Marks&Spencer SSC BA 4 0 en(FILEminimizer)

7/27/2019 Marks&Spencer SSC BA 4 0 en(FILEminimizer)

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Storage and retrieval machine Operating Instructions Operation

1475400 1Marks&Spencer_SSC_BA_4_0_en/2013-06-04

Table of contents

Page

4 OPERATION .......................................................................................................... 4

4.1 General .................................................................................................................. 4

4.2 Control elements .................................................................................................. 5

4.2.1 Aisle entrance ....................................................................................................... 5

4.2.2 Aisle panel control elements ............................................................................... 5

4.2.3 Control elements on emergency control cabinet ............................................... 7

4.2.4 Visualization .......................................................................................................... 9

4.2.5 Control panel Siemens TP 177B .......................................................................... 9

4.2.5.1 General panel functions ..................................................................................... 10

4.2.5.2 Navigation bar ..................................................................................................... 13

4.2.5.3 Status messages ................................................................................................ 14

4.2.5.4 Main menu (Main) screen ................................................................................... 15

4.2.5.4.1 MFS orders screen ............................................................................................. 16

4.2.5.4.2 Faults screen....................................................................................................... 17

4.2.5.4.3 Fault history screen ............................................................................................ 18

4.2.5.5 Semi screen......................................................................................................... 19

4.2.5.6 Service screen .................................................................................................... 20

4.2.5.7 Data screen ......................................................................................................... 21

4.2.5.7.1 LU info screen ..................................................................................................... 22

4.2.5.7.2 Storage DIF (direct interface) screen ................................................................ 23

4.2.5.7.3 Retrieval DIF (direct interface) screen .............................................................. 24

4.2.5.7.4 Drives screen ...................................................................................................... 25

4.2.5.7.5 Operating hours screen ..................................................................................... 26

4.2.5.7.6 LHD top view screen .......................................................................................... 27

4.2.5.7.7 Load handling device (LHD) screen .................................................................. 28

4.2.5.7.8 PLC inputs screen .............................................................................................. 29

4.2.5.7.9 PLC outputs screen ............................................................................................ 30

4.2.5.8 Options screen .................................................................................................... 31

4.2.5.8.1 Commissioning Service screen......................................................................... 32

4.3 Safety devices ..................................................................................................... 33

4.3.1 Driving aisle safety devices ............................................................................... 33


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Operation Operating instructions Storage and retrieval machine


4.3.2 Safety equipment at storage and retrieval machine ......................................... 34

4.3.2.1 Mechanical safety equipment at storage and retrieval machine ..................... 34

4.3.2.2 Electrical safety equipment at storage and retrieval machine ........................ 344.3.2.3 Other safety devices ........................................................................................... 35

4.4 Activation requirements for Automatic/Semi/Service mode ........................... 35

4.4.1 Check list - Test activities for Semi- and Service Mode .................................. 36

4.5 Operation modes ................................................................................................. 36

4.5.1 Automatic mode .................................................................................................. 36

4.5.1.1 Starting Automatic Mode .................................................................................... 36

4.5.1.2 Operation in Automatic Mode ............................................................................ 374.5.1.3 Automatic order processing interrupted ........................................................... 37

4.5.1.4 Deletion of active automatic order ..................................................................... 37

4.5.1.5 Deactivation of automatic mode ........................................................................ 38

4.5.2 Semi mode ........................................................................................................... 38

4.5.2.1 Switching on Semi mode externally .................................................................. 38

4.5.2.2 Switching on Semi mode on board .................................................................... 39

4.5.2.3 Approach rack compartment coordinates ........................................................ 39

4.5.2.4 Rack compartment coordinates ......................................................................... 394.5.2.4.1 Preconditions for entry of coordinates ............................................................ 41

4.5.2.4.2 Entering target coordinates ................................................................................ 43

4.5.2.4.3 Execution of semi orders .................................................................................... 43

4.5.2.5 Serving rack compartment with load handling device (LHD) .......................... 44

4.5.2.6 Semi-Mode after interruption of Automatic Mode ............................................ 45

4.5.2.7 Deactivation of Semi mode ................................................................................. 45

4.5.3 Service mode ....................................................................................................... 45

4.5.3.1 Service mode without clearing ........................................................................... 46

4.5.3.1.1 Switching on Service Mode ................................................................................ 46

4.5.3.1.2 Running Service Mode ........................................................................................ 47

4.5.3.2 Service Mode with clearing ................................................................................ 48

4.5.3.2.1 Switch on Service Mode with clearing............................................................... 48

4.5.3.2.2 Running service mode with clearing ................................................................. 48

4.5.3.3 Stop service mode with clearing ........................................................................ 49

4.5.3.4 Service mode - Clearing without orbiter ............................................................ 49


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List of illustrations

Fig. 4-1 Schematic overview of control and communication system ............................................................... 4Fig. 4-2 Aisle panel control elements ............................................................................................................... 5Fig. 4-3 Desk SRM control panel ..................................................................................................................... 7Fig. 4-4 SRM emergency control panel: Control elements .............................................................................. 8Fig. 4-5 SRM overview in Visu ......................................................................................................................... 9Fig. 4-6 TP 177B Front and side view ............................................................................................................ 10Fig. 4-7 Bottom view of TP 177B DP ............................................................................................................. 10Fig. 4-8 Bottom view of TP 177B PN/DP ....................................................................................................... 10Fig. 4-9 Alphanumerical screen keyboard...................................................................................................... 11Fig. 4-10 Numerical screen keyboard .............................................................................................................. 12Fig. 4-11 Navigation bar ................................................................................................................................... 13Fig. 4-12 Operating state.................................................................................................................................. 13

Fig. 4-13 Main menu (main) ............................................................................................................................. 15Fig. 4-14 MFS orders ....................................................................................................................................... 16Fig. 4-15 Faults ................................................................................................................................................ 17Fig. 4-16 Fault history ....................................................................................................................................... 18Fig. 4-17 Semi .................................................................................................................................................. 19Fig. 4-18 Service screen .................................................................................................................................. 20Fig. 4-19 Service symbols ................................................................................................................................ 20Fig. 4-20 Data screen ....................................................................................................................................... 21Fig. 4-21 LU info screen ................................................................................................................................... 22Fig. 4-22 Storage DIF pallet / Muli ................................................................................................................ 23Fig. 4-23 Retrieval DIF Pallet / Muli (orbiter) ................................................................................................. 24Fig. 4-24 Drives screen .................................................................................................................................... 25Fig. 4-25 Operating hours ................................................................................................................................ 26

