MAXIPACKER RADIO SHUTTLE USERS MANUAL Snr: 05-960300 Manufacturer: Importer: EABAB - Arrimag S.A. Stalgatan 2 ‘Avenida del Valle 961 S-333 33 Smélandsstenar Oficina 2701 Santiago ‘SVERIGE Chile Tel: +46 371 34000 Tel: +56 95 790868 Fax: +46 371 31225 Fax: +56 41 390448. www.eab.seRadio Shuttle Users Manual Machine Description Operators Manual Installation and maintenance Spare Parts aoa wn we Circuit Diagram User Manual Updates Gre latest updates of documents in this manual can be found at the EAB website, Go to wmnw.eab.se and choose English by clicking atthe fag, (lick Contact , and fil in the form and your request, You wil receive a user name and a password which ale access to the documents, opies of drawings and cicuit diagrams can be obtained from the manufacture.Radio Shuttle RS96 Machine Description 1 Machine Description Specifications Machine Type No .. ‘lease refer to the label on the Radio Shuttle Pallet size and weight Battery service weight.. Co Please refer to the label on the Radio Shuttle 22 kg (48 Ib.) each cassette 12 V / 24 Ah each battery. 24 V / 24 Ah each cassette, 24 V 1 48 An total battery capacity. he machine may be used down to the lowest temperature as indicated on the machine card. Environmental conditions. Machine Card ‘The machine card contains information about the machine and the customer. Assemble Drawings In the manuals, circuit diagrams and spare part lsts, components of the Radio Shuttle are referred to with position numbers. These numbers can be found in the assemble drawings. The following points apply to position numbers: ‘+ An assembled component, such as the battery cassette, has just one position number. Included parts can be found in the spare part list ‘+ Identical components share the same position number. If there are, for example, four Identical components, this Is shown as "x4" next to the position number of ane of the ‘components, * Accomponent that is optional and not present on all machines is marked with the posi- ton number in a dotted circle. *+ Position numbers are shown within square brackets in manuals. Supplied dra Plan view Front and rear end Inside view CE conformity AA Declaration of Conformity is enclosed for deliveries to a country within the EU (Euro- ean Community). Control Program Set-up ‘The control program is adapted to the warehouse or plant in which the machine will be used, The delivery set-up is shown on the form “Software Setup”. This form can be used for notes of future changes. A control program change is done by the supplier or by service personnel according to separate instructions, Revisién 2004-05-24 Tab 1 page 1Radio Shuttle MACHINE CARD MASKINKORT MASCHINENKARTE PLAQUE DE MACHINE 3 i Aah 05 - 960300 05-%0299 » 891230013, » BNZ3013 433,92 MHz Frutera San Fernando S.A rut, 86381.300 K, Avda.E] Bosque Norte Oficina 1002 Santioago CHILE 2008-09-28MAXIPACKER RS96 1200x1000 1-037 I =GIA IVE 8-8KOT ft 00010021 9654 YaNIVdIXVH ® @® @QHE ? @®|© = ip | e@ Wel als @d « : : mG) es Lasting 892340220 Contact pad Anliggningsdyna Y 323 892300612 _Lever (right, rear) Lyftarm héger bakre 892300201 Bearing journal Lagertapp 185440601 Lubricant nipple ‘Smérjnippel 847655530 _Ball bearing Kullager 185105520 Circlip Usring 892340220 Contact pad Anliggningsdyna Edition 2005-09-01 ‘Spare Part List page 7 of 8Radio Shuttle type: 891230013 Spare Parts ‘Artsno followed by * is optional and not prasent on all machines ‘Aan. (0 av * ar tlval och finns inte PB samiga maskiner POS ELID ART DESCRIPTION / BESKRIVNING 124 892400304 Chain sprocket Kedjehjul 848600040 Clamping sleeve ‘Spainninylsa 125 848210282 Roller chain, 282 mm Rullkedja, 282 mm 848300100 Chain connecting link Kedjelés 126 892300214 Guide bushing Styrhyisa 127 892240620 _ Battery support Batterifack 128 892200420 Scraper ‘Avskrapare 892240421 Attachment scraper Faste avskrapare 892240422 Clamping plate klimbricka - 844100050 Anti slip tape, underside, 1 roll Edition 2005-09-01 Halktejp, undersida, 1 rulle ‘Spare Part List page 8 of 8INSTALLATION AND USE yacker charge station can hold two battery chargers meaning that two sets of batteries can be charged at the same time. If the maxipacker plant include severel shuttles or if they are used in continuous service, several charge stations can be placed together. WARNING The charge station may under no circumstances be used before itis fixed to the floor! Unless fixed, the station will fall forward when bat- teries are placed in an outdrawn drawer. Page tof?VO Radio Shuttle RS96 Circuit Diagram Table of Contents Part Contents Page 5a Circuit diagram 1 5.2 ‘Wiring of the PLC 2 53 Machine type alteration 4 Annex Circuit diagram 5.1. Circuit diagram In the circutt diagrams, components of