Copyright © 2001-2022 Woodgrove Digital Engineering P⁄L. All rights reserved. Last revised:14th December 2022 CREDITS LINKS
Industrial Automation



Woodgrove Digital Engineering






MOVEMENT CONTROLLER

          This version incorporates all changes up to Change 433
                                                  Date 25-MAR-20


OPERATOR'S MANUAL



                     Copyright 1984-2020

             WOODGROVE DIGITAL ENGINEERING PTY. LTD.
          Australian Business Number (ABN) 44002794452

                      All rights reserved.

Contents

+

Prologue

 

    Using this Document

 

    Introduction

+

General Instructions

+

    Entering Information

 

        Typing Instructions

+

        Microsoft Windows Operation

 

            Starting the Operator Interface

 

            Switching Windows

 

            Window Repositioning

 

            Window Resizing

 

            Raising, Lowering and Minimising Windows

 

            Widgets and Drawing Areas

 

            Button Operation

 

            Scroll Bar Operation

+

        Data

 

            Moving the Cursor Through the Field

 

            Deleting Characters from the Field

 

            Select, Cut, and Paste

 

        Name

 

        Character

 

        Numeric

 

        Date

 

        Time

 

        Symbolic Numeric

 

        Symbolic Name

 

        Where

 

        Current Time

 

        Password

 

        Screen Editing

+

        Memo

 

            Key Assignments

 

            Basic Editing

 

            Cursor Movement

 

            Screen Movement

 

            Find

 

            Find and Replace

 

            Insert or Overtype Mode

 

            Deleting Text

 

            Select, Cut and Paste

 

            Key Sequence Macros - Learning

 

            Repeating Key Strokes and Macros

 

            Exiting from the Editor

 

        Attribute

 

        Miscellaneous Data

 

        Baud Rates

 

        Store Reference

 

        Crane and Palletiser Alarms

 

        Load Detection Indices

 

        Photocell Arrangement

 

        Fault Assistance

 

        Destination

 

        Heavy-Unit-Load Conveyor Device Condition

 

        Heavy-Unit-Load Conveyor Device Character

 

        Heavy-Unit-Load Conveyor Device I/O Comments

 

        Heavy-Unit-Load Conveyor Device Pause Need

 

        Turn Peg Pattern

 

        Layer Arrangement

 

        Phone Number

 

        Post Code and Post Code Mask

 

        Pick Area Reference

 

        Pick Area Type Division's Address Offset

 

        Pick Area Address Patches

 

        Pick-to-Light Unit Internal Memory Address

 

        Compartment References

 

        Pick Compartment Length and Width

 

        Response Codes

 

        TCP-IP Host

 

        TCP-IP Port

 

        Key

 

    Set of Fields

+

    Menus

 

        When Using the More DOS-Like Interface

 

        Setting Function Keys to Access the Menus

+

    Viewing Data

+

        General

 

            Menu Bar

 

            What's On the Display

 

            Moving the Window Around the File

 

            Expanding Record Details

+

            Restricting the Records Displayed

 

                Given Text in Any Field ([CONTROL F])

 

                Given Text in a Field (Restrict/Match)

 

                A Run of Records (First/Last)

 

                A Given Group in Linked Lists

+

                Records Satisfying an Expression

 

                    Modify All Satisfying Records

 

            Move Up/Down in Linked Lists

 

            Copy or Cut from Linked Lists

+

        Maintenance Viewing Data

 

            Changing the Field Contents

 

            Editing the Entire Record and Deleting

 

            Add New Records (Insert)

 

            Restrict to a Single Record

 

            Multiple Record Editing (Kollecting)

 

            Refreshing the Display

 

        Report Viewing Data

+

    Help

 

        Display Format

 

        Moving by Lines and Columns

 

        Moving by Pages

 

        Moving to Beginnings and Ends

 

        Moving to References

 

        Moving to an Arbitrary Section

 

        Help on Using Help

 

        Moving Directly to the Encompassing Sections

 

        Changing Manuals

 

        Exitting

+

    Changing the Colours

+

        Select the Colour for the Chosen Purpose

 

            Edit the Shade of the Colour

 

            Edit the Colour's Palette Directly

 

            Edit the Colour's Name

+

            Edit the Colour's Purpose

 

                Finish Changing the Purpose

 

            Finish Changing the Colours

+

    Select the Font

 

        Edit Bitmap (Button) Font

 

        Finish Selecting the Font

+

Specific Instructions

 

    Single Display Function Mode

 

    Main Menu

 

    Log Off

+

    Operations

+

        Heavy-Unit-Load Conveyors

 

            Push Buttons

 

            Presentation of Loads

+

            Presentation of the Plant

 

                Details of Conveyor or Device

+

                Devices for Americold

 

                    Access Gate Status

 

                    Emergency Stops

 

                    Sirens

 