Fig. 4-26 LHD Top view screen ........................................................................................................................ 27Fig. 4-27 LHD screen ....................................................................................................................................... 28Fig. 4-28 Light barrier symbols ......................................................................................................................... 28Fig. 4-29 Switch symbols ................................................................................................................................. 28Fig. 4-30 PLC inputs screen ............................................................................................................................. 29Fig. 4-31 PLC outputs ...................................................................................................................................... 30Fig. 4-32 Options screen .................................................................................................................................. 31Fig. 4-33 Commissioning Service screen ......................................................................................................... 32Fig. 4-34 System of coordinates ...................................................................................................................... 42

Revision history and version control

Date Reason (first issue, modification, revision, etc.) Responsible person Version

2012-05 First issue Weiglmeir 0


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4 Operation

4.1 General

The plant features 4 double-deep pallet storages and retrieval machines each of which is equipped with a tele-scope fork.

Fig. 4-1 shows a schematic overview of the control and communication system.

Fig. 4-1 Schematic overview of control and communication system


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4.2 Control elements

There are various locations from where the storage

and retrieval machine can be operated in the differ-ent operation modes. For an overview, see Table 1.

The control panel shown in Fig. 4-1 (aisle controlpanel, see. Chapter4.2.4) which is installed be-tween the aisles is used for controlling the machinein semiautomatic operation. Via this panel, up to 2neighboring SRMs can be monitored and operated(in semiautomatic mode).

4.2.1 Aisle entrance

The aisle door giving access to the storage and re-trieval machine can only be opened using the keywith special locking function (from key switch Au-to/Local/Semi see Fig. 4-2).

4.2.2 Aisle panel control elements

Via the Auto/Semi/Local key switch (1) (see Fig.4-2), the following functions can be performed:

Here, you can preset operation modes Automat-ic/Semi and manual mode (see Section 4.5).

In Automatic or Semi position, you canacknowledge current faults on the SRM usingthe fault ackn. button (4) (see Section 4.5).

If Local is selected, the user can control themachine from within the aisle (key can be takenout).

Use the Automatic On (2) or Automatic Off (3)buttons to turn automatic operation of the SRMon/off while the key switch is in Auto position.

With the >Emergency Stop< pushbutton (6) theSRM can be switched off in case of an emergency.

With the aisle main switch (5), power supply to theSRM can be cut off.

Fig. 4-2 Aisle panel control elements

HBW aisle entrance SRM

1. >AUTO/SEMI/LOCAL< key switch2. Automatic on3. Automatic off4. Acknowledge fault5. Aisle main switch6. External emergency stop pushbutton

543

2

1

6


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Usability

Enabled control station(Mode)

KEY SWITCH

stationary con-trol cabinet

SRMemergency

control panelClear

stationary control cabinetVISU

(AUTO mode)Auto Auto off

stationary control cabinet /aisle control panel

(SEMI mode)SEMI Auto off

SRM emergency control panel /hoisting platform control panel

(SERVICE or SEMI mode)

Local Local X

Table 1: Usability in key switch positions

Illuminatedpushbut-

tonsDescription Function Lamp

2.1

AUTO ON

(green)

activates AUTO

see Section 4.5

Lamp on Automatic on

Lamp flashing Automatic mode is beingdeactivated,

home position was requestedor machine in Semi operation mode

Lamp off Automatic/Semi is off

2.2

AUTO OFFswitches AUTO offsee Section 4.5

no illuminated pushbutton

2.3

ACKNOW-LEDGE FAULT(red)

Acknowledge faultsee Chapter 5

Lamp on Fault

Lamp flashing Fault, waiting for shutdownfault cannot be acknowledged yet

2.4

Aisle access(white)

Request aisle ac-cess

Lamp on Aisle access permitted

Lamp flashing Aisle access requested butnot enabled yet

Table 2 : Illuminated pushbuttons


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4.2.3 Control elements on emergency control cabinet

Fig. 4-3 Desk SRM control panel

SRM emergency controlpanel

1 >Manual/Auto< keyswitch

2 >Acknowledgefault< pushbutton

3 Switch button>Clear / Travel

without orbiterEmergency stopEmergency Stop< pushbutton (4) the SRM can be switched offin case of an emergency.

Illuminated pushbutton >Acknow. fault< (2) is used for acknowledgingfaults.

The release button (6) releases SRM movement in Semi and Service op-

eration modes.

4

5

32

1


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In each SRM, the SRM emergency control panel isinstalled on the emergency control panel, as shownin Fig. 4-4. Here, the hoisting platform control panelis installed (see Section 4.2.4) which can be used

for monitoring the relevant SRM and controlling it inSemi or Service mode.

Fig. 4-4 SRM emergency control panel: Control elements


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4.2.4 Visualization

Via the visualization system (VISU), basic functions can be controlled. The visualization computer is installed at

the I-point. Refer to the VISU operating instructions for information on how to open the control and overviewscreens for SRM.

Fig. 4-5 SRM overview in Visu

Via the VISU the whole plant can be controlled, i.e.,

The individual controllers (SRM and CSC) can be switched on or off in automatic mode.

The operating conditions and faults are indicated.

In a separate menu, faults can be sorted according to control group and type, displayed and printed, ifnecessary.

Faults can be acknowledged. (see Chapter 5).

SRM home position travel can be requested.

4.2.5 Control panel Siemens TP 177B

Via the control panel Siemens TP 177B, the storage and retrieval machine can be monitored and controlled. Inorder to use a panel for controlling the machine, the key switches must be in the correct position (see Table 1).

Control panel views


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WarningDon't use any pointed or sharp objects for selecting the required control object, this might damage the plasticsurface of the touch screen.

