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AutoCrib RoboCrib 2000 E Operation Manual Download Page 32

Troubleshooting 

 

32 | 

P a g e

 

 

Problem:  Open Door error message or LED does not turn on when door is open 

 

1. 

 

Test all doors using Console screen 

 

 

Login to the RoboCrib software as a supervisor and select the Console button. 

 

Actuate each individual door by using the LON ## command (## - Representing the door number) 

 

If all LED lights turn on when the door opens, continue troubleshooting steps.  Otherwise, use the 
spare door provided with the RoboCrib. 

 

2.  Manually test the doors 

 

 

Turn the controller off.

 

 

Remove the left door screws and open the left door.

 

 

Detach the ribbon cable from door 1.

 

 

Turn the controller on.

 

 

Verify the door switch is in the Run position.

 

 

Restart the RoboCrib software.  If the machine calibrates successfully, the faulty door has been 
located.  Replace this door with the spare provided with the RoboCrib.  

 

 

If the RoboCrib cannot calibrate, continue with the steps below.

 

o

 Turn the controller off.

 

o

 Reattach the ribbon cable to the door.

 

o

 Unplug the next door.

 

o

 Turn the controller on.

 

o

 Restart the RoboCrib software.  If the machine calibrates successfully, the faulty door has been 

located.  Replace this door with the spare provided with the RoboCrib.

 

o

 If the RoboCrib cannot calibrate, continue with steps (i) through (v) to find the problematic door.  

 
 

 

 

Summary of Contents for RoboCrib 2000 E

Page 1: ...3011 S CRODDY WAY SANTA ANA CA 92704 Phone 800 671 6501 RoboCrib 2000 Model E Operations Manual Last Revision July 2009 ...

Page 2: ...rranty period covers all components sub systems and complete machines subject to the limitations and exclusions below Any parts or services replaced or serviced pursuant to this warranty are warranted only for the balance of the remaining warranty period AutoCrib will dispatch an AutoCrib technician authorized AutoCrib dealer technician or a certified third party technician to your facility to per...

Page 3: ... modifications or general neglect including electrical spikes surges and sags caused by poor power management thunderstorms or acts of god or lack of normal power conditioning for electronic manufacturing equipment 2 Damage caused by exposure to liquid spills collision fire theft freezing vandalism riot war explosion or objects striking the machine such as fork trucks or exposure to abnormally cor...

Page 4: ...during normal business hours pursuant and subject to the foregoing provisions Regardless of whether the buyer s limited remedy has failed of its essential purpose AutoCrib shall not be liable in any event for any special indirect incidental or consequential damages including but not limited to lost profits nor shall any claim or recovery of any kind exceed the purchase price of the machine or syst...

Page 5: ...TING COMMON PROBLEMS 24 INSTALL OR REPLACE THE TOUCH SCREEN DISPLAY MODEL C ONLY 24 SYSTEM WILL NOT CALIBRATE 24 SOFTWARE WILL NOT INITIATE THE CALIBRATION SEQUENCE 24 ROBOCRIB WILL NOT DISPENSE 24 MANUAL SWITCHES ARE NOT OPERATIONAL 25 BIN DOOR WILL NOT OPEN 25 REPLACEMENT OF CONTROLLER 25 CHAIN NEEDS TO BE REMOUNTED BECAUSE IT HAS BROKEN OR COME OFF OF THE GEARS 25 PROBLEM RECEIVING A JAM OR STA...

Page 6: ... ARMS AND TRAY ASSEMBLIES 36 CALIBRATOIN AND ALIGNMENT 37 BIN DOORS AND BAFFLE ASSEMBLIES 37 APPENDIX 38 APPENDIX I 38 ROBOCRIB CONTROLLER COMMANDS 38 APPENDIX II 39 EXPLANATION OF ERRORS ON A ROBOCRIB 39 JAM ERRORS 41 DOOR MAINTENANCE 50 ROBOCRIB 2000 BIN LAYOUT 52 CARE AND MAINTENANCE 53 REPAIRS 53 CLEANING 53 CLEANING STAINLESS STEEL SURFACES 53 SAFTELY INSPECTION 53 ...

