators 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. Cyan represents that the crane is in manual mode.

2. Red represents that the crane as the safety override key switch active.
3. Blue represents that the crane is automatic mode.
4. Green represents that the crane is operating automatically.
5. Turquoise represents that the crane is in automatic finish mode.
5.5.4.3 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.

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 for semi-automatic mode.

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.

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. 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.
2. 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).
3. Travel, were the entered number represents the desired horizontal location, for the crane (from 1 to 60).
4. Hoist, were the entered number represents the desired vertical location, for the crane (from 1 to 8).
5. 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.

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 00 01: initialization of a command,

o 30 31: movement to the target location,
o 70 74: pick or drop procedure,
o 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.

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

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 operators 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.

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.

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 Check the elements in the electrical cabinet.
3 Limit switch travel, +L01-408S1 The crane travelled over the limit switch.
Override safety and in manual mode put the
crane back to the working area. Check for
reasons.
4 Limit switch speed governor hoist - rope; +L01-408S2 Check the switch and the status of the speed
regulator rope.
5 E-STOP push button main cabinet, +L01-409S1 Release the stop button on the cabinet.
6 E-STOP over rail , +L01-409K1 Close aisle door or release the stop button on
outside cabinets.
7 Limit switch speed governor hoist - overspeed; +L01- Visually check the status of the crane,
410S3 especially the lifting carriage ant the ropes.
Repair the damage. When everything is OK,
release the switch.
8 Protection travel and hoist brakes, +L01-420Q1 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 The crane travelled over the limit switch.
Override safety and in manual mode put the
crane back to the working area. Check for
reasons.
13 Limit switch catching device - jaws, +L02-427S2 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.
14 Cabin door open - to main cabinet, +L02-428S1 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 Remove the pallet or material (plastic foil) that
was triggered in the gap between the crane and
a rack.
18 No clearance between crane and left rack, +L02-43515 Remove the pallet or material (plastic foil) that
a rack.
19 Axis error: travel Error on corresponding drive. See TO and DO
drive messages for details. Make sure that
crane can move freely.
20 Axis error: hoist Error on corresponding drive. See TO and DO
21 Axis error: forks SD Error on corresponding drive. See TO and DO
22 Axis error: forks DD Error on corresponding drive. See TO and DO

24 Travel motor running too long, +EXT-418M1 Something is blocking the movement. Check for
reasons.
25 Hoist motor running too long, +EXT-416M1 Something is blocking the movement. Check for
reasons.
26 Forks SD motor running too long, +EXT-421M1 Something is blocking the movement. Check for
reasons.
27 Forks DD motor running too long, +EXT-422M1 Something is blocking the movement. Check for
reasons.
28 Communication error with transport system PLC The conveyor PLC is not responding.
(receive direction) - Switch on the electrical cabinet.
- Check communication cables and optical link.
- Reset communication through SCADA system.
29 Communication error with transport system PLC (send Same as above.
direction)
30 Communication error with MFCS (receive direction) MFCS is not responding.
31 Communication error with MFCS (send direction) MFCS is not responding.
32 Enormous value of absolute encoder or magnet Check absolute encoder value and both magnet
switches - travel switches.
34 Erroneous value of absolute encoder or magnet Check absolute encoder value and both magnet
switches - hoist switches.
40 Automatic start not possible: wrong location Check entered location.
41 Automatic start not possible: crane occupied Pickup is not possible if there is already a pallet
on the crane.
42 Automatic start not possible: crane is empty Drop is not possible if crane is empty.
43 Barcode mismatch MFCS has issued a command for a pallet which
is not on crane.
44 Underweight Check the load, remove it if it is too heavy.
Calibrate the load sensor.
45 Overweight Check the load, remove it if it is too heavy.
Calibrate the load sensor.
46 No clearance between crane and rack 1 Remove the pallet or material (plastic foil) that
a rack.
47 No clearance between crane and rack 2 Remove the pallet or material (plastic foil) that
a rack.
48 Material picture differs from sensor The material picture occupancy and the sensor
436B1 state differ.
49 Material movement not successful The crane has performed movement, but the
status of occupancy sensor has not changed.
Check the situation.
50 Transport system conveyor not ready Check if transport system is without alarms and
in automatic mode.
51 MFCS error MFCS has requested the crane to raise an error.
Usually due to the too long pickup/deposit
operation on conveyors.
52 Automatic start not possible: fork not in the middle Place both forks manually to middle position
and check both sensors 435B3 and 435B4.
53 Sagging of Axis hoist Hoist brake malfunction, check hoist motor
brake.
54 Crane out of working area (travel) Software limit switch was triggered. Move the
crane back to the working area.
55 Crane out of working area (hoist) Software limit switch was triggered. Move the
56 Crane out of working area (fork SD) Software limit switch was triggered. Move the
57 Crane out of working area (fork DD) Software limit switch was triggered. Move the
60 Deposit to rack not possible - location occupied (side=1, Rack location is occupied, or sensor is not
depth=1) working properly 433B1.
64 Pick from rack not possible - location empty (side=1, Rack location is empty, or sensor is not working
depth=1) properly 433B1.
68 Pick from rack not possible - depth 1 occupied (side=1, Rack location of first depth is occupied, or
depth=2) sensor is not working properly 434B1.
69 Pick from rack not possible - depth 1 occupied (side=2, Rack location of first depth is occupied, or
depth=2) sensor is not working properly 434B2.
71 E-STOP push button, CP101 Release stop button on the cabinet.
72 Door to C101 open Close the door at aisle entry.
73 Light grid - MLG, T10 Check light grid, remove any obstacles and
reset error.
74 Light grid - MLG, T110 Check light grid, remove any obstacles and
reset error.
75 E-STOP push button, CP401 Release stop button on the cabinet.
115 Service M required Maintenance of crane is required. After
maintenance is done, confirmation on
operators panel is needed.
116 Service 3M required Maintenance of crane is required. After

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 icon row.