The feedback of the fields corresponds to the feedback on the computer, some buttons will be shown against ashaded background to indicate that they are active.

Fields with an input function are indicated in the whole project by black text on white background.

If an input field is activated, a keyboard will be displayed for entry of the values. Depending on the type of varia-ble, numerical or alphanumerical keys will be available.

Fig. 4-9 Alphanumerical screen keyboard


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Fig. 4-10 Numerical screen keyboard

In the upper bar, the current input is displayed, the character to the left of the cursor is deleted by pressing theBSP (Backspace) button; to confirm your entry, press (Return), to cancel it, press ESC (Escape).

The project is divided in individual screens, some of which are only available to users with extended rights (ad-ministrator).


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4.2.5.2 Navigation bar

In all screens, except for the overview screen, you will see the navigation bar shown in

Fig. 4-11:

Fig. 4-11 Navigation bar

It enables quick navigation through the different screens and provides an overview of the currently selected

storage and retrieval machine.

1 Switch to Main menu (Main) screen

2 Switch to Semi screen (control in semi-automatic operation mode)

3 Switch to Service screen (control in manual operation mode)

4 Switch to Data screen (data overview screen)

5 Switch to Options screen (options menu)

6 Status (see Section 4.2.5.3); switch to Faults screen

7 Type and number of selected storage and retrieval machine

8 Operating state (see Fig. 4-12)

Value Symbol Meaning

0 Off

1 Automatic mode

2 Service mode

3 Long-time block

4 Em. stop

5 Fault

6 Reference travel operation

7 Semi mode

Fig. 4-12 Operating state

1 2 3 4 5

6 7 8


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4.2.5.3 Status messages

The status message shows the current message, warning or fault of the selected storage and retrieval machine.

The texts are identical to the visualization messages. The status messages are described in detail in chapter 5.In addition to the plain text of the message, a number and the corresponding bit are displayed. In this way, themeaning can be identified quickly.

Press the status message to open Faults. This is necessary to identify the cause of a fault as all current mes-sages are displayed here in chronological order.


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2

1

3

6

987

10

54

11

4.2.5.4 Main menu (Main) screen

Fig. 4-13 Main menu (main)

The main menu provides an overview of the currentstate of the storage and retrieval machine.

1 Displays actual and set coordinates of the se-lected storage and retrieval machine

2 MFS orders

3 Faults: Display of current faults

4 Semi on: activate semi-automatic operation

from selected storage and retrieval machine5 Service on: activate Service mode at storage

and retrieval machine on emergency controlpanel (only hoisting platform control panel inthe case of pallet SRM).

6 Off: Switch off semi-automatic / service mode.

7 The field (Semi OK) indicates if the conditions

for activation of semi mode are met ( ).

8 The field (Semi OK) indicates if the conditions

for activation of semi mode are met ( ) (onlyhoisting platform control panel in the case ofpallet SRM).

9 By slow flashing ( 1 Hz) the field indicatesthat communication with the controller hasbeen established.

10 In this field, the status messages are displayed

Note

The Service switch is only visible at the storage and retrieval machine, asthis is the only place where this oper-ation mode is permissible.


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4.2.5.4.1 MFS orders screen

Fig. 4-14 MFS orders

The MFS order screen displays the current ordersas well as the telegram contents.

1 Use these buttons to select the orders, thetype of the chosen order is displayed in themiddle.

2 Delete order (if possible).

1

2


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4.2.5.4.2 Faults screen

Fig. 4-15 Faults

In the Faults screen, messages and additional in-formation are displayed. The content of this screenis updated by the controller continuously. Thismeans that only current fault messages are dis-played.

1 In order to enable easy troubleshooting, themessages are sorted in chronological order(the message on top was the first messagethat arrived).

2 Above the fault messages, the coordinate atwhich the fault was triggered is displayed.

3 Use this button to acknowledge the fault (seeChapter 5). The field can only be used whenthe key switch is in the correct position.

4 Press this button, to display the fault historyscreen.

The symbol in the status bar shows that additionalmessages are present.

Emergency stop faults can only be acknowledged inkey switch positions Service or Semi. In this case,an additional message appears in the panel show-ing that the fault can only be acknowledged at themachine.

3

1

2

4


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4.2.5.4.3 Fault history screen

Fig. 4-16 Fault history

In the Fault history screen, messages and addi-tional information are displayed. The content of thisscreen is updated by the controller continuously.This means that current fault messages and faultmessages already acknowledged are displayed.

1 The faults are marked with a time and datestamp and are displayed in chronological order(the top message is the most current one).

2 The current date and time is also displayed.

3 Press this button, to return to the Fault screenfrom where you can access the menu bar(Main, Semi, etc.).

1

2 3


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4.2.5.5 Semi screen

Fig. 4-17 Semi

In Semi screen, the semi order to be executed canbe configured after selection of Semi mode. In thisprocess, the machine moves to the specified posi-tion in semi-automatic mode.

1 Display of actual and set positions as well asactual coordinates and current step in fork andpositioning step sequence.

2 Input fields for set coordinates.

3 Switch: get bring.

4 Switch: with fork cycle without fork cycle (=positioning only).

5 Go: starts the semi order.

6 Stop: deletes the semi order (only while drivesare stopped and semi order is active).

7 Press Horn to activate the start-up warningsignal and to test the signal horn.

8 Status line: is displayed in Semi mode. Here,it is indicated if a semi order is active or possi-ble or why the input is not correct.

9 Selection of pallet type

semi not possible

2

1

3

4

5

7

8

69


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4.2.5.6 Service screen

Fig. 4-18 Service screen

In the Service menu you can move all axes in jogmode. After selection and setup, the drive can bemoved in jog mode.

Setting options:

1 This area provides an overview of the first sixdrives. For each drive, the actual position(ACT pos.), the set position (SET pos.) andthe actual coordinate (ACT) are displayed. Thecurrently selected drive is shown against agray background.

2 To select the drive press buttons >,

the name of the selected drive is displayed inthe text field in the middle. As soon as the endof the list is reached, press the button again to

jump to the opposite end of the list.

