Micrografx Designer 7 - th sh 250 e · C CHECK-LIST FOR MODULAR LIFT "KARDEX-SHUTTLE" C-1 D FIELD-QUALITY-REPORT D-1 III TECHNICAL MANUAL Table of contents 03/98. SHUTTLE 250 BELLHEIMER

BELLHEIMER METALLWERK GMBH

Technical Manual

SHUTTLE 250BELLHEIMER METALLWERK GMBH

Technical Manual

1 INTRODUCTION _______________________________________________1.1 PURPOSE AND FUNCTIONS OF THE MANUAL 1.11.2 SAFETY 1.1

2 OPERATING MANUAL __________________________________________2.1 OPERATING MANUAL 2.1

3 UNIT DESCRIPTION ____________________________________________3.1 SECTIONAL VIEW WITH MAIN MEASUREMENTS 3.13.2 SECTIONAL VIEW (STANDARD ACCESS) 3.23.3 HEIGHT STEPS 3.3

4 OUTLINE ____________________________________________________4.1 LAYOUT PLAN 4.14.2 PRESSURE OF FOUNDATION 4.2

5 TECHNICAL DATA _____________________________________________5.1 TECHNICAL DATA 5.1

6 PACKING ____________________________________________________6.1 STORAGE OF SHIPPING BOX 6.16.2 TRANSPORTATION OF SHIPPING BOXES 6.26.3 UNPACKING OF PARTS 6.2

7 MAIN COMPONENTS ___________________________________________7.1 BASIC UNIT 7.17.2 HEIGHT MODULES 7.17.3 EQUIPMENT 7.1

8 ASSEMBLY TOOLS ____________________________________________8.1 ASSEMBLY TOOLS 8.1

Tool list 8.18.2 ASSEMBLY AIDS AND SAFETY EQUIPMENT 8.1

9 UNIT ASSEMBLY ______________________________________________9.1 OUTLINE DRAWING 9.19.2 BASIC UNIT 9.29.2.1 ASSEMBLY OF PREASSEMBLED BASIC UNIT 9.2

Alignment and anchorage of the unit 9.29.2.2 ASSEMBLY OF A "DIASSEMBLED" BASIC UNIT 9.39.3 ASSEMBLY OF HEIGHT MODULES 9.4

Adjustment of doors 9.5Door gap 9.5Function control of door system 9.5

9.4 MOUNTING OF THE MIDDLE UNIT COVER 9.69.5 INSERTION AND ASSEMBLY OF LIFT CHAINS 9.69.6 ASSEMBLY OF UPPER LIMIT STOPS FOR FIXED SHELF ALLOCATION 9.79.7 ASSEMBLY OF UPPER LIMIT STOPS FOR OPTIMIZED STORAGE HEIGHT 9.7

Table of contentsTECHNICAL MANUAL

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BELLHEIMER METALLWERK GMBHSHUTTLE 250

Technical Manual

9.8 ASSEMBLING THE ENERGY CHAIN 9.89.9 ALIGNMENT OF EXTRACTOR 9.89.9.1 Alignment of the extractor in the direction of depth 9.89.9.2 Alignment of the extractor in the direction of width 9.99.10 TEST RUN 9.99.11 INSERTION OF SHELF BRACKETS 9.109.12 ASSEMBLY OF UNIT COVER FRONT AND REAR 9.109.13 INSERTION OF ASSEMBLY PANELS 9.119.14 CLOSING OF SERVICE OPENINGS 9.119.15 ATTACHING THE STICKERS 9.119.16 ELECTRIC 9.119.17 PRODUCT OBSERVATION DURING IN THE ASSEMBLY PHASE 9.11

10 OPERATION __________________________________________________10.1 GENERAL EXAMINATIONS 10.110.1.1 Deaerating the lift motor 10.110.1.2 Checking the Voltage 10.110.1.3 Frequency converter 10.110.2 BASE SETUP 10.110.2.1 Switches, jumpers and connectors on the Module GS140 10.110.2.2 Checking the bus termination for the network shuttle 10.210.2.3 GS145 10.210.2.4 Check mode switch GS136 (Binary Code) 10.210.2.5 Adjust Accident Protection Light Barrier according to

Technical Description WERAC for Optical Adjustment 10.210.3 FINE ADJUSTMENT 10.210.3.1 Lift and extractor 10.210.3.2 Hard stop top/bottom 10.210.3.3 Soft stop top/bottom 10.210.3.4 Adjusting the lift's ZERO reference position 10.210.3.5 Checking the extractor’s direction of rotation 10.310.4 INITIALIZING 10.310.4.1 Recognition of storage positions 10.310.4.2 Fine adjustment of stop position front/rear 10.410.4.3 Blocking of storage place positions 10.410.4.4 Checking of photocells with GS136 HDIF (if available) 10.410.4.5 Checking the height detection’s single-light barrier (If Installed) 10.510.4.6 Recognition of the light barrier position 10.510.4.7 Checking and adjusting the proximity switches in the access opening 10.510.4.8 Recognition of tray location 10.510.4.9 Assignment of the tray number and height detection 10.510.5 OPTIONS 10.610.5.1 Manual, complete tray extraction 10.610.5.2 Tray extraction with fork-lift truck 10.610.5.3 Automatic, complete tray extraction 10.610.5.4 Automatic tray extraction for conveyor track 10.710.5.5 Lifting magnet 10.7

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Technical Manual

10.5.6 Position display 10.710.5.7 Slide 10.710.5.8 Double extraction 10.810.5.9 Double tray 10.810.5.10 Multiple Workstations (Slave Workstation) 10.910.5.11 Extractor movement stops at overheight protection against damage

of the slide/casing 10.910.5.12 Extractor movement stops in case of overheight base table in double tray

function has overheight 10.910.5.13 Lock table 10.1010.6 FINAL ACTIVITIES 10.1010.6.1 Starting - test 10.1010.7 FREQUENCY CONVERTER 10.10

ParameterlistsShuttle 250 with GS131 (NORD) 10.11Shuttle 250 with GS145 (NORD) 10.14Shuttle 500 with GS145 (NORD) 10.17Shuttle 500 with 4kW, NORD-drive 10.20Shuttle 250 with 2.2kW, SEW-drive 10.23

10.8 LAYOUT PLAN 10.2410.9 INFORMATION 10.2610.9.1 Technical Updating from software revision1.01 onward 10.2610.9.2 Informations and tips 10.2610.9.2.1 Inserting/deleting a tray into/from the data memory 10.2610.9.2.2 A tray to be stored is pushed onto another tray 10.2610.9.2.3 A tray connot be stored, although a shelf position is vacant 10.2610.9.2.4 The lowest shelf position has not been detected 10.2610.9.2.5 E75, the shelf distance remained under the minimum (125mm / from SIF V3.05 100mm)

signalled by service function „997“ 10.2610.9.2.6 E15, the stop tolerance of the lift has not been observed 10.2610.9.2.7 E38 extractor function has not been carried out in previewed time 10.2710.9.2.8 Lift does not move / wrong frequency 10.2710.9.2.9 Exposure to sunlight PLS Werac 10.2710.9.2.10 Fixed storage mode with GS136 HDIF 10.2710.9.2.11 E72 10.2710.9.12 If the extractor does not work after a service (HARD-STOP Bottom) 10.2710.9.2.13 Replacement of reflex-light sensors B5, B6 10.27

11 MAINTENANCE REGULATIONS _________________________________11.1 MAINTENANCE REGULATIONS 11.1

12 PARTS LIST _________________________________________________

12.1 PURPOSE AND STRUCTURE OF PARTS LISTS 12.112.2 TABLE OF CONTENTS OF PARTS LIST 12.1

13 APPENDIX __________________________________________________A ATTACHING THE STICKERS A-1B MOTOR DOCUMENTS B-1C CHECK-LIST FOR MODULAR LIFT "KARDEX-SHUTTLE" C-1D FIELD-QUALITY-REPORT D-1

III

TECHNICAL MANUAL Table of contents

03/98


Technical Manual

INTRODUCTION1

1.1 11/98

!1.1 PURPOSE AND FUNCTIONS OF THE MANUAL

The manual will help service technicians to assemble, initiallyoperate and maintain the Shuttle 250.

Due to their height these units cannot be delivered completelyassembled. Therefore,this manual will give a sufficientoverview of the design and functions of the unit.

In addition to assembly and adjustment instructions, itcontains a detailed overview of all mechanical and electricalparts as well as spare part numbers of standard units.

By means of the type and serial no. (see type plate), we are ableto determine the parts that have been used for special units.

Please pay attention to the accompanyingdocuments which are enclosed with every unit.Particularly, at special execution you will findthere, should the occasion arise, additional detailand hints for assembly and/or initial operation.

Only under strict observance of this manual a perfect qualityof a unit can be guaranteed.

The information in this manual is as complete,exact and current as possible. It is subject totechnical modification and improvement ìn theinterest of progressive development.

We reserve the right to make alterations andimprovements in accordance with the progressi-ve development. You will be informed about themost important alterations with our TechnicalInstruction Letter (TIL).

1.2 SAFETY

The safety regulations have to be strictly observedin order to enable the operator to work at the unitwithout danger. The enclosed manufacturersinstructions, especially chapt. 8.1, should beread before and observed during assembly,maintenance and initial operation.

A procedure against the mentioned regulations endangerspersons and is inadmissible.

For assembly, maintenance and service operations it is absolutelynecessary to have safety equipment.

This equipment should contain a crash protection (rope withsafety snap hook and a safety belt), a safety helmet, a ladderor other safety aids of equal value.

The correct use of the safety equipment is described inchapt.8.

Riding along on the Extractor is not allowed !

Any modifications, especially those concerningsafety devices, must be approved in writing by themanufacturer. Unauthorized modifications areprohibited and lead to cancellation of liability. Inaddition to the loss of warranty, the operatingpersonnel will be exposed to an unforeseeableinvolved risk of danger.

In this case the operator assumes all risk.

Please make sure that the relevant national safetyregulations will be observed (eg. regulationsconcerning accidet prevention of the employer´sliability insurance association) with all assemblyworks and that all necessary auxiliary aids will beavailable to the assembly personnel.

If several units are installed side by side withoutinterior service doors, during service work on theinside of one unit, the respective units on eachside of the unit to be serviced also have to be shutdown. The main switches of these units have tobe secured with padlocks, in order to prevent anundesired restart.

Valid for SUVA (Swiss Accident InsuranceCompany) - conformity:

Are several units leant side by side as a block inwhich the inner standard service doors are notassembled, then safety inbetween doors,protected with a limit switch, must be installed atthe gateways between the single units.

The CE-label (regulation in all EU countries), theGS-label and, if applicable, further labelsregarding safety or special technical demandsare only permitted to be attached after completeassembly and initial operation (including functionaltest of all safety devices) of the unit. Assemblyand initial operation may only be executed bytrained authorized service technicians.

This manual is no substitute for a special training

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Technical Manual

2.1 OPERATING MANUAL

The operating manual is enclosed with the delivery documents of SHUTTLE with the basic unit in a ringbinder.i

OPERATING MANUAL

2.1

2

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S h u t t l e


Technical Manual3.1

3 UNIT DESCRIPTION

3.1 SECTIONAL VIEW WITH MAIN MEASUREMENTS

03/98

= Unit depth= Unit width= Tray depth= Tray width= Table height

UD UW TD TW TH


Technical Manual

3

3.2

UNIT DESCRIPTION

3.2 SECTIONAL VIEW (STANDARD ACCESS)

01/98

Control

59

UH

- X

- T

H -

1102

TH

- 50

3

1043

TH

48

455

XU

H -

455

- X

UH

acce

ss o

peni

ng

with door: TH min = 853 mm TH max = UH - 1797 mm

without door: TH min = 453 mm TH max = UH - 1372 mm height optimizedTH max = UH - 1222 mm fixed shelf

fixed shelf allocation: X = 175 mm

height optimized storage: X = 300 mm

848


Technical Manual

3.3 HEIGHT STEPS

3.3

3 UNIT DESCRIPTION

03/98

700800

900100011001200

14001300

2100

89

10

11

12

13

89

10

11

12

13

89

10

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89

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1400

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00

10000990098009700960095009400930092009100900089008800870086008500840083008200810080007900780077007600750074007300720071007000690068006700660065006400630062006100600059005800570056005500540053005200510050004900480047004600450044004300420041004000390038003700360035003400330032003100300029002800

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000


Technical Manual

The eight perpendicular guide profiles in the end frames are the carrying profiles, which lead the gravityinto the basic frame (weight loading surfaces). The weight loading surfaces set up the foot print for thewhole unit.

4.1 LAYOUT PLAN

i

4LAYOUT

4.101/98

130 mm

TW +330

TD x

3 +

197

= =

20

0T

D -

289

TD

+ 7

1,5

==

==

30

0

ø 21

contact surface ST 37 , 8 mm thick

shim plates150x150 mm

TW = Tray WidthTD = Tray Depth

load column

drilled hole for bottom anchorage

FRONT

If you need shim plates for a perpendicularassembly of the unit, these plates must beunderlaid at the load columns

The evenness of the floor must be within the per-missible allowance of 8mm within a distance of 3m.

130

120

max. 8mm

3 m


Technical Manual

Engineers should consider this data for statical calculations concerning floor or ceiling load capacity.

= 4661,8 cm²

4.2 PRESSURE OF FOUNDATION

[cm²]

4.2

4

01/98

SUPPORTING UNIT SURFACE

Weight loading surface = (BT [mm] + 71,5) x 130 x 4100

UNIT WEIGHT

unit weight (kg) = basic unit + height modules + No. of trays + (tray load + tray weight) +

(no. of shelves x shelf weight)

Gg (kg) = Gg dead + VA x (BZ + BG) + (LWA x LWG)

unit gravity (N) = unit weight x 9,81

Fg (N) = Gg (Kg) x 9,81

EXAMPLE

SHUTTLE 825 x 825 x GH 620076 shelves40 trays

weight loading surface = (825 + 71,5) x 130 x 4100

basic unit + height modules = 740 + 3 x 262 = 1526 kgtray load = 250 kgtray weight = 17 kgshelf weight = 3 kg

Gg = 1526 + 40 x (250 + 17) + (76 x 3)Gg = 12434 kg

Fg = 12434 kg x 9,81Fg = 121978 N

BT=tray depth, Gg=unit weight, BA=no. of trays, BZ=tray load, BG=tray weigth, Gg dead=dead weight of unit,LWA=no. of shelves, LWG=shelf weight, Fg=unit weight, VA=height modules

LAYOUT


Technical Manual

max. power consumption : 4,5 KVA

connection: 3/N/PE 400V 50/60 HZor 3/PE 400V 50/60 HZ +

1/N/PE 230V 50/6

fuse: 3x16 A sluggishFor applications with residual currentoperated device in the customer´spower supply line, note:Leakage current max. 80 mA

safety devices: accident protection light barriers inaccess opening

safety against fracture of carrier chains: 10-times

allowed environment temperature:during operation: + 50 C ... + 500 Cother: - 200 C ... + 700 C

allowed rel. air humidity: 10 % ... 90 %

max. change of temperature:during operation: 150 C / hother: 100 C / 5 min.

Condensate must be removed before operation.

Access for service from side.

Units can be placed side by side.

Distance to the wall both sides min. 250 mm.

