Eng

Operator instructions forFlat Sort Machine

Flat sort machine installation FS1CARRY

Poznan, Poland

EQ-P-CPO.128Prepared by: Equinox MHE BV

Version: 1.0Date: 10-05-2010

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Equinox MHE bvPastoorslaan 572182 BW HillegomThe Netherlands

Flat Sort machine Operator instructions

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Revision Date By Remark

1.0 10-05-2010 F. Methorst Final

EQUINOX M.H.E. BV (“EQUINOX”)PROPRIETARY AND CONFIDENTIAL INFORMATION

PROPRIETARY and CONFIDENTIALEquinox MHE bv - Iban NL.28 INGB0665430477 - K.v.K. 28100151 Leiden - BTW NL 812989314.B.01

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The information contained herein is the PROPRIETARY and CONFIDENTIAL property of EQUINOX and may not be disclosed, reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express prior written permission of EQUINOX.

EQUINOX may have patents or pending patent applications, trademarks, copyrights or other intellectual property rights covering subject matter in this document.

The furnishing of this document does not give you license to these patents, trademarks, copyrights or other intellectual property except as expressly provided in a written license agreement from EQUINOX.

COPYRIGHT

The copyright for these operating instructions remains with Equinox MHE BV. The operating instructions contain technical regulations and drawings which may not be reproduced partially or in full, transmitted by any means, utilized without permission for competitive purposes or disclosed to third parties.

Table of contentTABLE OF CONTENT..........................................................................................................................................4

1 SORT MACHINE OVERVIEW..................................................................................................................5


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1.1 TOTAL OVERVIEW.......................................................................................................................................51.1.1 Platform 1..........................................................................................................................................6

1.2 PRIOR TO EACH OPERATION........................................................................................................................71.3 PROCEDURE FOR ACCIDENTS OR MALFUNCTIONING...................................................................................7

2 SAFETY.........................................................................................................................................................8

2.1 BASIC SAFETY INSTRUCTIONS.....................................................................................................................82.2 INTENDED USE.............................................................................................................................................82.3 INCORRECT USE...........................................................................................................................................82.4 SPECIALISTS................................................................................................................................................82.5 DANGERS.....................................................................................................................................................82.6 INTERFACES TO OTHER DEVICES.................................................................................................................92.7 SORT MACHINE SAFETY LIGHT SYSTEM......................................................................................................9

3 PRODUCT SPECIFICATIONS................................................................................................................10

3.1 SORT OF PRODUCTS...................................................................................................................................103.2 PRODUCT DIMENSIONS..............................................................................................................................10

4 INDUCTING PRODUCTS.........................................................................................................................11

4.1 INDUCTION STATION..................................................................................................................................114.1.1 Induction screen / monitor..............................................................................................................114.1.2 Cash desk scanner...........................................................................................................................114.1.3 Start and stop button.......................................................................................................................114.1.4 Emergency stop...............................................................................................................................11

4.2 SCANNING THE PRODUCT BY HAND...........................................................................................................114.3 INDUCTING PRODUCTS...............................................................................................................................114.4 HOW TO SAFELY INDUCT ITEMS INTO THE SORTING SYSTEM...................................................................134.5 PROHIBITED!!!!..........................................................................................................................................15

5 ASSIGNING CLIENT BOX.......................................................................................................................16

5.1 ASSIGN A BOX TO THE SORT MACHINE SYSTEM........................................................................................165.2 FULL BOX..................................................................................................................................................16

6 AVAILABLE FUNCTIONS ON THE DROP STATIONS.....................................................................17

6.1.1 Light on drop station:......................................................................................................................176.1.2 Drop station suspend/release:.........................................................................................................176.1.3 Carton Cut-off :...............................................................................................................................176.1.4 Carton Assign :...............................................................................................................................17

7 ERROR MESSAGES ON SORT MACHINE CONTROL PC SCREEN.............................................18

8 COMPANY INFORMATION...................................................................................................................22

8.1 ABOUT US..................................................................................................................................................228.2 Contact information..................................................................................................................................22


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1 Sort machine overview

1.1 Total overview


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PLATFORM B

PLATFORM A

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1.1.1 Platform 1

I1 = Induction station 1I2 = Induction station 2I3 = Induction station 3I4 = Induction station 4I5 = Induction station 5I6 = Induction station 6I7 = Induction station 7I8 = Induction station 8CS1 = Scanner system 1CS2 = Scanner system 2


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I1 I2 I3

SD

I4

SD

I8 I7 I6 I5

CS1

CS2

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1.2 Prior to each operation Check the sort machine for visible damage. Pay particular attention to the closing stations,

carriers and protective equipment; Ensure that all safety equipment and emergency stops are functioning correctly; Make sure that only authorized persons are in the sort machines work area; Always remove materials and objects which are not required from the work area; Provide instructions about and monitor correct loading of the sort machine system.