the Radio Shuttle are referred to with electrical iden- tification numbers according to the standard SS-EN 60204, Position numbers, found in the assemble drawings, are noted within brackets, Labels with electrical identification numbers are placed next to the components in the Radio Shuttle, A number of identical components can have unique electrical identification numbers but share the same position number, Machine types ‘The circuit dlagram is common for all machine types. In the circuit diagram, components that vary between types are framed and marked with the text "Type dependent’. ‘Type and number of components vary between machine types. In the following listing of PLC wiring, @ component that may be missing is marked with * Revision 2604-06-10 Tab 5 page fRadio Shuttle RS96 Circuit Diagram 5.2__Wiring of the PLC Inputs Digital inputs, PLC unit.N3 xo xt x2 Re} x4 6 x6 x7 x10 xa x2 x13 x14 x15 X16 x17 Encoder B1, distance measurement, pulse Encoder B1, distance measurement, pulse Radio receiver U1, IN button pressed Radio receiver U1, OUT button pressed Radio receiver U1, STOP button pressed * Radio receiver U2, Fi button pressed * Radio receiver U2, F2 button pressed Interface module K4, fault indication drive motor controller, fault=24V Interface module KS, fault indication liting motor controller, fault=24V Inductive sensor S4, lift position detection, eccenter in front of sensor=24V Photocells S7, $8, $9, $10, colision hazard sensor, object within detection range = 24V Photocell $11, ral hote detection, hole=24V Photocell $12, pallet edge detection, covered with pallet=24v Photocell $13, pallet edge detection, covered with pallet=24V Photocell $14, front pallet detection (detects a pallet in the P/D position when the RS reverses carrying an unloaded pallet), pallet detected=24V Photocell S15, front pallet detection, see S14 Digital inputs, PLC unit N4 x20 X21 x22 x23 x24 x26 x27 x31 x32 x33 x34 x35 x36 x37 Photocell S16, rear pallet detection (detects a pallet in the rack when the RS moves forward carrying a loaded pallet), pallet detected=24V Photocell $17, rear pallet detection, see S16 Photocell $18, small pallet edge detectioi, covered with pallet=24V Photocell $19, smail pallet edge detection, covered with pallet=24V Photiocell $20, pallet size verification, covered with pallet=24V Photocell $21, pallet size verification, covered with paliet=24V Photocell $22, pallet size verification (special), covered with pallet=24V Spare Spare Spare Spare Spare Machine type coding, please refer to pait 5.3 below Machine type coding Machine type coding Machine type coding Revision 2004-06-10 Tab 5 page 2Radio Shuttle RS96 Circuit Diagram Analogue inputs, PLC unit N6 Chi Motor controller Ni, drivermotor current monitor Ch2 Motor controller N2, lftirig motor current monitor Ch3 Voltage transducer N7, battery voltage Ch4 Voltage transducer NNZ, sensing edge $5 and $6 surveillance Outputs Digital outputs, PLC unit N3 YO Timer relay K3, resets delay time for automatic switch-off Yi Relay &3, power supply to lifting motor controller N2 Y2___Relay K2, power supply to driving motor.controller NI Y3_ Lamp Hi, front end, green Y4 Lamp 8, front end, red YS * Lamp H6, front end, yellow, mode indication 6 * Lamp H5, front end, yellow, mode indication Y7 Lamp H7, H8, rear end, white flashlight LED Y10 Lamp H9, H10, front end, white flashlight LED Y11___Lamp H4, front end, battery capacity indicator, green light LED 12 Lamp H4, front end, red light LED (Y114+Y12 make yellow light) Yi3_ Lamp H11, H12, H13, H14, down facing biue aiming lights Y14 —_Photocells $7, $9, voltage supply through terminal 27, 29 Y15___Photocells $8, S10, voltage supply through terminal 28, 30 Y16 Spare Yu? Spare Analogue outputs, PLC unit N5 cht cha Drive motor controller N1, speed control Lifting motor controller N2, speed control Reviston 2004-06-10 Tab 5 page 3Radio Shuttle RS96 Circuit Diagram 5.3 Machine type alteration ‘The machine can be altered with added or changed functions. Some upgrades call for ‘added or changed component while others can be made by changes in the control pro- gram. a Please contact the supplier for information about which upgrades that is possible to do fon the machine. Coding of the PLC ‘The PLC input X34 is used to give the control program information about the maximum load capacity. x in the chart below mean that 24 V is connected to the input. 