Page 7: ...oller Power Panel 255 805 Hub 5 Port 775 525 RP Door Assembly 312 001 Key Replacement 2 per set 775 525 S RP Door Assembly Frameless 282 112 Keyboard Cover 770 404 Door Solenoid Latch Assembly 770 150 Leveling Foot Pad Set 170 376 Door Ribbon Cable 329 900 2 Logo and Model Panel 282 105 Keyboard Trackpad USB 371 241 Main Platter Lock Bracket 610 252 RP Touch Screen Replacement Kit 990 781 Pin In H...

Page 8: ...hat this machine be hooked up to the proper voltage and polarity for your country Use a Voltmeter to verify voltage and polarity Should the reading be any different from a normal reading or if you are unsure of what the reading should be contact an electrician CAUTION Different countries may have unique plug arrangements Ensure that the machine is properly grounded before operating CAUTION The mac...

Page 9: ...e RoboCrib to its final location Store the pallet and straps for possible future use Installation 1 Locate the keys attached to the keyboard plate by zip tie 2 Unlock the Controller Access Door and the Computer Access Door 3 Remove the Logo Sign pin in hex driver and leveling feet stored in a box behind the computer The box will also contain a spare door network hub CAT5 cables and spare fasteners...

Page 10: ...er Locking Bolt and Clamp The Main platter locking bolt and clamp is located on the sensor bracket below bin door 1 Loosen the lock nuts and unscrew the bolt using two 9 16 wrenches Removing Top Arm Lock Remove the Top Arm Lock by removing the two 3 8 hex bolts that hold the lock bracket to the crossbar The bracket slides off the end of the stack support arm Retain the bolts brackets and nuts for ...

Page 11: ...Avoid using circuits that have loads or surges from adjacent equipment 3 Position the UPS so that the RoboCrib power cord can be attached Attach the cord to a battery protected outlet on the UPS 4 Route the CAT5 cable into the machine along the same path as the power cord Attach the CAT5 cable from the NIC card 4 on diagram located at the bottom of the computer to the LAN drop provided by the cust...

Page 12: ...g each motor please note how the platters should react to the movement See the appendix for a drawing of the motors platters and bins 2 Test the door baffle by positioning the Direction switch in either the CW or CCW position and actuating the Baffle switch Main Main Platter the entire internal array will rotate LSP Large Sub Platter 3 individual and 3 groups of 3 trays assemblies will rotate SS3 ...

Page 13: ...r LAN settings Turn off the AutoCrib software STEP 2 Restore the Database Unzip the file database received from AutoCrib s customer service department into C Program Files Microsoft SQL Server MSSQL 1 MSSQL Backup Start the Microsoft SQL Server Management Studio software Connect to the server o Server Name Computer Name AUTOCRIB53 o Authentication SQL Server Authentication o Login sa o Password Au...

Page 14: ...hin the Specify Database screen Highlight the BAK file saved in C Program Files Microsoft SQL Server MSSQL 1 MSSQL Backup Then select OK Select OK in the Specify Backup screen Within the Select the backup sets to restore menu check the Restore box In the upper left hand corner of the screen under the Select a page menu select Options ...

Page 15: ...QL Data The select OK Under the Recovery state menu verify Leave the database ready to use by rolling back uncommitted transactions Additional transaction logs cannot be restored RESTORE WITH RECOVERY is selected Select OK Once the message The restore of database autocrib53 completed successfully appears select OK CONGRATULATIONS The database has now been restored and you are ready to begin using ...

Page 16: ...Navigate to Tools Options Locations o Verify the following Server Management Station pc Name autocrib53 i e mgmtstation autocrib53 OR Management Station IP Address autocrib53 i e 192 168 168 24 autocrib53 Database Name autocrib53 Username sa Password AutoCrib2005 This password will be encrypted o If the RoboCrib is not viewing the correct database select Edit and enter the correct server name data...

Page 17: ...ration Open the door panel and manually open the door o Swing the door back and forth to loosen the spring o Look to see if the plunger is aligned with the door latch If the alignment is off adjust the door up or down depending on how the door shifted during shipment o While the doors are closed there should be an equal amount of space between the top and bottom of each door o See further Bin Door...