5.1 TECHNICAL DATA

required room height: unit height+ 60 mm

unit height: min: 2 800 mmmax: 10 000 mm

height steps: 100 mm

lift speed: 0,7 m / sec.

store and restore speed: 0,3 m / sec.

total load cross: 1)

max. load per tray: 250 kg(standard)

unit width: (standard) see chapter 3.1

unit depth: (standard) see chapter 3.1

inside tray measurements: see chapter 3.1

tray distance: max.: 750 mmmin.: 125 mm

max. part heights: tray distanceminus 10 mm

shelf slot distance: 25 mm

noise level: ca. 65 dba

drive lift AC: 2,2KW

drive Extractor AC: 0,25 KW

operating time lift: 60 %

operating time Extractor: 25 %

average power consumption: 3 KVA

5.1

5TECHNICAL DATA

09/98

1) See also type plate details

w.o. rack reinforcement 0m-7m 2 x 10 000kgwith rack reinforcement 0m-7m 2 x 15 000kgw.o. rack reinforcement 7,1m-10m 2 x 7 500kgwith rack reinforcement 7,1m-10m 2 x 10 000kg

with add.rack reinforcement and 0m-17m 2 x 20 000kgraised load


Technical Manual

6.1 STORAGE OF SHIPPING BOXES

Should it be required to store the units for a longer period oftime, the following has to be observed:

The shipping boxes must if possible be placed on evenground or the vertical end beams must be supprted.

The shipping boxes cannot stay in the rain for a longperiod.

No heavy objects may be put on the boxes withoutappropriate support beams, the covers are notconstructed for weight bearing.

To prevent development of condensation (danger ofrust) on the unit, sudden changes of temperature mustbe avoided.

For overseas transportations the units are packed intowelded foil which must not be damaged.

CF

0

CF

0

6 PACKING

6.1 01/98


Technical Manual

6.2 TRANSPORTATION OF SHIPPING BOXES

Transport of shipping boxes and pre-assembledunits.

Please pay attention to the symbols printed on thepackings.

the side up

protect from rain and humidity

handle with care

Use forklift with sufficient length of forks.

If using a crane, it is important to pay attention to thechain symbols indicated on the crates

The unit parts should always be left in the shippingbox until at the place of destination.

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6PACKING

6.3 UNPACKING OF PARTS

When unpacking the boxes care should be taken of small partsand documents so they are not thrown away with the packingmaterial.

Accompanying documents such as circuit diagram andoperating instruction are enclosed in the panel box betweenthe panels.

You will find a packing list in each box. By means of this listmissing or damaged parts should be checked to ensurepossible claims on time.

The preassembled basic unit has to betransported on a pallet until at place of destination.The unit has to be taken off the pallet as describedin section 9.2.1 (Installation of perassembledbasic unit)

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6.203/98


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SHUTTLE 250

Technical Manual

77.1 BASIC UNIT

a) height modules

b) basic frame with lift drive

c) extractor

d) access opening with/without doors

e) panels of lower area

f) service doors

g) shelf for control

h) control panel

i) extractor chain

j) top cover

7.2 HEIGHT MODULES

k) end frames 700 - 1400mm

l) panels

7.3 EQUIPMENT

m) set of shelves

n) tray

o) table

p) small parts and accessories

Details see unit components in the parts list.

MAIN COMPONENTS

7.1


Technical Manual

8ASSEMBLY TOOLS

8.2 ASSEMBLY AIDS AND SAFETY EQUIPMENT

padlock (shackle max. 8mm)chalkendless sling bandmeter stick (approx. 10m)cordspirit level, plum line and surveyor´s staff (1,5 m)drillmasonry drilL, Ø 18electric screw driver with 10,13,17, and torxnut.mounting supports (could be ordered from the factory:Id.No. 100835.8) or, alternatively, wooden beams,as described belowboards (2 enclosed with basic unit)assembly barinsulating tape2 wooden beams (60mm thick) for lifting of basic unitfrom palletfolding ladder (folded approx.1.05m)

8.1 ASSEMBLY TOOLS

To guarantee a perfect assembly, please make sure beforeassembly that the following tools and aids are available.

Tool list:

Tools (usage): Sizes:

for hexagon head bolts:(fork wrench, SW 7 M 4hexagon socket wrench, SW 8 M 5hexagon ring wrench) SW 10 M 6

SW 13 M 8SW 17 M10SW 19 M12SW 24 M16

for hexagon socket headcap bolts: SW 4 M 5(hexagon socket head wrench) SW 5 M 6

for torx:(socket head wrench) T 40 M 8

for slotted head bolts: SB 1,0 M 4SB 1,2 M 5SB 1,6 M 6

for cross recessed head bolts: KS 2 M 4 +M 5

multimeterline indicatorwire stripperwire end ferrule nippertool for removal of module clipsportable search light

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8.103/98

For the assembly of height modules the followingequipment is indispensable:

- Mounting supports and walking boards in sufficientquantity

- A lifting platform with appropriate protection forassembly work.

- A fork lift with permissible lift basket or a crane.End frames and panels may only be assembled after astable working surface has been installed. To install thisworking surface mounting supports and walking boards areimperative. The walking boards are delivered with the baseunit. Mounting supports can be ordered from the factory.At least 2 walking boards and 4 mounting supports perheight module (working surface) are required. Themounting supports are inserted into the grid of the guideprofiles (a) in the end frame and serve as a ladder to theservice engineer. By placing the walking boards onto themounting supports, a stable work surface is established.

The usage of wooden boards from the cratepacking material as walking boards is notpermissible.

a

Alternatively to the mounting supports, 4 wooden beamswith sufficient carrying capacity may be used. It is veryimportant that the wooden beams have a large enoughdiameter and that they are of high quality.

The usage of wooden boards from the cratepacking material as mounting supports is notpermissible.

The required length of the wooden beams equals the cleartray width plus 80 mm.

The wooden beams are placed directly onto the shelfbrackets and mounted (e.g. with a screw clamp). Afterthe wooden beams have been secured against slipping, thewalking boards can be placed on top.

Mounting supports Walking boards

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Technical Manual

8 ASSEMBLY TOOLS

SAFETY EQUIPMENT

A Safety helmet

B Rope with safety snap hook

max. hook diameter d= 12mm

C Catching belt form A or B

For further assembly aid afolding ladder could beused, which can be insertedin segments through thelower access opening anderected in the lift shaft.

Catching belt form A

1) mounting ring

2) shoulder strap

3) belly-belt

4) sitting belt

5) belt for the leg

Catching belt form B

1) mounting ring

2) shoulder strap

3) safety belt

A

B

C

D

In the lift shaft of the unit horizontal, cross members arearranged in the endframes in distances of 700mm from aheight of approx. 2500mm onwards.

Connecting profiles (D) are screwed on these cross membersfor the lateral stability.

Four holes are punched in each connecting profile (D), whichare intended for engaging spring snaps of the protectionagainst falling.

01/988.2


Technical Manual

9UNIT ASSEMBLY

The basic unit is pre-assembled and adjusted in the factory.

The height is: 1. With normal pallet: 2340 mm

(end frames 2008mm + cover 92mm + palette 240mm),

2. With pallet for transport of containers: 2260 mm

(end frames 2008mm + cover 92mm + pallet 160mm),

Possible deviations in measurements of the wood of the pallets are calculated within the measurement ofthe pallets. You must only assemble the height modules and adjust the complete unit at the customer´s.

9.1 OUTLINE DRAWING

Before assembling the unit the corner outline should besketched properly with chalk at the place of set up.

It is imperative that the unit is assembled squareand level. Only then, a trouble-free and low-wearing unit run is possible.

In most cases the floor is not level, in which case the unit mustbe shimmed with the plates provided at certain places (8positions).

The shims must be level in unit depth, unit width, anddiagonal in all areas of the drawn unit surface.

To avoid slipping, secure the shims with adhesive tape, on thebottom.

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9.101/98

ø 21

FRONT

shim plates 150x150 mm

load column

drilled hole for bottom anchorage

thread for lifting bolts (8)


Technical Manual

9 UNIT ASSEMBLY

9.2 BASIC UNIT

9.2.1 INSTALLATION OF PREASSEMBLEDBASIC UNIT

The base unit is transported complete, on the pallet, to its finaldestination. Remove protective foil and enclosed walkingboards.

Remove both service panels.

Remove lift chains and shelves for weight reduction.

Lift basic unit from pallet with a fork lift. For this the middleunit cover (upper sprocket axle) was assembled on the basicunit.

Drive with forks of the lift above the extractor into servicedoor opening. Lift forks up to 100 mm below of cover.

The upper sprocket axle and the lip of the covermust not be damaged (touched).

Place one wooden beam, at min. 60 mm thick, on each forkand drive theforks below of both cross members of the middlecover.

Do not lift the unit at the base spreaders.

Lift the basic unit from the pallet and set it in the aligned placeof destination. Check if all shim plates are firmly fixed.

Picture of transport hints for basic unit.

!As already mentioned in chapter 9.1, the alignmentof the unit is of essential importance for a perfectlyoperating unit. Therefore these activities have tobe carried out very carefully and thoroughly.

Alignment and Anchorage of the unit

Turn the lifting bolts provided in the thread of the base frameand underlay every bolt with compensation plates. Align baseframe by means of the lifting bolts (Check by measuring baseframe in depth and width with water level and graduated ruler).Then underlay places of perpendicular guide profiles withcompensation plates until the base frameis securely underlaid.Then again check alignment of the unit.

The lifting bolts can be used in case of an emptyunit only! Never use the lifting bolts to support asthe surface pressure between bolt and bottomafter loading the units is so large that thesupporting effect gets lost.

For anchorage of the unit high performancepins are provided. The base frame of Shuttleis prepared for anchoring pins (see page 9.1).

For anchorage of base frame with the foundation drill ahole of at min. 100 mm depth and a diameter of 18 mm throughthe provided mounting holes at the base.

Then drive in the high performance pins M12 and tightenthem.

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Water LevelLifting bolt

Shim Plates Base Frame

Load Column

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9.2 03/98


Technical Manual

9UNIT ASSEMBLY

03/98 9.3

UD

UW

UD = Unit depth; UW = Unit width

1

2

5

6

7

8

3

4

9.2.2 ASSEMBLY OF A "DISASSEMBLED"BASIC UNIT

If the basic component of a Shuttle is delivered disassembledto the client , when assemblying it must be looked that thebasic endframes are screwed to the base frame in the rightorder .

For an easier assembly, the distance between the fastenings

of the base frame (e.g. 1 and 5, 2 and 6, etc.) must be larger

than it is theoretically necessary.

If the assembly is not done in the right order, it is possible

that an endframe is placed nearer the middle of the unit,

through which the depth distance of the endframes would

be too little and so the extractor would jam in the running

surface.

Order of Assembly:

1. Place the endframes upon the base frames.

2. Set in all the fastening screws but withoutscrewing in.

3. Now screw down firmly the fastening screwsof the inner stabilizer profiles (5/6 or 7/8).The endframes would then be pulled tawardsthe inside and the extractor running surfacesget the required distance.

4. Finally, fasten screws 1-4 firmly.

If the circumstances permit it, an opening betweenstabilizer profile and the base frame fasteningcan now be available. Please don’t try to close thisopening turning the screws firmly!

This opening does not cause any problems whenoperating the unit.

9.3 ASSEMBLY OF HEIGHT MODULES

Make sure that all assembly aids are available at the place ofassembly (look at chapter 8).

Until beginning with assembly of the height modules the middlecover (upper deflection) must be unscrewed. This cover willbe replaced later.

Mind assembly position of the cover for laterassembly.

Release the bolts at the upper middle guide profiles and lift thecover from the basic unit.

The complete units are properly and professionallypre-assembled at the factory. Duringtransportation, however, the units may be subjectto unforeseeable circumstances. Therefore, acheck of the connections, especially the boltedconnections, on the base unit is specified by themanufacturer:

- Align the parts if necessary.

- Verify the boltings for tightness.

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Technical Manual

9 UNIT ASSEMBLY

!Begin with assembly of height modules according to theassembly instruction for the unit.

To assemble the unit up to its complete height the single heightmodules have to be put one upon the other and also bolted. Itis very important that the horizontal perpendicular impacts areexactly adjusted and then fixed.

Always assemble one height module and check itfor its correct fitting before beginning with the nextone.

Bolt a small and a big impactconnector with bolts and washersin each guide profile of the alreadyassembled end frames.Bolt themonly as far as that the impactconnectors are bevelled on thetop.This facilitates the fitting of theendframes.

Now, place the end frames whichare to be assembled upon the alreadyassembled endframe so, that theperpendicular guide profiles areguided over the pre-assembled impact connector.Bolt theendframes with bolts and washers with the impact connectors.The bolts are first firmly fixed after adjustment of the completeheight module (end frames and panels).

The stability of the unit is only guaranteed afterthe installation of panels and the tightening of allboltings. Therefore, during the assembly ofheight modules, extra attention has to be paid tosafety.

Starting at a unit height of 10 m, if possible, theunit should be propped up against the building(e.g. a wall or the ceiling (with units reachingacross several floors)). Note: A firm joining,however, e.g. such as bolting, is not permitted.

We recommend to contact the manufacturers atBellheim (design department) for sugestions.

!

03/989.4

2008

3408

4808

6908

7000

Entnahmehöhe 853

BMaßstab:

Bearbeitungs-zustand:

Gezeichnet:

Datum:

Geprüft:

Mat.:

Zuschnitt:

Nr. Datum Änderung

Blatt Nr. von

Produkt:

Zeichnungs Nr.:

Freimaßtoleranzen +/- 0,5 mm

Benennung:

Bellheimer Metallwerk GmbH

A

Noack

17.01.95

Montageanweisung

Entnahmehöhe 853 SHUTTLE

XXXXXX.X

510

75


Technical Manual

9UNIT ASSEMBLY

A

To guarantee a perfectly operating unit the unitwidth in the area of the extractor guide must bemeasured again and if necessary corrected.

To give the height module thenecessary stability oneconnecting profile must bebolted with four torx boltsonto all vertical crossmembers(A) .

Assemble the unit up to its final height as described.

Both panels of the uppermost height module serve as serviceopenings and therefore are inserted and bolted and could beassembled from the outside in contrast to all other panels.These panels are assembled in the end (see 9.14).

Adjustment of door

As already mentioned, the door can be adapted to the unitwidth due to its movable rollers. Move the rollers to the veryoutside until the door is free of clearance and in the center ofthe guide.

Door gap

The gap between the closed slidingdoors should be as small as possibleand it should be even with regard tothe total unit width. If this is not thecase, the gap can be adjusted bymoving the shoulder bolt.

Function control of doorsystem

Check smooth and clearance-free flow of both doors. Checkif the locking mechanism is functioning perfectly when thedoor is closed. If this is not the case, please check if the slotin the lower door corresponds to the lock.

Align the end frames at the cornersand fix every corner with two hex.bolts, tooth washers, and nuts (A).Then insert the panels, adjust themto the corresponding heightmodules and bolt them down onthe upper corners (B). Herewithyou achieve the correct heightmodule alignment. (Once the panelsare installed, the corners are verydifficult to align.)

On units with doors, the upper door guide parts(shipped loosely, in horizontal position, on theaccess roof) must be bolted with firmly assembleddoor guides. Two countersunk bolts hex., washers,and self-lock nuts per door guide. For transportreasons, the door guides consist of two parts.

If you have already fixed the upper parts of the guide, controlthe position and function of the doors.

Control the position of the door ropes. They must be putaround the deflection rollers so that the exterior rope isin the door guide.

The upper door must hangdownwards on the ends of theropes and be inserted in theslots of the supporting channel.Please note that the washermust be inserted into theopening.

As the doors can be adjusted in their width bydislocating the rollers, the door can be re -adjusted ifnecessary.

