Shuttle Racking Brochure
Contents
1. Battery duration Continuous 10h 22h SH 20 Ex a 5 mil kJ zl Sm L m Packaging amp Handling The shuttle is delivered packaged in a fumigated wooden crate to meet international standards Take care when opening the box Only move the shuttle with a forklift capable of lifting the weight Maximum weight of the shuttle including case approx 350kg The shuttle is delivered wrapped in a protective film or barrier bag which can create condensation and moisture if left in for a long period of time Upon receipt remove the shuttle unit from the wooden box In order to avoid damage to electronics and mechanical parts take care when fitting the components and charging the batteries of the shuttle and the Remote Control Pallet Structure The shuttle is designed to transport wooden pallets as standard Note The shuttle is capable of carrying different types of loads such as steel and plastic pallets The shuttle system will need to be designed specifically for these applications prior to the project and upon submission of engineering drawings sample c o the manufacturer Automha for testing system functionality It is important that all the pallets have a central block as shown Standard Equipment Each Machine N 1 LED Remote control N 1 Lithium battery N 2 Eyebolts N 1 Lithium battery charging station N 1 User s manual N 1 Wooden box2. To reset an alarm go into the menu item in the list of the remote control READ ALARMS Entering and exiting the command menu all the alarms are reset If entering the READ ALARMS menu item you can not reset the alarm contact the supplier Once the safety bumpers have been activated the shuttle will sound an alarm Once the the shuttle alarm has been activated it will wait 60 seconds after which it will resume the mission In an emergency the red mushroom emergency stop button on the front and rear of all shuttle units can be used STANDARD FUNCTIONS When the shuttle unit receives a mission it automatically beeps for 1 second to alert the operator that the mission has been accepted Command Menu LOAD UNLOAD CONTINUOUS UNLOADING Description The load function is activated by pressing the IN button on the remote control At any time the STOP button on the remote control can be pressed to stop the movement of the shuttle during the mission immediately Legend Home1 front warehouse Home2 rear warehouse These descriptions identify the opposite ends of the warehouse The unload function is activated by pressing the OUT button on the remote control You can not change the function of unloading pallets already set The Continuous Unloading function is activated by pressing the continuous unload button on the remote control This feature allows the entire lane of a channel to be unloaded without having to
3. Warranty 12 months All mechanical and electronic equipment is covered by a 12 months warranty effective from the shipping date Labour transport and accommodation costs are chargeable During the warranty period we will repair the machine free of charge Contact your supplier for details Any other indemnity is excluded and any direct or indirect damage of any nature and type included temporary unavailability of the machine cannot be claimed Warranty does not apply to components not used according to the instruction given by the supplier Incorrect use will invalidate the warranty The pallet shuttle unit should be serviced after 12 months or 60 000 mission which ever comes first Additional cost The shuttle battery uses Lithium technology with high performance and low weight against standard AGM batteries with the same capacity Capacity 53Ah shuttle battery weight 14kg against 40kg of AGM units The battery contains Nr 2 warranty seals Nr 1 Shock sensor Nr 1 START button IS STRICTLY FORBIDDEN TO OPEN THE COVER OF THE BATTERY BREAKING THE SEALS INVALIDATES THE WARRANTY Do not tamper with the casing Do not remove seals Do not open the cover for any reason Do not use as an external power supply for other purposes The battery pack is fitted within an impact indicator when activated the warranty is void When unused the battery pack loses 3 of its capacity per month when less than 21V
4. A Workspace Creation Tel 0800 975 4933 Email salesQavantauk com Web www avantauk com E vezarine Floors M Steel Partitions l Pallet Racking Esheiving Systems Workplace Equipment E Office Interiors Avanta UK Ltd e Unit B1 e Astra Park e Parkside Lane e Leeds e West Yorkshire e LS11 5SZ