3 Here, you can set the speed at which the driveis to be operated via the drop-down menu. V0-V4 are speed levels up to a max. of 0.5 m/s.Use >|< to center the forks.

4 The direction of operation must be preset us-ing this switch.

5 Display of the current status of the selecteddrive (see Fig. 4-19).

6 Indicates if the drive has reached its set posi-tion (see Fig. 4-19).

7 Press Horn to activate the start-up warningsignal and to test the signal horn.

Field Symbol Meaning

6 Drive in position

5 Drive stopped

5 Drive running

Fig. 4-19 Service symbols

1

2

3 4

5

6

7


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4.2.5.7 Data screen

Fig. 4-20 Data screen

The Data screen branches off to the data of thestorage and retrieval machine. Press buttons 1 to 9to open the corresponding overview screen:

1 LU Info provides information on the transportunits on the load handling device (LHD).

2 Direct storage interface.

3 Direct retrieval interface.

4 Drives / drive controller.

5 Operating hours (if available).

6 LHD top view shows a top view of all relevantsensors of the LHDs.

7 LHD shows a side view of other relevantsensors.

8 PLC inputs.

9 PLC outputs.

Stock image

7

6

5

4

3

2

1

8

9


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4.2.5.7.1 LU info screen

Fig. 4-21 LU info screen

In the LU info screen all properties of the transportgoods measured by the storage and retrieval ma-chine are shown.

1 LHD occupation.

2 Recycle bin for deleting and re-measuring ofLU info (only possible from emergency controlpanel if storage and retrieval machine wasswitched off).

width

1

2

4 5

3


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4.2.5.7.2 Storage DIF (direct interface) screen

Fig. 4-22 Storage DIF pallet / Muli

For each hand-over station (storage/retrievalplace), a Direct Interface is provided.

Via this interface, coupling signals coordinating theload handling procedure are exchanged.

If several hand-over stations are provided, they canbe represented separately:

1 Coupling signals from CS -> SRM

2 Coupling signals from SRM -> CS

3 Selection of storage place

1 2

3


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4.2.5.7.3 Retrieval DIF (direct interface) screen

Fig. 4-23 Retrieval DIF Pallet / Muli (orbiter)

For each hand-over station (storage/retrieval place),a Direct Interface is provided.

Via this interface, coupling signals coordinating theload handling procedureare exchanged.

The interface representation in the touch panel isused both for representation of the orbiters and ofthe machines with a Muli.

If several hand-over stations are provided, they canbe represented separately:

1 Coupling signals from CS -> SRM

2 Coupling signals from SRM -> CS

3 Selection of retrieval place

1 2

3


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4.2.5.7.4 Drives screen

Fig. 4-24 Drives screen

The Drives screen shows the details (1) of the in-dividual drives. To select the LHD press buttons (2)>, the name of the selected drive is alwaysdisplayed in the middle of the text field.

2

1


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4.2.5.7.5 Operating hours screen

Fig. 4-25 Operating hours

The Operating hours screen shows the operatinghours since the time of commissioning (1) and thelast maintenance inspection (2). When the keyswitch is in the correct position, the maintenance in-terval (3) can be set, and the operating hours canbe reset in the maintenance inspection (4).

21 3 4


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4.2.5.7.6 LHD top view screen

Fig. 4-26 LHD Top view screen

In the LHD Top view screen, the most importantinput signals are displayed.

1 Depth 1 fine positioning left2 Depth 2 fine positioning left (if applicable)3 Depth 1 fine positioning right4 Depth 2 fine positioning right (if applicable)5 Fork in middle6 fork occupied7 Muli is flush with left side8 Muli is flush with right side

9 Chain conveyor speed v1/v2 left10 Chain conveyor speed v1/v2 right11 Chain conveyor stop left12 Chain conveyor stop right13 Clearance left14 Clearance right15 Cap check left (if applicable)16 Cap check right (if applicable)17 Cable end (if applicable)18 Switch to side view19 Selection of LHD (also >>)

1

156

516

2

3

4

79

11

13

8

10

12

14

18

17

19


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4.2.5.7.7 Load handling device (LHD) screen

Fig. 4-27 LHD screen

In the LHD screen, the input signals for palletheight and compartment occupation are displayed.

The graphical elements used have the followingmeaning:

Symbol Meaning

Signal = 0

Signal = 1;light barrier sees reflector,light sensor sees object

Fig. 4-28 Light barrier symbols

Symbol Meaning

Signal = 0

Signal = 1;Switch actuated

Fig. 4-29 Switch symbols


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4.2.5.7.8 PLC inputs screen

Fig. 4-30 PLC inputs screen

In the PLC Inputs screen, all input signals are dis-played.


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4.2.5.7.9 PLC outputs screen

Fig. 4-31 PLC outputs

In the PLC Outputs screen, all output signals aredisplayed.


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4.2.5.8 Options screen

Fig. 4-32 Options screen

In the Options screen, you can change the panelsettings and use additional functions.

1 In order to improve the readability of the dis-play, you can also control the contrast here.

2 The Clean button (2) enables cleaning of thetouchscreen by opening a screen for 45 se-conds which prevents accidental pressing ofbuttons. The remaining time is displayed by acount-down bar.

3 Press the button Change language to switchthrough the available project languages.

4 Login or More >> (9) opens the loginscreen for SSI Schfer service staff. In order

to use the additional options, you will have tolog in with your user name and password.

5 Logout enables manual logout. However, af-ter a certain time of inactivity, the user will belogged off automatically.

6 Branch off to Service screen

7 Branch off to TP Install screen.

8 Branch off to TP Messages screen.

9 see (4)

16

8

9

2

3

4

5

7


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4.2.5.8.1 Commissioning Servicescreen

Fig. 4-33 Commissioning Service screen

In the Commissioning Service screen, the drivescan be moved without encoders and presets can beperformed.