After this pre-assembly you can adjust and fix the heightmodule.

B

A

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03/98 9.5


Technical Manual

9 UNIT ASSEMBLY

Rear

B

A

!

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01/989.6

9.5 INSERTION AND ASSEMBLY OF LIFTCHAINS

If several units are delivered at the same time,always install the chains in pairs.As the chains are tied up in pairs and theirbeginnings marked with a label, we recommendto open these cords only just before insertionof the chains. The marked beginning of thechain has to be attached to the holding deviceon the extractor from below.

Then insert both lift chains. The chains must be laidsymetrically over the sprocket axle (both hanging parts musthave the same length). As an aid, you could use a rope of thesame length. As a security measure to prevent thechains from rolling off, it is a good idea to couple thechain ends with a cable clip, which is cut off again at thetime of assembly. Then, mount at each end of the twochains a threaded rod with a chain joint for the suspension ofthe extractor chain .

The cotter pins of the chain joint must point to theoutside.

Fix the hanging down front chainstrand with two nuts and twowashers to the extractor.

Now, lay the hanging down rearchain strand around the lowersprocket axle (chain wheel/driveshaft) and insert the threaded rodthrough the holding device on theextractor.

Then assemble:

a) the sleeve above the pin, b) the compression spring above the sleeve,

c) the washerd) both hex. nuts M12

9.4 MOUNTING OF THE MIDDLE UNIT COVER

The unit cover consists of seven parts: the middle part,2 bearing members with pocket wheel, 2cross members anda front and a rear part for each.

After having inserted the 2 bearing members into the middleguide profiles, bolt them to these guide profiles (B).

After completion of the before-mentioned assembling steps,fit the cross-traverse to the bearing traverse (A) withscrews and put then the center sheet onto the bearing andcross traverses.

Do not forget to adjust the top middle cover (A).To be even, flush with the last height module (B)on the sides.Both front and rear top covers are assembledlater.

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Technical Manual

9UNIT ASSEMBLY

There are two variations of upper limit stops: one for fixedstorage height and one optimnzed storage height.

9.6 ASSEMBLY OF UPPER LIMIT STOPS FORFIXED SHELF ALLOCATION

The device for the fixed storage height consists of both limitstop switches for hard and soft stop above and the switchprofile as operating device at the chain.The switch assemblyis completely pre assembled and is fixed to the upper left of thebearing member (pocket wheel).

The switch profile is bolted to the chain,clamped, with4 hex. head bolts,4 hex. nuts and 4 tooth washers.The distance between the upper edge of the cross member atthe extractor and the end of the diagonal at the switch profile(upper edge of lateral terminal boards) depends on the max.storage height .

9.7 ASSEMBLY OF UPPER LIMIT STOPS FOROPTIMIZED STORAGE HEIGHT

The execution for optimized storage height consists of bothlimit stop switches for hard and soft stop and the safety ceilingas operating device. Two special shelf brackets, which areinserted into the slots of the rear height modules on the top,serve as assembly points for the safety ceiling and bothswitches. The limit switch support bracket is bolted at the leftspecial shelf bracket with two hex. head bolts, with twospring washers, two washers, four and two hex. nuts. Thetwo limit stop switches for hard- and soft-stop are fixed at thelimit stop switch support bracket with two fillister head capscrew-bolt, two washers and three nuts.Now, the safety ceiling is placed onto the brackets and boltedwith two shoulder bolts (as rotational axis), two washers andhex. nuts at each side.

Check safety ceiling for function by lifting it in the area of thelift. The safety plate is correctly assembled, if first soft-stopand then hard-stop is operated.

138

20

Cover

Switch position for Softstop

Switch position for Hardstop =rocker horizontal

Access

275

Parts

Section

Access

Softstop

Hardstop

03/98 9.7

Extractor

Softstop

95

X

Hardstop

Switch unit assy.

Curve of limit stop

Cover

X = 170 at max. part height ≤ 190mm

A

A

A-A

X = max. part height - 20 at max. part height > 190mm


Technical Manual

9 UNIT ASSEMBLY

9.9 ALIGNMENT OF EXTRACTOR

To be able to align the extractor it must hang freely in the liftchains.

In order to check resp. set (up) the extractor alignment, theextractor should be located approximately at access height.

The extractor lays on rubber buffers in the basic unit and wasaligned in unloaded status. In this condition the hardstopswitch below is operated and therefore the safety circuit is notactive.

To be able to move the extractor to around extraction height,proceed as described in chapter 10.3.2 (Bridge „BYPASS“).

Drive the extractor approx. at access height.

9.9.1 Alignment of the extractor in the directionof depth

The extractor is aligned in the direction of depth with awater level by adjusting the 8 rollers. The rollers have tobe aligned in such a way that they are flush in alignmentwith the guide profile (d) and that the extractor ispositioned centrically to the perpendicular guides. Thepressure of the rollers against the guide profile may only beso strong that they can still be rotated with difficulty byhand. The rollers are adjusted as follows:

01/989.8

9.8 ASSEMBLING THE ENERGY CHAIN

The energy chain is to be fitted with srews at height A onthe center joint of the right side parts according to theattached assembling instructions (for this purpose, twofish-plates have to be bent down at the fitting sheet, whichalready had been mounted to the energy chain before).From here, the cables are dressed along the center joint upto the shuttle roof passing by the sectional strut into theterminal box. At the center joint, they are to be fitted withcable binders at a distance of approx. 1 m. In the terminalbox, the cables are fixed with clamps at exactly theposition where the shielding is open and are connected tothe cables coming from the lift control. The dressing ofthese cables is carried through between the first sectionalstruts.

At the extractor, the energy chain has to be fastened withscrews to the energy chain mount (see assemblinginstructions, chapter 12, fig. 6). The connectors are to beconnected to the multiway connector and the cables areattached with clamps where the shielding is open. Inconclusion, the shielding sheet has to be mounted.

ATTENTION! For all cable joints it has to beobserved that the contact between theshielding and the assembling sheet is perfect.!

GH

A

Energieketteenergy chain

G H A L[ m m ] [ m m ] [ m m ]

f r o m to2 8 0 0 4 2 0 0 2 0 8 0 2 4 0 64 3 0 0 5 6 0 0 2 7 8 0 3 0 9 65 7 0 0 7 0 0 0 3 4 8 0 3 8 3 27 1 0 0 8 4 0 0 4 1 8 0 4 5 2 28 5 0 0 9 8 0 0 4 8 8 0 5 2 1 29 9 0 0 1 1 2 0 0 5 5 8 0 5 9 0 2

1 1 3 0 0 1 2 6 0 0 6 2 8 0 6 5 9 21 2 7 0 0 1 4 0 0 0 6 9 8 0 7 3 2 81 4 1 0 0 1 5 4 0 0 7 6 8 0 8 0 1 81 5 5 0 0 1 6 8 0 0 8 3 8 0 8 7 0 81 6 9 0 0 1 8 2 0 0 9 0 8 0 9 3 9 81 8 3 0 0 1 9 6 0 0 9 7 8 0 1 0 0 8 81 9 7 0 0 2 1 0 0 0 1 0 4 8 0 1 0 8 2 42 1 1 0 0 2 2 4 0 0 1 1 1 8 0 1 1 5 1 42 2 5 0 0 2 3 8 0 0 1 1 8 8 0 1 2 2 0 42 3 9 0 0 2 5 2 0 0 1 2 5 8 0 1 2 8 9 42 5 3 0 0 2 6 6 0 0 1 3 2 8 0 1 3 6 3 02 6 7 0 0 2 8 0 0 0 1 3 9 8 0 1 4 3 2 02 8 1 0 0 2 9 4 0 0 1 4 6 8 0 1 5 0 1 02 9 5 0 0 3 0 8 0 0 1 5 3 8 0 1 5 7 0 0

L = length of energy chain


Technical Manual

9UNIT ASSEMBLY

11/98 9.9

!Loosen carriage bolts (a).

Carriage bolts (a) should only be a little, as the roller

device (b) must be adjustment parallel.

Move roller device (b) in desired direction.

Before tightening the bolts, check the extractor’s directionof depth with a water level.

Tighten carriage bolts with torque 35 Nm and fix and lockadjusting bolt (c).

9.9.2 Alignment of the extractor in the directionof width

Alignment in the direction of width is also done with awater level. For this, the lift suspension (rear chain strand)can be adjusted by two nuts (e). If during this process,the tension spring changes from a block length of approx.55 mm, the block length has to be regulated. The blocklength of the tension spring is regulated by turning the fineadjustment nut (f).

While regulating the tension spring, the extractor has tobe loaded (load of 250 kg [Shuttle 250] resp. 500 kg[Shuttle 500]). Should it not be possible to regulate thetension spring to a block length of approx. 55 mm in thisway, then the chain has to be moved from the lowerdeflection by one or more sprockets of the chainwheel.Finally, the extractor is measured in diagonaldirection and if necessary adjusted in the middle. Afteralignment all bolts and nuts at the roller carriers and theextractor suspension are tightened and/or locked oncemore.

9.10 TEST RUN

After completion of all electrical and mechanical tasks, a testrun must be carried out. Pay attention to strange running noise.

Check extractor in different positions in the unit for exact andperfect run in the guides. Due to the respective unit height anadjustment could be necessary.

Before operating the unit check if all assemblyaids have been removed. (mounting aids,walkingboards, etc.) It has to be ensured that no things(wooden parts, ladders etc.) are in the lower areaof the baseframe. Exact functioning of the safetydevices has to be ensured.Hard-, Softstop above and below.

!

a bcd

Van

ishi

ng li

ne

Gui

de p

rofil

e

==

Load250kg for Shuttle 250500 kg for Shuttle 500

==

ca. 5

5mm

e f


Technical Manual

9 UNIT ASSEMBLY

1.

2.

3.

5.

6.

4.

Cover

Assembly Panel

Panel

9.11 INSERTION OF SHELF BRACKETS

The shelf brackets are installed according to their execution(fixed or height optimized storage height). At a fixed storageheight the shelf brackets are installed in the grid of the max .storage height. At height optimized storage height the distancescould be according to the customer´s wish.

In this connection the following minimum dimensionshave to be observed.

lowest brackets 455 m m

uppermost brackets atfixed shelf allocation 175 m mheight optimized storage 300 m m

distance of bracketsmin. 125 m mmax. 750 m m

The brackets are to be inserted in pairs.

The brackets must be assembled at the same height in the leftand right endframes.

As an aid counting holes are punched into the guide profiles indistances of 100 mm (all 4 punchings).

At first, the brackets are inserted with the horizontal clutches(1) and then secured with the perpendicular clutches (2) indownward direction, all while checking the engaging of thesafety catch.

9.10 01/98

9.12 ASSEMBLY OF UNIT COVER FRONT ANDREAR

Rest both outer covers and bolt them at the end of the middlecover with hex. head bolts, washers and tooth washers andnuts. After alignment, the covers are bolted with the moduleswith hex. head bolts, washers and nuts and all bolts are firmlyfastened. While checkins that panels, top covers are even andflush with top height modules.


Technical Manual

9UNIT ASSEMBLY

9.13 INSERTION OF ASSEMBLY PANELS

1. The upper panel is fastened on the lower side withthree threaded bolts, washers, tooth washers and hex.nuts.

2. Bend back the flaps of the top cover at the perforation.

3. Insert the assembly panel in the lower panel with thethreaded bolts.

4. Safety chains are hooked into the long holes of thecover and the assembly panel.

5. Press against the bend out flaps.

6. Fasten from above with 3 hex. head bolts and washers,which are screwed into the outer cover.

The mounting of the assembly panel should bethe last process, otherwise certain assembly worksare not or only possible more difficult.

9.14 CLOSING OF SERVICE OPENINGS

In the end the service doors are inserted. Six Pal-nuts M6 areinserted in the mounting holes of the doorframe and the dooris fastened with six oval head bolts M6.

9.15 ATTACHING THE STICKERS

You will find the marking and warning signs enclosed with thedocuments to the unit.

Position and kind of signs please look at thedrawing (Appendix A).

9.16 ELECTRIC

Please find electrical information and thecorresponding circuit diagrams enclosed withthe basic unit.

Before initial operation of a unit, the protectiveconductor system has to be checked accordingto EN 60 204-1 20.2 (IEC 204-1 20.2) and a checkof the direct-current resistivity according toEN 60 204 -1 20.3 (IEC 204-1 20.3) has to beperformed.

9.1101/98

9.17 PRODUCT OBSERVATION IN THEASSEMBLY PHASE

For the purpose of an analysis of the productcharacteristics as well as for an early detection of weakspots during the assembly of the device, the assemblingengineer has to prepare the field-quality report, FQR(assembly report), which is part of the accompanyingdocuments of the shipped unit (documents), and which hasto be sent back to the factory in Bellheim. This reportenables a prompt introduction of actions to eliminate thedetected weak spots as well as an observation of effects ofalready introduced provisions.

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SHUTTLE 250 / 500BELLHEIMER METALLWERK GMBH

Technical Manual

OPERATION 10

10.1

10.1 GENERAL EXAMINATIONS

10.1.1 Deaerating the Lift Motor

Remove wick before putting SHUTTLE into operation orafter a longer storage.

10.1.2 Checking the Voltage

Check the power input voltage and control voltage(see order).

10.1.3 Frequency Converter

The frequency converter’s setting has to be checked forthe respective application. See also the operatinginstructions, frequency converter, and the tablescontaining the para-meters (10.7). The frequencyconverter has been set by the factory (Bellheim).Therefore, only a random check for complete data loss isnecessary. The cable shielding of the lift and extractormotors has to be checked with regard to a continuous andextensive joining.

10.2 BASE SETUP

10.2.1 Switches, Jumpers and Connectors on theModule GS140“OPTIONS”Switches x12. . . . . . . . x19 1 2 3 4 5 6 7 8n switch closed, o switch open

Switch 1o Optimized storagen Fixed storage mode

Switch 2o Tray lock

Switch 3o Height detection by Module GS136n Module GS136 not existent

Switch 4o Rocker (safety panel)n No rocker (no safety panel)

Switch 5Module GS191 installedSet-up of telegram formatn T3o T4 / T5Without Module GS191- without functionSwitches6 7n n Single workstationo n Master workstationn o Additional workstation

Switch 8Indicate errors in the internal communication o No (Default setting)

n Yes

From the software version SIF 3.0 on, the module revisionGS140-3 is required. For this purpose, the jumpers x43and x44 have to be put on 512.If a software version smaller than SIF3.0 is installed on themodule revision GS140-3, then the jumpers x43 and x44have to be put on 256.

In the case of T3S applications, the IC D4 has to beinstalled. Attention! Note jumper x20 MODE

Jumper x20 MODE smaller software revision SIF 3.0MODE 1 without functionMODE 2 standardMODE- T3SAttention: For T3LCD version 2.xx MODE 1

Jumper x20 MODE from SIF 3.0 onMODE 1 T3S, standard

From software version SIF 3.04 on, the following jumpershave to be plugged, if the following functions/plugs are notconnected.

Jumper GS140x29:1, x29:2 (BAL) extractor movementstops at overheight. Protection against damage of theslide / casing.

Jumper GS140 x36:3, x36:4 (ERRIN) extractor movementstops at overheight. Base shelf with double-tray functionhas overheight.

GS140 ERR-IN

BAL

1

1

Figure 23

EXT-PH.

1

03/98

Figure 1


Technical Manual

10 OPERATION

SHUTTLE 250 / 500

10.2

10.2.2 Checking the Bus Termination for theNetwork Shuttle

The bus termination must be closed at the start and theend module ( only one network cable is connected to thestart and the end module, respectively).