5. button on the cover of the battery The shuttle power button ON OFF will flash for approx 3 4 seconds after which the shuttle is ready for use While the button is flashing the shuttle carries out an automatic check of all electrical controls and software and run diagnostic testing of all of the safety modules The operator must ensure that the channel where the shuttle is located is clear Lift the shuttle with a suitable forklift truck insert the forks under the shuttle and lift the satellite by the guides on the bottom of unit Lift the shuttle ensuring the ON OFF button is towards the operator of the forklift and place it in the racking The forklift operator controller of the shuttle unit must always ensure the lane channel end stop is present the minimum size 60x70mm to prevent accidental falls from pallet racking due to external causes and or abnormal situations due to incorrect handling of the shuttle Care must be taken at all times when handling the shuttle unit When loaded with a pallet the shuttle must never be moved with a fork lift truck The shuttle unit will not accept any input for the remote control when it is outside the lane channel on a forklift in automatic or in manual mode for safety reasons All personnel must be clear of the area where the forklift and shuttle are operating Do not enter any part of a system where the shuttle is operating 10 Antenna The screen on the
6. count the pallets in each channel until the counting function is deactivated within the Read Menu Pallet PALLET The shuttle is accurate and reliable for counting pallets errors are due to structural conditions of pallets moved The margin of error is 1 2 pallets Error due to the structure of the pallet The supplier is not responsible for any inaccurate counting of pallets The continuous load function allows the operator to speed up the operations of loading material into the channel To activate this function press the IN button on the remote control The shuttle will recognize in automatic mode the presence of the pallet in H1 in case of any pallets movements the Automha shuttle will wait 10 seconds after stopping the mission and will need to be reactivated press the button on the remote control The continuous load function when activated it replaces the function of normal load ory 34 3 Ka 5 Li 19 The information contained in this manual is provided to protect the shuttle unit and it s functionality over time The shuttle contains electronic components that can be damaged by low temperatures if not operated in the correct manner It s essential that the manual is read understood and the actions stated are implemented For proper use follow the instructions below THE SHUTTLE UNIT MUST REMAIN AT THE OPERATING TEMPERATURE The speed of the pallet shuttle unit used in cold storage will be
7. if more than 21V 1 per month Always charge the battery every month if unused for a minimum of 5 5 hours Remove the battery from the charger once charging is complete Do not carry the battery inside the cab of the truck for any reason carry the battery by hand A unique feature of this battery pack is the absence of a memory effect so it is possible in an emergency to recharge for less than the optimum time for charging The battery pack can be on charge for more than 5 5 hours the charger automatically stops charging when the battery level reaches 100 Please note that correct fitting of the battery is important Incorrect positioning of the connectors leading to their damage will invalidate the warranty If the shuttle is not to be used for a prolonged period of time remove the battery from the shuttle unit and keep at room temperature and free of moisture Battery Pack Quick Guide INSERTING THE BATTERY amp STARTING THE SHUTTLE Insert the battery pack into the shuttle Press and hold the START button on the cover of the battery min 7sec Turn on the shuttle by pressing the button ON OFF on the front of the shuttle Release the START button on the cover of the battery TURNING OFF THE BATTERY amp REMOVING FROM THE SHUTTLE Turn off the shuttle by pressing the ON OFF button on the front of the shuttle Extract the battery pack from the shuttle BATTERY CHARGE Charge the battery im
