Avanta Shuttle Racking
Avanta Shuttle Racking
1 January 2013
Pallet Shuttle
USER GUIDE
Workspace Creation
Call: 0800 975 4933
Contents
Introduction 3
General Description 4
Pallet Structure 6
Stndard Equipment 6
Warrenty 7
Battery Detail 8
Shuttle Power-on 10
Safety Bumpers 16
Shuttle Functions 16
Standard Functions
Optional Functions
Maintenance 22
Standards 23
Moresecure understands the information in this leaflet is correct at the date of publication. All reasonable care has been taken to make it
as complete and accurate as possible, no liability can be accepted for any inaccuracies or omissions.
Introduction
CAUTION:
Read this manual before installing and using the Pallet shuttle.
The information contained in this manual must be followed and is intended as a guide to
protect people, property and provide a safe working area when using the shuttle device.
The pallet shuttle contains components that can be damaged if used incorrectly.
For any questions regarding the functionality of the shuttle system, contact your supplier
service & support department.
The shuttle must only be used by personnel who have received training from the supplier.
The shuttle must be operated in line with the details in this manual.
RECOMMENDATIONS:
a) Before using the shuttle carefully read the operating instructions supplied.
b) While using the shuttle, the operator using the system must be the only
person in the working area.
c) The radio control unit must be charged for at least 12 hours
before initial use to avoid potentially damaging the battery.
d) Charge the shuttles lithium battery for a minimum of 5.5 hours.
e) Do not open the shuttle main body for any reason without permission from
the supplier.
f) There are no user servicable parts inside the main body of the shuttle.
g) The standard warranty period is 12 months.
h) If the shuttles lithium battery remains unused, re-charge after one month for
a minimum of 5.5 hours.
i) The shuttle is suitable for use in dry, dust free environments.
3
General Description
The pallet shuttle is powered by an innovative lithium ion battery. The machine runs on
specially designed rails that allow the storage of material loaded on pallets / containers of
wood or other material, in a pallet racking system specifically designed for the application.
The shuttle, is able to pick up, deposit and reorder the pallets with extreme precision.
The shuttle contains:
- Nr. 2 Proximity sensors
- Nr. 2 Inductive sensor STOP
- Nr. 1 Lithium Battery
- Nr. 2 Pallet safety sensor
- Nr. 2 Emergency buttons
- Nr. 1 ON/OFF button
- Nr. 2 Safety bumpers
Shuttle operators must be trained and competent in the use of the equipment. Every person
who has access to the working area the shuttle must be aware of the active and passive
safety systems.
SHUTTLE MODELS
MODEL MAX LOAD (Kg) PALLET DEPTH(mm) PALLET FRONT(mm)
SHUTTLE VERSIONS
ST = Standard: Ambient environment (+0°C a +45°C).
BZ = Below Zero: Cold Store (-1°C a -30°C).
4
Datasheet
PERFORMANCE MOTORS
Speed with load 30-33 m/min Running 700 W
Speed empty 63-66 m/min Lifting 400 W
Working range 10 -16 h REMOTE CONTROL
BATTERY Kind RF
Kind Ion MNC Display LED
Voltage 24V Language ENG-CN-RU-
DE-PLFR
Capacity 53 Ah
Protection IP65
Weight 14Kg
Power supply Lithium
Charger 240/50 Vac/Hz
Battery 500mAh
Charging time 80% 3 h
TX consumption 55mA
Charging time 100% 5,5
RX consumption 50mA
Batteries quantity 1
Stand-by function 3min.
Battery life Min. 900 charges
Battery duration Continuous
COLOUR 10h-22h
Chassis: RAL 6032 Cover: RAL 7035
5
Packaging & Handling
The shuttle is delivered packaged in a fumigated wooden crate to meet international standards.
- Take care when opening the box.
- Only move the shuttle with a forklift capable of lifting the weight.
- Maximum weight of the shuttle (including case) = approx. 350kg
- The shuttle, is delivered wrapped in a
protective film or barrier bag which can create
condensation and moisture if left in for a long
period of time.
- Upon receipt, remove the shuttle unit
from the wooden box.
- In order to avoid damage to electronics and
mechanical parts, take care when fitting the
components and charging the batteries of the
shuttle and the Remote Control.
Pallet Structure
The shuttle is designed to transport wooden pallets as standard.
Note: - The shuttle is capable of carrying different
types of loads, such as steel and plastic pallets.
The shuttle system will need to be designed
specifically for these applications prior to the
project and upon submission of engineering
drawings / sample c / o the manufacturer
Automha (for testing system functionality).
It is important that all the pallets have a central
block as shown.
Standard Equipment
Each Machine
- N° 1 LED Remote control
- N° 1 Lithium battery
- N° 2 Eyebolts
- N° 1 Lithium battery charging station
- N° 1 User’s manual
- N° 1 Wooden box
6
Warranty - 12 months
All mechanical and electronic equipment is covered by a 12 months warranty effective from
the shipping date. Labour, transport and accommodation costs are chargeable.
During the warranty period we will repair the machine free of charge.