2] contiguration The shuttie is designed for a maximum load of 1000 kg. a x| The shuttle Is designed for a maximum load of 1500 kg. ‘The PLC inputs X35 to X37 are used to give the control program information about the present component and function configuration of the machine, x in the chart below mean. t 24 V is connected to the input. tha BSS 2] 3] $3| Configuration x[x]x x x | Basic configuration, one radio receiver (U1) Service mode, please refer to part 7 of the Service Manual for information, (Note 1) x] x| | Option 1, two radio receivers (Ui and U2) and lamps H5 and H6, Required for REORGANISATION, SHOW PALLET and FORCED UNLOAD modes as well as UFO/FIFO operation and handling of DOUBLE PALLETS. x] |x| Option 2, as option 1 with photocelis directed upwards (S18, $19, $20 and S21) for indication of two pallet sizes. Required for COMBI operation. x ‘Option 3, as option 2 with photocell $22. Required as complement for COMBI ‘operation if pallet size can not be identified by using photocells $18-21. Procedure 1) Assemble and/or modify necessary components. 2) Modify connections X35-37 according to the chart above. 3) Modify the contro! program set-up according to instructions in part 8 of the Service Manual. (Note 1) Note 1 The Service Manual (parts 6, 7 and 8) is available to qualified service personnel, Revision 2004-06-10 "Tab 5 page 4ou ee [tees aoe G2zte TE OF 'xB4 oOOKE 1, beri (va) uunaissoubwits e€€ ece~3s YOXKEROSE XOXEEOSE “KeXKEZOST “xKEXE 96Su 311 9 cou a0ay IS OTONY the) ON! 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Position numbers are shown within square bracket, e.9. [100], Power supply during service activities During service work and adjustments described in the Service Manual, the cover [101] needs to be removed. In order to supply the machine during service work, a fully charged battery cassette should be placed in a battery compartment. AQ | WARNING When covers are removed and supply voltage is applied, a large number of crushing hazerds exists. IF fauit exists in the machine, a motor can perform uncontrolled ‘movernents, i Make sure that no measuring probe wires get stuck in any sprocket wheel. ‘Trouble shooting ‘Tab 7 contains instructions for trouble shooting and a description of the Service Mode that can be used for component testing. Software The control software can be adapted for a certain installation. An instruction for this is supplied with the separately sold Setup Terminal. Updates ‘The latest revisions of service manual documents are available at the EAB home site, ‘www.eab.se. A password is needed to access the documents. Revision 2005-02-21 “Tab 6 page 2 of 20Radio Shuttle RS 96 Service Manual Page 3 6.1.1 Driving Motor Controller Ni ‘The driving motor is controlled by a solid state controller, The unit shall be marked SOABLTE-EB3, The speed is controlled by an analogue signal from the PLC. HW ae. eae Factory set-up for drive motor controller N41 swi | swa | swa | swa | sws | swe | sw7 | swe | swo [swio Pos | ON | ON | OFF | oFF | ON | OFF | OFF | OFF | OFF | OFF Adjustment of potentiometer Pi - LOOP GAIN ‘The power must be turned off during adjustment of Pi. Connect an ohmmeter between the Molex terminal "2 SIGNAL GND” and the point of ‘measuring at Pi. (Refer to the enlarging In the figure above) ‘Adjust PL until the resistance is 6 KO, Pt is a 12 turn, 25 k@ potentiometer. Each clock ‘wise turn lowers the resistance 2 ko. Adjustment of potentiometer P2 - CURRENT LIMIT ‘The power must be turned off during adjustment of P2. ‘Connect an chmmeter between the Molex terminal “2 SIGNAL GND” and the point of ‘measuring at P2. ‘Adjust P2 until the resistance is 35 ko, P2 is a 12 turn, 50 ka potentiometer. Each clockwise turn raises the resistance 4 ka. Revision 2005-02-21 "Tab 6 page 3 of 20Radio Shuttle RS 96 Service Manual Page 4 Adjustment of potentiometer P3 - REF IN GAIN During adjustment of P3, the service mode must be activated in drive motor mode, (The service mode is described under tab 7) y) 2) 3) 4) Meke sure that the motor testis set for driving motor control, Ifthe motor is ro- ‘ating, push 4 or © until it stops, Push the # radio transmitter button once. ‘Check the control voltage to the controler. The voltage at the analogue output Chi (cable 037, 038) at the PLC unit NS shall be 2,0 V. If needed, push # or nti this voltage is present, Measure the voltage to the driving motor between terminals “i - MOTOR” and "2 + MOTOR". Adjust P3 until this voltage is 5,0 V. Push the ‘ radio transmitter button once. The voltage at the analogue output ‘Chi (cable 037, 038) at the PLC unit NS shall rise to 4,0 V. Check that the voltage to the driving motor between terminals “1 - MOTOR” and “2+ MOTOR" Is 10,0 V. Adjustment of potentiometer P4 - TEST/OFFSET During adjustment of P4, the service mode must be activated in drive motor mode, (The service mode is described under tab 7) y 2 3) ‘Make sure that the motor testis set for driving motor control by checking that the POWER OFF lamp is flashing, Push the STOP radio