8. supplier The shuttle must be operated in line with the details in this manual RECOMMENDATIONS Before using the shuttle carefully read the operating instructions supplied While using the shuttle the operator using the system must be the only person in the working area The radio control unit must be charged for at least 12 hours before initial use to avoid potentially damaging the battery Charge the shuttles lithium battery for a minimum of 5 5 hours Do not open the shuttle main body for any reason without permission from the supplier There are no user servicable parts inside the main body of the shuttle The standard warranty period is 12 months If the shuttles lithium battery remains unused re charge after one month for a minimum of 5 5 hours The shuttle is suitable for use in dry dust free environments THE MANUFACTURER IS NOT RESPONSIBLE FOR ANY DAMAGE OR FAILURE TO CAUSED BY IMPROPER OR INCORRECT USE OF THE EQUIPMENT Ul ki g ani kJ zl SE a SHL Sil _ q 3k e The pallet shuttle is powered by an innovative lithium ion battery The machine runs on specially designed rails that allow the storage of material loaded on pallets containers of wood or other material in a pallet racking system specifically designed for the application The shuttle is able to pick up deposit and reorder the pallets with extreme precision The shuttle contains Nr 2 Proximity sensors Nr 2 Inductive
9. MARY Inside the Pre cell Temperature Ambient freezer gt 5 C gt 15 C Environment The shuttle must remain Battery Remote control Battery active in work or supplied charging charging storage from the external red box Recharging not allowed Maintenance Battery charging Remote control storage Battery substitution Yes Yes Yes WARNINGS Moving the machine from the cold store to an area at room temperature and vice versa can Cause condensation due to thermal shock This must be avoided If this has to be done pass the unit through the pre cell refrigerator thoroughly dry to avoid the formation of ice on the optics of the sensor when within the cell The shuttle is designed and manufactured to reduce maintenance to a minimum The shuttle is semi automatic the operator must perform the following actions before each use Operation Frequency Mode GENERAL SENSOR CLEANING Each use Dry cloth CLEANING SHUTTLE SURFACES Each 7 days Moist cloth CHECK SHUTTLE STATUS Each use x CHECK SHUTTLE COMPLETE SERVICE Each 60 000 missions Specialised or 1 per year technician We recommend maintenance of the machine at least once a year or every 60 000 missions to check required mechanical amp electronic components Please note that the shuttle pops up a warning beep and the display on the remote control when it s time to service recommended For the maintenance of channels and for recovery of shuttle inside the racking the sup
10. Remote control displays the status READY Ready to be used The remote control is now ready to LED Display be used Pallet In Pallet Out Each remote control can command up to 4 machines at the same time Compacting Continuous by selecting the appropriate number Stop Unloading 1 to 4 Forward CRU Lower Down rd Backward MO Horn Manual Functions See Page 13 Management Software Only to be used in exceptional Menu Programming circumstances WARNINGS Do not tamper with the casing of the remote control Any evidence of tampering will invalidate the warranty Do not allow the remote control to come into contact with water liquid The battery in the remote control can only be purchased from the manufacturer Charge the remote control for 12 hours before its first use Charge the remote control at room temperature Recharge the transmitter for a minimum of 12 hours each charging In the event of any problems contact the supplier THE STOP BUTTON RED IS ALWAYS ACTIVATE ON THE REMOTE CONTROL BATTERY DATA Typical Battery use at 20C in continuous TX RX min 16h max 22h Typical Battery use at 30C in continuous TX RX min 10h max 14h Typical Battery use at 20C in stand by 43 days All the tests and checks based on laboratory findings REMOTE CONTROL FUNCTIONALITY The normal operating condition involves turning on the remote signal for 30 as a result of pressing a button and the signal remains active as long as the butt
11. Uu gt 9 oO Ly LV mo am nm n an Workspace Creation Call 0800 975 4933 Introduction General Description Datasheet amp Rack Specification Packaging amp Handling Pallet Structure Stndard Equipment Warrenty Battery Detail Battery Pack Quick Guide Shuttle Power on Placing the Shuttle into the Channel Remote Control Overview Remote Control Operation Remote Control Menu Automatic Commands Other Commands Manual Commands Safety Bumpers Shuttle Functions Standard Functions Optional Functions Cold Store Applications Maintenance Standards oo OO a A Q 10 10 11 12 14 16 16 20 22 23 Moresecure understands the information in this leaflet is correct at the date of publication All reasonable care has been taken to make it as complete and accurate as possible no liability can be accepted for any inaccuracies or omissions CAUTION Read this manual before installing and using the Pallet shuttle The information contained in this manual must be followed and is intended as a guide to protect people property and provide a safe working area when using the shuttle device The pallet shuttle contains components that can be damaged if used incorrectly For any questions regarding the functionality of the shuttle system contact your supplier service amp support department The shuttle must only be used by personnel who have received training from the