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 for each
service separately.
Reset button can be pressed only if service is done according to scheduled maintenance plan!

5.6 Shuttle S401

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.

Safety switches, which limit the shuttles movement area: travelling (208S1).
Mushroom safety button on main cabinet.
Doors for accessing the shuttle area from both ends of aisle.
Light grids.
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.
5.6.3 Regimes and modes of operation

The shuttle distinguishes between operation regimes:
Local regime:
o Manual mode
Remote regime:
o Automatic mode
Auto finish mode,
No regime.
Local regime is used, when operator needs to control shuttle from operators 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
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.
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.
aisle entrance enclosure key to LOCAL, and shuttle key to LOCAL
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.
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.
In automatic mode, the shuttle is completely autonomous, and its movements are unpredictable.


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.

case of emergency stop is needed. If the button is pressed, the shuttle will brake on emergency ramp, this can cause

5.6.4.2 HMI
Physical position is given as a numbered value, presenting coordinates in millimetres: Shuttles horizontal
position.
Nearest logical position (conveyor) designated with index giving the logical coordinate.
5.6.4.2.1 Buttons
execute an action.
Button Action
Opens the shuttle manual operation screen, for a detailed description check Chapter
5.6.4.4.1
5.6.4.4.2
Opens the shuttle sensor screen, for a detailed description check Chapter 5.6.4.3.
is present, the button flashes red.

which the operator can edit shuttle parameters.

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:
achieved when keys arent in appropriate positions. Shuttle movement is not possible.
Shuttle is in local regime and can be controlled via the operators 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.

Colour meaning:
1. Cyan represents that the shuttle is in manual mode.

2. Red represents that the shuttle as the safety override key switch active.
3. Blue represents that the shuttle is automatic mode.
4. Green represents that the shuttle is operating automatically.
5. Turquoise represents that the shuttle is in automatic finish mode.
5.6.4.3 Sensors
The sensors screen contains overview of shuttle sensors. Each sensor is represented by a circle accompanied with the
active, it is presented as a green circle or red if its safety related.

5.6.4.3.1 Shuttle
Figure 5.43 Shuttle sensors screen
If the shuttle is occupied, field with palette barcode number is displayed.

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 for local mode, or button for semi-automatic mode.
5.6.4.4.1 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).
F6, F7 - Conveyor movement (F6 forward, F7 backward).
F8 - Reset faults.

Figure 5.44 Manual mode shuttle screen
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
Chapter 5.6.4.2.3.
devices.
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.

Input fields:
6. Command, where the operator selects the desired action from a drop-down list:
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.
7. Travel, were the entered number represents the desired horizontal location conveyor number.
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 40 41: deck pick or drop procedure,
o 90 99: alarm or other finalization steps.

dd Deck state machine for each deck independently:
o 0: initialization of a command,
o 70 72: conveyor movement,
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.



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.
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.
Figure 5.47 Operator's panel: the teaching screen.
The parameter screen on operators panel enables users to save the parameter settings of the shuttle to the file on the
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.

Figure 5.48 Accessing the parameter files from 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.


1 Fuse control 230 VAC, +L01-203F1, 203F3 Check the elements in the electrical cabinet.
3 Limit switch travel, +L01-208S1 Satellite travelled over the limit switch. Override
safety and in manual mode put the crane back to the
working area. Check for reasons.
4 E-STOP over rail - doors, +L01-209K1 Close aisle door or release the stop button on
outside cabinets.
5 E-STOP push button, +L01-211A1 Release the stop button on the cabinet.
6 Protection travel fan motor, +L01-220Q2 Check the elements in the electrical cabinet.
7 Protection conveyor brake, +L01-221Q1 Check the elements in the electrical cabinet.
8 Axis error: travel Error on corresponding drive. See TO and DO drive
messages for details. Make sure that crane can move
freely.
9 Axis error: conveyor C401 Error on corresponding drive. See TO and DO drive
messages for details. Make sure that crane can move
freely.
reasons.
12 Conveyor C401 motor running too long, +EXT-221M1 Something is blocking the movement. Check for
reasons.
13 Communication error with transport system PLC (receive The conveyor PLC is not responding.
direction) - Switch on the electrical cabinet.
14 Communication error with transport system PLC (send The conveyor PLC is not responding.
direction) - Switch on the electrical cabinet.
17 Enormous value of absolute encoder or magnet switches - Check absolute encoder value and both magnet
travel switches.
18 Shuttle travel out of range Software limit switch was triggered. Move satellite
back to the working area.
19 Material mismatch: place C401 Deck material occupancy differ from sensor state.
20 Automatic start not possible: bad target Check entered location.
21 Automatic start not possible: deck is empty Drop is not possible if satellite is empty.
22 Automatic start not possible: deck is occupied Pick is not possible if there is already a pallet on the
deck.
23 Material movement not successful The machine has performed movement, but the
status of occupancy sensor has not changed. Check
the situation.
24 Transport system conveyor not ready - pick Check if transport system is without alarms and in
automatic mode.
25 Transport system conveyor not ready - deposit Check if transport system is without alarms and in
automatic mode.
65 No clearance between shuttle and transporter 12 Remove obstacle and check sensor on transport
system.