                    Various Lamps

 

                    Detierers, Their Doors & Consoles

 

                    Fork lift Detection Loops

 

                    Sizing Stations

 

                    Board Checkers

 

                    Controlled Doors

 

                    Alignment Bars

 

                    Pallet Stands

 

                    Crane Fork Detection, Guard Photocells

 

                    Fire Alarms

 

                    Smoke Detectors

 

                    Scissor Lifts

 

                    Start/Stop Push-Buttons

 

                    Barcode Readers

 

                    Hold on MCR

 

                Stacks of Pallets

+

            Control of Loads

 

                Additional Details for Americold

 

                Modifying Several (KOLLECT TO EDIT)

 

            Zoomed Display

+

            Push Button Control of the Plant: Overview

 

                Control of Standard Devices

+

                Controlling Devices for Americold

 

                    Sirens

 

                    Various Lamps

 

                    Detierers

 

                    Controlled Doors

 

                    Alignment Bars

 

                    Pallet Stands

 

                    Scissor Lifts

 

                    Barcode Readers

 

                    Hold on MCR

 

            Push Button Control of the Plant: Zoomed

+

            Deleting and Creating Loads

 

                Deleting Loads Unknown to the System

 

            Presentation of the Cranes

 

            Keep No-Reads at Scanner (HOLD NO READ)

 

            Retrieve Empty Pallets (FETCH EMPTIES)

 

            Reject Control (1/2 REJECT FREEZER/CHILLER)

 

            Fast Putaway (GO ANY-WHERE)

 

            Trunk Line Purge (TRUNK PURGE)

 

            Outfeeding Loads (OUTFEED LOAD)

 

            Multilevel Conveyor Systems (LEVEL CHANGE)

 

            Displaying Conveyor Alarms (ALARM LIST)

 

            Changing the Appearance (EDIT DIAGRAM)

 

            Conveyor Mode (CONVEYOR MODE)

 

            Archive Log Files (FLOPPY ARCHIVE)

 

            Pick Face Loads Not Seen

 

            Checking the Linked Lists

 

            Checking the Communications Ports

+

        Conveyor Alarms

 

            Communications Failure Alarms

 

            Task Killed Alarms

+

        Stores Diagram

+

            Graphical Representation

+

                Presentation of the Locations

 

                    Full and Part Loads

 

                    Total Numbers of Loads & Vacancies

 

                    Presenting Vacant, Disabled, Etc

 

                    Pallet Detection System

 

                    Bad Configuration Data

 

                    Movement Class and Product Group

 

                Presentation of the Crane

 

            Moving the Window About the Store

 

            Moving the Cursor About the Store

+

            Examining and Modifying Location

+

                Displaying the Full Location Details

 

                    Pallet Coming to Location

+

                Modifying the Location Details

 

                    Prioritising Replenishment

 

                Modifying Several Locations At Once

 

                Deleting and Inserting Loads

 

            Inhibited Locations

 

            Changing the Appearance

 

            Select Loads for Retrieval

 

            Restricting the Display

+

        Crane Commands and Alarms

+

            Status List

 

                LT in/out of position

 

                HL in low/in high/out of position

 

                Forks position

 

                Manual

 

                Out Of Service

 

                Light Curtain

 

                Conveyor Alarm

 

                Alarm change

 

                Loaded Status

 

                MCR deenergised

 

                LT no speed enable

 

                HL no speed enable

 

                Key switch manual

 

                Correction limit

 

                Catching dev bypass

 

                Off-centre to left

 

                Off-centre to right

 

                Bin occupied left

 

                Bin occupied right

 

                Bin occ'd far left

 

                Bin occ'd far right

 

                Hoist down stop

 

                Hoist up stop

 

                LT reverse stop

 

                LT forward stop

 

                LT drive failure

 

                HL drive failure

 

                Forks drive failure

 

                Hoist safety fault

 

                MCC 24V Power Fail

 

                24V supply failure

 

                No conveyor system

 

                Communications fail

 

                Cabinet too cold

 

                Cabinet too warm

 

                Full current bypass

 

                Cabin position

 

                Over-height 1

 

                Over-height 2

 

                Over-height 3

 

                Over-height 4

 

                Over-height 5

 

                Over-height 6

 

                Over-height 7

 

                Over-height 8

 

                Long Travel Motion

 

                Hoist Motion

 

                Forks Motion

 

            Graphical Status

+

            Alarms

 

                MCR is off

 

                24VDC is off

 

                HL circuit breaker

 

                LT circuit breaker

 

                Forks circuit b'ker

 

                HL drive fault

 

                LT drive fault

 

                Forks drive fault

 

                HL thermal overload

 

                LT thermal overload

 

                Forks thermal O/L

 

                HL thermistor trip

 

                LT thermistor trip

 

                Forks thermistor tr

 

                Cabin too cold

 

                Cabin too warm

 