Example 1 single/multiple workstation(s) without height detector interface

GS132 n n n n JP2 Bus interfaceGS145 n n n n JP14 Lift extractor interface

Example 2 single workstation with heightdetector interface(GS 136)

GS136 n n n n JP2 Height detector interfaceGS132 o o o o JP2 Bus interfaceGS145 n n n n JP14 Lift extractor interface

Example 3 three workstations with heightdetector interface (GS 136)

GS136 n n n n three workstations with heightdetector interface (GS 136)

GS136 o o o o JP2 Height detector interface Slave workstation 1

GS136 o o o o JP2 Height detector interface Master workstation

GS132 o o o o JP2 Bus interfaceGS145 n n n n JP14 Lift extractor interface

10.2.3 GS145Set the frequency converter control (see lay-out plan ofModule GS145, figure 21).Setting 1 - NORD SK3600/3 SPAttention: Display on the frequency converterNORDAC SK 3600/3-SP Gnd

Setting 2 - NORD SK2200/ 3CT - NORD SK4000/ 3CT - SEW Movitrac 2,2kW

10.2.4 Check Mode Switch GS136 (Binary Code)

GS136 o1 n2 n3 n4 J1Master workstation

GS136 n1 o2 n3 n4 J1Slave workstation 1

GS136 o1 o2 n3 n4 J1Slave workstation 2

10.2.5 Adjust Accident Protection Light Barrieraccording to Technical Description WERAC forOptical Adjustment

To facilitate and improve the transmitter adjustment, a lightmeasurement receiver WEM 1 can be ordered. Forinformation on WEM 1 please contact SCI Bellheim.

10.3 FINE ADJUSTMENT

10.3.1 Lift and ExtractorCheck incorporation of the extractor.Reflex-light sensors B5, B6 on the extractor must havesufficient distance to the roller track (see lay-out planextractor).

Run lift manually up/downF activate service function “998”.F “arrow open”ð lift moves up

F „S"ð lift moves down

Error:Is the direction of rotation wrong, then two wires have to beinterchanged on the frequency converter’s output terminals(U, V, W).Does the lift slip while stopping, then remove the bridge atthe brake rectifier in the lift motor.When the frequency converter does not generate outputpower (“Zero”/Lift does not move), please refer to section“Information and Tips”, chapter 10.9.3.8.

10.3.2 Hard Stop Top/BottomIn the case of appliances with a width of over 1600mm,hard and soft stop are installed twice at the top (left andright side).Attention. Check as well.F Move lift up/down as described in 10.3.1F activate and hold “HARD STOP” “S3/S4”.ð lift stops, safety circuit decreases

F connect bridge “BYPASS” in the control to service andmove lift out of the “HARD STOP” by means of thekeyboard.

F reverse the bridge “BYPASS” in the control.

10.3.3 SOFT STOP Top/BottomF Move lift down as described under 10.3.1F Activate and hold “SOFT STOP” “B2” manually when

lift is moving.ðlift stops.

F move lift to opposite direction.ð lift must not continue to move in the same

direction.

10.3.4 Adjusting the Lift's ZERO Reference PositionF Check shuttle and drive to be able to take the measure A from the following table. Shuttle Drive Measure A (Figure 2A)

250 kg 2,2 KW NORD 9-13mm500kg 2,2 KW NORD 5 -7 mm500kg 4,0 KW NORD 10-14mm

FMove switching ramp at the lift entirely upwards (see figure 3).FMove lift downwards as described under 10.3.1 until lift stops at proximity switch „B2“.ð Lift stops at „SOFT-STOP“ „B2“.ð LED on the proximity switch „B2“ must light up.

03/98


Technical Manual

OPERATION 10

10.3

FCheck the switching ramp distance (1-3 mm) to the proximity switch „B2“ as well as the parallelism and, if appropriate, readjust and move again as described under 10.23.1 into the SOFT-STOP.FAffix the marker line to the proximity switch „B2“ as described in figure 2. Important! From this marker line, the measure A later has to be measured/ adjusted downwards.F Activate „F4 0“.ð Lift stops at ZERO reference, see figure 2A.

F The measure A has to be adjusted with the switching ramp. The switching ramp has to be readjusted downwards at a distance of approx. 5 mm and subsequently activate „F4 0“, that is to approach the measure A step by step.ðThe lift’s ZERO reference is thus adjusted.

F It has to be ensured that this position is underneaththe lowest storage position. The optical switches B5and B6 (for the recognition of the shelf positions) onthe extractor must not be activated.

Figure 2

1-3mm

Figure 2A

1-3mm

A

Trigger edge

Marker line

Switching ramp

Switching ramp

Marker line

Trigger edge

Ramp up

B2

Bild 17

Shift ramp

Figure 3

10.3.5 Checking the Extractor’s Direction of Rotation

F activate service function „998“.F move lift manually into a range, where the extractor

fingers cannot cause any damage (workstation).F with the keys „F3““1", the extractor has to rotate to the

left ←.F with the keys „F3““2", the extractor has to rotate to the

right →.The extractor fingers have to be in the lower, centralposition after this check.

M

top

bottom

front

Figure 3

Error:If the direction of rotation is opposite, reverse two phases(L1 and L2) at the motor/the motor main supply inputterminal.

10.4 INITIALIZING

10.4.1 Recognition of the Storage Positions

F adjust base setting to fixed storage mode/optimizedstorage (see 10.2.1)

FactorsShuttle Drive Factor250Kg 2,2KW NORD 129,30500Kg 2,2KW NORD 223,00500Kg 4,0KW NORD 116,40250Kg 2,2KW SEW 121,40

The factors can only be altered after the point. Thefactor before the point is firmly integrated in thefirmware.F check shuttle, motor, factor and firmware for

the service function „997“.F activate service function „997“.ð lift moves to ZERO reference position.ð lift moves from the „zero reference position“ upwards

to the upper „SOFT STOP“. When the lift passes theworkstation, note which storage position has to beregistered for the workstation (see display).

F the number of the workstation has to be entered whenrequested.ð lift moves to workstation.

03/98

Figure 4


Technical Manual

10 OPERATION

SHUTTLE 250 / 500

10.4

If the number of a workstation has not been noted, thenthe shelf position can be counted starting with the loweststorage position. If a wrong number was entered, it can becorrected by using the keys „service function 991“.Attention: Note 10.4.3.

10.4.2 Fine Adjustment of Stop Position Front/RearThe functions of the switches „CARRIER 20-27“ on the Mo-dule GS140 are defined as follows:

Front RearValues 1 2 4 8 1 2 4 8Switches 1 2 3 4 5 6 7 8

20 27

The switches are coded in binary, i.e. 16 settings arepossible (1 Bit = 1,5 mm).n switch closed, o switch openExample for front/backSignificance 1 2 4 8Switch setting n n n n 0mm No increase

n n n o 12,0mm Neutralo o o o 22,5mm Max. increaseo o n n 4,5mm Example

F activate service function „998“.F „F4“ + „0“.ð lift moves to the zero reference position

F „F4" + „1"ð lift moves to the lowest storage position in the rear.

F „F4“ + „4“ðlift moves to workstation.

By moving to the positions „F4" „1“ and „F4" „4“, the fineadjustment can be carried through. The function „F4"„ 0“ isonly necessary once (after entry of the service function„998“).

With the help of the following test, the incrementalencoder shall be checked.F „F4" „7"ð lift moves to uppermost shelf location.

Check the stop position of the uppermost shelfposition.F move at random to about 4-5 shelf positions and check

their stop positions.Should a correction be necessary, see keyboard T3Shuttle Manual, Stop Shifting Corrections for Non-Linear Stop Tolerances (always correct a shuttlefrom bottom to top, the scroll mode F2 adds / F3substracts all shelf positions from the current tableposition upwards. In case of only one workstation,only this shelf position will be modified).

Shuttle Drive mm Increment250 kg 2,2 KW NORD 1 5,172500kg 2,2KW NORD 1 8,92500kg 4,0KW NORD 1 4,65

10.4.3 Blocking of Storage Place PositionsF Assemblies, which are recognized as storage positions

such as e.g. rack reinforcement (for units > 7000), controldrawer, etc. have to be blocked. See keyboard T 3Shuttle Operating Manual, Blocking of a Storage PlacePosition (scroll mode, enter 89 in the field storage height).

A storage shelf below and above a rack reinforcementmust be at a distance of at least 125 mm.

10.4.4 Checking of Photocells with GS136 HDIF (if available)

Set-up of the “MODE”-switchesThe switch set-up is binary coded.n switch closed, o switch openSignificance 1 2 4 8MODE-switch 1 2 3 4Switch setting n n n n Module logged off

o n n n Master workstationn o n n 1. Additional workstationo o n n 2. Additional workstation

F activate service mode „993“ð The LEDs on all installed photocells must light up. In

case of adjusting problems, see figure 5.F interrupt the light beam of all the installed photocells.ð when a light beam is interrupted, the respective

LED will switch off.F Check the minimal recognition of a 4 mm diameter with

a shining item.

The photocells must be installed as follows:

receiver ← transmitter

transmitter → receiverreceiver ← transmittertransmitter → receiver

_______ workstation

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Technical Manual

OPERATION 10

10.5

10.4.5 Checking the Height Detection’s Single-Light Barrier (If Installed)

F Check the minimal recognition with a shining item with adiameter of 4 mm.

If the light beam is not interrupted, the LED on thereceiver must be on.The light barrier’s sensitivity can be adjusted on thereceiver (the receiver has an accessible potentio-meter on the rear side).The LED on the transmitter is constantly lit.transmitter → receiver

10.4.6 Recognition of the Light Barrier Position

The recognition of the light barrier position for the heightdetection must always be carried out.

The recognition has to be carried out for each workstationstarting with the master workstation (do not forget toregister other workstations).F activate service function „994“ð lift moves to access level

F install the photocell blocker (25mm) on the extractor for the interruption of the light beam.

F confirm READY with the key „S“ð recognition of the light barrier positionð lift moves to the access level

F remove photocell blockerF confirm READY with the key „S“.The recognized light barrier position, the height, as well asthe assignment to an input on the Module GS136 appearon the display.

10.4.7 Checking and Adjusting the ProximitySwitches in the Access Opening

F switch off main powerF adjust proximity switches „1B3“ and „1B4“ in level with

the lower edge, see 10.8 lay-out plan access opening.F switch on main powerð lift moves to access opening

F dampen proximity switch „1B5“F dampen and hold both proximity switches, „1B3“ and

„1B4, simultaneously.ð Both LEDs must light up.ð extractor fingers in „finger hold“ position (tray stop).

Note:In order to reduce the danger of jamming of the extractorfingers, a time delay of approx. 1 sec is programmed forthe proximity switches „1B3“ and „1B4“.

Swith 1B4 controls the locking, switch 1B3 controls therelease of the „finger hold“ action (tray stop).

10.4.8 Recognition of Tray LocationAttention! Check fixed storage mode / optimized storageonce more. After activation of the service function „996“,the setting must not be modified again.F activate service function „996“.

10.4.9 Assignment of the Tray Number and HeightDetection

F activate service function „995“Attention!If this function is carried through with a loaded shuttle,then the proposed tray number or a new tray number canbe entered. Without a tray, the control will not show anyreaction. After this function, the fixed storage mode/optimized storage must not be reversed any more.

The set-up of a standard shuttle is now finished. If optionsare installed, see options.

All functions and options concerning the access openingare to be checked for each workstation:foldable table, automatical tray extraction, lifting magnet,position display, slide, double extraction, height detection,etc.

J 3 J 4 J 5 J 6

G S13 6

1 2 3 4 5 6 7 8 9 10 11 12 1 3 1 4 15 16IN

G N D

Test points J3 - J6 to GMD

optimalwith DVW settingapprox. 2.1 VAC

bad

Figure 14

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Figure 5


Technical Manual

10 OPERATION

SHUTTLE 250 / 500

10.6

10.5 OPTIONS

Attention: Check the base setting/control parameters withthe options to be checked.

10.5.1 Manual, Complete Tray Extraction(Foldable Table)See figure 6

10.5.2 Tray Extraction With Fork-Lift Truck (Foldable Table)

See figure 6

10.5.1 und 10.5.2 Identical Check RunF move foldable table in position „table up“, so that limit

sensors 1S2/1Se are locked.F select tray nnnð tray will be moved into access opening.ð tray number will be shown in the display

F confirm with „S“ð tray will be stored.

Simulate Error with Limit Sensors 1S2 and 1S3F move foldable table in position „table up“, so that limit

sensors 1S2/1Se are locked incorrectly.F select tray nnnð tray will be moved into access opening

F operate unlock leverð If the „finger hold“ action is activated, the error E78

must be shown, the „finger hold“ action remains.„Finger hold“ action is off.F operate unlock lever.ð error E78 will be shown.

10.5.3 Automatic, Complete Tray Extraction(Foldable Table)

F move foldable table in position „table up“, so that limit sensors 1S2/1Se are locked.

F select tray nnnð tray will be moved into access openingð unlock lever will be lifted automaticallyð tray will be moved onto the tableð tray number will be shown in the display

When the tray reaches the proximity switch 1B2,the motors 1M1 and 1M2 must switch off at once.If the motors are not switched off at once, theproximity switch 1B2 is not recognized.F activate „S“ð unlock lever is lifted automatically.ð tray is moved into the access opening.ð tray is stored.

Simulate Error With Limit Sensors 1S2 and 1S3F move foldable table in position „table up“, so that limit

sensors 1S2/1Se are locked incorrectly.F select tray nnnð tray will be moved into access openingð error E78 is displayed.

Figure 17 Foldable table + Automatic, complete tray extraction Control parameter „4c“: parameter 2

1Y1TO Lifting Magnet

1M1TO Motor

1M2TO Motor

1S2 Table up OK

1S2 Table up OK

1B2TO Tray on table

1S4 Table up/down1S4 Table up/down

1S3 Table up OK

1S2 Table up OK

Figure 16 Foldable table Manual complete tray extraction Tray extraction with fork-lift truck Control parameter „4c“: parameter 1

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OPERATION 10

10.7

10.5.4 Automatic Tray Extraction for Conveyor Track(Without Table)

No tray should be in the access opening.F operate proximity switch 1B1TO briefly.ð tray is moved into access opening. Check motor in

the access opening for correct direction of rotation. Ifthe check is carried out without a tray, themotor is switched off after a certain time.

10.5.7 SlideNo tray is to be in the access opening.

F adjust belt and limit sensors 1S11 and 1S12.F activate service function „998“.ð green lamp lights up.

F operate “F3“,“7“ð slide opens.

F operate „F3“, „8“.ðslide closes.

F operate simultaneously limit sensors 1S13 and 1S13 andhold them.ð SR-circuit will be activated automatically.ð green lamp lights up.

F interrupt PLS.ð SR-circuit must not decrease!!!!

Information:1S12 normally closed contact (NCC), 1S13 and1S14 normally open contact (NOC) in the SR-circuit, i.e. when the door is closed and a tray is inthe access opening the SR-circuit is bridged.Door closed - 1S12 not operated.Door open - 1S11 not operated.

1B1TO External tray (activate retraction)

Figure 18Automatic Tray Extraction for Conveyor Track Control parameter „4c“: parameter 3

1Y1TO Lifting Magnet

1M1TO Motor

1S12

1S131S14

Schieber 1S11

1S11 Slide not completely open1S12 Slide not closed1S13 Tray in extraction 1S14 Tray in extraction 1M1 Slide motor open/close Figure 19

10.5.5 Lifting Magnet

F select tray nnnð tray will be moved into access opening

F operate „arrow open“-keyð in the active „finger hold“ mode, the fingers are removed.ð lifting magnet lifts the unlock lever.