system.
system.
system.
system.
system.
71 No clearance between shuttle and conveyors - path not Remove the pallet or material (plastic foil) that was
clear jammed in the gap between the shuttle and
conveyors.
72 E-STOP push button, CP101 Release the stop button on the cabinet.
79 Door to shuttle open Close door.
80 Door to C101 open Close door.
83 Light grid - MLG, T10 Check light grid, remove any obstacles and reset
error.
error.
error.
90 Barcode mismatch: deck MFCS has issued a command for a pallet which is not
on crane.
91 MFCS: unknown error MFCS has requested the crane to raise an error.
Usually due to the too long pickup/deposit operation
on conveyors.
92 MFCS: synchronization failure MFCS has requested the crane to raise an error.
115 Service M required Maintenance of crane is required. After maintenance
is done, confirmation on operators panel is needed.
116 Service 3M required Maintenance of crane is required. After maintenance


In many situations, when the pallet movement is not successfully performed by shuttle, the manual intervention is
required.
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.
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.


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
service separately.

5.7 Shuttle S501

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.

Safety switches, which limit the shuttles movement area: travelling (308S1).
Mushroom safety button on main cabinet.
Doors for accessing the shuttle area from both ends of aisle.
Light grids.
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.
5.7.3 Regimes and modes of operation

The shuttle distinguishes between operation regimes:
Local regime:
o Manual mode
Remote regime:
o Automatic mode
Auto finish mode,
No regime.
Local regime is used, when operator needs to control shuttle from operators 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
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.
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.
aisle entrance enclosure key to LOCAL, and shuttle key to LOCAL
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.
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.
In automatic mode, the shuttle is completely autonomous, and its movements are unpredictable.


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.

case of emergency stop is needed. If the button is pressed, the shuttle will brake on emergency ramp, this can cause

5.7.4.2 HMI
Physical position is given as a numbered value, presenting coordinates in millimetres: Shuttles horizontal
position and inclination position for both decks.
Nearest logical position (slot in a rack, conveyor) designated with two indices giving the logical coordinate
5.7.4.2.1 Buttons
execute an action.
Button Action
Opens the shuttle manual operation screen, for a detailed description check Chapter
5.7.4.4.1
5.7.4.4.2
Opens the shuttle sensor screen, for a detailed description check Chapter 5.7.4.3

is present, the button flashes red.
which the operator can edit shuttle parameters.

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:
achieved when keys arent in appropriate positions. Shuttle movement is not possible.
Shuttle is in local regime and can be controlled via the operators 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.

Colour meaning:
1. Cyan represents that the shuttle is in manual mode.

2. Red represents that the shuttle as the safety override key switch active.
3. Blue represents that the shuttle is automatic mode.
4. Green represents that the shuttle is operating automatically.
5. Turquoise represents that the shuttle is in automatic finish mode.
5.7.4.3 Sensors
The sensors screen contains overview of shuttle sensors. Each sensor is represented by a circle accompanied with the
active, it is presented as a green circle or red if its safety related.

5.7.4.3.1 Shuttle
Figure 5.59 Shuttle sensors screen
If the shuttle is occupied, field with palette barcode number is displayed.

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 for semi-automatic mode.

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
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
Chapter 5.7.4.2.3.
devices.

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.
Input fields:
8. Command, where the operator selects the desired action from a drop-down list. There are three options for
each deck:
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.
Shuttle can pick from two conveyors simultaneously.
Shuttle can drop in rack construction simultaneously if rack slots are close to each other.

Start button.
Cancel button.
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 10 12: deck inclination referencing,
o 40 41: deck pick or drop procedure,
o 90 99: alarm or other finalization steps.
dd Deck state machine for each deck independently:
o 0: initialization of a command,
o 60 61: inclination movement down,
o 70 72: conveyor movement,
o 80 81: inclination movement horizontal position,
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.



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.
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.
Figure 5.63 Operator's panel: the teaching screen.
The parameter screen on operators panel enables users to save the parameter settings of the shuttle to the file on the
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.

Figure 5.64 Accessing the parameter files from 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.


1 Fuse control 230 VAC, +L01-303F1, 303F2 Check the elements in the electrical cabinet.
3 Limit switch travel, +L01-308S1 Satellite travelled over the limit switch. Override
safety and in manual mode put the crane back to
the working area. Check for reasons.
4 E-STOP over rail - doors, +L01-309K1 Close aisle door or release the stop button on
outside cabinets.
5 E-STOP push button, +L01-309S1 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 No clearance between trolley and left rack, +L01- Remove the pallet or material (plastic foil) that was
334B5 jammed in the gap between the shuttle and a rack.
12 No clearance between trolley and right rack, +L01- Remove the pallet or material (plastic foil) that was
334B6 jammed in the gap between the shuttle and a rack.
13 Axis error: travel Error on corresponding drive. See TO and DO drive
messages for details. Make sure that crane can
move freely.
14 Axis error: inclination C501 Error on corresponding drive. See TO and DO drive
move freely.
15 Axis error: inclination C502 Error on corresponding drive. See TO and DO drive
move freely.
move freely.
move freely.
reasons.
20 Inclination C501 motor running too long, +EXT- Something is blocking the movement. Check for
322M1 reasons.
21 Inclination C502 motor running too long, +EXT- Something is blocking the movement. Check for
325M1 reasons.
22 Conveyor C501 motor running too long, +EXT- Something is blocking the movement. Check for
321M1 reasons.
23 Conveyor C502 motor running too long, +EXT- Something is blocking the movement. Check for
324M1 reasons.
(receive direction) - Switch on the electrical cabinet.
(send direction) - Switch on the electrical cabinet.