                Load Off Centre

 

                Load correct'n fail

 

                Off-centre fouled

 

                Load seems too wide

 

                Catch block set

 

                Slack rope

 

                Rope overload

 

                Hoist over-speed

 

                Speed govenor trip

 

                Hoist whole current

 

                Hoist too slow

 

                HL hunting too slow

 

                LT too slow

 

                LT hunting too slow

 

                Forks 2 slow left

 

                Forks 2 slow right

 

                Hoist too high

 

                Hoist too low

 

                LT overrun

 

                Cabin door open

 

                Gate is open

 

                Trolley problems

 

                Communications bad

 

                Pickup got nothing

 

                Deposit still loaded

 

                Pickup but loaded

 

                Deposit but no load

 

                Forbidden slot

 

                Bad command

 

                LT location bad

 

                HL location bad

 

                Empty or blocked

 

                Location empty

 

                Location full

 

                HL bad screen

 

                LT bad screen

 

                HL stalled

 

                LT stalled

 

                LT stalled/centred?

 

                Lost fork limit sw.

 

                Forks switch lost

 

                Overall Watchdog

 

                High load manual

 

                High load automatic

 

                Cabin too slow down

 

                Pickup not going

 

                Empty Pallet in Way

 

                Cabin too slow up

 

                Pickup not centred

 

                Deposit not centred

 

                LT wrong card

 

                Hoist wrong card

 

                Can't centre forks

 

                Fork recovery fail

 

                Off LT when forking

 

                Off HL when forking

 

                LT reader blocked

 

                HL reader blocked

 

                LT brake release on

 

                Buffer shifted back

 

                Buffer shifted fwd.

 

                Emergency stop

 

                LT at both ends

 

                HL at both ends

 

                Cabin up and down

 

                HL at low & hi stop

 

                HL wrong for magnet

 

                LT wrong for magnet

+

            Automatic Command Queue

 

                Command Presentation Format

 

                Governing Command

 

                Checking Software Messages

+

            Turning Off and On Automatic Commands

 

                Inhibiting the Crane

 

            Turning Off and On Retrieval Commands

 

            Putting the Crane Back Service

+

            Operator Commands

+

                Non-Motion Commands

 

                    Reset alarms

 

                    Energise main contactor

 

                    Set out of service

 

                    Set in service

 

                    Abort current cycle

 

                    Kill next cycle

+

                Motion Commands

 

                    Movement test cycle

 

                    Pickup test cycle

 

                    Deposit test cycle

 

                    Goto crane infeed

 

                    Goto crane outfeed

 

                    Park at Maintenance Bay

 

                    Store a load

 

                    Retrieve a load

 

                    Deposit the load on board

 

                    Relocate a load in the rack

 

                    Run test cycles

 

                Modify Current Command

 

                Kill Governing Command

 

                Remote Manual Crane Control

 

                Initialise Crane PLC

 

                Save Crane PLC Configuration

 

                Restore Crane PLC Configur'n

+

        Retrieve from Stores by Location (new)

 

            Creating Retrieval Requests

 

            Deleting Retrieval Requests

 

            Prioritise, Modify, or Delete

 

            Submitting the Schedule

+

        Retrieve from Stores by Location

 

            Reading Schedules

 

            Creation of Schedules

 

            Modification of Schedules

 

            Sequencing Schedules

 

            Deleting Schedules

+

        Review Loads Being Retrieved

 

            Prioritise, Modify, or Delete

+

        Enter Orders for Picking

 

            Reading Schedules

 

            Creation of Schedules

 

            Modification of Schedules

 

            Sequencing Schedules

 

            Using Templates

+

        Replenish the Pick Areas

 

            Reading Schedules

 

            Creation of Schedules

 

            Modification of Schedules

 

            Sequencing Schedules

 

            Using Templates

+

        Cartons Within the Conveyor System

 

            Reading Schedules

 

            Creation of Schedules

 

            Modification of Schedules

 

            Sequencing Schedules

+

        Carton Conveyor System

 

            Push Buttons

 

            Carton Conveyor System Status

 

            Alarms

 

            Tally of Cases

 

            Conveyor Mode

 

            Device Mode

 

            Setting Case Lengths

 

            Pick-To-Light System Status

+

            Pick Area Mode

+

                Examining a Pick Area

+

                    Monitor Memory

 

                        Read-Write

 

            Changing the Appearance

 

            Defining Views of the Conveyor System

+

        Palletiser Status and Commands

 

            Push Buttons

 

            Alarms

 

            Tally of Cases

 

            Finish Load

 

            Reject Pallet

 

            Palletiser Semi-Automatic

+

            Palletiser Manual Mode

 

                Motors Versus Solenoids

 

                Palletiser Gates

 

                Palletiser Compress

 

                Palletiser Pilot Lamps

 

            Edit Cartons

 