1 Buttons for shutdown of position measurementsystem of the corresponding axis.

2 Press these buttons to perform a preset of therelevant drive.

3 Press the buttons to deactivate the orbiter.Press it again to activate it again.

4 Press this button to perform a lamp test (indi-cator lamps)

1 2

3


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4.3 Safety devices

For the protection of persons and equipment, vari-

ous safety devices are provided. They are ex-plained in detail in the following sections

Note

Additionally, the safety and warningreferences in Chapter 2, Safety, arebinding on the operator and the oper-ating staff

Warning

Familiarize yourself with the func-tion of the safety devices for yourown safety before operating the

unit. In case safety devices are notcomplete or don't work properlyreport to your superior immediate-ly. (see Annex A, Daily inspectionwork).

4.3.1 Driving aisle safety devices

The following description of the safety devices pro-

vides an overview of the mechanical and electricalsafety devices.

The driving aisle of the SRM is secured against un-authorized access by fences and barriers. The aisleaccess doors (4 and 7) are provided with limitswitches which are integrated in the safety circuitsin the control cabinet and, via the contact conduc-tor, in the emergency-off circuit of the storage andretrieval machine.

The driving lane buffers (5) brake down the storageand retrieval machine in case of failure of the brakeof the traveling mechanism or failure of end position

switches.

With the aisle main switch (1), power supply to theSRM can be cut off.

The storage and retrieval machine is protectedagainst unintentional start-up by means of the >Au-to/Semi/Local< (3) key switch (special locking sys-tem) provided at the aisle entrance.


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4.3.2 Safety equipment at storageand retrieval machine

The mechanical and electrical safety devices of thestorage and retrieval machine described below pro-tect the operating staff from injuries and the storageand retrieval machine from material damage.

Daily checks must be carried out before commenc-ing the work to make sure that the safety devicesare installed and work properly.

4.3.2.1 Mechanical safety equipmentat storage and retrieval ma-chine

A safety harness with safety catching device isprovided in the control room to facilitate climbingup/down the hoisting platform.

Warning

The safety harness with safetycatching device must always beused.

Danger of falling !

Familiarize yourself with the func-tion of the safety harness and thesafety catching device

The storage and retrieval machine is protectedagainst unintentional start-up by means of the>Auto/Manual< key switch (special locking sys-tem) provided at the aisle entrance and the stor-age and retrieval machine.

Warning

Never enter the aisle without hav-ing the key with you!

There is the risk that somebody ac-tivates the storage and retrievalmachine from the outside!

Never go directly from one aisle tothe other. Always switch off themachine from the outside and takethe key with you!

The mechanical safety catching device is acti-vated by the speed limiter.

Buffers are provided at the hoisting platform endpositions to stop the hoisting platform in anemergency situation.

4.3.2.2 Electrical safety equipment atstorage and retrieval machine

Two types of electrical safety devices prevent theoperating staff from injuries and the storage and re-trieval machine and its subassemblies from materialdamage in case of malfunction of the unit or failureof the control system:

1. Hardware interlocks

2. Software interlocks

Hardware interlocks

These are emergency-stop switches which switchoff the storage and retrieval machine in a safe

manner:

1. Main switch, control cabinet

2. Emergency stop button on aisle panel

3. Emergency stop pushbutton on SRM emer-

gency control panel

4. Emergency-stop switch at traveling unit

5. Emergency-stop switch at hoisting unit

6. Catching device

7. Speed controller

8. Regulator rope monitoring

9. End position speed monitoring in X-direction

10. External em. stop

Warning

In case of danger for persons orequipment:

Press emergency stop button!

In Service Mode, the emergency-stop switches 4, 5,6, 7, 8, 9 and 10 (see above) can be bridged andthus be made ineffective by actuating the Switchbutton>Clear / Travel without orbiter< in emergency con-trol panel (see Fig. 4-3) in the emergency controlpanel.

Software interlocks

The software interlocks are designed according tothe state of the art and the applicable standards.

If the program detects that an interlock was violat-ed, a fault will be triggered and a fault messagedisplayed.

For information on faults and repair of faults, seeChapter 5


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4.3.2.3 Other safety devices

Signal horn

A warning signal sounds at the storage and retriev-al machine if:

the Horn key is pressed at the SRM controlterminal (in Semi- and Service Mode)

a position measurement system was preset andthe preset was OK,

Automatic mode is switched on

3 seconds permanent sound of signal horn,

Fire alarm was triggered (sequence: short short short short pause) and

as startup warning in fire department mode.

Signal horn test

Press the Horn key to test the function of the sig-nal horn.

Note

In case an indicator fails or in case ofmalfunctions, inform the maintenancestaff immediately.

4.4 Activation requirements forAutomatic/Semi/Service mode

Prior to switching on the storage and retrieval ma-chine, the following conditions must be fulfilled forall operation modes:

Unlock all emergency off devices.

Repair all faults of the storage and retrieval ma-chine if this is required by the operation mode(exception, e.g. faults by deactivated encodersin service mode, see Chapter 5).

Remove fire department equipment (controlpanels, interlocks, etc.).

Acknowledge faults.

Close SRM aisle door.

Persons are not allowed to stay in the SRM aisleduring operation, remove any foreign objects.

Additional conditions for Service mode:

Switch >Auto/Semi/Local< on storage and re-trieval machine aisle panel must be set to Lo-cal.

Switch >Auto/Manual< on emergency controlpanel must be set to "Manual" so that control isenabled on the control panel.

Additional conditions for Semi-Mode:

LHD has to be in center position (exception: afork cycle initiated in Semi-Mode was interrupt-

ed). Switches >Auto/Semi/Local< at aisle panel of

storage and retrieval machine must be set toSemi and switch >Auto/Manual< on storageand retrieval machine must be set to Auto forcontrol outside of aisle

For operation from the emergency control panel,the key switches at the aisle control panel andthe emergency control panel must be set to Lo-cal and Manual position, respectively.

Additional conditions for Automatic mode:

Fork must be in center position (exception: stor-age and retrieval machine was stopped whileexecuting an order).

The fire department cage must be in its center-ing position (type XL at X=106, Y=1, S=1, D=2 instock image).

Switches >Auto/Manual< on storage and re-trieval machine and at aisle panel of storage andretrieval machine must be set to Auto.

Warning

The storage and retrieval machinewill start automatically after activa-tion.

Danger! Risk of fatal injuries ormaterial damage !