28 Enormous value of absolute encoder or magnet Check absolute encoder value and both magnet
switches - travel switches.
29 Trolley travel out of range Software limit switch was triggered. Move satellite
back to the working area.
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 Automatic start NOT possible: deck is occupied - Pick is not possible if there is already a pallet on the
C501 deck.
45 Automatic start NOT possible: deck is occupied - Pick is not possible if there is already a pallet on the
C502 deck.
46 Material movement not successful - C501 The machine has performed movement, but the
the situation.
47 Material movement not successful - C502 The machine has performed movement, but the
the situation.
48 Transport system conveyor NOT ready - pick C501 Check if transport system is without alarms and in
automatic mode.
49 Transport system conveyor NOT ready - pick C502 Check if transport system is without alarms and in
automatic mode.
50 Transport system conveyor NOT ready - drop C501 Check if transport system is without alarms and in
automatic mode.
51 Transport system conveyor NOT ready - drop C502 Check if transport system is without alarms and in
automatic mode.
error.
error.
error.
55 Inclination not alligned: C501 Check that deck is in horizontal position and
properly homed.
56 Inclination not alligned: C502 Check that deck is in horizontal position and
properly homed.
58 Deposit not allowed, rack occupied: C501 Dynamic rack is occupied, or sensor is not adjusted
properly.
59 Deposit not allowed, rack occupied: C502 Dynamic rack is occupied, or sensor is not adjusted
properly.
62 Door opened, CP501 Close door.
63 Door opened, CP502 Close door.
64 No clearance between shuttle and T023 Remove obstacle and check sensor on transport
system.

system.
system.
system.
68 No clearance between shuttle and rack 52, place X = Remove obstacle and check sensor on transport
1..5 system.
6..12 system.
13..19 system.
20..24 system.
111 Barcode mismatch: deck C501 MFCS has issued a command for a pallet which is
not on crane.
112 Barcode mismatch: deck C502 MFCS has issued a command for a pallet which is
not on crane.
113 MFCS: unknown error MFCS has requested the crane to raise an error.
Usually due to the too long pickup/deposit
operation on conveyors.
114 MFCS: synchronization failure MFCS has requested the crane to raise an error.
115 Service M required Maintenance of crane is required. After
maintenance is done, confirmation on operators
panel is needed.
panel is needed.
panel is needed.
panel is needed.

In many situations, when the pallet movement is not successfully performed by shuttle, the manual intervention is
required.
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.

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.


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
service separately.

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.
UI
PLC CORE Database
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.

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 response-
From 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.).

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

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:

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.

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

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.

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),
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

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,

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 (*).

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.

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.

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.

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.

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.

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.

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

7 MAINTENANCE
7.1 Mechanical maintenance

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 To be checked Chapter

Pos. Name - to be maintained Instructions
1 motorgearbox 2.000 / 6 oil level control read SIEMENS
smoothnes by
running
cleaning of the
4.000 / 12 cooling ribs
control of the brake
clearance
-oil changing
2 Housing unit with 1.000 / 3 breakdown replace
bearing wear out replace
2.000 / 6 -lubrication Aralub SKA 00
3 Driving sprocket 2.000 / 6 breakdown replace
wear out replace
4 Clamping device 2.000 / 6 attachment replace

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 To be checked

Pos. Name - to be maintained Instructions Chapter
1 Bearing 2.000 / 6 breakdown replace
wear out replace
2 Sprocket 2.000 / 6 breakdown replace
wear out replace
3 Chain 1.000 / 3 breakdown replace
wear out replace
4 Chain guiding 1.000 / 3 breakdown replace
wear out replace

7 MAINTENANCE
7.1.1.1.3 Lubrication plan
Table 7.3 Lubrication plan of the chain conveyor
Pos. Name Lubrication interval Lubricator Quantity of Way of

(days) lubricator lubrication
1 Motorgearboxes according to SIEMENS
documentation
2 Chain 90 WKS special Sprey
3 Housing unit with bearings 90 FOR LPD-2 til lubricator with hand tool
Aralub SKA comes out
00
Lubrication scheme
Figure 7.3 Lubrication scheme of the chain conveyor

7 MAINTENANCE
Daily inspection

carry out sound control of the rollers and gearboxes.

check all bolts
General inspection

5 years

7 MAINTENANCE
ATTENTION 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

1 motorgearbox 2.000 / 6 oil level read SIEMENS 13
control
smoothnes by
running
4.000 / 12 cleaning of the
cooling ribs
control of the
brake clearance
- oil changing
2 Timing sprocket 1.000 / 3 breakdown replace
wear out replace
3 Taper Lock bush 4.000 / 12 attachment replace
4 Driving timing belt 2.000 / 6 breakdown replace

wear out replace
5 Driven timing belt 2.000 / 6 breakdown replace
wear out replace

7 MAINTENANCE
6 Roller 4.000 / 12 breakdown of replace

bearings replace
wear out
Table 7.5 Lubrication parts of the roller conveyor
Pos. Name Lubrication interval (days) Lubricator Quantity of Way of

lubricator lubrication
documentation
Lubrication scheme
Figure 7.5 Lubrication scheme of the roller conveyor

7 MAINTENANCE
Daily inspection

carry out sound control of the rollers and gearboxes.