            Running Without a Barcode Reader

 

            Disabling the Glue Spray

 

            Writing Pattern Data

 

            Accessing the Pallet Conveyor System

 

            Accessing the Carton Conveyor System

+

        Machine Status Display

+

            Configuration for Americold

 

                Controls

+

    Produce Reports

 

        Event Log Historic Report

 

        Load Log Historic Report

 

        Conveyor Alarm Summary Report

 

        Produce Report Listing Store Occupancy

 

        Produce Report Showing Store Matrix

 

        Crane Alarm Summary Report

 

        Crane Movement Tally Report

 

        Crane Cycle Log Report

+

    Communication Reports

 

        Opening a Communications Report Window

 

        Leaving a Communications Report Window

 

        Help with the Protocol

 

        PLC Communications Report

 

        Produce Report of Pick-to-Light Comm's

 

        Produce Report of Barcode Scanner Comm's

 

        Produce Report of TCP-IP Communications

+

    Configuration

+

        Control Mode of Operation

 

            Full Description of this Window

+

            The Variables Intended to be Presented

 

                Override Palletiser Barcode Scanner

 

                Stacker Crane To Find Vacancy

 

                Stacker Crane Store:Retrieve Ratio

 

                High Level Crane Inhibiting

 

                Alarm Summary Period

 

        Enter or Modify the Conveyor Alarms

 

        Enter or Modify Products

 

        Enter or Modify the Crane Alarms

 

        Enter or Modify the Crane States

 

        Enter or Modify the Countries

 

        Enter or Modify the States/Provinces

 

        Enter or Modify the Towns/Suburbs/Cities

 

        Enter or Modify the Customers

 

        Enter or Modify the Products

 

        Enter or Modify Palletiser Alarms

+

        Enter or Modify Palletiser Patterns

 

            Edit Row Definition

 

            Viewing Patterns

 

            Applying the Patterns

 

        Enter or Modify Palletiser Product Data

 

        Enter or Modify Machine States

 

        Enter or Modify Machine Alarms

 

        Enter or Modify Machine Controls

+

    Maintenance

+

        Set Network Definition Data

 

            Full Description of this Window

+

            The Variables Intended to be Presented

 

                TCP-IP Addresses

 

                TCP-IP Ports

 

                FTP User Text Fields

 

                Directories for Host Communications

 

        Set Current Time and Date

 

        Modify List of Users

 

        Archive List of Events to Floppy Disc

 

        Archive Load Movements to Floppy Disc

 

        Backup Database to Floppy

 

        Restore Database from Floppy

+

    System Definition

+

        Initial Software Configuration

 

            Full Description of this Window

+

            The Variables Intended to be Presented

 

                Selection of Communications Boards

 

                Presentation of Loads

 

                Defining the Conveyor System

 

                Delay Between Crane Test Cycles

+

        Defining the Heavy-Unit-Load Conveyor System

 

            PLC Source code

 

            Graphical Representation

 

            Steps in the System Definition

+

        Enter or Modify Device Types

 

            Navigating the Selection Windows

 

            Modify, Add and Cancel Lines

 

            Defining the Device Type

 

            Defining the Device Type's Alarm

 

            Defining the Device Type's Output

 

            Defining the Device Type's Input

+

            Defining the Device Input's Condition

 

                Specifying Device Condition Matching

 

                Overview Image Colour

 

                Overview Image Pixel Editing

+

                Zoomed Image Editing

 

                    Circles

 

                    Characters

 

                    Lines

 

                    Rectangles

 

                    Semi-Circles

 

                    Numeric Display

 

                    Bargraph

 

                    Change or Add Specifications

 

                    Conveniently Add Text Strings

 

                    Reordering Image Specifications

 

                    Relocating the Entire Image

 

                Duplicating Images

+

        Fast Definition of Conveyor System

 

            Erase System Definition

+

            Enter Run of Conveyors

 

                Enter the Details of Rear Conveyor

 

                Select Forward or Reverse Transfers

 

                Enter Names of Subsequent Conveyors

 

                Ending the Run of Conveyors

 

                Repeat for the Next Run

 

                Must Be Turntable or Elevator

 

                Ending the Last Run of Conveyors

 

                Multi-Load Two-Way Conveyors Notes

 

            Conveyor Lengths and Rise-Falls

 

            Enter Destinations for Decision Points

 

            Enter or Modify the Devices

 

        Enter or Modify the Conveyors

 

        Enter or Modify the Transfers

 

        Enter or Modify the P.E. Placement

 

        Enter or Modify Explicit Device Alarm

+

        Create, Edit, Compile and Execute

+

            Overview of the Steps

 

                Overview of the Generation Step

 

                Overview of the Editing Step

 

                Overview of the Compilation Step

 

                Overview of the Listing Step

 

                Overview of the Loading Step

+

            Syntax of the PLC Source Code

+

                Program Header

 