transmitter button once. ‘Check the control voltage to the controller. The voltage at the analogue output Chi (cable 037, 038) at the PLC unit NS shall be 0,0 V. If needed, push or ‘until this voltage is present, ‘Measure the voltage to the driving motor between terminals ™1 + MOTOR”. Adjust P4 until this voltage is 0,0 V. MOTOR” and “2 Revision 2005-02-23 Tab 6 page 4 0f 20Radio Shuttle RS 96 ‘Service Manual Page 5 6.1.2 Lifting Motor Controller N2 The lifting motor is controlled by a solid state controller. The unit shall be marked SOABLTB-EB2. The speed is controlled by an analogue signal from the PLC. Factory set-up for lifting motor controller N2 Swit | swa | sw3 | swa | sws | swe | sw7 | swe | swo [swio Pos | On | on | oFF | OFF | oFF | OFF | OFF | OFF | OFF | OFF Adjustment of potentiometer P1 - LOOP GAIN ‘The power must be turned off during adjustment of Pi. Connect an ohmmeter between the Molex terminal "2 SIGNAL GND" and the point of ‘measuring at P1. (Refer to the enlarging in the figure for part 6.1.1 above) Adjust PA until the resistance is 6 KO. Pt is a 12 turn, 25 kee potentiometer. Each clock- wise turn lowers the resistance 2 ka. Adjustment of potentiometer P2 - CURRENT LIMIT ‘The power must be turned off during adjustment of P2. Connect an ohmmeter between the Molex terminal “2 SIGNAL GND" and the point of ‘measuring at P2, ‘Adjust P2 until the resistance is 45 KO. P2 is a 12 turn, 50 KO potentiometer. Each ‘dockwise turn raises the resistance 4 ka. Adjustment of potentiometer P3 - REF IN GAIN During adjustment of P3, the service mode must be activated in lifting motor mode. (The service mode is described under tab 7) 1) Make sure that the motor testis set for lifting motor control, Push and hold the ‘radio transmitter button. 2) Check the control voltage to the controller. The voltage at the analogue outout CCh2 (cable 040, 041) at the PLC unit NS shall be 5,0 V. 3) Measure the voltage to the driving motor between terminals “t - MOTOR" and "2 + MOTOR". Adjust P3 until this voltage is 12,0 V. Adjustment of potentiometer P4 - TEST/OFFSET 1) Make sure that the motor test is set for lifting motor control. Push the STOP radio transmitter button once. 2) Check the control voltage to the controller. The voltage at the analogue output (Cha (cable 040, 041) at the PLC unit NS shall be 0,0 V, 3) Measure the voltage to the driving motor between terminals “1 - MOTOR” and “2 + MOTOR”. Adjust P4 until this voltage is 0,0 V. Revision 2005-02-21 "Tab 6 page 5 oF 20Radio Shuttle RS 96 Service Manual Page 6 6.1.3 Interface modules K4 and K5 Two interface modules are used to connect the drive and liting motor controllers to the PLC. Inputs and outputs on the PLC uses 24 V while the controller use 5 V. Module K4 and KS is a 5 V to 24 V type and is used for the fault indication from the mo- tor controller to the PLC. No adjustment Is needed. 6.1.4 Measurement interface N7 ‘The PLC is equipped with analogue inputs capable of measuring 0 to 10 VDC. As the battery voltage Is 24 V and over, this voltage has to be converted to suit the PLC input, This is done with a resistance network housed in N7, No adjustment is possibie. Ifthe values measured at outputs 3/5 or 7/9 are wrong, the odie needs to be repaired or replaced. ‘S5=Front sensing edge 470 Ohm S5=Rear sensing edge 470 Ohm Rt=10 kOohm, R2 = 5.1 kOhm 3 = 470 Ohm, R4=820 Ohm R5=47 Ohm i=0.33 uF, C2: Vi=t7eiscv ‘Connection: 1=424V from battery 2=- from battery and S=battery voltage measurement 4 and 6=connection, front sensing edge 7 and 9=sensing edge voltage measurement Sand 10 connection, rear sensing edge Measurement interface connection: Terminal 1 and 2: 24V supply voltage. ‘A: Output for battery voltage measurement. (Connected to analogue PLC input) B: Output for sensing edge voltage measure- ‘ment. (Connected to analague PLC input) C: Front sensing edge, D: Rear sensing edge, Revision 2005-02-27 Tab 6 page 6 of 20Radio Shuttle RS 96 Service Manual Page 7 Measurement interface function check 1) Measure the battery supply voltage at terminal 1 + and 2 -, 2) Measure the voltage at output A, terminal 3 + and 5 -, The voltage shall be 1/3 of the battery supply voltage, 3) Make sure that both sensing edges are properly connected. Front edge to C and rear edge to D. 4) Measure the voltage at output 8, terminal 7 + and 9 -, The measurement inter- face function is correct when the voltage corresponds to the table below. (OK means that the sensing edge is connected and not pressed. Cifrontsens. edge | Di rearsens.edge | Biterm. 7-9, voltage OK OK 42-44V Not connected OK 60-61 OK Not connected 57-59 Nat connected Not connected 94-97 Pressed OK 00-02v | OK Pressed 44-130 Sensing edge replacement 41) Disconnect the wires and pull the rubber strip out of the aluminium profile, 2) Check the aluminium profile, adjust if needed and mount a new rubber strip. 