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

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

7 MAINTENANCE
ATTENTION 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

1 motorgearbox 2.000 / 6 oil level control read SIEMENS 13
smoothnes by
running
cleaning of the
clearance
- oil changing
2 Timing sprocket 1.000 / 3 breakdown replace
wear out replace
3 Taper Lock bush 4.000 / 12 attachment replace
4 Driving timing belt 2.000 / 6 breakdown replace

wear out replace
5 Driven timing belt 2.000 / 6 breakdown replace

7 MAINTENANCE
wear out replace

6 Roller 4.000 / 12 breakdown of replace
bearings replace
wear out
Table 7.7 Lubrication parts of the roller conveyor

documentation
Lubrication scheme
Figure 7.7 Lubrication scheme of the roller conveyor

7 MAINTENANCE
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.

control of the tension of the driving chain

check all bolts
General inspection

5 years

7 MAINTENANCE
Lifting device
1 4 6 3 5
2 7
Figure 7.8 Maintanance parts of the lifting device

7 MAINTENANCE
Table 7.8 Maintanance parts of the lifting device

smoothnes by
running
cleaning of the
clearance
- oil changing
2 Gliding bearing 2.000 / 6 breakdown replace
wear out replace
3 Clamping device 2.000 / 6 attachment replace
4 Driving sprocket 2.000 / 6 breakdown replace

wear out replace
5 Driven sprocket 2.000 / 6 breakdown replace
wear out replace
6 Driving chain 1.000 / 3 breakdown replace
wear out replace
-lubrication WKS special
-lubrication -Aralub SKA 00
Table 7.9 Lubrication parts of the lifting device

documentation
2 Chain 90 WKS special Sprey
3 Housing unit with bearings 90 FOR LPD-2 til lubricator with hand tool
00

7 MAINTENANCE
Lubrication scheme
3 1 2
Figure 7.9 Lubrication scheme of the lifting device

7 MAINTENANCE
7.1.1.5 Stopper
Daily inspection
Make visual control that the lines of conveying the pallet of chainand roller conveyor are perpendicural. Also check
paralelity of the stopper.

control of the guiding linear profiles and trolleys

check all bolts
General inspection

5 years

7 MAINTENANCE
Figure 7.10 Maintanance parts of the stopper
Table 7.10 Maintanance parts of the stopper

smoothnes by
running
cleaning of the
clearance
- oil changing
2 Linear guiding 2.000 / 6 breakdown replace
wear out replace
3 Trolley 2.000 / 6 breakdown replace
wear out replace
-lubricate -Aralub SKA 00

7 MAINTENANCE
Table 7.11 Lubrication parts of the stopper

documentation
2 Trolley 90 FOR LPD-2 til lubricator with hand tool
00
Lubrication scheme
Figure 7.11 Lubrication scheme of the stopper

7 MAINTENANCE
7.1.1.6 Contour check
Weight control
Figure 7.12 Maintanance parts of the weight control
Table 7.12 Maintanance parts of the weight control

1 Weighting cells 1.000 / 3 breakdown replace

7 MAINTENANCE
Pallet base control
Figure 7.13 Maintanance parts of the base control
Table 7.13 Maintanance parts of the base control

1 Supporting wheels 2.000 / 6 breakdown replace
wear out replace
2 Guiding wheels 2.000 / 6 breakdown replace
wear out replace

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

7 MAINTENANCE
Table 7.14 Maintanance parts of the driving set

smoothnes by
running
cleaning of the
clearance
- oil changing
2 Driving wheel 1.000 / 3 breakdown replace
wear out replace
2.000 / 6 -lubrication -Aralub SKA 00
4 Guiding wheel 1.000 / 3 breakdown replace
wear out replace
5 Brush 1.000 / 3 breakdown replace
wear out replace
Tilting table
2 1 3
Figure 7.15 Maintanance parts of the tilting table
Table 7.15 Maintanance parts of the tilting table

smoothnes by
running
cleaning of the
clearance
- oil changing
2 rod end 2.000 / 6 breakdown replace
wear out replace

7 MAINTENANCE
3 gliding bearing 1.000 / 3 wear out replace
Other elements
1 2
Figure 7.16 Other maintanance parts
Table 7.16 Other maintanance parts

1 Buffer 4.000 / 12 breakdown read LEBEN 13
2 Current collector 1.000 / 3 wear out replace

-fixing -tighten fixing bolts
7.1.2.1.1 Roller conveyor
Maintenance of the roller conveyor is described in the Chapter 7.1.1.3

7 MAINTENANCE
7.1.2.2 Lubrication plan
Table 7.17 Lubrication elements of the shuttle

documentation
2 Housing units with bearings 90 FOR LPD-2 till lubrication with hand
Aralub SKA come out lubrication tool
00
3 Roller conveyor according to instructions
for roller conveyor
Lubrication scheme
2 3
1
Figure 7.17 Lubrication elements of the shuttle

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

smoothnes by
running
cleaning of the
clearance
- oil changing
7 MAINTENANCE
2 Driving wheel 1.000 / 3 breakdown replace

wear out replace
2.000 / 6 -lubrication -Aralub SKA 00
4 Guiding wheel 1.000 / 3 breakdown replace
wear out replace
5 Brush 1.000 / 3 breakdown replace
wear out replace
Other elements
1 2
Figure 7.19 Other maintanance elements
Table 7.19 Other maintanance elements