10.5.6 Position DisplayF push „P“-keyð LED in the „P“-key lights up.

F enter 000.

F enter 01.ð first position LED lights up.

F push „C“-keyð first position LED switches off.

F enter 02.ð second position LED lights up.

F push „C“-keyðsecond position LED switches off.

All position LEDs have to be checked in this way.

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10 OPERATION

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10.8

10.5.8 Double Extraction

F adjust proximity switches in level with the lower edge(readjust if the tray is not recognized).

F move a tray into the double extraction during standardoperation.ð tray is in the double extraction.

F push the „S“-key.ð tray is stored (1B6 and 1B7 seem to be ok).

F move a tray into the double extraction during standardoperation.

F detach and hold the poximity switch 1B6 so that the traywill not be recognized. Fasten the proximity switch withscrews temporarily in this position.

F „push the „S“-keyðE50 -> 1B6 is ok.

F fasten proximity switch 1B6 correctly again. Tray is still in the double extraction.F switch power supply off.F lift the proximity switch 1B7 so that the tray will not be

recognized. Hold 1B7 in this position.F switch power supply on.F push „S“-key.ð E43 -> 1B7 is ok.

10.5.9 Double Tray

F Check the function of light barriers B1T, B1R and B2T,B2R.

If the double tray has been moved downward correctly, the above-mentioned light barriers must not be interrupted. If a double tray has not been moved downward correctly, this must be recognized and shown in the LEDs IN17 and IN18 (see figure 12). The double tray can only be operated with the manual switch S1 on the Module GS146, if no travel direction is displayed, i.e. the LEDs OUT11 and OUT 12 must be off. With the service function „998“, the travel direction is switched off.F move a table with a double tray into the access opening

during standard operation.ð table is in the access opening.

F store table.F move a double tray into the access opening during

standard operation.ð double tray is in the access opening.

F store double tray.The extractor’s stop function in the storage mode isto be controlled exactly and repeatedly to ensurethat the double tray locks exactly on the base tray.

Double tray

LED green yellow

Figure 11

Pos

ition

dou

ble

tray

top

fron

t

Pos

ition

dou

ble

tray

top

rear

vaca

nt

vaca

nt

vaca

nt

vaca

nt

vaca

nt

vaca

nt

Dou

ble

tray

dow

n

Dou

ble

tray

up

End

pos

ition

top

mot

or 1

End

pos

ition

top

mot

or 2

End

pos

ition

bot

tom

mot

or 1

End

pos

ition

bot

tom

mot

or 2

up

downvaca

nt

GS146

IN 1

7

IN 1

7IN

18

IN 2

3A

IN 2

3B

IN 2

4A

IN 2

4B

IN 1

9

IN 2

0

IN 2

1

IN 2

2

OU

T 11

OU

T 12

OU

T 5

Motor

B1T, B1R Table top frontB2T, B2R Table top rear

Figure 10

Top view

Front

B2R Receiver

B2T Transmitter

B1R Receiver

B1T Transmitter

1B6

1B7

1B6 Proximity switch tray in extraction1B7 Proximity switch tray in position Figure 20

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Figure 10

Figure 11

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Technical Manual

OPERATION 10

10.9

10.5.10 Multiple Workstations (Slave Workstation)

Connection on the modules:1. Slave workstation GS132 SLAVE 1 Workstation No. 22. Slave workstation GS141 SLAVE 2 Workstation No. 33. Slave workstation GS141 SLAVE 3 Workstation No. 44. Slave workstation GS141 SLAVE 4 Workstation No. 55. Slave workstation GS141 SLAVE 5 Workstation No. 6If the Module GS141 is used for the option multipleworkstations, this has to be installed once in theappliance on the Module GS140 in the masterworkstation. The slave workstations SLAVE 2 -SLAVE 5 will be connected to this module.Attention! It is absolutely essential to connect theslave workstations in a rising order. If a slaveworkstation is connected on the Module GS141, plugjumper A/I, see figure 12.

SLAVE 1

GS1321

x 5

x 4

x 3

x2x7 x6

J P 2

x2

Jumper

1

Height

Depth

Position

Figure 12

Example:No SLAVE 1 connected

SLAVE 2

SLAVE 3

SLAVE 4

SLAVE 5

GS141

AI

AI

AI

AI

x3

x4

x5

x6

x7

1

1

1

1

1

Jumper 1

1

AI

AI

Example 2:SLAVE is connected

Figure 13

Example 1:No SLAVE connected

A

B

A Extractor movement stops at overheight Protection against damage of the slide/casing

B Extractor movement stops at overheight Base tray in double tray function has overheight.

Figure 22

10.5.11 Extractor Movement Stops at OverheightProtection Against Damage of the Slide/Casing (see Figure 15, A)

This function is active when a tray is transportedfrom the access opening to the extractor. When thelight barrier is interrupted, the extractor movementwill be stopped at once.F insert a tray during standard operation and interrupt the light barrier during the extractor movement. ð the extractor movement will be stopped at once.

10.5.12 Extractor Movement Stops in Case ofOverheightBase Table in Double Tray Function hasOverheight (see Figure 15, B)

This function is active when a base tray is transportedfrom the access opening to the extractor and a double trayis in „hold-up“ position in the extractor. When the lightbarrier is interrupted, the extractor movement will bestopped at once.F insert a base tray (with double tray) in the access opening.F store tray and interrupt light barrier during extractor movement. ð the extractor movement will be stopped at once.

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Figure 13

Figure 14

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Technical Manual

10 OPERATION

SHUTTLE 250 / 500

10.10

10.5.13 Lock Table

This function can be activated by an additional keyswitch (see operating manual). The key switch isconnected to the Module GS140 x30:1 and x30:2(x30:1, x30:2 open -> no tray locked).

10.6 FINAL ACTIVITIES

F Conduct several storage tests.F Check the distances between the shelves for

correspondance with the heights of the heightdetection photocells.

F Conduct a load test. At max. load, the lift may onlydrop by max. 2mm.

The starting is finished here.

10.6.1 Starting - Test

After a successfully starting and before deliverying theunit to the client, the faultless starting of the unit must becertified on the test book (see chapter 13-C) by acompetent person.

NORDAC vector

S K 2 2 0 0 / 3 C T

Enter

Field Field Value Value backward forward greater less

Figure 21

10.7 Frequency Converter

Brief operating instruction for the CT frequency converter.

The data programmed in the frequency convertercan be modified/viewed as follows:Figure 16 Starting point

F „Field forward“ („Field backward“) With each key stroke, a menu group option will be displayed as depicted below:

F/Hz P/KW cos 0.0 0.0 0.0

Base parametersmotor datacontrol parameterscontrol terminalsadditional functionsinformationservice

F„Value greater“, „Value less“ Values or contents are modified. Modifications have to be confirmed with „Enter“.F „Enter“

By pushing the „Enter“-key, the menu group will be changed or a changed menu function adopted/saved.F„Field forward“ and „Field backward“ simultaneously.

One menu step backward.

For more information, we refer to the operating instructionsNORDAC. These operating instruction are part of theaccompanging documents of each shipped unit.

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Technical Manual

OPERATION 10

10.11

Table List of Parameters Frequency Converter NORD SK2200/3CT in SHUTTLE 250 with Module GS131

REV2.0Are columns of the parameter sets P1-P4 blank, then the factory settings are effective. The hatched fieldscontain menu points which can only be seen in a specific configuration. A field that cannot be seen is marked ‘—’.

Nord vector - SK2200/3 CT

Base ParametersLift Function UP >350 Down>350 Up <350 Down<350

Menu Text Factory Setting P1 P2 P3 P4Parameter set 1 Select parameter set (n=1...4)copy parameter fromn → n 2 → 1 Select parameter set (n=1...4)Acceleration time 2.00 sec 1.30 0.90 0.90 0.30Deceleration time 2.00 sec 0.35 0.35 0.20 0.20Minimal frequ. 0 Hz 3.0 3.0 3.0 3.0Maximal frequ. 70 Hz 66.5 70.0 30.0 30.0Control mode ISD-modeOperating mode analog

Motor DataLift Function Up >350 Down>350 Up <350 Down<350

Menu Text Factory Setting P1 P2 P3 P4Standard motor 2.2 KWRated frequency 50HzRated speed 1415min -1

Rated current 5.00ARated voltage 400VRated power 2.20KWRated Cos(PHI) 0.80Motor circuitry starStator resistance 2.650Ohm 3.3 3.3 3.3 3.3

Control ParametersLift Function Up >350 Down>350 Up <350 Down<350

Menu Text Factory Setting P1 P2 P3 P4Acceleration delay onCurrent limit 1 7.7A 8.0 8.0 8.0 8.0Current limit 2 8.2ADeceleration delay offDisconnection ramp onBreak-point frequency 50Hz ↓ --- ↓ --- ↓ --- ↓ ---Static boost 20.00VDynamic boost offTime dynamic boost 0.0sDC-brake offtime DC-brake 1.0s ↓ --- ↓ --- ↓ --- ↓ ---DC-brake voltage 20.00VNominal value delay off 0.10 0.15 0.10 0.15Ramp down offSafety circuit offSlip compression onAuto. freq. increase offMoment limit off

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10.12

Control TerminalsLift Function Up >350 Down>350 Up <350 Down<350

Menu Text Factory Setting P1 P2 P3 P4Mode conn. input 0-10V limitedAlignment 1: 0%→ 0.00VAlignment 1: 100%→ 10.00VFilter Conn. input 1 offRadio Conn. input 2 noneAlignment 2: 0%→ 0.00V ↓ --- ↓ --- ↓ --- ↓ ---Alignment 2: 100%→ 10.00VFilter Conn. input2 offFrequency 100% 50HzPI-controller P 100%PI-controller I 10%/sLimit PI-controller 10.00HzCurrent limit 100% 8.2AMoment limit 100% 100%Analog output OFFStandard analog output 100% ---Digital input 2 release leftDigital input 3 Fixed frequency 1Digital input 4 Parameter set 1Digital input 5 Parameter set 2Digital input 6 error quitRelease active edgeMotor temp. protect. offRelay 1 Function. Current: Off

Frequ: OffBrake: OffOver-curr.: OffTemp.: OffAcceleration: OffSlip: OffMom. limit.: OffM gen.: Off

Relay 1 Logic OR ↓ --- ↓ --- ↓ --- ↓ ---Relay 1 Current 5.50ARelay 1 IHyst. 10%Relay 1 Freq. 50.50HzRelay 1 Trailing 100min -1

Relay 1 Slip 300%Relay 1 Mom. limit 300%Relay 2 Functions Current: Off

Frequ: OffBrake: OnTemp.: OffOver-curr.: OffAcceler.: OffTrailing: OffSlip: OffMom. limit: OffM gen.: OffFs = F: OffInac. F: Off

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OPERATION 10

10.13

Lift Function Up >350 Down>350 Up <350 Down<350Menu Text Factory Setting P1 P2 P3 P4Relay 2 Logic OR ↓ --- ↓ --- ↓ --- ↓ ---Relay 2 Current 5.50ARelay 2 IHyst. 10%Relay 2 Freq. 50.50HzRelay 2 Trailing 100min -1

Relay 2 Slip 300%Relay 2 Mom. limit 300%

Additional FunctionsLift Function Up >350 Down>350 Up <350 Down<350

Menu Text Factory Setting P1 P2 P3 P4Language EnglishKey control offFactory setting Enter * Attention: Do not strike the ‘Enter’-key!!Password 0Change password 0Fixed frequency 1 10HzFixed frequency 2 20HzFixed frequency 3 40HzLoss reduction offSwitching frequency 8KHzFade-out 1 high offFade-out 1 low offFade-out 2 high offFade-out 2 low offQuick-stop error offQuick-stop time 0.1s --- --- --- ---Autom. quit offAbs. min. frequ. 1.0Hz 2.00 2.00 2.00 2.00USS - mode slaveInterface localUSS - baud. 9600 baudUSS - address 0USS - time Out 0.0sRstat adaption offServo mode off ↓ --- ↓ --- ↓ --- ↓ ---Pick-up rotation speed 4096Rot. speed controller P 100%Rot. speed controller I 10%/s

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10 OPERATION

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10.14

Table List of Parameters Frequency Inverter NORD SK2200/3CT in SHUTTLE 250 with Module GS145.

REV2.0Are columns of the parameter sets P1-P4 blank, then the factory settings are effective. The hatched fieldscontain menu points which can only be seen in a specific configuration. A field that cannot be seen is marked ‘—’.

Nord vector - SK2200/3 CT (converter - software 4026 006 and higher! Run versions smaller 006 onlywith REV 1.1 or update)

Base ParametersShuttle Function Lift Up Lift down Extractor

Menu Text Factory Setting P1 P2 P3 P4Parameter set 1 Select Parameter set (n=1...4)Copy parameterfrom n → n 2 → 1 Select Parameter set (n=1...4)Acceleration time 2.00 sec 0.90 0.80 0.60Deceleration time 2.00 sec 0.35 0.35 0.05Min. frequency 0 Hz 3.0 3.0Max. frequency 70 Hz 66.5 70.0 50.0Control mode ISD-mode LinearOperating mode analog

Motor dataShuttle Function Lift Up Lift Down Extractor

Menu Text Factory Setting P1 P2 P3 P4Standard motor 2.2 KW 0.37Rated frequency 50Hz ↓ ---Rated speed 1415min -1

Rated current 5.00ARated voltage 400VRated power 2.20KWRated Cos(PHI) 0.80Motor circuitry starStator resistance 2.650Ohm 3.3 3.3

Control ParametersShuttle Function Lift Up Lift Down Extractor

Menu Text Factory Setting P1 P2 P3 P4Acceleration delay on Off OffCurrent limit 1 7.7ACurrent limit 2 8.2ADeceleration delay offDisconnection ramp onBreak-point frequency 50Hz ↓ --- ↓ ---Static boost 20.00V 70Dynamic boost offTime dynamic boost 0.0s ---DC-brake offDC-brake time 1.0s ↓ --- ↓ --- ↓ ---DC-brake voltage 20.00VNominal value delay off 0.05 0.15Ramp down offSafety circuit offSlip comp. On ---Auto. freq. increase OffMoment limit Off 160% ---

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OPERATION 10

10.15

Control TerminalsShuttle Function Lift Up Lift Down Extractor

Menu Text Factory Setting P1 P2 P3 P4Mode conn. input 0-10V limitedAlignment1: 0%→ 0.00VAlignment1: 100%→ 10.00VFilter Conn. input 1 offRadio Conn. input 2 noneAlignment 2: 0%→ 0.00V ↓ --- ↓ --- ↓ ---Alignment 2: 100%→ 10.00VFilter Conn. input2 offFrequency 100% 50HzPI-controller P 100%PI-controller I 10%/sLimit PI-controller 10.00HzCurrent limit 100% 8.2AMoment limit 100% 100%Analog output OFFStandard anal. output 100% ---Digital input 2 release leftDigital input 3 fixed frequency 1 Suspend VoltageDigital input 4 parameter set 1Digital input 5 parameter set 2Digital input 6 error quitRelease active edgeMotor temp. protect. offRelay 1 Function Current: Off


Relay 1 Logic OR ↓ --- ↓ --- ↓ ---Relay 1 Current 5.50ARelay 1 IHyst. 10%Relay 1 Freq. 50.50HzRelay 1 Cont. 100min -1



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10 OPERATION

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10.16

Shuttle Function Lift Up Lift Down ExtractorMenu Text Factory Setting P1 P2 P3 P4Relay 2 Logic OR ↓ --- ↓ --- ↓ ---Relay 2 Current 5.50ARelay 2 IHyst. 10%Relay 2 Freq. 50.50HzRelay 2 Trailing 100min -1


Additional FunctionsShuttle Function Lift Up Lift Down Extractor

Menu Text Factory Setting P1 P2 P3 P4Language EnglishKey control offFactory setting Enter * Attention: Do not strike the ‘Enter’-key!!Password 0Change password 0Fixed frequency 1 10HzFixed frequency 2 20HzFixed frequency 3 40HzLoss reduction offSwitching frequency 8KHzFade-out 1 high offFade-out 1 low offFade-out 2 high offFade-out 2 low offQuick-stop error offQuick-stop time 0.1s ---Autom. quit off alwaysAbs. min. frequ. 1.0Hz 2.00 2.00USS - mode slaveInterface localUSS - baud. 9600 baudUSS - address 0USS - time Out 0.0sRstat adaption offServo mode off ↓ --- ↓ --- ↓ ---Pick-up rotation speed 4096Rot. speed controller P 100%Rot. speed controller I 10%/sT- PT1 Slip 80 ms 30T- PT1 Isq 50 ms 25T- PT1 Isd 50 ms 25T- PT1 Speed 15 ms

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OPERATION 10

10.17

Table List of Parameters Frequency Inverter NORD SK2200/3CT in SHUTTLE 500 with Module GS145

REV1.1Are columns of the parameter sets P1-P4 blank, then the factory settings are effective. The hatched fields contain menu pointswhich are only visible in a specific configuration. A field that cannot be seen is marked ‘—’.