Contact your supplier for details.
Any other indemnity is excluded, and any direct or indirect damage of any nature and type,
included temporary unavailability of the machine, cannot be claimed.
Warranty does not apply to components not used according to the instruction given by the
supplier.
Incorrect use will invalidate the warranty.
The pallet shuttle unit should be serviced after 12 months or 60.000 mission which ever
comes first. (Additional cost)
7
Battery Detail
The shuttle battery uses Lithium technology with high performance and low weight against
standard AGM batteries with the same capacity.
Capacity 53Ah shuttle battery: - weight 14kg against 40kg of AGM units.
The battery contains:
Nr. 2 warranty seals
Nr. 1 Shock sensor
Nr. 1 START button
IS STRICTLY FORBIDDEN TO OPEN THE COVER OF THE BATTERY, BREAKING THE
SEALS, INVALIDATES THE WARRANTY.
- Do not tamper with the casing
- Do not remove seals
- Do not open the cover for any reason
- Do not use as an external power supply for other purposes
- The battery pack is fitted within an impact indicator, when activated the warranty is void.
- When unused, the battery pack loses 3% of its capacity per month when less than 21V,
if more than 21V - 1% per month.
- Always charge the battery every month if unused for a minimum of 5.5 hours
- Remove the battery from the charger once charging is complete.
- Do not carry the battery inside the cab of the truck for any reason, carry the battery
by hand.
A unique feature of this battery pack is the absence of a “memory effect”, so it is possible,
in an emergency, to recharge for less than the optimum time for charging.
The battery pack can be on charge for more than 5.5 hours, the charger automatically stops
charging when the battery level reaches 100%.
Please note that correct fitting of the battery is important. Incorrect positioning of the
connectors leading to their damage will invalidate the warranty.
If the shuttle is not to be used for a prolonged period of time, remove the battery from the
shuttle unit and keep at room temperature and free of moisture.
8
Battery Pack Quick Guide
INSERTING THE BATTERY & STARTING THE SHUTTLE
- Insert the battery pack into the shuttle
- Press and hold the START button on the cover of the battery (min.7sec)
- Turn on the shuttle by pressing the button (ON / OFF) on the front of the shuttle
- Release the START button on the cover of the battery
BATTERY CHARGE
Charge the battery immediately as soon as the battery is low
- Insert the battery into the battery charger compartment
- Turn on the battery charger using 0-1 key.
- The CHG LED blinks
- When the CHG LED stops flashing, the battery is fully charged
9
Shuttle Power-on
Insert the battery pack into the shuttle battery compartment
Press and hold the start button on the cover of the battery for 7 seconds, continue to hold
the START button down and press the ON / OFF on the front of the shuttle.
Once the shuttle is activated (the on / off button is illuminated) you can release the START
button on the cover of the battery.
The shuttle power button ON / OFF will flash for approx. 3/4 seconds, after which the
shuttle is ready for use.
While the button is flashing, the shuttle carries out an automatic check of all electrical
controls and software and run diagnostic testing of all of the safety modules.
10
Remote Control Overview
Antenna
The screen on the Remote control
displays the status.
READY Ready to be used
The remote control is now ready to
LED Display be used.
Pallet In
Each remote control can command
Pallet Out
up to 4 machines at the same time
Compacting Continuous by selecting the appropriate number
Stop Unloading (1 to 4).
Forward
Lift Up
Lower Down
Backward
shuttle
Number Manual Functions - See Page 13
Horn
Management Software (Only to be used in exceptional
Menu Programming circumstances)
WARNINGS
- Do not tamper with the casing of the remote control.
- Any evidence of tampering will invalidate the warranty.
- Do not allow the remote control to come into contact with water / liquid.
- The battery in the remote control can only be purchased from the manufacturer.
- Charge the remote control for 12 hours before its first use
- Charge the remote control at room temperature
- Recharge the transmitter for a minimum of 12 hours each charging
- In the event of any problems, contact the supplier.
THE STOP BUTTON (RED) IS ALWAYS ACTIVATE ON THE REMOTE CONTROL
BATTERY DATA
- Typical Battery use at +20C in continuous TX-RX: min 16h max 22h
- Typical Battery use at -30C in continuous TX-RX: min 10h max 14h
- Typical Battery use at +20C in stand-by: 43 days
All the tests and checks based on laboratory findings.
11
Remote Control Operation
AUTOMATIC COMMANDS
Commands can be sent simultaneously to multiple shuttle units.
Command Menu Description
IN Load.
OUT Unload
Continuous unloading.
OTHER COMMANDS
Command Menu Description
F Software programming
12
MANUAL COMMANDS
Only to be used in exceptional circumstances
Commands can be sent only to a single shuttle in manual mode.
While in manual handling mode all the security checks are not enabled.
The supplier / manufacturer is not responsible for damage to property / persons caused
by the operator or conductor in manual handling.
While in manual handling the shuttle recognizes only the end of the aisle and does not
recognize the presence of any pallets present in the channel lane.
Command Menu Description
UP Lift UP.
FWD Forward.
BKW Backward.