1 Buffer 4.000 / 12 breakdown read LEBEN 13
2 Current collector 1.000 / 3 wear out replace

-fixing -tighten fixing bolts
7.1.3.1.1 Chain conveyor
Maintanance of the chain conveyor is described in the Chapter 7.1.1.1

7 MAINTENANCE
7.1.3.2 Lubrication plan
Table 7.20 Lubrication elements of the shuttle

documentation
2 Housing units with bearings 90 FOR LPD-2 till lubrication with hand
Aralub SKA come out lubrication tool
00
3 Chain conveyor according to instructions
for chain conveyor
Lubrication scheme
2 3
Figure 7.20 Lubrication scheme of the shuttle

7 MAINTENANCE
7.1.4 Crane
ATTENTION Before any interference on the lifting unit, put the lifting carriage onto shock absorbers
situated on the bottom carrier.
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 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!

7 MAINTENANCE
7.1.4.1 Bottom carriage
Table 7.21 Bottom carriage
Pos. Name Working To be checked Instructions Chapter

hours - to be maintained
6 Wheel 4.600 damage Replace wheel
wear
19 Motor a with 2.000 oil level Read SIEMENS 16
conical reduction travel ease instruction, call
gear 2.300 cleaning cooling ways SIEMENS service
test brake shoes, test working air
slot, change oil 10 mm replace
0,3<air slot<1,2
20 Two row cylinder damage Replace bearing
bearing 3.000 wear
- lubricate Lubricate with Aralub
SKA or Multitop
21 Leading wheel damage Leading wheel
1.200 wearing out change
travel ease
noise at run Lubricate
22 Locking device 4.600 fixing Clamp set
tightening momentum replace
22 22
20 20
6 6
19
Figure 7.21 Bottom carriage

21
21

7 MAINTENANCE
7.1.4.2 Lifting carriage
Table 7.22 Lifting carriage

6 Telescopic forks 3.000 damage Read EUROFORK 16
travel ease manual
noise at run
wear
- lubricate
7 Load pin 4.600 damage Read TECSIS manual 16
function
6
Figure 7.22 Lifting carriage

7 MAINTENANCE
7.1.4.3 Upper girder
Table 7.23 Upper girder

9 Leading wheel 4.600 damage Leading wheel
travel ease replace
noise at run
wear
10 Shrink disc 4.600 fixing Clamp set
11 Pulley 4.600 damage Replace pulley
wear
firm fixing
- no need for maintenance
11 9
10
Figure 7.23 Upper girder

7 MAINTENANCE
7.1.4.4 Wheels on the lifting carriage
Table 7.24 Wheels on the lifting carriage

3 Wheel 230x36 1.200 wear Leading wheel
damage replace
travel ease Aralub SKA 00 or
noise at run Multitop
- lubricate
4 Wheel 230x30 1.200 damage Leading wheel replace
- lubricate
19 Guiding wheel 1.200 wear Leading wheel
damage replace
- lubricate
20 Guiding wheel 1.200 wear Leading wheel
with axle damage replace
- lubricate
21 Bearing damage Replace bearing
3.000 wear Lubricate with Aralub
- lubricate SKA or Multitop
22 Bearing damage Replace bearing
3.000 wear Lubricate with Aralub
- lubricate SKA or Multitop
27 DU Bush 1.200 wear Sliding washer
replace
28 DU Washer 1.200 wear Sliding bearing
replace

7 MAINTENANCE
16
19
21
18
19
20
27
28
20
3
27
17
28
22
Figure 7.24 Wheels on the lifting carriage

7 MAINTENANCE
7.1.4.5 Lifting unit
Table 7.25 Lifting unit

1 Rope drum 4.600 damage Replace rope drum
leading profile worn out
9 Steel rope 2.300 damage Replace rope
appearance of excessive wear Daily inspection of its
look!!!
11 Motor with conical 2.000 oil level Read SEW instruction, 16
reduction gear Travel ease call SEW service
cleaning of cooling ways
test brake shoes 10 mm replace
test working air slot
change oil 0,3<air slot<1,2
11
Figure 7.25 Lifting unit

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.

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 6 x d = 132 mm 30 x d = 660 mm

Degree of wear 13 26
(number of damaged wires)

7 MAINTENANCE
7.1.4.7 Catching device
Table 7.27 Catching device

15 Catching device 4.600 function Read THYSSEN manual 16
air slot
grip jaws wear
Figure 7.27 Catching device

7 MAINTENANCE
7.1.4.8 Speed regulator
Table 7.28 Speed regulator

9 Speed governor 4.600 function Replace speed 16
governor
10 Rope wheel 4.600 damage Replace rope wheel
wear
travel ease
suitability of furnishing
11 Steel rope 1.000 damage Replace steel rope
appearance of excessive wear
- set (to strain)
10
11
Figure 7.28 Speed regulator

7 MAINTENANCE
7.1.4.9 Ladder
Table 7.29 Ladder
Pos. Name Working hours To be checked Instructions Chapter

- to be maintained
8-11 Protection against Verify at each function Replace protection 16
fall use!!! damage against fall
DANGER OF
DEATH
12 Steel rope damage Replace steel rope
appearance of
4.600 excessive wear
- set (to strain)
12
11
10
8 9
Figure 7.29 Ladder

7 MAINTENANCE
7.1.4.10 Cable chain
Table 7.30 Cable chain

19 Cable chain 4.600 function Replace cable chain in
damage full length or only
torsion damaged links
19
Figure 7.30 Cable chain