1.3 Procedure for accidents or malfunctioningIn case of an accident

Stop the device and ensure that it cannot be started accidentally; If necessary, apply first aid treatment and make an emergency call; Inform a specialist to check the machine; Only restart the device after it has been deemed safe and released by a specialist.

In case of malfunctioning Operators are only allowed to eliminate faults which are clearly related to an operator error!

The danger zones of the sort machine system are covered by guards and protective equipment;

Stop the device immediately and ensure that it cannot be started accidentally; In case of stuck material: Remove the material and check equipment; Always make sure that nobody can be injured before restarting the sort machine.


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2 Safety

2.1 Basic safety instructionsThe sort machine meets the highest technical specifications and is safe to operate after correct installation.

Nevertheless, dangers may still arise during utilization: Danger of death or personal injury to operators and others; Adverse effects on the sort machine and other areas.

Read these operating instructions carefully and adhere to the information contained herein to ensure safe conveyor operation.

Important!Non-adherence to the information in these operating instructions can result in life-threatening injuries!

2.2 Intended useThe sort machine is intended for use in industrial environments and should only be applied for sorting sort able goods, e. g. parcels, letters, clothing, books, handbags.The sort machine is intended for certain application areas only, its defined capacity limits must not be exceeded during operation. Any other use is not permitted.

Users are not permitted to carry out alterations or modifications which will have an adverse effect on safety.

2.3 Incorrect useThe sort machine system is not intended for transporting people, bulk goods, small parts, rolling parts (e. g. bottles), barrel-shaped parts and dimensionally instable parts.

2.4 SpecialistsSpecialists are personnel who have the knowledge to read and understand the operating instructions and the ability to carry out work professionally while observing national regulations.

2.5 DangersThis section provides information about various dangers and damages which may occur when operating the sort machine system.

Only carry out maintenance and repair work once the machine has been de-energized and measures have been taken to ensure that it cannot be started accidentally;

Organize additional safety measures for passageways and to stop people, except for operators, reaching into the operating sort machine;

Never remove protective covers; Regularly inspect safety equipment / emergency stops; Never reach into a live machine; Never wear loose clothing; Never wear jewelry, such as necklaces or bracelets; If you have long hair, always wear a hair net; Always remove materials and objects which are not required for sorting purposes from the

work area; Regulate and monitor the position of goods; Regularly inspect the conveyor for visible damage;


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Stop the device immediately and ensure that it cannot be started accidentally in the event of: Smoke, unusual noises, trapped or broken goods, defective support stands, side guides or accessory appliances;

A specialist must locate the source of the fault immediately; Do not put your hand(s) between trays during operation; Do not put your hands inside the sort machine behind the red plastic glass during operation; Do not put your head inside the sort machine during operation; Do not climb inside the sort machine during operation; Do not climb on the sort machine during operation; Carry out maintenance and inspections regularly; Only use original spare parts.

2.6 Interfaces to other devicesDanger zones can arise when integrating the sort machine into a logistic system. These zones will not be described in these operating instructions and must be analyzed during installation and initial start-up of the respective system.

After connecting the sort machine to other modules, machines, destinations or equipment, always check the entire system for new danger zones prior to initial start-up.

2.7 Sort machine safety light systemTo prevent operators using the machine, when it is in a state that it can be dangerous for man en machine, signal towers have been placed in the areas that are covered by the views of all the operators.

These signal towers show the state of the machine according to the following color scheme

Green light: - Normal situation;- Machine is in operation;- No action required.

Orange light: - Cautious situation;- Machine has been stopped by the automatic crash detection

system of the sort machine;- Take action before starting the machine!

Red light: - Emergency situation;- Machine has been stopped by an emergency stop;- Take immediate action according to the proper procedures!

At the bottom of each signal tower a signal horn is placed to notify the operator(s) that the machine is started up and will start moving in 2 seconds.