                    PLC-5 Series

 

                    SLC-500 Series

 

                Program Tail

 

                Setting the Ladder File's Name

 

                Making the Emulator's Task Easier

 

                Specifying Which Data Files to Use

 

                Definition of Program Constants

 

                Declaring Data Elements

 

                Setting Values into Data Elements

 

                Include Source Code from other Files

+

                PLC Rung Statements

 

                    Branches

 

                    Test Instructions

 

                    Output and File Instructions

 

                    Subroutines

 

                    Jumps and Labels

 

                    Instruction Shorthand

 

                    Unsupported or New Instructions

 

                    Arithmetic Expressions

 

                    Boolean Expressions

 

                    Precedence of Instructions

 

                    Examples of Instructions

 

                Breaking Data Elements into Components

 

                Referencing Subroutines Outside of JSR

 

                Remarks - Comments

 

                Conditional Compilation

 

                Repeated Compilation

 

                Macros

 

                Evaluating Constants Earlier

 

                Embedding Macro Calls into Symbols

+

            Create PLC Code and Operator Interface

 

                Single Step

+

            Edit Boolean File

 

                Key Assignments

 

                Basic Editing

 

                Cursor Movement

 

                Screen Movement

 

                Scroll Bars

 

                Find

 

                Find and Replace

 

                Insert or Overtype Mode

 

                Deleting Text

 

                Select, Cut and Paste

 

                Key Sequence Macros - Learning

 

                Repeating Key Strokes and Macros

 

                Edit Other Source Files

 

                Exiting from the Editor

+

            Compile Conveyor Code

 

                List of Errors

 

            List the Compiler Log File

 

            Load PLC Emulator

+

        Define the Crane and Rack Arrangement

 

            Erase Previous Crane and Rack Definition

 

            Set the Number of Cranes

 

            Define the Racking

 

            Define the Conveyor System Infeeds

 

            Define the Conveyor System Outfeeds

+

        Enter or Modify the Carton Conveyors

 

            Push Buttons

 

            Record List

 

            Defining the Conveyor Types

 

            Naming the Zones

+

            Defining the Conveyors

 

                Interactive Conveyor Editing

 

            Placing the Devices

 

            Setting Compartment Sizes

 

            Format of Pick Area Types

 

            Defining the Pick Areas

+

            Addressing the Pick Areas

 

                Harness Wiring

 

                Setting Adjacency

 

                Running the Wires

 

                Patch the Shelves

 

                Setting the Addresses

 

                Allocating Communications Channels

 

                Writing to the Field

+

            Global Editing

 

                Just Do Some

 

            Changing the Appearance

 

        Enter or Modify the Palletisers

+

        Enter or Modify Machine Definition

 

            Navigating the Selection Windows

 

            Modify, Add and Cancel Lines

 

            Defining the Machine

 

            Defining the Window Areas

 

            Select/Organise Inputs for an Area

+

            Defining the Machine Input's Condition

 

                Specifying Machine Condition Matching

+

                Machine Image Editing

 

                    Circles

 

                    Characters

 

                    Lines

 

                    Rectangles

 

                    Semi-Circles

 

                    Numeric Display

 

                    Bargraph

 

                    Change or Add Specifications

 

                    Conveniently Add Text Strings

 

                    Reordering Image Specifications

 

                    Relocating the Entire Image

 

                Duplicating Images

 

            Viewing the Assembled Display

+

    Special Functions

+

        Edit Databases

 

            Screen Attributes

 

            Menu Text and Security

 

            Database Privilege

 

            Crane Commands and Security

 

            Crane Manual Commands

 

            Crane Bit Descriptions

 

            Palletiser Commands

 

            Carton Conveyor Commands

 

            Path Names

 

            Configuration Data

 

            Fault Assistance

 

            Carton Conveyor Alarms

 

            Terminal Configuration

 

            Carton Conveyor PLCs

 

            Conveyor PLC Definition

 

            Zone Channel Definition

 

            Standby Channel Definition

 

            Channel Setup

 

            PLC Setup

 

            Conveyors from which to Zoom

 

            Barcode Scanners

 

            Terminal Locations

+

            General

 

                Small Words

 

        Monitor Communications

 

        Terminal Interface Via Serial Port

+

        Monitor and Adjust the PLC Memory

 

            Ladder Program Display

 

            Emulation Break-Points

 

        Monitor Securing to Standby

 

        Monitor Threads of Execution

+

        Restore Factory Default Settings

 

            Restore text for this list

 

            Erase data restrictions & function keys

 

            Erase record of PLC data et cetera

 

            Set time standards and current standard

 

            Set database prompts and privileges

 

            Set user database

 

            Set names for the lists of loads

 

            Initialise log files: events, comms etc.