Page 18: ...e Purchasing report category of the Reports module STEP 7 Stock RoboCrib At the RoboCrib insert the badge number and PIN Note At least one employee must be setup as a stocker in the AutoCrib software Select the Stock Auto Tag buttons Insert the tag number noted on the Inventory Input Sheet report The RoboCrib will prompt the following o Is tag complete Yes all items on the tag are available for st...

Page 19: ... platters until the first bin on the Inventory Input Sheet is in front of the door Once the door opens place the appropriate item into the bin Close the door to stock the next bin NOTE If the tag is not complete you will be asked if the part can be fulfilled for each line on the tag Physical by Bin At the RoboCrib insert the badge number and PIN Note At least one employee must be setup as a stocke...

Page 20: ...ware Return At the RoboCrib insert the badge number and PIN Select the Return button Select the item you wish to return by either scrolling down or search for the item Press Enter Highlight the desired item Insert the quantity being returned into the appropriate field return scrap or regrind Place the item in the correct return location regrind bin active RoboCrib bin or trash Note An item can onl...

Page 21: ...e the bin has been positioned in front of the doors you must open the door LON DD D is for door number I e LON 15 will open door 15 An invalid bin number will return an error E2 If the tray configuration is unknown please refer to the number scheme provided at the time of installation Other commands that can be used o RSA Report Status All If system is calibrated and all doors are closed the syste...

Page 22: ...Standard Reports module within the Purchasing report category o The proper bins will align to the door The RoboCrib program will display the item and the bin it is assigned to Once the bin has been stocked close the door The RoboCrib program will display the next item to be stocked and the bin it is assigned to Continue this process until the stocking procedure has been completed o The process may...

Page 23: ...Crib software will not start o Exit the RoboCrib software o Launch the MTTTY program from the desktop o Select the File menu Com Port Select COM2 Connect o The software will position a black cursor in the lower left of the editor screen o To fetch a bin type FET BBB P B is for Bin Number P is for Baffle Position I e FET 21L 3 will call bin 21L and set the baffle position for a fourth pie o Baffle ...

Page 24: ...ection Step 3 System will not Calibrate The RoboCrib will automatically begin the calibration procedure when the RoboCrib software is started If the machine is unable to calibrate the software will provide the user with an error message Please refer to Appendix II Software will not Initiate the Calibration Sequence Verify all doors are closed or set the bin door bypass switch to TEST Controller po...

Page 25: ... the Right Front panel section so that the display and controller are accessible Disconnect the door wiring motor wiring sensor wiring on top of the controller DB9 cable and power cable from the computer Remove the controller panel door Remove the four screws that hold the control panel to the vertical Z channels Chain needs to be remounted because it has broken or come off of the gears Position t...

Page 26: ...locks counterclockwise Remove the left door hold down screws using a 1 Phillips driver The left door will swing open The bin doors and baffle assembly are mounted to the door unlike other RoboCribs NOTE THE MOTORS WILL TURN AND THE BINS WILL MOVE WHEN THE LEFT DOOR IS OPEN ALWAYS EXERCISE CAUTION WHEN REACHING INTO THE MACHINE OR USING THE MANUAL SWITCHES WHEN THE LEFT DOOR IS OPEN ...

Page 27: ...eached from the front or top remove the right access panel using the 5 32 pin in hex driver to remove the security screws 3 Issue from RoboCrib Once the jam has been cleared rotate the LSP and SSP motors 360 degrees to verify the stacks are not being impeded Replace the rear panel close the left door and replace the door retaining screws Close the right door and secure with the locks Start the sof...

Page 28: ...ed completely If the headers are properly in place use a voltmeter or continuity tester to verify the continuity of each lead back to its corresponding pin at the motor location Call AutoCrib technical support for assistance The headers and corresponding systems are H1 BAFFLE 5 PINS WHITE BROWN BLUE NONE RED BLACK H2 LSP 8 PINS RED WHITE BLACK GREEN BLUE NONE ORANGE BROWN H3 BIN DOORS 26 PIN RIBBO...