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4.4.1 Check list - Test activitiesfor Semi- and Service Mode

Valid only if storage and retrieval machine is ata standstill

Check function of aisle door contact switches *.

Check function of emergency-stop pushbuttons*.

Check function of lighting.

Signal horn test.

Note

* Actuate door contact and/or emer-gency-off pushbutton after switching

on Semi-/Service Mode.

The storage and retrieval machinemust be switched off and the corre-sponding message appears in thefault display

4.5 Operation modes

Three operating modes are possible:

1. Automatic mode as standard mode(see Section 4.5.1),

2. Semi mode to convey pallets manually (seeSection 4.5.2) and

3. Service mode to eliminate faults (see Section4.5.3).

Note

Manual or Automatic Mode (see Sec-tion ) is preset via the key switch atthe SRM aisle entrance (see Section

4.2).

4.5.1 Automatic mode

In automatic mode, the orders are executed auto-matically by the storage and retrieval machine viathe Material Flow System (MFS)

4.5.1.1 Starting Automatic Mode

On SRM control cabinet Turn >Manual/Auto< key switch on storage and

retrieval machine to "Auto" and take out key

The operating staff must leave the aisle.

Warning

Persons are not allowed to stay inthe SRM aisle during operation,remove any foreign objects.

The storage and retrieval machinewill start automatically after activa-tion.

Danger!Risk of possibly fatal injuries ormaterial damage!

At aisle entrance

Fulfill startup requirements (see Section 4.4).

Put the key taken out of the storage and retrievalmachine into the >Auto/Semi/Local< key switchon the aisle panel, turn it to Auto and press theAuto On button.

The signal horn sounds for 3 seconds to an-nounce the activation of Automatic Mode.


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Via VISU Terminal

Fulfill startup requirements (see Section 4.4).

Key switches on storage and retrieval machine

and aisle panel must be set to Auto Switch on storage and retrieval machine at VISU

in C-Desk Menu (see VISU operating instruc-tions)

The signal horn sounds for 3 seconds to an-nounce the activation of Automatic Mode.

4.5.1.2 Operation in Automatic Mode

After activation of automatic mode, the storage andretrieval machine can process the orders issued bythe MFS.

The following types of orders are possible:

Get Storage and retrieval machinereceives the order to pick upone or two pallets from thestorage place or the rack

Bring Storage and retrieval machinereceives the order to put oneor two pallets on the retrievalplace or into the rack

Positioning Storage and retrieval machinereceives the order to move to

a certain coordinate.

Fire alarm opera-tion

When the storage and retrievalmachine receives the Firealarm signal, it will move to aspecial position once the au-tomatic order has been com-pleted. This can only happen ifthe storage and retrieval ma-chine was in automatic modewhen the fire alarm occurred.

Home positiontravel

Via the >Home Position< but-ton at the VISU or the control

terminal or via a MFS homeposition travel command, anorder is sent to the storageand retrieval machine:

In this case the storageand retrieval machinemoves to the mainte-nance position (for easyaccess to emergencycontrol panel) and Au-tomatic Mode isswitched off

4.5.1.3 Automatic order processinginterrupted

In case of malfunctions the storage and retrieval

machine is turned off.

In order to repair faults, another operating mode(Semi or Service mode) can be selected now.

After eliminating the fault and restarting AutomaticMode, automatic order processing is continued.

If, in Automatic mode, the storage and retrieval ma-chine has stopped as a result of a fault with the forkextended, the automatic order will remain active. Inthis case, it should be tried to repair the cause ofthe fault in Service mode and to complete the orderafter that.

4.5.1.4 Deletion of active automaticorder

An automatic order can be deleted either via theVisualization in the control room or from the SRMcontrol terminal.

On Visu terminal

Set all >Manual/Auto< key switches (1) (see Fig.4-2 and Fig. 4-3) on the storage and retrieval

machine to "Auto"

Via the VISU the order to be processed by thestorage and retrieval machine can be deleted(see VISU operating instructions). You can de-lete either the active order or the buffered order.

On SRM control terminal

Set key switch according to control station.

Note

Do not turn operation modes on.


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Fig. 4-14) and select active or buffered order.

Press button with cross (2) .

Display shows zeros; switch to send orderscreen, here you will see the order with infor-

mation deleted.

Automatic

Active orders are deleted automatically at thestorage and retrieval machine if the forks are incenter position and a manual intervention is per-formed, e.g. aisle door opened or Semi / Servicemode activated.

4.5.1.5 Deactivation of automaticmode

At aisle entrance

Press Automatic Off button on aisle desk. Thestorage and retrieval machine will complete itsactive order, this is signaled by the green "Au-tomatic On" button flashing. As soon as the or-der has been completed, the storage and re-trieval machine will be turned off.

Via VISU Terminal:

On the VISU (see Chapter Error! Referencesource not found.), press button "SRM off".


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4.5.2 Semi mode

In this semiautomatic operation mode, orders can

be entered by the user manually, which is not pos-sible in automatic mode. This operation mode canbe used:

for manual storage and retrieval of goods(see chapter4.5.2.5) and

for approaching compartment coordinates (fortroubleshooting, test and inspection operations)(see chapter4.5.2.3).

All interlocks necessary for the operation are active.

Note

If goods are moved to another storage

place, the stock image in the MFS hasto be updated accordingly via a stockimage update telegram.

4.5.2.1 Switching on Semi mode ex-ternally

At aisle entrance

Turn key switch >Auto/Local/Semi< (see Fig. 4-2)to >Semi.

On aisle control panel

1. Fulfill startup requirements (see Section 4.4).

On the control panel, a checkmark will ap-pear below the Semi button (see Fig. 4-13)

Fig. 4-13

2. Press button Semi on on control panel.

The Start-up routine in process status mes-sage will be displayed on the control panel.

After a short time, the status message disap-pears, Semi mode is activated and theSemi mode screen is displayed (seeFig. 4-17).

Now, the storage and retrieval machine is ready forSemi mode


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4.5.2.2 Switching on Semi mode onboard

At aisle entrance

1. Turn key switch "Auto/Semi/Local" (see Fig. 4-2)to "Local" and take out the key (1).

2. Put on safety harness.

3. Request aisle access by pressing the illuminatedpushbutton [aisle access]. The lamp of the but-ton will be flashing. As soon as the lamp lightsup steadily, you can enter the aisle.