3) Connect the wires and perform a measurement interface function check. 6.1.5 Automatic switch-off timer relay {K1 Is used to delay automatic switch-off, The function is as follows: ‘As long as no command is receved (no button is pushed on the radio transmitter), K1 is Counting time up towards the set delay time. If no button has been pushed when the delay time hes elapsed, the Radio Shuttle will be switched off, Every time @ button is pushed, the time counting is reset to zero from PLC output YO. Switch 1 0.1 to 1 seconds 1 to 10 seconds 6 to 60 seconds 1 to 10 minutes 6 to 60 minutes 1 to 10 hours Factory setting 10 to 100 hours 8 Factory setting Revision 2005-02-21 "Tab 6 page 7 oF 20Radio Shuttle RS 96 Service Manual Page 8 6.1.6 Programmable Logic Controller, PLC ‘The Programmable Logic Controller, PLC, is placed under a cover sheet, mounted with 4 screws, The PLC is supplied with a backup battery and depends on this battery to maintain run-time statistics, ‘The control program is stored in a EEPROM (electrically erasable programmable read only ‘memery) cassette which do not depend on the backup battery to keep the contral pro- ‘gram in memory. Backup battery and EEPROM cassette replacement 1) Switch the Radio Shuttle power off 5 ‘and remove the cover [101]. 2) Remove the cover plate over the PLC box [34] 3) Carefully remove the cover labelled “"MITSUBISHI...Transistor unit" from the main PLC unit. Backup battery Jn order to secure correct function, the backup battery of the controller should be re- laced every third year. For battery part no., please refer to the spare parts list. If the battery replacement fails, run-time statistics can be reset to zero, Pe O° i ce o a 4) Loosen the white connector © and remove the old battery ©, 2) Place a new battery in the case and connect it, The new battery must be con- nected within 30 seconds to avoid data loss, 3) Replace all covers. 4) Always make a supervised test run before putting the Radio Shuttle back in op- eration. Revision 2005-02-21 Tab 6 page 8 of 20,Radio Shuttle RS 96 Service Manual Page 9 Control program memory cassette ‘The EEPROM cassette © is located under the PLC cover. Make sure that the Radio Shuttle power is turned off before replacing the cassette, 1) Use the tip-up wire handle @ when loosen the old cassette from the PLC. 2) Make sure that the switch @ on the new cassette is in the OFF position before tthe cassette is put in place, 3) Push down the cassette firmly and fold down the wire handle. 4) Check that the rubber spacer, used to keep the cassette pressed in place, is correctly placed in the PLC cover. 5) Mount aif covers and cover sheets, 6) Always perform a supervised test run in the racking before the shuttle is put back in operation, 6.1.7 Lamps All the lamps are of light emitting diode (LED) type. This means that ‘they must be Connected exactly as shown in the circuit diagram. If the connecting wires are mied up, the lamp will not light up. 6.1.8 Battery and fuses ‘The batteries are maintenance free and shall be replaced when they no longer have the necessary capacity, \When replacing batteries, make sure that the cables are connected to the battery poles in the sarne way as from the supplier. To avoid damage if a short circuit occurs between the batteries and the circuit breaker, a fuse is placed in the battery cassette. This fuse is located at the cable to the batteries, During normal use, this fuse should not blow. If it has, the cause must be investigated before the fuse is replaced and the battery cassette connected, Falling to do so can result in grave damages to the machine wiring. Revision 2005-02-21 “Tab 6 page 9 oF 20Radio Shuttle RS 96 Service Manual Page 10 6.1.9 Rail hole detection photocell ‘This photocell detects holes in the Radio Shuttle rail, telling the shuttle where the home and end positions are located. ‘To maintain correct function on S11, without interference from reflections caused by the rail, tis Important that the light beam of the photocell is spotted at the centre of the hole of the In this photocell, the optics and electronics are separate units connected with an optic fibre. The optics is mounted at the inner wall of the machine casing and the electron- ics at the bottom of the casing, ‘The detection distance of the photocell is adjusted according to the following instruc- ton: ~ Remove the cover [101]. Connect a battery cassette and switch on the Radio ‘Shuttle according to normal procedures, — Make sure that there is a free space at the side of the machine in front of Sis bre