12. continually press the OUT button for each pallet in the channel The function of continuous unloading is programmed to work in the following way the shuttle picks up the first pallet and takes it to the home location The shuttle waits for the user to pick up the pallet before proceeding with the mission Remove the pallet in the home location subsequently the shuttle will start to pick up the pallet next and so on 16 STANDARD FUNCTIONS continued Command Menu DIST MIX MANUAL COMMANDS Description Gap between pallets Minimum 20mm up to maximum 150mm The WRITE DISTANCE function on the menu allows the operator to adjust the distance between the pallets within the channel The distance between the pallets is based on the actual pallet distance rather than the load This distance does not allow for any over hang of the load over the ends of the pallet The supplier assumes no responsibility for damage to goods due to improper use of the function or consequences for plant and equipment Missions counter Only use this function in exceptional cases Take care when operating the shuttle manually The operator is responsible for any damage to the goods and or machine not all controls are activated during manual handling for any questions please contact the supplier OPTIONAL FUNCTIONS Command Menu COMPACTING PUSH Description THIS FUNCTION IS NOT AVAILABLE WITH MULTI PALLET Conditio
13. decreased by 20 at full speed the formation of ice along the guide may cause the machine to lose traction The shuttle unit must always remain inside of the refrigerator to avoid condensation that may occur by the transition from cold storage at cold temperature to an area at room temperature with higher temperature When the shuttle unit is inside the cold store unused it must fitted with the power supply unit delivered with the kit BZ Below Zero to keep the electronics warm Red box provided Remove the battery and then plug in the red power adapter supplied After inserting the adapter into the battery compartment of the shuttle follow the instructions below Turn on the power supply by pressing the ON OFF button on the cover Turn shuttle on using the green button ON OFF The shuttle battery is equipped with heating resistors Self heating only in a refrigerator The heating system is activated when the cell temperature is below 5 C Celsius The heating system is turned off when cells reach a temperature gt to 10 Celsius BATTERY CHARGING The battery pack must be charged outside the operating cold store Recharge the batteries from temperature gt 5 C and lt 45 C It is important to avoid condensation wipe with a dry cloth before charging fitting the battery BATTERY CHANGE When the shuttle battery requires charging recharge then the substitution can be made in the cold room 20 SUM
14. mediately as soon as the battery is low Insert the battery into the battery charger compartment Turn on the battery charger using 0 1 key The CHG LED blinks When the CHG LED stops flashing the battery is fully charged TURNING OFF THE BATTERY CHARGER amp REMOVING THE BATTERY Turn off the charger by pressing the button 0 1 Remove the battery from the charger compartment CHECK THE ALARMS OF THE CHARGER Insert the battery into the charging station Wait a minimum of 7 seconds and check if any of the following alarms are displayed VA VTC Description OFF OFF No alarm ON OFF Battery level is low ON OFF Battery temperature is too high ON ON Get beyond the minimum BATTERY PACK RECHARGING Always turn off the charger before removing the battery Do not connect the charger to the mains without the battery inserted Use only the charger supplied by the manufacturer DO NOT use other similar chargers Do not leave the battery pack in the charger without power on The location of the battery charging station is important it must be at a low humidity and at a temperature 5 C to 45 C esL Insert the battery pack into the shuttle battery compartment Press and hold the start button on the cover of the battery for 7 seconds continue to hold the START button down and press the ON OFF on the front of the shuttle Once the shuttle is activated the on off button is illuminated you can release the START