On control cabinet or emergency control panel

4. Open aisle entrance door and go to the driver'scabin. If access to the hoisting platform is via aladder, use appropriate safeguards to preventfalling down.

5. Insert key and turn >Manual/Auto< key switch(1) on emergency control panel (see Fig. 4-3) to"Manual".


On the control panel, checkmarks will appearbelow the "Semi" and "Service" buttons (seeFig. 4-13)).

7. Press button Semi on on control panel.


After a short time, the status message disap-pears, Semi mode is activated and theSemi mode screen is displayed (see Fig. 4-17).

Now, the storage and retrieval machine is ready forSemi mode.

Note

In Semi mode with operator on board,the storage and retrieval machine willmove at a maximum speed of 0.5 m/sin all axes.

4.5.2.3 Approach rack compartmentcoordinates

Compartment coordinates can be approached with-out picking/bringing load. The coordinates can beselected by the operator. Coordinates which are notsuitable for the selected load goods type cannot beapproached.

4.5.2.4 Rack compartment coordi-nates

Range of rack compartment coordinates

X-coordinate X 1 to X 69

Y-coordinate Y 1 to Y 11

Page 1 = left, 2 = right

Depth 1 - 5


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Storage places

SRM 1 X 1 Y1 S2 T1

SRM 2 X 1 Y1 S1 T1

SRM 3 X 1 Y1 S2 T1

SRM 4 X 1 Y1 S1 T1

SRM 5 X 1 Y1 S2 T1

SRM 6 X 1 Y1 S1 T1

SRM 7 X 1 Y1 S2 T1

SRM 8 X 1 Y1 S1 T1

SRM 9 X 1 Y1 S2 T1

SRM 10 X 1 Y1 S1 T1

SRM 11 X 1 Y1 S2 T1

SRM 12 X 1 Y1 S1 T1

Retrieval places

SRM 1 X 1 Y1 S1 T1

SRM 2 X 1 Y1 S2 T1

SRM 3 X 1 Y1 S1 T1

SRM 4 X 1 Y1 S2 T1

SRM 5 X 1 Y1 S1 T1

SRM 6 X 1 Y1 S2 T1

SRM 7 X 1 Y1 S1 T1

SRM 8 X 1 Y1 S2 T1

SRM 9 X 1 Y1 S1 T1

SRM 10 X 1 Y1 S2 T1

SRM 11 X 1 Y1 S1 T1

SRM 12 X 1 Y1 S2 T1


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Blocked rack compartments

The following compartments are disabled and can

be approached but not served for this reason. Fig-ure 0 represents all values of the corresponding ax-is.

SRM 1

X Y Page Depth

02-09 1-11 1 03-05

62-69 1-11 1 03-05

10-69 1-11 203 for

Indu/Chep

SRM 2-11X Y Page Depth

02-09 1-11 1,2 03-05

62-69 1-11 1,2 03-05

10-61 1-11 1,203 for

Indu/Chep

SRM 12

X Y Page Depth

02-09 1-11 2 03-05

62-69 1-11 2 03-05

10-69 1-11 103 for

Indu/Chep

Height classes

Height class 1 SRM 1-12

X Y Page Depth

01-69 1 1,2 1-5


X Y Page Depth01-69 2-7 1,2 1-5


X Y Page Depth

01-69 9-11 1,2 1-5

4.5.2.4.1 Preconditions forentry of coordinates

LAM in center position

The z-axis / orbiter must be in center posi-tion, and the center switches must be OK(see Fig. 4-26).

If these conditions are met, the text Entry possibleis displayed in the Semi Order screen (see Fig. 4-17).


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Fig. 4-34 System of coordinates

left sideS=1

right sideS=2

Center positionLoad handling device

Forward

Backward

Xmax

1

Ymax

1

Z

Y

X

Depth DD=2

D=1

D=0

D=1D=2


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4.5.2.4.2 Entering target coordinates

Semi orders are entered in Semi screen (see

Fig. 4-17). In order for the coordinate to be ap-proached only, without fork cycle must be dis-played in the button (4).

The target coordinates X, Y, side and depth are se-lected by pressing the corresponding buttons of thetarget coordinate. This is only possible if Semi-Mode is active.

The coordinates are entered via a numerical key-board (see Fig. 4-10).

The coordinate last entered is displayed.

The number entered is checked for validity of

the rack compartment coordinates.

Note

If the coordinate cannot be ap-proached, a message is displayed inthe status line, the order cannot bestarted.

By pressing the GO button in the Semiscreen (see Fig. 4-17), the semi order is startedif it is executable.

Status message Semi order in process signals

the execution of the semi order. The Entry pos-sible message disappears.

4.5.2.4.3 Execution of semi orders

If controlled from the outside, the storage and

retrieval machine starts the travel operation im-mediately after receipt of the order.

If operator is on board, travel operations will onlybe executed if the release button is pressed (seeFig. 4-3).

The release button at the same time per-forms a dead man function. If the button is re-leased, the Semi-Order is stopped. The stor-age and retrieval machine is deceleratedelectrically until it is at a standstill. Press thebutton again to continue the order.

To cancel the semi order press the Stop

button when the machine is at a standstill.

If the storage and retrieval machine has com-pleted the order or if the order was canceled, thetext Semi order in process disappears and En-try possible is displayed again.

The storage and retrieval machine is ready foraccepting new semi orders.

Note

If a semi order is active, the storageand retrieval machine cannot beswitched off with the OFF switch(Fig. 4-13)


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4.5.2.6 Semi-Mode after interruptionof Automatic Mode

If Automatic Mode was interrupted and the storageand retrieval machine is afterwards to be operatedin Semi-Mode or in Service mode the following ap-plies:

As soon as the operator enters the aisle, thecurrent order will be deleted by the MFC auto-matically. Now, the operator must restore theoriginal state, i.e. move the pallet to its startingposition and the orbiter back to the SRM.

In the case of a fault at the storage/retrieval sta-tion to the conveyor plant, the original state mustbe restored, too, when the aisle is entered.