 

            Initialise communications log files

 

            Set prompts for the configuration data

 

            Set the configuration data itself

 

            Set text and character graphics colours

 

            Set graphic shape names and colours

 

            Set menu text and associated privilege

 

            Set menu structure

 

            Set small words for non-capitalisation

 

            Set default keys for the editor

 

            Set terminal locations

 

            Set types of PLCs

 

            Set PLC communications hardware options

 

            Set heavy-unit-load device pause scenarios

 

            Set Heavy-Unit-Load Conveyor names

 

            Set Heavy-Unit-Load Conveyor alarm names

 

            Erase crane retrievals

 

            Set crane command, status and alarm text

 

            Set crane manual commands

 

            Set crane bit descriptions

 

            Set shelf digit and special request data

 

            Set PTL RAM memory location descriptions

 

            Set carton conveyor device types

 

            Set carton conveyor alarms

 

            Set carton command names & security

 

            Set barcode scanner fixed data

 

            Set palletiser alarm text

 

            Set palletiser command names & security

 

            Set channel names

 

            Set baud rate definitions

 

            Set Allen-Bradley file definitions

 

            Set customisation option text

 

        Import to and Export from the Database

 

        Save and Restore Crane PLC Configuration

 

    Exit

Prologue

This document is the "Operator's Manual" for the "Movement Controller". Also associated with this system are the "Technical Manual" and the "Software Manual".

This section includes the two introductory sections: "Using this Document", and "Introduction".

The "Using this Document" section gives an overview of each section of the document.

The "Introduction" gives a brief overview of the plant, its function, and an overview of this software.

Using this Document

This section gives an overview of each section of the document.

This document is divided into three major sections.  These are:

  • Prologue
  • General Instructions
  • Specific Instructions

The "Prologue" includes the two introductory sections: "Using this Document", and "Introduction".  The "Using this Document" section (this section) gives an overview of each section of the document, while the "Introduction" section gives a brief overview of the system's function.

The "General Instructions" describe the features of the Movement Controller software common to all or several windows.  Much of the information in this section may be second nature to persons with personal computer experience, whereas the more unique sections are best referred to when referenced from the "Specific Instructions".

The "Specific Instructions" describe the operation of individual windows.  This section is arranged in the same way as the windows are presented in the Movement Controller software.  This section should be read in conjunction with operating the windows to which they relate.  References are made throughout this section to the various subsections of the "General Instructions".  It should be sufficient to refer to these references the first time they are encountered.

Note: The term, "windows" is used to refer to the Microsoft Windows "windows" as well as occasional selection windows within "drawing areas".

In the printed document, cross-section references are made using the section and subsection numbers, separated by dots, followed by the final subsection name, and the entire string enclosed in double quotation marks.  When presented via the Movement Controller's help system, cross-section references are made using the final subsection name, enclosed in double quotation marks and highlighted as a hyper-text link.  When presented via an HTML rendering program, cross-section references are made using the final subsection name rendered as a hyper-text link.  For example, this section would be referred to as the section titled: "Using this Document".

Introduction

This manual describes the operation of Woodgrove Digital Engineering's "Movement Controller" software.

The software is designed to control: Heavy-Unit-Load Conveyors, carton conveyors, palletisers and other machines, load storage and retrieval cranes (herein referred to as just "cranes"), and pick-to-light systems.

The major functions of the software are:

  • communications to the various sub-systems,
  • issuing instructions to and monitoring status from these sub-systems,
  • coordination of the interaction between these sub-systems,
  • interfacing to the operator,
  • logging of alarms, operator actions, and load movements,
  • definition of the sub-systems and the operator interface,
  • provision of diagnostic windows.

The major function of the system definition is to configure:

  • the Heavy-Unit-Load Conveyors PLC code and operator interface,
  • the carton conveyors and pick-to-light control algorithms and operator interface,
  • the palletiser patterns,
  • the cranes and load storage racking configuration,
  • the definition of graphics, alarms and status for other types of machines.

Please note that there is also available an HTTP interface to the Movement Controller. This interface is available to any HTTP client (that is an Internet browser such as Internet Explorer, Firefox, Google Chrome, Opera, Safari, ...) by entering the URL: "http://###.###.###.###/8080", where "###.###.###.###" is the IP address of the main computer.  This manual does not describe the use of this interface, but, once you are familiar with the standard operator interface described here, you should not need further help to navigate and use the HTTP interface.

Although there is no operator instructions available for the HTTP interface, considerable technical information is available in the section of the SOFTWARE MANUAL titled: "HTTP (Web or Internet) Interface".

General Instructions

This section describes the features of the Movement Controller software common to all or several windows.

Much of the information in this section may be second nature to persons with personal computer experience, whereas the more unique sections are best referred to when referenced from the "Specific Instructions" section.

Entering Information

This section describes, firstly, the way the rest of the document will refer to the keys, then goes on to describe the general methods of entering data via the Movement Controller software.