optics. > Put switch @ on S11 to position SET, ~ Hold a white paper in front of S11:s fibre optics at @ distance of 20 mm. = Push and hold button © on S11 for at least 2 seconds. When the button is re leased, the orange LED (light emitting di: de) is lit, ~ Hold the paper in front of Sis fibre op- ties at a distance of 70 - 80 mm. ~ Push and hold button @ for at least 2 sec- Conds. When the button is released, also the green LED is lit, = Put switch @ on S11 to position RUN, Setting at operation During operation, the switches © to @ should be in the following positions: ‘Switch @; RUN ‘Switch @: OFF ‘Switch ®: D.ON Revision 2005-02-21 “Tab 6 page 10 oF 20Radio Shuttle RS 96 Service Manual Page 11 .1.10 Radio receiver Each radio receiver can control three functions. Receiver U1 Is used for IN, OUT and STOP commands while U2 Is used for FI and F2. Receiver U2 is present only ifthe machine Is equipped with more modes than [AUTO] and remotely controlled opera- tions, Up to 242 Radio Shuttles can be controlled from a single radio transmitter. Every Ra- dio Shuttle in a storage room must be set to its own, unique code, called the address. Both tecelvers U1 and U2 must be set to the same address on the of Jo radio receher DIPswiteh ©. = ‘After changing to @ new address, the SS label on the front of the shuttle, as well as the machine label, must be = changed to the correct number. Al- ways make a supervised test run af- Pg, Hetsero0 ter resetting the radio switches, EHNA ‘Switch number Position| 2 | 2|3/4/s5|6|7]2| 9/12 mf a — cert |“ Warehouse common [Adds to address Fifa sa [ [1s] 6 [2 ° aflafes [3 = [s[x]x[x[e feo fo ojo Switch 1 Sets control button function to Y\4/ STOP or F1/F2. On receiver UL this switch shall be set to "-" and on U2 to "+". Switch 2-5 These switches shail be set identically on all receivers in a warehouse, by default to "", Switch 6-10 These switches sets the address. The figures in the table shall be added to get the desired address number. For example, address 167 is made up of switch 6 in position "+" (162), switch 7 in postion (0), switch 8 in position "=" (0), switch 9 in position “o” (3) and switch 10 in position "+" (2), together making up the address 162+04043+2=167, Revision 2005-05-21 “Tab 6 page Lt of 20Radio Shuttle RS 96 Service Manual Page 12 6.1.11 Radio transmitter ‘The radio transmitter can control one of 242 Radio Shutties by selecting the appropriate address with the buttons 0 to 9. O CJ _Ifan instalation includes more than 242 Radio Shuttles, these must be divided into groups, common for the whole warehouse, Please consult the supplier if this is required. ‘The intemal switches 1 to 8 are factory set to position "." ‘and may only be changed after consulting the supplier. 2305678 : 4 ‘The radio transmitter is equipped with a built-in antenna that TH 's used even when the transmitter is placed in the truck cas- sette, ‘The battery used is a 9 V alkaline type. This battery is dis- ‘connected when the transmitter is placed in the truck cas- ssette. However, if the battery is completely discharged, the Oo transmitter cannot switch to truck cassette power supply. In this case, replace the battery. Revision 2005-02-21 “Tab 6 page 12 of 20Radio Shuttle RS 96 Service Manual Page 13 6.1.12 Pallet detection photocelis ‘These photocells ($14, S15, $16 and $17) are used to detect when the Radio Shuttle comes close to a pallet in the rack. On detection, the speed is lowered and the shuttle 's prepared to stop. ‘Wrong or missing function of these photocells can lead to damages or, in the worst ‘case, a pallet being pushed out of the rack. Therefore, these photocells are doubled and should be set up identically, Adjustment of detection distance 1) 2) 3) Remove the cover [101]. Connect a battery cassette and put the machine into service made. Please refer to tab 7. Make sure that no one send an unintentional ‘command, Repeat for all four photocells: ~ Open the cover ©. For easy access, the cover can be removed from the photocell when opened. Tt might be necessary to dismount the photocell bracket from the machine in order to access the set screw, ~~ Move 2 wooden plate towards and away from the photocell and verify that the LED turns on and off. The activation of the photocell is also indicated by the white motion indicators [10]. — Adjust the set screw @ until the indication distance is 800 mm (32°), ‘Clockwise turn increases the detecting distance. Anti-clockwise turn reduces the detect- ing distance, Put the covers back and mount the brackets in the front and reat end. if there ~are seals between the machine case and the brackets, make sure that they are mounted without wrinkles and without restraining the light flow from and to