Nord vector - SK2200/3 CT (Software 4026 006 and higher)

Base ParametersShuttle Function Lift Up Lift Down Extractor

Menu Text Factory Setting P1 P2 P3 P4Parameter set 1 Select Parameter set (n=1...4)Copy parameterfrom n → n 2 → 1 Select Parameter set (n=1...4)Acceleration time 2.00 sec 0.40 0.50 0.30Deceleration time 2.00 sec 0.45 0.35 0.15Min. frequency 0 Hz 6.5 5.5Max. frequency 70 Hz 60 65 36.0Control mode ISD-mode LinearOperating mode analog

Motor dataShuttle Function Lift Up Lift Down Extractor

Menu Text Factory Setting P1 P2 P3 P4Standard motor 2.2 KW 0.37Rated frequency 50Hz ↓ ---Rated speed 1415min -1

Rated current 5.00ARated voltage 400VRated power 2.20KWRated Cos(PHI) 0.80Motor circuitry starStator resistance 2.650Ohm 3.3 3.3

Control ParametersShuttle Function Lift Up Lift Down Extractor

Menu Text Factory Setting P1 P2 P3 P4Acceleration delay on Off OffCurrent limit 1 7.7ACurrent limit 2 8.2ADeceleration delay offDisconnection ramp onBreak-point frequency 50Hz ↓ --- ↓ ---Static boost 20.00V 60Dynamic boost offTime dynamic boost 0.0s ---DC-brake offDC-brake time 1.0s ↓ --- ↓ --- ↓ ---DC-brake voltage 20.00VNominal value delay off 0.05 0.15Ramp down offSafety circuit offSlip comp. On ---Auto. freq. increase OffMoment limit Off 170% ---

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10.18

Control TerminalsShuttle Function Lift Up Lift Down Extractor

Menu Text Factory Setting P1 P2 P3 P4Mode Conn. input 0-10V limitedAlignment 1: 0%→ 0.00VAlignment 1: 100%→ 10.00VFilter Conn. input 1 offRadio Conn. input 2 noneAlignment 2: 0%→ 0.00V ↓ --- ↓ --- ↓ ---Alignment 2: 100%→ 10.00VFilter Conn. input2 offFrequency 100% 50HzPI-controller P 100%PI-controller I 10%/sLimit PI-controller 10.00HzCurrent limit 100% 8.2AMoment limit 100% 100%Analog output OFFStandard anal. output 100%Digital input 2 release leftDigital input 3 Fixed frequency 1 Suspend VoltageDigital input 4 Parameter set 1Digital input 5 Parameter set 2Digital input 6 error quitRelease active edgeMotor temp. protect. offRelay 1 Function. Current: Off


Relay 1 Logic OR ↓ --- ↓ --- ↓ ---Relay 1 Current 5.50ARelay 1 IHyst. 10%Relay 1 Freq. 50.50HzRelay 1 Trail. 100min -1


Frequ: OffBrake: OnTemp.: OffOver-curr.: OffAcceler.: OffTrail.: OffSlip: OffMom. limit: OffM gen.: OffFs = F: OffInac. F: Off

continues next page

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OPERATION 10

10.19

Shuttle Function Lift Up Lift Down ExtractorMenu Text Factory Setting P1 P2 P3 P4Relay 2 Logic OR ↓ --- ↓ --- ↓ ---Relay 2 Current 5.50ARelay 2 IHyst. 10%Relay 2 Freq. 50.50HzRelay 2 Trail. 100min -1



Menu Text Factory Setting P1 P2 P3 P4Language EnglishKey control offFactory setting Enter * Attention: Do not strike the ‘Enter’-key!!Password 0Change password 0Fixed frequency 1 10HzFixed frequency 2 20HzFixed frequency 3 40HzLoss reduction offSwitching frequency 8KHz 16 16 16Fade-out 1 high offFade-out 1 low offFade-out 2 high offFade-out 2 low offQuick-stop error offQuick-stop time 0.1s ---Autom. quit offAbs. min. frequ. 1.0Hz 2.00 2.00USS - mode slaveInterface localUSS - baud. 9600 baudUSS - address 0USS - time Out 0.0sRstat adaption offServo mode off ↓ --- ↓ --- ↓ ---Pick-up rotation speed 4096Rot. speed controller P 100%Rot. speed controller I 10%/sT- PT1 Slip 80 ms 30T- PT1 Isq 50 ms 25T- PT1 Isd 50 ms 25T- PT1 Speed 15 ms

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10 OPERATION

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10.20

List of Parameters for Frequency Converter NORD SK4000/3CT in Shuttle 500 with 4kW- Drive

Only the values which differ from the factory setting (NORD) are shown. Only those values have to be adjustedin the course of an initialization of the converter. The hatched fields remain invisible in some configurations.

Subject to modifications!

Base ParametersShuttle Function Lift Up Lift down Extractor

Menu Text Factory Setting(NORD)

P1 P2 P3 P4

Parameter set 1 Select Parameter set (n=1...4)Copy parameterfrom n → n 2 → 1 Select Parameter set (n=1...4)Acceleration time 2.00 sec 0.65 0.7 0.30Deceleration time 2.00 sec 0.4 0.35 0.15Min. frequency 0 Hz 4.0 3.0Max. frequency 70 Hz 58 62 36.0Control mode ISD-mode linearOperating mode analog

Motor DataShuttle Function Lift Up Lift down Extractor

Menu Text Factory Setting P1 P2 P3 P4Standard motor 4.0 KW 4.0 4.0 0.37Rated frequency 50HzRated speed 1430min -1

Rated current 9.00ARated voltage 400V - notRated power 4.40KW visible-Rated Cos(PHI) 0.78Motor circuitry mesh star starStator resistance 2.5 Ohm 1.65 1.65No-load current 5.63 A

Control ParametersShuttle Function Lift Up Lift down Extractor

Menu Text Factory Setting P1 P2 P3 P4Acceleration delay ON OFF OFFCurrent limit 1 13.5 A 3Current limit 2 14.5 A 3.2Deceleration delay OFFDisconnection ramp ONBreak-point frequency 50HzStatic boost 15.0V 60Dynamic boost OFFTime dynamic boost 0.0sDC-brake OFFDC-brake time 1.0sDC-brake voltage 20.0VNominal value delay OFF 0.1 0.1Ramp down OFFSafety circuit OFFSlip comp. ONAuto. freq. increase OFF

Moment limit OFF 190% 150%

01/98


Technical Manual

OPERATION 10

10.21

Control TerminalsShuttle Function Lift Up Lift down Extractor

Menu Text Factory Setting P1 P2 P3 P4Mode Conn. input 0-10V limitedAlignment 1: 0%→ 0.00VAlignment 1: 100%→ 10.00VFilter Conn. input 1 offRadio Conn. input 2 noneAlignment 2: 0%→ 0.00V ↓ --- ↓ ---Alignment 2: 100%→ 10.00VFilter Conn. input2 offFrequency 100% 50HzPI-controller P 100%PI-controller I 10%/sLimit PI-controller 10.00HzCurrent limit 100% 8.2AMoment limit 100% 100%Analog output OFFStandard anal. output 100%Digital input 2 release leftDigital input 3 Fixed frequency 1 Suspend VoltageDigital input 4 Parameter set 1Digital input 5 Parameter set 2Digital input 6 error quitRelease active edgeMotor temp. protect. offRelay 1 Function Current: Off


Relay 1 Logic ORRelay 1 Current 5.50ARelay 1 IHyst. 10%Relay 1 Freq. 50.50HzRelay 1 Cont. 100min -1



01/98


Technical Manual

10 OPERATION

SHUTTLE 250 / 500

10.22

Shuttle Function Lift Up Lift Down ExtractorMenu Text Factory Setting P1 P2 P3 P4Relay 2 Logic ORRelay 2 Current 5.50ARelay 2 IHyst. 10%Relay 2 Freq. 50.50HzRelay 2 Trailing 100min -1



Menu Text Factory Setting P1 P2 P3 P4Language EnglishKey control offFactory setting Enter * Attention: Do not strike the ‘Enter’-key!!Password 0Change password 0Fixed frequency 1 10HzFixed frequency 2 20HzFixed frequency 3 40Hz 36Loss reduction offSwitching frequency 8KHzFade-out 1 high offFade-out 1 low offFade-out 2 high offFade-out 2 low offQuick-stop error offQuick-stop time 0.1sAutom. quit off alwaysAbs. min. frequ. 1.0Hz 2.0 2.0 0.3USS - mode slaveInterface localUSS - baud. 9600 baudUSS - address 0USS - time Out 0.0sRstat adaption offServo mode offPick-up rotation speed 4096Rot. speed controller P 100%Rot. speed controller I 10%/sT- PT1 Slip* 90 ms 40T- PT1 Isq* 80 ms 25T- PT1 Isd* 80 ms 25T- PT1 Speed 15 ms

* Should these values be invisible, select the menu function „service“ and change the password into the value „65“.

01/98


Technical Manual

OPERATION 10

10.23

List of Parameters for Frequency Converter SEW Movitrac, 2.2 kW in Shuttle 250with SEW- Drive System

Only the values differing from the factory setting (SEW) are shown. Please observe the order for the adjustment.Possible alternative values are in brackets.

Entry of Values:Move the cursor with the keys → /← to the appropriate position. Enter then the respective number (e.g. “802”)with the keys ↑/↓. Move with ‘→ ‘ right and select the respective value: e.g. „off“.Reset the cursor with ‘← ‘ and enter the next number, e.g. “120”. The values are then automatically saved. Thekeys “E” and “Q” are not used.

0. Presetting

802 Short menu OFF830 Factory setting Yes

(only necessary, if FI wasmodified by mistake, sub-sequently reset parameters)

1. Nominal Values/Integrators

120 1. Integrator t11 - up 0.9 s121 1. Integratort11 - down 0.25 s122 t11 S-Abrai.: 1130 2. Integrator t12 up/down 0140 t13 Quick-stop ramp 0123 1. Integrator t21 - up 0.5 s124 1. Intergrator t21 - down 0.1 s

2. Frequency Characteristics

200 Characteristic1:fmin1 3.0 Hz202 fmax 62 Hz260 Start-/Stop-Frequency 1 1.8 Hz210 Characteristic 2:fmin2 0 Hz261 Start-/Stop-Frequency 2 0 Hz

3. Motor Parameters

310 Rated current motor 1 100 %320 Imax 1 150 %321 Boost 1 75 %322 IxR 1 5 %

323 Slip 1 3.5 Hz

325 PWM- Frequency 1 8326 DC magnetization time 200 ms327 Post-magnetization time 150 ms328 Measure motor No329 Motor voltage 1 420 V350 Parameter switching Yes330 Rated current motor 2 20%340 Imax2 130%341 Boost2 100%342 IxR 1 5 %343 Slip 1 3.5 Hz344 PWM- Frequency 1 8345 DC magnetization time 200 ms346 Post-magnetization time 150 ms347 Measure motor No349 Motor voltage 1 420 V

6. Terminal Occupancy

600 Terminal 42 left/stop601 Release/Stop release602 Integr.-Switch. t2/t1 P-Switch.

7. Control Functions

710 Lifting device- function 1 Yes

01/98


Technical Manual

10 OPERATION

SHUTTLE 250 / 500

10.24

10.8 LAYOUT PLAN

HARD-STOP TOP

SOFT-STOP TOP for appliances > 1600mm

S3 HARD-STOP TOP

S7 SOFT-STOP TOP

EXTRACTOR

ACCESS AREA 1

1A6 KEYBOARD

LIFT CONTROL

Figure 1

B1 INCREMENTAL ENCODERM1 LIFT MOTOR

S4 HARD-STOP BOTTOM

B2 SOFT-STOP BOTTOM

Motor

Top View

Front

Figure 9

B6 Storage Angle Rear

B9 Tray Locking Rear (Option)

B4 Finger DownB7 Tray

B8 Tray Locking FrontB3 Stop Position

B5 Storage Angle Front

1Q1

1S8

1S1

1B1RP

1B3RP

1B51B4

1B1TP

1B3TP

1B3

1H8

1B2TP1B2RP

1H1

1S1E

1H2

1B41B3

Q1 Main Switch1H1 Control Voltage “On”1H2 Computer Interface “Yellow”1S8 Switch “Ready for Operation”1S1E Lighting Switch1S1 Emergency Switch1B3 Proximity Switch “Tray at Position Front Left”1B4 Proximity Switch “Tray at Position Front Right”1B5 Proximity Switch “Tray at Access”

1B1TP Transmitter Light Barrier Accident Prevention1B2TP1B3TP

1B1RP Receiver Light Barrier Accident Prevention1B2RP1B3RP Figure 2

03/98

Figure 17

Figure 18

Figure 19


Technical Manual

OPERATION 10

10.25

frontleft

front right

B3 Stop Position

B8 Tray Lockingfront

B4 Fingers down

B9 Tray Lockingrear

M

M

Stop Position Fingers Down

M

M

Fingers up

B3

Pos

ition

M

M

Tray Locking Front Trya Locking RearB

3 P

ositi

on

M

M

B8Tray Lockingfront

B9 Tray Lockingrear

Figure 8

frontleft

front right

B8 Tray Lockingfront

B4 Fingers down

B9 Tray Lockingrear

B3 Stop Position

B4 Fingers down B4 Fingers down

frontleft

front right

frontleft

front right

B8Tray Lockingfront

B9 Tray Lockingrear

Erro

rre

d

gree

n

red

yello

w green

-

+

Setting 1

-

+

Setting 2

yello

w

Nominal Value 1

Electronic Sys. Release right/up

Parameter Switching 1

Vacant

Figure15

IN1

IN2

IN3

IN4

IN5

IN6

IN7

IN8

IN9

IN10

IN11

IN12

IN13

IN14

IN15

IN16

IN25

OU

T3

OU

T4

IN30

IN31

IN32

SWV1

SWV2

SWV3

OUT6

OUT7

OUT8

OUT9

OUT10

S1Nominal Value 2

Nominal Value 3

Electronic Sys. Releaseleft/down

Parameter Switching 2

FR

EQ

U F

requ

ency

sig

nal r

elay

FR

EQ

U In

terf

eren

ce s

igna

l rel

ayLi

ft an

d E

xtra

ctor

The

rmos

tat

FR

EQ

U S

witc

hing

Ext

ract

or

FR

EQ

U S

witc

hing

Lift

Vac

ant

Ext

ract

or T

able

Loc

king

Rea

rE

xtra

ctor

Tab

le L

ocki

ng F

ront

Tab

le o

n E

xtra

ctor

Ext

ract

or S

tora

ge A

ngle

Rea

r

Ext

ract

or S

tora

ge A

ngle

Fro

ntE

xtra

ctor

Fin

gers

Dow

nE

xtra

ctor

Sto

p P

ositi

onV

acan

t

Vac

ant

Vac

ant

SR

-Circ

uit

Sof

t-Sto

p To

p

Sof

t-S

top

Bot

tom

Inc.