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3 Product specifications

3.1 Sort of productsProducts that are sorted by the Equinox MHE BV sorting system are non-critical products such as garments and hand bags. Non critical products are products that will not damage or break easily when inducting them into the sorting system.

These products:- do not have a sticky surface;- package is not damaged;- do not have loose ends that can be picked up by the machine.

3.2 Product dimensionsTo sort the products via the sort machine system the product dimensions have to be between the given minimum and maximum dimensions (height, width, length and weight).

Volume:L [mm] W [mm] H [mm]

Max. 650 450 200Min. 70 70 2

Weight: W [kg]

Max. 5Min. 0,02

All the products have to be inducted in the middle of the barcode in the tray with the long side of the product in the direction of the sort machine.

The aero-dynamical aspects of products are also a factor. In particular light-weight products with large surface, such as A4 paper sheets, fly away when they are sorted. The supervisor has to check whether light products can be sorted or not.

Products that have one or more of its dimensions fall outside of the given measurements may not be inducted into the sorting system. This could cause serious damage to the machine!


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4 Inducting productsAt the induction stations on the platforms the items will be inducted into the sort machine machine.This must be done according to the right procedures. The following paragraphs will explain these procedures and their tools.

4.1 Induction stationThe induction station is the basis for the operator. At this location the operator will scan the items and place them in the sort machine system.

4.1.1 Induction screen / monitorOn this screen the operator can see what item and the amount of the item that must be inducted.

For the usage of the Equinox MHE BV Exact software that runs on the touch screens see manual: “ESS_Carry_Poznan_short”.

4.1.2 Cash desk scannerWith the scanner the operator scans the barcode of the item which sends the data to the sorer system. At this moment the sorting system knows which item will be inducted and finds the location where to drop the item.After scanning the item the operator can place the item into one of the trays.

4.1.3 Start and stop button At induction stations 1 and 5 a start and stop button are mounted to start and stop the machine.

4.1.4 Emergency stopAll induction screens are equipped with an emergency stop that will directly stop the total sorting system. Sort machine, conveyors and lift.

4.2 Scanning the product by handTo sort the product to the right customer the sorting system first needs to know what kind of product will be inducted. To get the information into the system the product barcode has to be scanned via a scanner that is located in the induction screen.

The following steps explain how to scan the product:- Keep the, to be inducted, product with its, good visible barcode, in front of the scanner;- The scanner will make a sound, bleep, to let you know that it did identify the barcode;- The monitor on the induction screen now shows a green area with the amount of this item to

be inducted (only one item per tray is allowed);- This amount of items can be inducted into the sort machine without scanning the barcode

again;- After the right amount of items is inducted the screen will turn red and the next product item

can be scanned.

4.3 Inducting productsTo drop the product at the right client station the item has to be inducted into the machine, on to a tray. This inducting has to happen the proper way so there will be no damage to the product, machine and / or inductor. The following steps explain how to induct the product the right and most secure way for both operator and machine:


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- Place the product with its long side aligned to the trays long side;- Place the product in the middle of the tray; - Place only one (1) product per tray per induction station.

If the product is inducted the wrong way do not try to get it out or try to put it right . When this occurs follow the next steps:

- Directly push on the e-stop button on the bottom of the induction screen to stop the sort machine;

- Tell the supervisor which item was induction wrongly;- The super visor will place the item the right way into the tray;

- Supervisor will start up the machine.


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4.4 How to Safely induct items into the sorting system.

1. Scan the barcode of the product.

2. After barcode has been scanned (manually or automatically) the screen shows a green area with the amount of the still to be inducted items.

3. Only induct one large or small item per tray per induction station

Wrong way!


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4. Put the product in centre of the tray half with the long sides aligned.

Wrong way!

5. Place big items in the centre of the tray. Beware that nothing of the items fall over the tray.

Wrong way!

6. Stop with inducting the product when the amount area on the screen turns red.


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4.5 Prohibited!!!!

1. Arm / hand between trays. 2. Touch the inside of the machine.


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5 Assigning client box

5.1 Assign a box to the sort machine system.For manually operate the box assigning at the beginning of a wave or batch follow the next steps:

- Light, of the PTL module, at each drop station that will be used is turned red;- Place an empty box on the table, with the barcode facing outside of the sort machine;- Scan the barcode on the sort machine, next to the red button, with the mobile scanner;- Scan the barcode on the empty box in the station;- Light of the PTL module is turned off;- Box is now linked to the drop station / client and can be used.