Typing Instructions

Throughout this manual, instructions to type a sequence of keys will be followed by a string of characters contained within a pair of double quotation marks or a pair of square brackets.  If the quotation marks are used the enclosed characters are to be typed in as presented.

Certain keys (or modified keys) do not correspond to characters, so the keys are instead described within the square brackets.  Examples are: [RETURN], [ENTER], [BACKSPACE], [INSERT], [DELETE], [UP], [DOWN], [LEFT], [RIGHT], [PAGE UP], [PAGE DOWN], [HOME], [END], [F1] to [F10], [GREY PLUS], and [GREY MINUS].

[UP], [DOWN], [LEFT], and [RIGHT] are collectively referred to as the cursor control keys, and are grouped together and labelled with arrows pointing in the appropriate direction.

[HOME], [END], [PAGE UP], [PAGE DOWN], [INSERT], and [DELETE] are labelled as described or abbreviated.

[HOME], [END], [PAGE UP], [PAGE DOWN], [INSERT], [DELETE] and the cursor control keys are provided on the numeric key-pad, sharing real estate with the numbers "0" to "4", "6" to "9" and the dot.  The function performed by these keys is governed by the "Num Lock" key and the "Shift" key.  If the keyboard also provides these control keys on separate keypads, it is better to leave the "Num Lock" engaged and use the numeric key-pad to enter numbers.  In cases where you are not expected to enter numbers or text, the keys on the numeric key-pad will be treated as though the "Num Lock" had not been engaged.

In some instances the Movement Controller will treat the use of the cursor keys provided with the numeric key-pad differently to those with the separate key-pad.  Where a distinction is to be made, the key name will be preceded by the word NUMERIC or SEPARATE to refer to the key with the numeric key-pad or separate key-pad respectively.  For example, the [RIGHT] key will be referred to as [NUMERIC RIGHT] or [SEPARATE RIGHT].

[GREY PLUS] and [GREY MINUS] are those associated with the numeric key-pad and marked "+" and "-" respectively, and are not equivalent with similarly marked keys on the main key-pad.

[ESCAPE] is usually marked "Esc", while [RETURN] may be labelled with the word "Enter" or with a left arrow with a bent shaft.

[BACKSPACE] is usually marked with a left arrow and sometimes with the word "Backspace", and is positioned at the top right hand corner of the main key-pad, directly above the [RETURN] key.

[ENTER] is associated with the numeric key-pad and usually labelled with the word "Enter"

[F1] to [F10] are always marked thus and are either to the left of the main key-pad or above it.  Some keyboards also offer [F11] and [F12].

[CAPS LOCK] and [NUM LOCK] are always marked thus and are toggle keys, whose current state is shown using appropriately labelled lamps on the keyboard, generally towards the top right.

The modifier keys are referred to herein as SHIFT, CONTROL and ALTERNATE.  To type a modified key, first press the appropriate modifier key, keeping it down while the key to be modified is typed in the usual manner.  The SHIFT key(s) are usually labelled with an up arrow or the word "Shift".  The CONTROL and ALTERNATE keys are usually labelled with the letters "Ctrl" and "Alt" respectively.  On some keyboards with two keys marked "Alt" the left-hand key might be the only suitable key.

Where alphabetic characters are to be entered, they should be entered from the correct case.

Microsoft Windows Operation

If you have opted for the more DOS-like interface, much of this section will be irrelevant.  For information on configuring a user for the more DOS-like interface and its impact, please refer to the section titled: "Modify List of Users".

The windows concept is intended to provide a more instinctive operator interface.  The result is that there are many ways to do most things, making the descriptions of these much more complex.  If you find this aspect of the manual baffling, you are probably best to ignore it and follow your instincts.

Another aspect of the windows concept is that the operator is much more in the driver's seat, telling the system what to do rather than being led by the system.  This provides added flexibility at the cost of simplicity.

Starting the Operator Interface

Before starting the operator interface, the "main" program must be running on the main computer and, unless you are wanting to run the operator interface on the main computer, the "connect" program must be running on the computer from which you wish to run the operator interface.

The "main" program is generally opened by double-clicking on the icon corresponding to this, and sporting the title: "Woodgrove MAIN".  This icon would simply run the "main" program without any command line arguments, from the directory (folder/library) containing the database.  There are command line arguments that can be used, and these are described in the section of the TECHNICAL MANUAL titled: "Command Line Parameters".

Similarly, the "connect" program is generally opened by double-clicking on the icon corresponding to this, and sporting the title: "Woodgrove CONNECT".  This icon would simply run the "connect" program with two command line arguments, the IP address of the main computer and the port number to be used (usually 129).