Enc

oder

Zer

otra

ckIn

c. E

ncod

er T

rack

A

Inc.

Enc

oder

Tra

ck B

03/98

Figure 20

Figure 21


Technical Manual

10 OPERATION

SHUTTLE 250 / 500

10.26

10.9 INFORMATION

10.9.1 Technical Updating from Software Revision1.01 onwardProximity switches 1B3 and 1B4 are no longer connectedin series. The function of the proximity switch 1B4 is thelocking, the function of B3 the unlocking. For the newlocation of incorporation of 1B3, we refer to the lay-outplan.Older appliances can be electrically updated. The locationof incorporation for 1B3 and 1B4 then remains unchanged.Furthermore, the base settings for Shuttle changed, see10.2.1.

10.9.2 Informations and Tips

10.9.2.1 Inserting/Deleting a Tray into/from the DataMemory

A tray will be inserted into the memory, when the function"tray from extractor to shelf position“ was carried throughcorrectly.A tray is deleted form the memory when the function „shelfposition to extractor“ was carried out correctly.

10.9.2.2 A Tray to be Stored is Pushed onto anotherTray.

A first-time operation with a loaded shuttle is carried out.If the function „996 Detection of Tray Position“ isactivated, it will be checked whether a tray is stored on ashelf position. The tray will be pulled onto the extractor.The proximity switch B7 verifies whether a tray is actuallyon the extractor. If this proximity switch is defective orbent too far down, the tray cannot be detected.

During the process of storing or extracting a tray, thepower or the appliance will be switched off. By doing so,the tray is positioned with one half on the extractor andwith one half on the storage position. After a manualcorrection it should be noted, whether the table of the shelfpositions is correct.

10.9.2.3 A Tray Connot be Stored, Although a ShelfPosition is Vacant

Check in the scroll-mode whether this shelf position isvacant or whether an undefined storage height isregistered.An undefined storage height might be caused by thefollowing cicumstances:After the service function „997 Detection of Shelf Positi-on“, all heights are undefined. The first-time operation hasnot been completely carried through.The shelf position for the access area had been enteredfirst incorrectly and was then corrected. The initial, wrongshelf position for the access area has to be corrected inthe scroll-mode. The undefined height (??) has to bechanged into 00.

10.9.2.4 The Lowest Shelf Position Has Not BeenDetectedSee 10.3.4

10.9.2.5 E75, The Shelf Distance Remained Underthe Minimum (125mm / from SIF V3.05100mm) Signalled by Service Function „997“

Check whether the minimal distance has beenobserved for the specified shelf position.The minimal distance has been observed (125 mm)for this shelf position.The minimal switch distance for the reflex-lightsensors B5 and B6 is 10 mm. Remains thedistance under this limit, it may occur that theproximity switch does not operate without fault. Theresult could be that several positions are detectedwithin a single shelf position.It may occur that painting scratches off the rollertrack and obstructs the area between vertical shelfsurface and reflex-light sensors.Attention! Do not switch off the appliance after E75.Note all wrong shelf positions. Activate servicefunction „998“. Check the wrong shelf position/s inthe scroll-mode by means of the „P“-key (TA3„CTRL P“).

10.9.2.6 E15, The Stop Tolerance of the Lift Has Not Been Observed

Check load of the lift.Check parameter sets frequency inverter.Check DC-braking resistance.

01/98


Technical Manual

OPERATION 10

10.27

10.9.2.7 E38 Extractor Function Has not Been Carried out in Previewed Time

Tray jammed.SR-circuit was interrupted for more than 50 sec.Error in the extractor control / GS145 OUT 4, see lay-outplan, figure 21, or contactor switching lift/extractor.

10.9.2.8 Lift Does Not Move / Wrong FrequencyCheck the frequency converter’s parameters according tothe list of parameters.Check output signals OUT6-OUT10, SW1-SW3 on GS145to the frequency converter, figure 21.

Parameter Code (Param. Switching 1/2)LED OUT9 LED OUT8 Parameter No.off off P1 (Lift up)off on P2 (Lift down)on off P3 vacanton on P4 (extractor)

Nominal Value Lift / ExtractorGS145 Lift ExtractorSWV Nom. Value max. Freq. max Freq.3 2 1 V 70Hz 50Hz0 0 0 10 70Hz 50Hz0 0 1 7,4 50Hz0 1 0 4 30Hz0 1 1 3,5 26,45Hz1 0 0 0 3Hz 3Hz1 0 1 0 3Hz 3Hz1 1 0 0 3Hz 3Hz1 1 1 0 3Hz 3Hz

10.9.2.9 Exposure to Sunlight PLS WeracRemedy: Mount red plexiglas behind the metal coverplate (SCI Bellheim).

10.9.2.10 Fixed Storage Mode with GS136 HDIFThe measured height is entered in the table.

10.9.2.11 E72If the FREQU’s display shows an error message, this errorcan be quitted with the button S1 on the Module GS145.The appliance does not need to be reset.

10.9.12 If the Extractor does not work after a Service(HARD-STOP Bottom)

Check bridge “BYPASS” in the control.

35 30

Gauge 3 Gauge4

258

Gauge 6 Gauge 6

Cable Color Beige

B6B5

Figure 7

10.9.2.13 Replacement of Reflex-Light Sensors B5, B6

If a reflex-light sensor B5 or B6 on the extractor isdefective, then the replacement has to be preadjusted asfollows: The adjustment is effected with gauges and theadjustment potentiometer on the sender as follows:Attention! Take note of the location of incorporation (seefigure 22).

LED on Reflex-Light Sensors B5/B6Gauge 3 Off adjust: of ON->FLASHES ->OFFGauge 4 On possibly readjust a little, if offGauge 5 OnGauge 6 Off

03/98

Figure 22


Technical Manual11.1

MAINTENANCE REGULATIONS11

11/98

11.1 MAINTENANCE REGULATIONS

The maintainance regulations are enclosed with the delivered documents of SHUTTLE with the basic unitin a ring binder.i


S h u t t l e

Id.-

Nr.

: 13

2501

.8 /

War

tun

gsv

. _ E


Parts list

12

FIG.1 MAIN ASSEMBLY 12.2

FIG.2 END FRAME 12.4

FIG.3 INTERNAL VIEW 12.5

FIG.3A RACK REINFORCEMENT 12.5a

FIG.3B RACK REINFORCEMENT AT 12.5bUNIT HEIGHTS > 7 M UP TO 26 M

FIG.3C RACK REINFORCEMENT AT 12.5cUNITS WITH RAISED LOAD

FIG.4 ACCESS 12.6

FIG.5 DOOR 12.8

FIG.6 EXTRACTOR 12.9

FIG.7 BASEFRAME 12.12

FIG.8 LIFT DRIVE 12.13

FIG.9 UPPER SPROCKET AND AXLE 12.14

FIG.10 ELECTRIC 12.15

FIG.11 INCREMENTAL COUNTER 12.16ON MOTOR

FIG.12 PHOTOCELLS LEFT AND RIGHT 12.17

FIG.13 HARD AND SOFT STOP LOWER 12.18

FIG.14A HARD AND SOFT STOP UPPER 12.19(OPTIMIZED MODE)

FIG.14B HARD AND SOFT STOP UPPER 12.20(FIXED MODE)

FIG.15 PROXIMITY SWITCH 12.21ACCESS OPENING

FIG.16 HEIGHT IDENTIFICATION 12.22

FIG.17 EXTRACTOR SAFETY SWITCHES 12.23

FIG.18 PROXIMITY SWITCH F. LOADING 12.24ON EXTRACTOR

FIG.19 PROXIMITY SWITCH FOR 12.25FINGER POSITIONS

FIG.20 PHOTOCELLS FOR THE 12.26SHELF POSITION

12.1 PURPOSE AND STRUCTURE OF THE PARTS LIST

The parts list gives you an exact overview of all mechanicaland electrical parts on a standard unit that can be exchanged

The parts list is made up as follows:

- drawings with item numbers and

- the relating part charts

These charts give you the item number of the concerned partand behind that you will find the company-internal partnumber (ident-no.) and the name of the part. Parts with noident-no. are specific to the unit or to application. Furthermore,DIN-standard parts do not have an ident-no., but the dimensionsand DIN-no. are given.

This way you can look for and order the part if replacement isnecessary.

When ordering, please state the ident-no. or the type/serial no.of the unit given on the upper part of the type plate.

DIN-standard parts can be ordered by means of the dimensionsand the DIN-marking or it may be possible to obtain themfrom other suppliers.

At all parts except for DIN-standard parts onlyoriginal replacements must be used, otherwiseliability is cancelled.!

PARTS LIST

12.2 TABLE OF CONTENTS OF THE PARTS LIST

09/98 12.1


Parts list

12 FIG.1MAIN ASSEMBLY

11/9812.2

1

2

6

8

13

11

12

9

10

14

7

15

3

5

4


Parts list

12FIG.1 MAIN ASSEMBLY

1 order no. side access panel20 214.3 oval head bolt M621 693.7 PAL-nut M6

2 order no. lower end frame assy.

3 order no. upper end frame 700 mm highorder no. upper end frame 800 mm highorder no. upper end frame 900 mm highorder no. upper end frame 1000 mm highorder no. upper end frame 1100 mm highorder no. upper end frame 1200 mm highorder no. upper end frame 1300 mm highorder no. upper end frame 1400 mm highATTENTION location see page 3.3

4 order no. top cover assy. middleM 6x16 hex. head boltDIN 933/8.8M 6 hex. nutDIN 934/8J 6,4 tooth washerDIN 1346,4 washerDIN 134

5 order no. top cover back/frontM 6 x 16 hex. head boltDIN 933/8.86,4 washerDIN 134J 6,4 tooth washerDIN 6797M6 hex. nutDIN 934/8

6 order no. lower panel

7 order no. upper panel 700 mm highorder no. upper panel 800 mm highorder no. upper panel 900 mm highorder no. upper panel 1000 mm highorder no. upper panel 1100 mm highorder no. upper panel 1200 mm highorder no. upper panel 1300 mm highorder no. upper panel 1400 mm highATTENTION location see page 3.3M 6 x 16 hex. head boltDIN 933J 6,4 tooth washerDIN 6797A 6 washerDIN 125/STM 6 hex. nutDIN 934/8

POS IDENT DESCRIPTION

8 order no. coutrol housing100 384.7 sliderM 8 x 25 verz. fillister head cap boltDIN 912/8.8100 382.1 handle PECO P225-132M8 x 16 fillister head cap boltDIN 912/8.8M 8 hex. nutDIN 934/83 273.0 zyl. lock

9 order no. access with or without door

10 order no. access panel lower

11 order no. panel-posting-table

12 order no. posting tableM 6 x 12 hex. head boltDIN 933/8.8J 6,4 tooth washerDIN 67976,4 washerDIN 134M 6 hex. nutDIN 934/8

13 order no. type plate

14 526.4 locating boltM 4 hex. nutDIN 934J 4,3 tooth washerDIN 6797A 4,3 washerDIN 7349

15 M 6 x 110 verz. hex. head boltDIN 931/8.8A 6,4 washerDIN 9021


01/98 12.3


Parts list

12

1

3

2

4

5

6

7

FIG.2

POS IDENT BENENNUNG

1 order no. endframe

2 103 152.5 connecting bracket small

3 103 153.3 connecting bracket large

4 M 8 x 20 hex. head boltDIN 933/8.88,4 washerDIN 134/ST

5 103154.1 connecting profile

6 38 400.8 Duo-Taptite M 8 x 18

7 M 6 x 20 hex. head boltDIN 933A 6,4 washerDIN 125/STM 6 hex. nutDIN 934/8J 6,4 tooth washerDIN 6797

ENDFRAME

11/9812.4


Parts list

12FIG.3 INTERNAL VIEW


1 order no. base frame see fig.7

2 order no. list motor see fig.8

3 29 282.1 levelling brackets

4 order no. tray support rightorder no. tray support left

5 order no. tray

6 order no. extractor cpl. see fig.6

7 order no. top safety plate (only for optimized mode)

8 20 214.3 dome head bolt M 66,4 washerDIN 134M 6 hex. nutDIN 934/8

9 order no. upper sprocket and axle assy.

10 order no. main chain DIN 8187 12B-1

11 order no. safety plate bracket leftorder no. safety plate bracket right

01/98

9

7

5

10

2

3

1

4

6

8

11

12.5


Parts list

12

12.5a09/98

32

ca.

350

Ger

äteh

öhe

/ uni

t hei

ght

Bei abweichender Entnahmehöhe gelten die Maße der Montage-anweisung der Entnahme.

At deviating access height,the measures of theassembly instruction of theaccess are valid.

4458

FIG.3A RACK REINFORCEMENT


Parts list

12

12.5b 09/98

4458

4458

4458

4458

4458

4200

4200

4200

4200

4200

4200

4200

4200

4200

4200

> 7 < 10 m

> 10 < 14 m

> 14 < 18 m

> 18 < 22 m

> 22 < 26 m

Rack reinforcement at units withraised load see FIG.3C

FIG.3BRACK REINFORCEMENT AT UNIT HEIGHTS > 7 M UP TO 26 M


Parts list

12

12.5c09/98

FIG.3C RACK REINFORCEMENT AT UNITS WITH RAISED LOAD

4458

4458

4458

4458

4458

4200

4200

4200

4200

4200

4200

4200

4200

4200

4200

7,1 - 10,9 m

11 - 15,1 m

15,2 - 19,3 m

19,4 - 23,5 m

23,6 - 26 m

bis/to 7 m

1600

+/-

200

1600

1600

1600

1600

1600


Parts list

12 FIG.4ACCESS

01/98

B

B A

A

B -BA -A

13

3

12 10

11 15

17

14

16

1

2

8

7

6

4

5

9

23

25

26

24

20

21

19

28 27 22

18

12.6


Parts list

12FIG.4

POS IDENT DESCRIPTION POS IDENT DESCRIPTION

23 M 4 x 8 slotted dome head boltDIN 85/4.84,3 washerDIN 125

24 M 6 x 12 boltDIN 933/8.8

25 20 214.3 oval head bolt M 6M 6 hex. nutDIN 934/8

26 order no. cross member tray release

27 16 359.2 fluorescent lamp

28 126 392.0 (Leuchte IL 1/18)4 687.0 slotted dome head bolt M 5 x 125,3 washerDIN 124M 5 hex.nutDIN 934

1 order no. access table cpl.