5.2 Full box.For manually operate a full box in the sort machine system complete the following steps:

- When the sort machine system notifies a full box in a station it will turn the light of this station red;

- Check the middle conveyor for an empty space to push the full box onto the conveyor;- Push the box onto the middle conveyor;- Place a new box and assign this box to the system(see chapter 6.1).


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6 Available functions on the drop stationsEach drop station is equipped with light and button. Following is the description of available functionality.

6.1.1 Light on drop station:- Light off – carton is assigned, drop station operational. If no carton assigned and light is off –

drop station is not used.- Light solid – drop station cut-off performed and there is no carton assigned to a drop station.

Light will also be solid when new wave is loaded to indicate that carton has to be assigned to this particular drop station.

- Blinking – drop station is suspended – no product will drop to such drop station.

6.1.2 Drop station suspend/release:- If drop station has to be temporally suspended – button should be shortly pressed on the drop

station that has to be suspended. - Pressing the button when drop station is in suspend state will release drop station and make it

available for sorting.- Light will be blinking when drop station is suspended.

6.1.3 Carton Cut-off :- If carton is assigned to a drop station (light is off) scanning drop station barcode will

automatically perform carton cut-off operation.- Light on the drop station will be solid after successful cut-off. New carton has to be assigned

to a drop station.

6.1.4 Carton Assign :- When drop station light is solid, scan drop station barcode first and than carton barcode with

RF or wireless scanner. If light goes off – carton was successfully assigned to drop station.

Important!Light on the drop station is indicating that items will not be dropped to this place until carton is not assigned or button is not pressed again (in case of suspend).


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7 Error messages on sort machine control pc screen

This paragraph contains information only needed by the system supervisor!

Stop Reason Text Device numbers Corrective actionsStopped from StarGaze N/A None - not a faultNot started N/A None – not a fault. Sorter was

never started since last computer reboot

Internal system error N/A Contact Equinox. If possible, do not start any software before computer is checked by Equinox

Eventer or RTX timeout N/A Contact Equinox. If possible, do not start any software before computer is checked by Equinox

Locked out for maintenance N/A Make sure that maintenance activities are finished, open “System lockout” window from Stargaze Actions menu and enter unlock password

No input from Encoder N 1 If motor not starting at all – problem is caused by faulty motor or inverter. If motors runs briefly before the fault – check encoder.

Motor input N activated 1-2 Make sure that it’s safe to restart the sorter and switch on maintenance switch near sorter motor

Motor overload N activated 1 Investigate reasons why one of the motors is overloading. It could be chain jam or some other mechanical problem. Do not attempt to restart sorter until mechanical problems are fixed.

Emergency stop N activated 120 – at induction 1121 – at induction 2`122 – at induction 3123 – at induction 4220 - at induction 5221– at induction 6222 – at induction 7223 – at induction 8


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224 – on panel 2 doorStop button N activated 1 – at induction 1

5 – at induction 599 – on panel door

Inverter fault N activated 11 – inverter 1 not ready signal12 – inverter 1 fault signal

Reset inverter by cycling panel power.

Emergency stop circuit N activated

1 Emergency stop button or pull cord is released but Preventa safety relay still has to be reset by turning key switch on the panel 1 door

External emergency stop N activated

100 Emergency stop signal is coming from the external system.

Low air pressure sensor N activated

1 Check and restore compressed air supply

Emergency pull cord N activated 124 – induction 5-8 side125 – inductions 1-4 side

Closing station crash PE N activated

10 and 20 inside.11 and 21 outside Location indicated by flashing orange light.

Check closing station for products stuck between tray and carrier. Check for broken trays. Reset fault by pressing orange button near closing station

Hanging garment crash PE N activated

10 or 20. Location indicated by flashing orange light.

Check trays around closing station for products hanging under the tray. Reset fault by pressing orange button near closing station

Inside confirmation PE failure (too many not seens)

73 – before induction 580 – before induction 1

Check solenoids to be sure that no solenoid is stuck and opening every tray. Check the photo eye and reflector alignment. Clear dust from the photo eye and reflector. Check for damaged cables. If photo eyes has been moved from it’s initial position – contact Equinox to recalibrated sorter.

Outside confirmation PE failure (too many not seens)

74 – before induction 5

Check solenoids to be sure that no solenoid is stuck and opening


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81 – before induction 1

every tray. Check the photo eye and reflector alignment. Clear dust from the photo eye and reflector. Check for damaged cables. If photo eyes has been moved from it’s initial position – contact Equinox to recalibrated sorter.