the photocell. Revision 2005-02-21 “Tab 6 page 13 of 20Radio Shuttle RS 96 Service Manual Page 14 6.1.13 Pallet position and size photocells Photocells are assembled in the mechine cover and directed upwards. These photocells detect the lower boards of the pailets and contro! machine position. If the machine can handle two pallet sizes (combi) additional photocell are used to decide pallet size. Depending on the placing of these photocells, they are exposed to contamination and damage. Detection range adjustment ‘The detection range must be such that the photocell detects the lower, but not the up- per, boards of the pallet ‘The detection range is adjustable using a screw driver, Check the detection distance by ‘moving the hand towards the photocell. The LED © should turn on when the hand is ‘about 80 to 100 mm from the photocell, Clockwise tum of the set screw @ in creases the detecting distance, ‘Antclockwise turn reduces the detecting UD astance. Photocell replacement The photocell shall be connected according to the following tabi Brown wire: Power supply +24V (positive) Blue wire: Power supply - (negative) Black wire: Signal to the PLC (+24V when an object is within the detec- tion distance) Revision 2005-02-21 Tab 6 page 14 of 20Radio Shuttle RS 96 Service Manual Page 15 6.1.14 Obstacle indication photocells In order to discover and indicate obstacles in the area over the racking cross beams and under the pallets loaded into the channel above the machine, photocells are ‘mounted in the front and rear end. When an obstacle is indicated, the speed is low cred to half the maximum speed. ‘As soon as the machine moves, these photocells are supplied with power from two PLC outputs, To eliminate interference, only one of the photocells in each direction is active at the same time. Function and detection distance check To check the function of the obstacle indication photocells, the machine must be put into service mode, please refer to tab 7. ‘These photocells have a fixed 1,5 m detection distance. ‘The detection distance is checked by approaching the photocell straight from the front while observing when the blue, downward directed position lights light up. If the de- tection distance deviate more than 200-300 mm from the fixed distance, the photocell ‘must be replaced, ‘The photocell brackets and mounting must also be inspected. It is important that the photocell is mounted in a way that directs the light beam completely horizontal. If not, the racking cross beams or pallets loaded into the racking can disturb the obstacle in- diction. Photocell replacement ‘The photocell shall be connected according to the following table: Brown wire: Power supply +24V (positive) Blue wire: Power supply - (negative) Black wire: Signal to the PLC (+24V when an object is within the detec- tion distance) 6.2.4 Drive wheel replacement To dismount the wheels, all six screws are loosened. Put three of the screws into the threaded holes in the outer ring. ‘Tighten the screws until the wheel comes off, If the damping sleeve falls apart, it must be assembled according to the illustration, Pull the clamping sleeve out of the worn out ‘wheel and clean all surfaces of the sleeve, Put the clamping sleeve into the new wheel and push the whee! and clamping sleeve inwards against the drive shaft spacer ring. Tighten all screws using 17 Nm tightening torque. Revision 2005-02-21 Tab 6 page 15 of 20Radio Shuttle RS 96 ‘Service Manual Page 16 6.2.2 Distance measuring pulse transducer Encoder B1 is a pulse transducer for measurement of travelling distance and indica- tion of movement. The encoder has two outputs, pulse A and pulse B, ‘The number of pulses is proportional to the travelled distance and the order, in which the pulses A and B occur, indicates travelling direction, The encoder does not need any adjustments, ‘The encoder is driven by a chain from the drive wheel axle, The chain shall be ten= sioned but not stretched. Pulse transducer chain adjustment ~ Loosen the screws ® enough to enable the encoder bracket to be moved. = Push the encoder in direction A with a force of 5 N. + Tighten the screws ®, Pulse transducer replacement = Loosen the transducer wires from the terminals +, -, 9 and 10. = _Dismount the chain by opening the chain-connecting link. = Dismount the transducer by loosing the screws ©. ~The sprocket whee! is fixed to the transducer axle using a set screw. The set screw ‘must be loosened before the sprocket wheel can be removed. = Replace the transducer and assemble everything In reverse order. = Carefully check that the sprocket wheels are aligned before the chain Is mounted. - Connect the transducer wires to the terminals, Be careful not to mix up the wires