7 MAINTENANCE
7.1.4.11 Instructions for lubrication
1. First condition for reliable operation of the stacker crane is careful execution of all prescribed inspections,
professional lubrication and maintenance.
2. 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.
3. 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.
4. 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
5. Maintain electrical motors and driving gears according to manufacturer's instructions.
NOTE:
Manufacturers 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
Pos. Name Lubrication Type of lubricant Quantity of Lubrication

frequency lubricant method
(days)
1 Electro-motor driving gears According to
the SIEMENS
manual
2 Bearings of running and leading 90 or as Aralub SKA 00 or Until grease With a manual
wheels necessary Multitop starts to get lubrication
out device
3 Leading wheels on the lifting 90 or as Aralub SKA 00 or Until grease With a manual
carriage necessary Multitop starts to get lubrication
out device
4 Rope of lifting unit 30 or as Shell Malleus GL or With a brush
necessary other suitable
lubricant
5 Telescopic forks Upon
manufacturer's
instructions

7 MAINTENANCE
7.1.4.12 Lubrication scheme
5
1
2
2
Figure 7.31 Lubrication scheme

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 Type of Subject of Realisation Performer Notice Instructions

activity Inspection method
Daily Functionality -entire Visual Operator before
inspection machine machine
-safety starts
devices
Daily Functionality safety devices Visual Operator before
inspection machine
starts
Daily Cleaning - entire Operator after
machine machine
-safety stops
devices
Daily Examination Lifting rope Visual Maintainer before
of wear machine
starts
Weekly Cleaning Rail Visual Maintainer before
machine
starts
Every three SERVICE ENTIRE MANUFACTU
months MACHINE RER or
REPAIRER
Annually SERVICE overloading Test MANUFACTU
device RER or
REPAIRER

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.

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.

8 SPARE PARTS
8.1 Mechanical parts
8.1.1 Conveyors system

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 Wippermann

Type 3

Pos. Name Plan, standard Manufacturer
1 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

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

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
14 1 Motorgearbox DF39-LA63MF4-L4/2N SIEMENS
16 2 Trolley LAH25BNZ NSK
8.1.1.6 Contour check weight control

1 WEIGHTING CELLS 7MH5113-3PD00/7MH4130- SIWAREX

4AE11/7MH5713-4AA00
8.1.1.7 Contour check pallet base control

1 Vulkolan Wheel HTH 82x100 BLICKLE
2 Vulkolan Wheel FSTH 125x25-15K BLICKLE
3 Flag 1157.100.10.04.005

8 SPARE PARTS
8.1.2 Shuttle C501

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

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

1 1 SHAFT 110 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 KAS129-LES180MM4EF-L260/100MHA- SIEMENS
CONICAL REDUCTION GEAR IN; Mounting position: M3A; P=18,5kW;
S1=100%; n=124min-1; I=11,80;
6 2 BEARING 23218-E1-XL-TVPB FAG

8 SPARE PARTS
7 2 GUIDING WHEEL WITH AXLE KEHT 110PP H&T

110
8 1 SHRINK DISC KTR 201-110x155 CLAMPEX
9 2 13 NO. 741020 PHOENIX
10 2 SEAL RING A105X140X12 DIN 3760
11 1 SEAL RING A90X110X12 DIN 3760
8.1.4.1.2 Wheels on lifting carriage
1 1 AXLE 0X142 710006 CGE

2 2 AXLE 80X183 710007 CGE
3 1 AXLE 50X160 710008 CGE
4 1 AXLE 70X87 710009 CGE
5 1 SPACER SLEEVE - 1 710013 CGE
6 1 SPACER SLEEVE - 1 710014 CGE
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 Upper girder
1 1 UPPER WHEEL AXLE 722005 CGE

2 1 PULLEY AXLE 722006 CGE
3 1 SAFETY RING 722007 CGE
4 1 SPACER RING 722031 CGE
5 2 POLYURETHANE WHEEL vk LF 150/40/325 VULKOPRIN
150X40
6 2 PULLEY 630 A 009.63.16 CAH
7 1 SHRINK DISC KTR 400 - 45x75 CLAMPEX
8 2 CIRCLIP 25X1,2 DIN 471

8 SPARE PARTS
8.1.4.1.4 Lifting unit

1 1 ELECTRICAL MOTOR WITH K189 LES180ZLJ4EF-L260/145MH-IN SIEMENS

CONICAL REDUCTION GEAR Mounting position M4A; P=22kW;
S1=100%; n=20min-1 ;I=74,35;
2 1 DIEPA
left coiled, cross-knitted, soaked, stress-
free, 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
1 1 CABLE CHAIN CABLE CHAIN TYPE: 27i.12.200.0 IGUS

10 LINKS
8.1.4.1.6 Speed regulator
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: DIEPA

right handed, strength class: galvanized;
1770N/mm2; L=37,5m; Rope ends:
protected;
8.1.4.1.7 Lifting carriage platform
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
1 2 SPIRAL SPRING DOOR HINGE NO. 0 FRIDAVO

2 2 DUAL BALL CATCH NO. 263-9010 DIRAK
4 4 RUBBER WASHER 75X25 ART. NO. 781100 PHOENIX
5 4 ART. NO. 741020 PHOENIX

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 R27DRS80M4BE2 A EUROFORK
HRTF
08N 2 ENCODER COUPLING ECOFLEX BKL/003 10 - SCTR154 A EUROFORK
10
09N 2 ENCODER PROFINET AFM60A-S4NB018X12 AFM60A- A EUROFORK
S4NB018X12
10N 6 P=1/2"x5/16" D. CHAIN L.=736,60 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.