Carrier cycle PE N covered too long

2 – BCC photo eye at induction 1

3 - BCC photo eye at induction 582 – rear plate before closing station before induction 583 - rear plate before closing station before induction 1

Check the photo eye and reflector alignment. Clear dust from the photo eye and reflector. Check for damaged cables. Check for tray with broken swivels about 1 meter after the photo eye

First carrier PE N covered too long

1 Check the photo eye and reflector alignment. Clear dust from the photo eye and reflector. Check for damaged cables

Inside confirmation PE N covered too long


Check the photo eye and reflector alignment. Clear dust from the photo eye and reflector. Check for damaged cables.

Outside confirmation PE N covered too long


Check the photo eye and reflector alignment. Clear dust from the photo eye and reflector. Check for damaged cables.

Encoder N speed too low 1 Typically caused by motor or inverter problems. If sorter runs at normal speed – check encoder

Encoder N speed too high 1 Faulty encoder – replace.

Divert fail limit reached on Divertor N

1 to 144 Repair faulty solenoid, or reroute products to another


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lane.Half open tray crash sensor N activated

10 or 20 location indicated by flashing orange light

Only inside or outside part of the tray opened for large product occupying the whole tray. Remove product (if any) from half open tray at closing station.

Broken tray sensor N activated 10, 11, 20, 21 – location indicated by flashing orange light

Signal phase difference between two BCC photo eyes is different from expected. Possibly damaged tray or some other mechanical problem with the tray

Too many full lanes Clear full lanes and restart the sorter

First carrier not found or First carrier PE N failure

1 Make sure that tray #1 has reflector attached and it’s seen by carrier #1 photo eye. This error can also be caused by incorrectly mounted or faulty encoder. The error can also occur if system is restarted after power loss on Panel 3

Round trip count error on First carrier PE N

1 This error is typically caused by problems with mechanical mounting of encoder. Less common cause is internal faults of the encoder itself. The error can also occur if system is restarted after power loss on Panel 3

Scanner N failure (too many noreads)

1 – for induction 1-42 – for induction 5-8

Scanner (camera) is transmitting data but not able to decode any barcoces. Repair the scanner.

Scanner N failure (too many not seens)

1 – for induction 1-42 – for induction 5-8

Scanner (camera) is not transmitting any data. Make sure that scanner is powered up and laser is ON. Check network cable from scanner to network switch


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8 Company information

8.1 About usEquinox is a logistics systems integrator providing turn-key solutions for your global supply chain.

Equinox's solutions provide for a high return on investment and help our clients' achieve bottom line

profitability and competitiveness. Our industry-proven software provides automated solutions for

clients' challenges both locally and world-wide. Equinox experts can create an optimal design based

on your needs and then implement that design, train your staff and provide round-the-clock customer

service and technical support.

Our clients are our partners. Not only do they benefit from Equinox solutions, they play an active role

in the development of new products to meet their changing needs in this active and competitive

economy.

Equinox's worldwide organization has 4 offices and more than 100 specialists in logistics, warehouse

management, software development, mechanical engineering, electrical engineering, implementation

and technical support. As this booklet provides an overview of our capabilities please do not hesitate

to contact us to explore how we can help your profitability

8.2 Contact informationYou can contact Equinox at the following addresses:

West Europe

Equinox MHE

Pastoorslaan 57

2182 BW Hillegom

Netherlands

tel. +31 252-526 000

www.EquinoxMHE.com

East Europe

UAB Equinox Europe

Zeimenos g. 9

Kaunas LT-3009

Lithuania

tel. + 370 37 386 812

North America

Equinox SCS INC.

3350 Shelby Street

Suite 200

Ontario, California 91764

USA

tel. +1 909 944 2511


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Asia Pacific

Equinox Australia LTD

Suite 1404, 401 Docklands Dr.

Docklands VIC 3008

Australia

tel. +61 3 9642 4466


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DocumentVersion

DatePage

: EQ-MAN-CPO.128-OP: 1.0: 10-05-2010: 24

PROPRIETARY and CONFIDENTIAL

Eng

Education

equinox mhe bvdocument

bv equinox proprietary

equinox mhe bv version

sort machine overview

flat sort machine version

sort of products

flat sort machineversion

operating instructions