15. n of operation of the function FIFO First in first out channel operation from both sides This function rearranges the position of the pallets in the channel storage Start conditions The last 3 positions of the channel must be free To activate this function press the button on the remote control NOTE During the function of COMPACTING PUSH the distances between the pallets selected by the remote control may vary by a few millimetres and not be complied with The shuttle assumes no responsibility for distances observed HL iL 17 a SE 2H OPTIONAL FUNCTIONS continued Command Menu COMPACTING PULL UNLOAD CONTINUOUS PLUS MULTI PALLET ANTI COLLISION Description FUNCTION IS NOT AVAILABLE WITH MULTI PALLET Condition of operation of the function FIFO First in first out channel operation from both sides This function rearranges the position of the pallets in the channel storage Start conditions The first 3 positions of the shelf must be free To activate this function press the button on the remote control The function Continuous Unload Plus allows you to speed up the unloading of the entire channel with multiple fork lift truck operators This function will replace the standard function of continuous unload The function can be interrupted at any time by pressing the red STOP button on the remote control To activate this function press the button for continuous
16. on is pressed After a period of inactivity of 30 the remote signal will return to standby L LM LM 11 SE BH ji E Ka SE ak Fa gan B 4 sun Sia e l i ZAN LA a ie Bs HA DE GA koy a A a JE gag re a a W G amp G Qu T N t LA L A NW NS w GAGE NVI LI Dama ACT E EE AUTOMATIC COMMANDS Commands can be sent simultaneously to multiple shuttle units Command Menu Description IN 5 Load OUT 3 Unload 3 Continuous unloading gt Compacting Optional not available with multi pallet applications STOP a Interrupt all cycles OTHER COMMANDS Command Menu Description HORN a Switch on the siren on the machine MENU ven Management menu F E Software programming 1 2 3 4 Allows the selection of a specific shuttle unit with which l o o you want to communicate the command will be confirmed by the a a a LED next to the number To make a selection you must hold down the button for 5 seconds until the LED lights To disconnect a selection hold again for 5 seconds until LED button goes out The remote control remembers the selected shuttle ID until it is deactivated 12 MANUAL COMMANDS Only to be used in exceptional circumstances Commands can be sent only to a single shuttle in manual mode While in manual handling mode all the security checks are not enabled The supplier manufacturer is not responsible for damage to property persons caused by
17. plier recommends the purchase of an AUTO SERVICE unit a maintenance carriage AUTO SERVICE USAGE Auto service Maintenance activities within the rack Shuttle recovery in case of damage due to an external cause Auto service features Crank manual handling Anchor rods with shuttle 22 SHUTTLE STANDARD Number ref 2006 42 2004 108 2006 95 EN ISO 12100 1 2003 EN ISO 12100 2 2003 Description Machine Directive Low Voltage Directive Electro Magnetic Compatibility Directive Machine safety Basic principles main planning principles Part 1 Basic terminology method ISO 12100 1 2003 Machine safety Basic principles main planning principles Part 2 technical principles ISO 12100 1 2003 EN 60204 1 Machine safety Machines electric equipment EN 13849 1 Machine safety Parts of the controlling system related to safety EN 13850 Machine safety Emergency stop device functional aspects Planning principles CE CE Conformity AUTOMHA SRL STANDARDS Number ref Description ISO 14001 Environmental management Systems OHSAS 18001 Health and Safety 2006 95 Electro Magnetic Compatibility Directive UNI EN ISO 9001 2000 Machine safety Basic principles main planning principles Part 1 Basic terminology method ISO 12100 1 2003 The Automha shuttle is manufactured in ITALY 23 a SE FAL la ELES A E o 5 SHL 2 L gt Fa m ho
18. sensor STOP Nr 1 Lithium Battery Nr 2 Pallet safety sensor Nr 2 Emergency buttons Nr 1 ON OFF button Nr 2 Safety bumpers Shuttle operators must be trained and competent in the use of the equipment Every person who has access to the working area the shuttle must be aware of the active and passive safety systems SHUTTLE MODELS MODEL MAX LOAD Kg PALLET DEPTH mm PALLET FRONT mm SAT 0812 LTH 1500 800 1200 SAT 1010 LTH 1500 1000 1000 SAT 1012 LTH 1500 1000 1200 SAT 1111 LTH 1500 1100 1100 SAT 1112 LTH 1500 1100 1200 SAT 1165 LTH 1500 1165 1165 SAT 1210 LTH 1500 1220 1016 SAT 1212 LTH 500 1200 1200 SAT 4840 LTH 1500 1220 1016 SAT 4048 LTH 1500 1016 1220 The maximum load of the shuttle is 1 500kg SHUTTLE VERSIONS ST Standard Ambient environment 0 C a 45 C BZ Below Zero Cold Store 1 C a 30 C PERFORMANCE Speed with load Speed empty Working range BATTERY Kind Voltage Capacity Weight Charger Charging time Charging time Batteries quantity Battery life Min COLOUR Chassis RAL 6032 Cover RAL 7035 30 33 m min 63 66 m min 10 16 h lon MNC 24V 53 Ah 14Kg 240 50 Vac Hz 80 3 h 100 5 5 1 900 charges MOTORS Running 700 W Lifting 400 W REMOTE CONTROL Kind RF Display LED Language ENG CN RU DE PLFR Protection IP65 Power supply Lithium Battery 500mANh TX consumption 55mMA RX consumption 50mMA Stand by function 3min