Page 29: ...en the door Login to the RoboCrib software as a supervisor Select the Console button Actuate the door by sending the open door command in the Console screen o LON Representing the door o If the door opened attempt to issue a tool through the RoboCrib software If the RoboCrib dispenses correctly there is no further troubleshooting that needs to take place o If the door did not open check the ribbon...

Page 30: ...Crib Turn the controller off Remove the entire door Place the jumper on the appropriate pin of the new door Install the new door and attach ribbon cable Turn the controller on and attempt to issue through the RoboCrib software If the RoboCrib dispenses correctly contact AutoCrib technical support to receive a replacement door If the RoboCrib does not dispense correctly contact AutoCrib technical s...

Page 31: ...f attempt to issue from the RoboCrib If the RoboCrib dispenses correctly no further troubleshooting is required 2 Adjustment of the back side solenoid encoder Turn the controller off Adjust the back encoder U3 position on the board that is behind the solenoid against the back wall of the door o Use a non magnetic flathead screwdriver and place it in between the encoder and the plunger wall o Push ...

Page 32: ...n the left door Detach the ribbon cable from door 1 Turn the controller on Verify the door switch is in the Run position Restart the RoboCrib software If the machine calibrates successfully the faulty door has been located Replace this door with the spare provided with the RoboCrib If the RoboCrib cannot calibrate continue with the steps below o Turn the controller off o Reattach the ribbon cable ...

Page 33: ...eyboard cleaner o DO NOT place any liquid into the keyboard This may damage the internal workings of the keyboard o AutoCrib suggests cleaner be applied to a rag before wiping the keyboard Touch Screen o Wipe the screen with a clean soft rag o 409 or a glass cleaner can be used on the rag o Never spray directly on the touch screen membrane This could damage or short the membrane o Replaceable plas...

Page 34: ... the chains by moving the motor mounts outward Hardware After 1 year and every year thereafter Keep bin doors free of build up Clean the touch screen DO NOT SPRAY DIRECTLY ON SCREEN Check for dropped product on the Main platter Check and adjust the tension on the chains Lube dry lube only the chains sprockets door hinges latch assemblies and plastic bearings ...

Page 35: ...er resistant screws o Types of Walls Right Front and Left Rear corner panels 2 each Right Rear and Left Front corner panels 2 each Back Panels 2 each Front Bin Door Panel 1 each Vertical Z Channel 2 upright rack mount rails which holds the Control Panel Touch screen Assembly RoboCrib Platters Main Platter MP o Large Center Platter o 4 8 diameter o Driven by the main platter motor and chain Large S...

Page 36: ...ub Platters are tensioned at the motor mount Wiring o There are two cables per system Motor Driver 2 cond 18 AWG Stranded BW 2 Attached with 093 pin and socket connectors Signal 5 cond 22 AWG Shielded Attached with Straight Line 156 connectors Slip Rings Replaced the Wire Wind Up indicators for MP and LSP 1 ea for Center Post 24 conductor 3 ea for LSP Posts 7 conductor These serve the Motor and Si...

Page 37: ...he computer The calibration sequence resets the home position for the RoboCrib program to bin 111 NOTE If bins do not align correctly contact AutoCrib for instructions on fine tuning the machine Bin Doors and Baffle Assemblies Bin Doors o There are 15 levels of delivery doors o Each door has an LED indicator which light red when the door is sensed to be open or unlatched o The doors are spring loa...

Page 38: ...imal unless otherwise noted FET abc d Fetch command abc Bin to be fetched a LSP number b SSP number c Bin number on platter d Baffle position c calibration status 0 not calibrated since power on 1 calibrated 2 encoder B error so internal position is wrong 3 platter reference mark not detected so wrap count may be wrong 4 platter reference mark was detected but was not within ref error limit 5 baff...

Page 39: ...None Notes This is the normal operating condition C Code Error Action Message C2 Encoder B Error Check wind count and attempt to recalibrate 3 times if unsuccessful system will lock touch screen and display error Encoder B not working on platter X See supervisor Notes Encoder B errors can be caused by a number of things The most common causes are follows 1 The drive chain on affected platter is to...