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

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

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

1 1 AUXILIARY SWITCH 1NC+1NO 5ST3010 Siemens

2 1 CIRCUIT BREAKER 400V 10KA, 3-POLE, C, 3A, D=70MM 5SY4303-7 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
11 1 CIRCUIT BREAKER 230/400V 10KA, 1-POLE, B, 10A, D=70MM 5SY4110-6 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
SSG15
SSG11

SSG12

8 SPARE PARTS

SSG13
8.2.2 Crane

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
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
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
28 1 Cable chain

8 SPARE PARTS

1 1 AUXILIARY SWITCH 1NC+1NO 5ST3010 Siemens

6 1 CIRCUIT BREAKER 230V 10KA, 1+N-POLE, C, 4A, D=70MM 5SY4504-7 Siemens
8 1 CONTACTOR RELAY, 3NO+1NC AC 230V, 50/60 HZ, 3RH2131-1AP00 Siemens
10 1 Relay Module LZS:RT4A4L24 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
Y01 Y01:SSG11
Y01 Y01:SSG12
Y01 Y01:SSG13
22 1 CES KEY-OPER.SWITCH, 2 POSITIONS O-I LATCHING 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


1 1 SIMOTION DRIVE-BASED CONTROL UNIT D425-2 DP/PN 6AU1425-2AD00-0AA0 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

8 SPARE PARTS

18 1 Cable chain


13 1 BLUE ILLUMINATED PUSHBUTTON 3SU1152-0AB50-1BA0 Siemens
14 1 EM. STOP MUSHROOM PUSHBUTTON 3SU1000-1HB20-0AA0 Siemens
Y01 Y01:SSG14
20 1 RED INDICATOR LIGHT WITH CONCENTRIC RINGS 3SU1102-6AA20-1AA0 Siemens
8.2.4 Shuttle C501


8 SPARE PARTS
1 1 SIMOTION DRIVE-BASED CONTROL UNIT D425-2 DP/PN 6AU1425-2AD00- 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
6 1 SINAMICS S120 DOUBLE MOMO 3A/3A D-TYPE 6SL3120-2TE13-0AD0 Siemens
8 1 SINAMICS S120 DOUBLE MOTOR MODULE 3A/3A 6SL3120-2TE13-0AA4 Siemens
12 1 KTP700 BASIC 6AV2123-2GB03- Siemens
0AX0
15 1 Proximity sensors IME18-08NPSZC0S SICK
19 1 Distance sensor DT35-B15251 SICK
22 1 Cable chain


13 1 BLUE ILLUMINATED PUSHBUTTON 3SU1152-0AB50-1BA0 Siemens
14 1 EM. STOP MUSHROOM PUSHBUTTON 3SU1000-1HB20-0AA0 Siemens
Y01 Y01:SSG15

8 SPARE PARTS

20 1 RED INDICATOR LIGHT WITH CONCENTRIC RINGS 3SU1102-6AA20-1AA0 Siemens

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High-bay rack warehouse

Abalioglu, Izmir, Turkey

3.1.3 Rotating movable parts hazard ......................................................................................... 74

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 3/251

5.1.1 Warehouse layout .......................................................................................................... 102

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 4/251

5.7.3 Regimes and modes of operation.................................................................................... 158

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 5/251

7.2.6 Photo-reflective, inductive and magnetic sensors ........................................................... 238

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 6/251

Figure 2.27 Tilting mechanismus .................................................................................................................. 46

Figure 5.15 Settings screen .........................................................................................................................117

Figure 5.65 Operators panel: parameter adjustment screen .......................................................................170

Figure 7.30 Cable chain ...............................................................................................................................233

Table 7.13 Maintanance parts of the base control ......................................................................................213

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 11/251

1.1 Purpose of the instructions

The manual is an integral part of the sytem safety. Therefore:

Before performing any operation, it is necessary to read the entire documentation

1.2 Safety symbols and warnings

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 12/251

Table 1.1 Notes and warnings

ADVICE It illustrates useful instructions related to work.

INFORMATION Important information!

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 13/251

1.3 Applicable Health and Safety Legislation

Table 1.2 Considered regulations and rules Standards

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 14/251

1.3.1 Basic Health and Safety Procedures

Only qualified staff can operate the system.

This chapter contains information and instructions relevant to:

the safety of the people responsible for running and maintenance;

what is or maybe be involved;

The employer shall be responsible for instructing staff regarding:

It is the responsibility of the employer to:

The operator must:

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 15/251

1.3.1.2 Basic first Aid Principles

1.3.1.3 Basic Safety Guide

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 16/251

limits of their duties;

Important notes for operators:

1.3.1.4 System of keys and Permits-to-work

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 17/251

1.3.2 After Servicing

1.3.3 Fire Precautions

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 18/251

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 19/251

1.4 Project Directory

Table 1.3 Contacts table

Role Organization Name & Address Contact Details

Mechanical Iskra impuls Kranj d.o.o tel.: +386 4 20 10 210

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 20/251

2.1 Basis of design

2.2 Purpose of the Installation

2.3 Applicable Standards

2.4 Mechanical equipment

2.4.1 Conveyor system

2.4.1.1.1 Technical description

Dimensions of the pallet is 1200mm x 800mm

GE DRS DEPO RAF SSTEMLER Kestel/Bursa/TURKEY 21/251

Table 2.1 Main parts of the chain conveyor