connected to terminals 9 and 10, = Green wire to terminal 9. Yellow wire to terminal 10. Revision 2005-02-24 "Tab 6 page 16 of 20Radio Shuttle RS 96 Service Manual Page 17 6.2.3 Drive chain Drive chain adjustment Loosen the nuts D, Move the drive motor in direction A until the chain can be pushed down approximately 5S mm using a force of 10 N. Tighten the nuts. Drive motor and gear replacement = Cut the strap holding the cable to the drive motor bracket, - Disconnect the cable junction above the drive motor. = Dismount the chain by opening the chain-connecting link. = Dismount the drive motor/gear bracket by loosing the screws @ ~ Dismount the sprocket wheel by loosing the lock washer attached to the gear axle, ~ Remove the bracket from the old gear and mount it, in the same position, at the new gear, = Mount sprocket wheel and lock washer. = Mount the drive motor/gear into the machine and tighten the screws @. + Connect the cable and fix it to the bracket using a new strap. + Mount the drive chain and adjust the chain tension, Before the machine Is used, the drive motor direction of rotation must be checked. Revision 2005-02-21 "Tab 6 page 17 of 20Radio Shuttle RS 96 Service Manual Page 18 6.2.4 Lift chain Lift chain adjustment Loosen the screws ©, one on each side ofthe chain tension sprocket wheel Push the chain tension sprocket wheel in direction A using @ force of 50 N. = Tighten the screws O. 6.25 Motor brush Inspection and replacement of drive / lifting motor brushes ‘The two brushes are held in place by threaded caps on both sides of the motor. = Unscrew the cap holding the brush. = Pull the brush out of the holder, + Measure the length of the brush: Length of new brush = 19mm Length of worn out brush = = Mount the brush by pushing it into the holder. Screw the cep back on. Revision 2005-02-21 “Tab 6 page 18 of 20Radio Shuttle RS 96 Service Manual Page 19 6.2.6 Lift mechanism WARNING \When checking and adjusting the iting movement, the machine can perform Lnexpected movements. Make sure thatthe iting mechanism is fully under- stood before doing any checks or adjustments, Description of the lifting movement ‘The lifting movement is accomplished by using eccentrically placed ball bearings on the rotating lifting axle, It s important that the retaining ring is adjusted to a position where the eccentric is in its upper deadlock position when the lifting axle stops, The loaded pallet will then be hold by the eccentric. If not, the load will be held by the breaking force of the lifting ‘motor, meaning that the load will sink during transport. Adjustment of stop position sensor The stop positions of the lifting axle is contolled by the inductive sensor $4 [20} ind= ‘ating the position ofthe adjustable retaining ring [115]. ‘The sensor should be adjusted to give a 0.51 mm gap A to the highest point of the retaining ring. Retaining ring ‘Sensor Figure 1 ‘The service mode for lifting motor test is best suited for the adjustment of the stop positions of the lifting axle. Please refer to tab 7. ‘The eccentric isin its upper deadlock position when the highest point is in contact with the contact pad of the lever and the measures B of figure 1 is equal. For adjustment and checking, please refer to the next page. ‘Revision 2005-02-21 Tab 6 page 19 of 20Radio Shuttle RS 96 Service Manual Page 20 Adjustment of stop position ‘When adjusting the stop position, the screws @ should be loosened just enough to allow the retaining ring to be turned, ~The retaining ring should be turned in the C direction if the lifting axle stops before: the eccentric reaches its upper deadlock position. The retaining ring should be turned in the D direction ifthe lifting axle stops when the eccentric has passed its upper deadlock postion, Figure 2 ‘Check and any final adjustments of the lifting axle stop position is done with the ma- chine and a loaded pallet placed in the racking. Put the machine into service mode for lifting motor test, 41) Place the machine in correct position under the pallet. 2) Let the machine lift the pallet and then turn the machine off using the OFF button. The breaking force of the lifting motor will now disappear. 3) If the pallet remains lifted, the stop position is correctly adjusted, If the pallet sink when the power is turned off, the direction of rotation of the ‘axle when sinking must be compared to the direction of rotation when lifting, During lifting, the axle rotates in direction D, ~ If the axle rotates in the same direction when sinking, the retainer ring should be tumed in direction D. Ifthe aoe rotates in the opposite direction when sinking, the retainer ring should bbe turned in direction C, Revision 2005-02-21 “Tab 6 page 20 0F 20,