Page 40: ...r is caused by a condition where the machine has rotated more than 84 pulses past where it expected to see the Ref mark on the affected platter This can be caused by a missing Ref tab or more likely the use of the manual platter movement switches If a user moves the platter in a direction that would move it pass the ref tab and then the machine fetches a bin in the opposite direction that conditio...

Page 41: ...tor is not functioning or disconnected or it s sensors encoders are not functioning and will occur at the beginning of the fetch cycle see diagram above The administrator should check the connections first Everything appears normal the next step would be to begin changing the components with a functioning platter to identify the problem part Speed Time Accel Ramp Move Cycle Decel Ramp S1 Full spee...

Page 42: ...of the machine and inspect the affect platter and chain for any possible obstructions If there are none the next step should be to attempt to move the platter with the manual switches If the machine will moves then proceed to the step 2 2 The other possible condition is the sensors encoder is not reporting the movement or pulses back to the controller This will cause the machine to stop immediatel...

Page 43: ...usually a soft jam and is caused by an item that is pinched between the chain and a sprocket This almost always happens on the LSP or serpentine chain The administrator should remove the side panel and inspect the chain for any obstructions Clear any obstructions and restart the machine so it recalibrates Speed Time Accel Ramp Move Cycle Decel Ramp S3 Full speed part Of move Check 1 Check 2 Fetch ...

Page 44: ...n S4 error indicates a hard jam This occurs when something stops the machine very quickly as opposed to just slowing it down in a soft jam condition The administrator should remove the side panel and inspect the machine for any obstructions Clear the obstructions restart the machine forcing a recalibration Speed Time Accel Ramp Move Cycle Decel Ramp S4 Full speed part Of move Check 1 Check 2 Fetch...

Page 45: ... The system on detection will immediately stop the rotation of all platters as a safety hazard has occurred The user only needs to close the door The system will automatically refetch the called bin These conditions are normally caused by an incomplete latching of a door by the previous user Instruct the user to retrain the users on proper door closure Speed Time Accel Ramp Move Cycle Decel Ramp S...

Page 46: ... position 5 or the outer most position and then refetch the bin in attempt to clear the jam If it fails on this attempt the system will abort and throw the baffle jam error If this occurs a system administrator must clear the clear the jam by manually actuating the door and clearing the jam After the jam is cleared the supervisor should manually position the baffle to position 1 or the innermost p...

Page 47: ...and forcing the machine to move in either the counter clockwise or clockwise position to its upper limits If this occurs the wind indicator lights will turn red on the control panel and power will be cut to the affected motor MP or LSP If this occurs the correct procedure is to center the platters manually using the manual switches You must move the platters until such time the wind indictor light...

Page 48: ...nable to reach the required speed by the time it reaches checkpoint 1 on the acceleration ramp This error is usually a soft jam and is caused by an item that is pinched between the chain and a sprocket This almost always happens on the LSP or serpentine chain The administrator should remove the side panel and inspect the chain for any obstructions Clear any obstructions and restart the machine so ...

Page 49: ...unable to reach the required speed by the time it reaches checkpoint 2 on the acceleration ramp This error is usually a soft jam and is caused by an item that is pinched between the chain and a sprocket This almost always happens on the LSP or serpentine chain The administrator should remove the side panel and inspect the chain for any obstructions Clear any obstructions and restart the machine so...

Page 50: ...ecommended as periodic maintenance of your system About every three months or more often if your machine is in a dusty dirty Environment PLEASE NOTE THIS PROCEDURE SHOULD BE PREFORMED PRIOR TO CONTACTING TECHNICAL SUPPORT FOR A STICKY DOOR PROBLEM Step 1 Remove the Door Assembly front panel from the machine Step 2 Remove the individual latch covers This will expose the door actuation mechanism Ste...

Page 51: ...Appendix 51 P a g e ...

Page 52: ...Appendix 52 P a g e ...

Page 53: ... for a relatively long period under unfavorable conditions e g extreme moisture If there is any indication that safe operation of the scale is no longer warranted Disconnect the equipment from power Notify AutoCrib Technical Support Cleaning Disconnect the scale from power unplug from the wall outlet and disconnect any data cables Make sure that no liquid penetrates the scale housing Do not use an...

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