19. the operator or conductor in manual handling While in manual handling the shuttle recognizes only the end of the aisle and does not recognize the presence of any pallets present in the channel lane Command Menu Description DOWN com Lower DOWN BKW EI Backward BKW UP mo ur Backward FAST E W A a D Al w y Saw E From the home screen press the MENU key to access the administration menu With FORWARD and BACKWARD buttons you can scroll through the items In menu management is not possible to send commands to automatically or manually operate the shuttle unit To enter and exit the various items you must press the MENU key to exit the MENU you must select the EXIT MENU on the screen REMOTE CONTROL MENU Command Menu Description READ STATUS Shows the shuttle unit status READ ALARMS Allows visibility of and reset of the shuttle alarms READ DATA Allows the operator to query the machine READ MISSION Shows the number of missions done by the machine WRITE DISTANCE Allows the operator to change the gap between each pallet READ PALLETS Allow the operator to activate and deactivate the inventory function optional EXIT MENU Allows the operator to exit from the menu Until the administration menu is exited the shuttle can not be used for manual or automatic tasks 14 ALARMS DESCRIPTION Alarm Description RUN MOTOR TEMP Running motor temperature more than 65 C BATTERY TEMP ALM Ba
20. ttery temperature signal BATTERY LOW VOLT Battery empty FUSE F1 FAULT Fuse F1 interrupt FUSE F2 FAULT Fuse F2 interrupt ACTIVE BUMPER Safety bumper has been activate d ENCODER FAULT Encoder does not read correctly OBSTACLE Traction control system has been activated BATTERY LOW Battery voltage level low BATTERY OVER Battery voltage lever over the standard signal MAX MOTOR TEMP Running motor temperature over the safety range gt 75 C CLEAN SENSORS Please clean the sensors Every 3 000 missions the shuttle will advise the operator to clean the sensors PALLET HEAVY The UDL weight is more than gt 1 500kg SERVICE Every 60 000 missions the shuttle will advise the operator to have the unit serviced Suggested CHECK DT20 Please check the functionality of the DT20 sensor When the battery voltage reaches the threshold of 23 5V the shuttle warns us with a sound 5 seconds siren 20 seconds silence When the battery voltage reaches the threshold of 22 8V the shuttle returns to H1 Home 1 front warehouse the unit will no longer accept missions and will automatically turn off after 1 minute At each attempt to restart the shuttle will remember that the battery is low and then turn off again after 1 minute To restore the normal situation the battery voltage must be greater than 25V HOW TO RESET AN ALARM When an alarm has been activated the shuttle alerts the operator through a short and steady sound until the alarm is reset
21. unload of the remote control FUNCTION IS NOT AVAILABLE WITH COMPACTING Two versions available MULTI FIFO MULTI LIFO Where enabled the Multi pallet function allows the storage in the individual channels of a warehouse different size pallets namely 800mm x 1200mm 1000mm x 1200mm 1200mm x 1200mm Press IN on the remote control to load Press OUT on the remote control to unload It is possible to use 2 shuttle units in the same channel allowing pallets to be handled in both directions To insert 2 shuttle units in the same channel the anti collision function will be required There are potential situations where the two shuttle units may travel too close to each other when used within the lane The units will sound an alarm warning the operator of the risk of collision between the two devices The anti collision function requires modifications to both the hardware and software 18 OPTIONAL FUNCTIONS continued Command Menu INVENTORY IN CONTINUOUS Description The inventory function allows the number of pallets stored in the warehouse to be counted The feature is optional and can be activated in the menu of the remote control item READ PALLET With FWD and BKW can enable and disable this function Once the administration menu is exited press the IN key to start counting The number of pallets is displayed in the menu management IMPORTANT Once activated the shuttle will continue to
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