13
Remote Control Menu
From the home screen, press the MENU key to access the administration menu.
With FORWARD and BACKWARD buttons you can scroll through the items.
In “menu management” is not possible to send commands to automatically or manually
operate the shuttle unit.
To enter and exit the various items you must press the MENU key to exit the MENU you
must select the EXIT MENU on the screen.
14
ALARMS DESCRIPTION
Alarm Description
When the battery voltage reaches the threshold of 23.5V the shuttle warns us with a sound
(5 seconds siren, 20 seconds silence).
When the battery voltage reaches the threshold of 22.8V the shuttle returns to H1 (Home1:
front warehouse), the unit will no longer accept missions and will automatically turn off after
1 minute. At each attempt to restart, the shuttle will remember that the battery is low and
then turn off again after 1 minute.
To restore the normal situation, the battery voltage must be greater than 25V.
15
Safety Bumpers
- Once the safety bumpers have been activated, the shuttle will sound an alarm
- Once the the shuttle alarm has been activated it will wait 60 seconds, after which it will
resume the mission.
- In an emergency, the red mushroom emergency stop button on the front and rear of all
shuttle units can be used.
Shuttle Functions
STANDARD FUNCTIONS
When the shuttle unit receives a mission it automatically beeps for 1 second to alert the
operator that the mission has been accepted.
Command Menu Description
16
STANDARD FUNCTIONS continued
Command Menu Description
OPTIONAL FUNCTIONS
Command Menu Description
17
OPTIONAL FUNCTIONS continued
Command Menu Description
18
OPTIONAL FUNCTIONS continued
Command Menu Description
19
Cold Store Applications
The information contained in this manual is provided to protect the shuttle unit and it’s
functionality over time.
The shuttle contains electronic components that can be damaged by low temperatures if not
operated in the correct manner. It’s essential that the manual is read, understood and the
actions stated are implemented.
For proper use, follow the instructions below: -
THE SHUTTLE UNIT MUST REMAIN AT THE OPERATING TEMPERATURE
The speed of the pallet shuttle unit used in cold storage will be decreased by 20%, at full
speed the formation of ice along the guide may cause the machine to lose traction.
The shuttle unit must always remain inside of the refrigerator to avoid condensation that may
occur by the transition from cold storage at cold temperature to an area at room
temperature with higher temperature.
When the shuttle unit is inside the cold store unused, it must fitted with the power supply
unit delivered with the kit BZ (Below Zero), to keep the electronics warm. (Red box provided)
Remove the battery and then plug in the red power
adapter supplied:
After inserting the adapter into the battery compartment
of the shuttle, follow the instructions below:
- Turn on the power supply by pressing the
ON/OFF button on the cover.
- Turn shuttle on using the green button ON/OFF
The shuttle battery is equipped with heating resistors.
Self-heating (only in a refrigerator):
The heating system is activated when the cell temperature is below +5 C Celsius.
The heating system is turned off when cells reach a temperature> = to +10 Celsius.
BATTERY CHARGING
The battery pack must be charged outside the operating cold store. Recharge the batteries
from temperature> +5 ° C and <+45 ° C
It is important to avoid condensation, wipe with a dry cloth before charging/fitting the battery
BATTERY CHANGE
When the shuttle battery requires charging, recharge, then the substitution can be made in
the cold room.
20
SUMMARY
Inside the Pre-cell Temperature Ambient
freezer (> +5°C) (> +15°C) Environment
The shuttle must remain Battery Remote control Battery
active in work or supplied charging charging storage
from the external red box
Recharging not allowed Maintenance Battery charging Remote control
storage
Battery substitution Yes Yes Yes
WARNINGS
Moving the machine from the cold store to an area at room temperature and vice versa can
cause condensation due to thermal shock.
This must be avoided!
If this has to be done, pass the unit through the pre-cell refrigerator, thoroughly dry to avoid
the formation of ice on the optics of the sensor when within the cell.
21
Maintenance
The shuttle is designed and manufactured to reduce maintenance to a minimum.
The shuttle is semi-automatic, the operator must perform the following actions before each
use.
We recommend maintenance of the machine at least once a year or every 60,000 missions,
to check required mechanical & electronic components.
Please note that the shuttle pops up a warning beep and the display on the remote control
when it's time to service (recommended).
For the maintenance of channels and for recovery of shuttle inside the racking, the supplier
recommends the purchase of an AUTO-SERVICE unit, a maintenance carriage.
AUTO-SERVICE USAGE:
Auto-service:-
- Maintenance activities within the rack
- Shuttle recovery in case of damage
due to an external cause
Auto-service features:
- Crank manual handling
- Anchor rods with shuttle
22
Standards
SHUTTLE STANDARD
Number ref. Description
23
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The information contained in this leaflet was accepted as correct at the date of publication. Although all reasonable care has been taken to make it
as complete and accurate as possible, no liability can be accepted for any inaccuracies or omissions. E + OE.
Avanta UK Ltd • Unit B1 • Astra Park • Parkside Lane • Leeds • West Yorkshire • LS11 5SZ