Once the fault has been repaired, the SRM canbe switched to automatic mode again, the MFCwill issue the order again.

The functions of the corresponding mode can beused if the storage and retrieval machine can beturned on.

Note

After manual intervention the orbitershave to be moved to center positionbefore starting Automatic Mode again.

4.5.2.7 Deactivation of Semi mode

Semi mode can be turned off in two different ways:

1. Press the Off button in the main menu to stopSemi-Mode.

2. Select another operating mode.

Turn key switch (Fig. 4-2/1) >Au-to/Semi/Local< on aisle panel from Semi toAuto

Switch >Manual/Auto key switch (Fig. 4-3/1)on the emergency control panel from Manu-al to Auto

Note

For shutdown by selection of anotheroperation mode

- the storage and retrieval machinemust be at a standstill and

- no order may be active anymore.

Otherwise, the storage and retrievalmachine will trigger a fault.

4.5.3 Service mode

Service Mode is an operation mode for adjustingsensors, eliminating the cause of faults and main-taining and repairing the storage and retrieval ma-chine. Travel operations in the different axes arepossible in inching mode.

It has to be distinguished between

Service Mode without clearing(see Section 4.5.3.1) and

Service Mode with clearing(see Section 4.5.3.2)

Warning

This mode may only be used by op-erating, maintenance and repair staffwhich is trained by SSI SCHFERNOELL.

Danger for persons and equipment!


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4.5.3.1 Service mode withoutclearing

4.5.3.1.1 Switching on Service Mode

At aisle entrance




On control cabinet or emergency control panel

4. Open aisle entrance door and go to the driver'scabin. If access to the hoisting platform is via aladder, use appropriate safeguards to preventfalling down.

5. Insert key and turn >Manual/Auto< key switch(1) on emergency control panel (see Fig. 4-3) to"Manual".


On the control panel, checkmarks will appear

below the "Semi" and "Service" buttons (seeFig. 4-13)).

7. Press function button Service ON (see on thecontrol panel.


After a short time the storage and retrievalmachine is active.

The status message on the control panel nolonger appears and the Service operatingmode is activated.

The panel will switch to " Service" screen au-tomatically see Fig. 4-18


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4.5.3.1.2 Running Service Mode

To run Service Mode you just need the NTOP Ser-

vice Menu (see Fig. 4-18)

Note

Only one axis can be addressed at atime in inching mode.

Warning

High risk of damage!

Carry out input and travel com-mands carefully.

In this mode many fault evalua-

tions are deactivated! There is the risk that the fork

takes up the transport goodsout-of center or the fork hits therack

Moving of axes

Select the required axis using the arrow buttons(see Fig.4-18/2). The traveling unit, hoisting unit,orbiter and chain conveyor are available

Preselect direction. Direction + means forwardin the case of the travel unit, up in the case ofthe hoist unit and to right in the case of the forks

Preselect speed, 4 different speed levels areavailable, with "V1" being the slowest speed(creeping).

Select symbol >||


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4.5.3.2 Service Mode with clearing

Service Mode with clearing must be selected in or-der to bypass safety interlocks. In addition to thatthe machine can be moved out of emergencyswitch-off positions in this mode.

4.5.3.2.1 Switch on Service Mode withclearing

At aisle entrance




At emergency control panel

1. Use key (Fig. 4-3/1) to open the aisle door.

2. Turn >Auto/Manual< key switch (1) on storageand retrieval machine to Manual.

3. press (and keep pressed) Switch button

>Clear / Travel without orbiter< on SRM emer-gency control panel (see Fig. 4-3).

4. Press Acknowledge fault pushbutton.

On the control panel, a checkmark will ap-pear if Service ok (see Fig. 4-13)

5. Press function button Service ON (see Fig. 4-13) on the control panel.


After a short time the storage and retrieval

machine is active. The status message on the control panel no

longer appears and the Service operatingmode is activated.

6. The panel will switch to "Service" screen auto-matically (see Fig. 4-18).

4.5.3.2.2 Running service mode withclearing

All axes can be addressed without interlocks via thecorresponding function keys. However, this is onlypossible at speed level V1.

Warning

This mode may only be used byoperating, maintenance and repairstaff which is trained by SSISchfer.

Danger of serious injuries and highrisk of damage!

Carry out input and travel com-

mands carefully. Safety switches are not effective

anymore.

In this operation mode almostall fault evaluations and safetyinterlocks are deactivated.

The following safety switches can be bypassed inthis mode:

Traveling unit end position/speed monitoring,

emergency limit stop switch of traveling unit,

emergency limit stop switch, hoist unit,

regulator rope break monitoring,

hoisting unit catching device and

speed regulator of hoisting unit.

The traveling unit and the hoisting unit can also bemoved with the fork extended.

As soon as the Switch button>Clear / Travel without orbiter< is actuated, thesesafety devices are bypassed and the machine is in

Service with clearing mode. As soon as theSwitchbutton>Clear / Travel without orbiter< is released, the ma-chine switches to Service mode, i.e. normal ser-vice mode (see Section 4.5.3.1.2).


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4.5.3.3 Stop service mode with clear-ing

Service mode can be turned off in two ways:

1. Press the "Off" function key in the main menu toswitch off the storage and retrieval machine.

2. Select another operating mode

* Switch >Manual/Auto key switch (1) (see Fig.4-2 orFig. 4-3) from "Manual" to "Auto"

Note

In case of malfunctions the storageand retrieval machine is turned off au-tomatically.

4.5.3.4 Service mode - Clearing with-out orbiter

In this operation mode, the SRM can be movedeven when the orbiter is not on the SRM. This op-eration mode is required to move the recovery trol-ley to the channel where the orbiter got stuck, forexample in order to move the orbiter back to theSRM in an emergency.

This function is activated as follows:

1. Turn >Clear < (see Fig. 4-3) key switch (3) toClearing without orbiter.

2. On the control panel (see Fig. 4-33 ), deactivatethe orbiter by pressing button LHD1 disable.

Note

Now, the SRM can be moved in Semimode or via MFC order without an or-biter cycle.

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