2 order no. access table support rightorder no. access table support left

3 4 388.5 slotted dome head bolt M 6 x 136,4 washerDIN 134M 6 hex. nutDIN 934/8

4 order no. access blind rightorder no. access blind left

5 order no. access panel rightorder no. access panel left

6 4 438.8 slotted dome head bolt M 5 x 8

7 100 252.6 tray stop right100 257.5 tray stop left

8 order no. tray stop release rod

9 3 x 16 spring pinsDIN 7346

10 M 5 x 16 verz. fillister head cap boltDIN 912

11 100 532.1 washer

12 M 5 x 10 verz. fillister head cap boltDIN 912

13 100 531.3 spacer

14 100 504.0 access roller

15 100 503.2 clevis pins with head roller shaftDIN 1444 ST

16 6,4 washerDIN 134173 351.4 securing clamp

18 order no. height sensor blind right see fig.16order no. height sensor blind left see fig.16

19 order no. roof support rightorder no. roof support left

20 order no. roof

21 526.4 locating pin4,3 washerDIN 134M 4 hex. nutDIN 934/8

22 order no. control panel

ACCESS

01/98 12.7


Parts list

12 FIG.5

257

Schließspalt einstellbarClosing gap adjustable

1

102

3

5

14

8

94

1312

11

6

7

DOOR


1 order no. upper door assy.

2 order no. lower door assy.

3 103 468.5 door guide r.h. assembled

4 103 469.3 door guide l.h. assembled

5 103 506.2 rope pulley

6 100 464.7 rope assy.

7 39 855.2 roller

8 38 937.9 sliding buffer

9 38 971.8 shoulder bolt M 6J 6,4 tooth washerDIN 6797A 6,4 washerDIN 125/ST

M 6 hex. nut, self. lockingDIN 958/8

10 3 273.0 cylinder lock

11 4 388.5 countersunk bolt M 6 x 13

12 136 118.7 potocell receiver see Fig.12

13 136 119.5 potocell receiver see Fig.12

14 M 6x10 boltDIN 7991/8.8M 6 hex. nut4543.5 washer

01/9812.8


Parts list

12

1

15 14

13

21

31

12 19

20 17

16

18

FIG.6 EXTRACTOR


1 order no. extractor cross section

2 order no. transport chain 5 08B-2 DIN 8187

3 order no. transport chain 4 08B-2 DIN 8187

4 100 537.0 transport finger left

5 100 536.2 transport finger right

6 100 217.9 proximity sensor plate

7 100 213.8 chain link long

8 100 216.1 chain link short 08B-2 DIN 8187

9 order no. chain 2 08B-2 DIN 8187



12 order no. cover guideM 4 x 8 tap might boltDIN 7516

13 100 169.2 proximity bracket4 426.3 slotted dome head bolt M 4 x 104,3 washerDIN 134M 4 hex. nutDIN 934/8

14 100 180.9 extractor roller bracket21 136.7 coach bolt M 8 x 308,4 washerDIN 134M 8 hex. nutDIN 980/8

15 101 537.9 Polyurethane wheel Poth 100/10P-NL35101 538.7 Axle10,5 DIN 134 washer101 539.5 hex. nut self lockingA11 DIN 7989 washer

01/98 12.9


Parts list

12

POS IDENT BENENNUNG

FIG.6EXTRACTOR

POS IDENT BENENNUNG

22 100 210.4 chain guide100 544.6 distance washer100 543.8 coach bolt M 5 x 25M 5 hex. nutDIN 985

23 100 189.0 chain tensionerM 4 x 16 shoulder boltDIN 912/12.9

24 100 541.2 spacer

25 100 540.4 bearing 6003-2RS1

26 100 192.4 sprocket

27 100 188.2 double sprocket rear

28 100 191.6 spacerDIN 988

29 100 548.7 double sprocket front

30 17 x 1 circlipDIN 471

31 103 519.5 belt sprocketA 6 x 6 x 25 feather keyDIN 6885M 5 x 10 thread boltDIN 914

16 100 206.2 distance marker21 136.7 coach bolt M 8 x 30M 8 hex. nutDIN 934/8

17 M 8 x 65 hex. head boltDIN 933/8.8M 8 hex. nutDIN 934/8

18 100 408.4 gear plateM 6 x 12 slotted head boltDIN 79136,4 washerDIN 134M 6 hex. nutDIN 934/8

19 100 580.0 extractor chain holding boltM 12 hex. nutDIN 934/839 872.7 chain link DIN 8187 S-12-B-1

20 100 581.8 sleeve13 washerDIN 1343 342.3 spring 3,2 x 25 x 113 C=5,065

21 100 224.5 drive belt100 225.2 chain link

01/98

"C-D"

2 8 67 5

3

2 4 7

22

7 5 9 7 5

2210 11

2423

28

26

27

25

29

30

"E-F"

12.10


Parts list

12FIG.6 EXTRACTOR

POS IDENT BENENNUNG POS IDENT BENENNUNG

32 104 968.3 roller D = 50

33 M6 hex. nutDIN 934/8104 267.5 sleeveM 6 x 40 Hex. head boltDIN 931/8.8

34 M 6 x 20 coach boltDIN 603/86,4 verz. washerDIN 134M 6 verz. hex. nutDIN 934/8

35 A-5 x 5 x 22 feather keyDIN 6885M 4 x 4 thread boltDIN 914

36 100 222.9 drive belt spocket P= 3/8", Z = 12

37 136 337.3 motor103 518.7 drive belt sprocketM 4 x 4 thread boltDIN 913

38 order no. drive shaft

39 M 5 x 12 slotted head boltDIN 7615-A

40 146 537.6 pipe clampM 4 x 12 cross recessed raised head bolt

41 146 537.6 pipe clampM 4 x 12 cross recessed raised head boltM 4 hex. nutDIN 394/8

42 M 6 x 16 hex. head boltDIN 933/8.86,4 washerDIN 134M 6 hex. nutDIN 985/8

43 M 6 x 20 hex. head boltDIN 965M 6 hex. nutDIN 985/8

44 105 336.2 cover guide

45 128 198.9 energy chain fixing

46 128 122.9 cover sheet steel

47 128 123.7 connector rail

48 M 6 x 16 hex. head boltDIN 933/8.8M4 hex. nutDIN 934/8

03/98

32 33 34 35

36

3738

39 40 41 42

444546

4748

43

12.11


Parts list

12

4

3

2

1

FIG.7BASEFRAME


1 order no. base frame

2 order no. cross member

3 M 8 x 20 hex. head boltDIN 933/8.8A 8 spring washerDIN 1278,4 MM washerDIN 134M 8 hex. nutDIN 934/8

4 104 428.8 rubber stop

01/9812.13


Parts list

12FIG.8 LIFT DRIVE


1 order no. motor 2,2 Kw

2 M 12 x 80 hex. head boltDIN 933/8.8A 13 washerDIN 125/STM 12 hex. nutDIN 934/8

3 order no. drive shaft

4 100 154.4 sprocket Z=21 3/4 x 7/16

5 B 8 x 7 x 39 keyDIN 6885

6 M 10 x 25 hex. head nutDIN 933/8.8100 139.5 washer 11/40 x 3

7 100 135.3 sleeve 35/47 x 30

8 100 138.7 bearing GG Pasey 35

9 M 12 x 40 hex. head boltDIN 933/8.8A 13 washerDIN 125/STM 12 hex. nutDIN 934/8

10 B12 x 8x 160 keyDIN 6885

11 see Fig.11 incremental counter

12 see Fig.7 base frame

03/98 12.13


Parts list

12 FIG.9UPPER SPROCKET AND AXLE


order no. upper sprocket and axle assy.

1 300 066.8 axle

2 order no. bearing tie-bar

3 103 440.4 sprocket Z=21 3/4 x 7/16

4 103 441.2 deep ball bearing

5 55 x 2 retaining ringDIN 472

6 103 438.8 sleeve

7 30 x 1,5 retaining ringDIN 471

01/98

3

4

1

5

2

6

7

12.14


Parts list

12

3

10

8 9

10

5

6

4

2a/b

1a/b

7


1a 16 293.3 limit switch, hard-stop upper

1b 38 968.4 limit switch, hard-stop upper

2a 16 293.3 limit switch, soft-stop upper

2b 38 968.4 limit switch, soft-stop upper

3 order no. control panel see Fig.4

4 126 294.8 incremental counter, lift see Fig.11

5 126 299.7 proximity switch, zero reference see Fig.13

6 16 293.3 limit switch, hard-stop lower see Fig.13

7 106993.9 proximity switch, tray at accesssee Fig.15 SH 250

7 126 291.4 proximity switch, tray at accesssee Fig.15 SH 500

8 136 118.7 accident protection light barrier, receiversee Fig.12

9 136 119.5 accident protection light barrier,transmitter see Fig.12

10 126 291.4 proximity switch, tray at pos. frontleft and right see Fig.15

Assemblies (a) for units with fixed mode

Assemblies (b) for units with optimized mode

FIG.10 ELECTRIC

01/98 12.15


Parts list

12 FIG.11


1 126 294.8 incremental counter lift

2 100 129.6 incremental counter bracket

3 M 4 x 8 shoulder boltDIN 84

4 3 344.9 clutch

5 3 343.1 blind nut

6 100 128.8 clutch axle

7 M 3 x 5 shoulder boltDIN 84

INCREMENTAL COUNTER ON MOTOR

01/9812.16


Parts list

12FIG.12 PHOTOCELLS LEFT AND RIGHT


1.1 103 468.5 door guide right assy. see Fig.5

1.2 103 469.3 door guide left assy. see Fig.5

2.1 100 341.7 blind left

2.2 100 340.9 blind right

3 136 119.5 werac transmitter

4 136118.7 werac receiver

5 4 388.5 countersunk bolt M 6 x 13 see Fig.5

6 M 4 hex. nutDIN 934/84,3 washerDIN 7349/AM 4 x 30 hex. head nutDIN 933/5.8

01/98

Ausführung ohneTür Ausfürung mit Tür

1.2 1.12.1 2.2

6

5

6

5

4

3

5

Model without door Model with door

12.17


Parts list

12 FIG.13


1 16 293.3 limit switch, soft stop lower

2 M 4 x 30 shoulder boltDIN 84/A/4.8M 4 hex. nutDIN 934/8J4,3 tooth washerDIN 6797

3 6 505.2 strain relief PG 13,5

4 126 407.6 proximity switch, zero reference

5 M 3 x 5 shoulder boltDIN 84/4.8

6 M 5 x 12 shoulder boltDIN 84/4.8M 5 hex. nutDIN 934/5

7 100 407.6 bracket

8 M 6 x 16 hex. head boltDIN 933/8.8M 6 hex. nutDIN 934/8A 6 spring lock washerDIN 127

HARD AND SOFT STOP LOWER

03/9812.18


Parts list

12FIG.14 A HARD AND SOFT STOP UPPER (OPTIMIZED MODE)

A

1

3

4

6

2

4

5

"A"


1 38 968.4 limit switch, soft stop upper

2 38 968.4 limit switch, hard stop upper


4 M 4 x 30 shoulder boltDIN 84/A/4.8J4,3 tooth washerDIN 6797M 4 hex. nutDIN 934/8

5 100 309.4 limit switch bracket

6 M 6 x 16 hex. head boltDIN 933/8.86,4 washerDIN 134A 6 spring washerDIN 127M 6 hex. nutDIN 934/8

03/98 12.19


Parts list

12 FIG.14 B


HARD AND SOFT STOP UPPER (FIXED MODE)

1 16 293.3 limit switch, soft-stop upper

2 16 293.3 limit switch, hard-stop upper


4 M 4 x 30 shoulder boltDIN 84/A/4.8J 4,3 tooth washerDIN 6797M 4 hex. nutDIN 934/8

5 300 478.5 bracket

6 100 413.4 switch profile

7 100 691.5 fixing plate

8 M 4 x 30 hex. head boltDIN 933/5.8M 4 hex. nutDIN 934/8

9 M 6 x 16 hex. head boltDIN 933A 6,4 washerDIN 125/STM 6 hex. nutDIN 934/8A 6 spring lock washerDIN 127

03/98

1

2

3

4

56

7

8

9

12.20


Parts list

12

1 126 291.4 proximity switch, front left and right

2 106 993.9 proximity switch, tray at access SH 250

2 126 291.4 proximity switch, tray at access SH 500

3 100 534.7 bracket

4 4 426.3 slotted dome head bolt M 4 x 10M 4 hex. nutDIN 934/8

5 M 3 x 5 shoulder boltDIN 84/4.8

FIG.15 PROXIMITY SWITCH ACCESS OPENING


proximity switch tray in position

proximity switch, tray at access

01/98

1

23

4

5

12.21


Parts list

12 FIG.16


1a 126 337.5 photocells transmitter126 338.3 photocells receiver

2a 126 169.2 self tapping bolt

1b 126 363.1 photocells transmitter126 364.9 photocells receiver

2b M 3 x 20 shoulder boltDIN 84/4.8M 3 hex. nutDIN 934/8

3b 100 702.0 photocell bracket

4b M 3 x 20 shoulder boltDIN 84/4.8M 3 hex. nutDIN 934/8

HEIGHT IDENTIFICATION

01/9812.22


Parts list

12FIG.17 EXTRACTOR SAFETY SWITCHES


1 136 337.3 Extractor motor

2 126 292.2 proximity switch stop position

3 126 293.0 reflection light barrier front shelf

4 126 293.0 reflection light barrier back shelf

5 126 292.0 proximity switch tray hold front

6 126 292.0 proximity switch "tray on extractor"

7 126 292.2 proximity switch "finger bottom"

8 126 292.2 proximity switch tray hold backOption

01/98

ANSICHT VON UNTENBOTTOM VIEW

HINTENBACK

VORNEFRONT

4

8

7

6

5

1

3

2

Option

12.23


Parts list

12 FIG.18PROXIMITY SWITCH FOR LOADING ON EXTRACTOR


1 126 292.2 proximity switch, tray on extractor

01/98

2

1

12.24


Parts list

12FIG.19


1 126 292.2 proximity switch, finger down

2 126 292.2 proximity switch, tray hold front

3 126 292.2 proximity switch, extractor stopposition

PROXIMITY SWITCH FOR FINGER POSITIONS ON EXTRACTOR

01/98 12.25


Parts list

12 FIG.20PHOTO CELLS FOR THE SHELF POSITION


1 126 293.0 reflex photocell for shelf front

2 126 293.0 reflex photocell for shelf rear

3 100 169.2 reflex photocell bracket

4 M 3 x 20 shoulder boltDIN 84/4.8A 3,2 washerDIN 125M 3 hex. nutDIN 934/8

5 4 426.3 coach bolt M 4 x 104,3 washerDIN 134M 4 hex. nutDIN 934/8

01/9812.26


Technical Manual

13APPENDIX

A ATTACHING THE STICKERS (ACCOMPANYING DOCUMENTS)

A-111/98


Technical Manual

13APPENDIX

B MOTOR DOCUMENTS

B-101/98


Technical Manual

13APPENDIX

C-1

C CHECK-LIST FOR MODULAR LIFT "KARDEX-SHUTTLE" (ACCOMPANYING DOCUMENTS)

01/98


Technical Manual

13APPENDIX

D-1

D FIELD-QUALITY-REPORT (ACCOMPANYING DOCUMENTS)

01/98

Documents

Micrografx Designer 7 - th sh 250 e · C CHECK-LIST FOR MODULAR LIFT "KARDEX-SHUTTLE" C-1 D FIELD-QUALITY-REPORT D-1 III TECHNICAL MANUAL Table of contents 03/98. SHUTTLE 250 BELLHEIMER