Once the "main" and "connect" programs are running, you may start the operator interface.  You would, generally, do this by double-clicking on the icon corresponding to it, and sporting the title: "Woodgrove OPERATOR".  This icon would simply run the "winmain" program without any command line arguments, from the directory (folder/library) from which "main" or "connect" had been run.  There are command line arguments that can be used, and these are described in the section of the TECHNICAL MANUAL titled: "Operator Interface in Single Display Function Mode" and the section of the TECHNICAL MANUAL titled: "Automatic Logging On".

When the operator interface is run, it will be presented as a bar across the top of the screen, sporting a title and, below that, a minimal meny bar containing the single item "File" and, below that, three status panes.  The first of these will be used to present any messages that may need to be given the operator.  The next two indicate who is logged in (initially no one, so it is left blank) and the privilege level associated with that operator (0 to 3).

Switching Windows

Once this application has been started, you can switch between this application and others that you might have open by a number of means including:

  • Moving the mouse pointer to window title bar of another application (you may need to first minimise this application to view other windows), then clicking on it (or anywhere within the window),
  • Moving the mouse pointer to the task-bar then clicking on the button describing the application you wish to switch to, and
  • Holding down the [ALTERNATE] key as you type [TAB] a number of times until the icon, of the application to which you wish to switch, is highlighted.

As well as there being windows for alternate applications, the Movement Controller's application window may have a number of windows open within it.  You will need to switch between these windows as well, which you can do a number of ways, including:

  • Moving the mouse pointer to window title bar of another window within the application, then clicking on it (or anywhere within the window - though this could cause an unintended action).
  • Typing the function key corresponding to the window you wish to switch to.
  • Holding down the [CONTROL] key as you type [TAB] a number of times until the window, to which you wish to switch, is presented in the foreground.
  • Holding down both the [CONTROL] and [SHIFT] keys as you type [TAB] to take you back to the previous window.
  • Typing the "`" (the back apostrohe, backtick, grave, back quote key) will switch focus to the main window, that which includes the "File" and "View" menu items, which can not be called up when cycling through the windows using the [CONTROL TAB] and [CONTROL SHIFT TAB] keys, but those keys can be used, subsequently,to return focus to one of the other windows.

Window Repositioning

This is generally achieved by moving the mouse to the window title, holding down the left mouse button and dragging the window to a new location.  The location of any main window - not dialogue windows and the like - will be remembered for the logged in user and used next time the window is created.

Window Resizing

This is generally achieved by moving the mouse to an edge or corner of the window, where the mouse pointer image is changed to a both ways arrow.  You are to then hold down the left mouse button and drag the edge or corner so as to set the size you desire.  The size of any main window - not dialogue windows and the like - will be remembered for the logged in user and used next time the window is created.

Raising, Lowering and Minimising Windows

The presentation of windows generally allows windows to overlap one another, with the result that one will be obscured by the other.  The obscured window is the "lower" window, while the other is the "upper".

It is, generally, sufficient to click any visible part of a window to raise it to the top.

Widgets and Drawing Areas

Items, such as windows, buttons, scroll bars, et cetera, are collectively known as "widgets".  Also numbered among the widgets is what is known as a "drawing area".  Most main windows include this widget, and present within it a mixture of text and drawings.

Drawings and fields of text behave similarly to widgets, in that they to can receive "focus" (indicated by a change of background colour or the presence of a cursor), however this focus is independent of the widget focusing, as only one widget is focused at any one time, whereas within a single drawing area there may be a focused drawing, and associated with that focused drawing may be several lines of text, with one of the lines also focused.

Button Operation

There are two types of button presented by the Movement Controller.  The operating-system-painted buttons, which are rectangular (of varying sizes), very light grey, and inscribed, and the buttons depicted using uniform rectangular drawings on a drawing area, providing two lines of text, with the first character enlarged.

Both sets of buttons indicate how they can be pressed using the keyboard.  In the case of the operating-system-painted buttons this is usually explicit, whereas in the case of the button drawings, this is indicated by the first, enlarged, character presented in the button.

Both button types can also be clicked.  The operating-system-painted buttons will depress, and will indicate that it is in operation by remaining depressed, while the button drawings will change colour to indicate that they are in operation.

Certain buttons (of either type) perform opposite operations depending upon whether the [SHIFT] key is used or not.  The corresponding mouse behaviour to using the [SHIFT] key with typing, is to click the righthand button, rather than the left, though you can also hold down the [SHIFT] key while left-clicking the mouse to achieve the same thing.  Note, though, that you can not use right-clicking to emulate the [SHIFT] key modification of a typed key when that key is activating a menu item rather than a button; to emulate the [SHIFT] key modification, when clicking on a menu item, you must to hold the [SHIFT] key while left-clicking; right-clicking does nothing.

Throughout this manual the key strokes needed to perform certain operations are described.  There will typically be a operating-system-painted button, inscribed with the key-stroke (and further text if required) to perform the same function.

Scroll Bar Operation

Most main windows are capable of providing a scroll bar if sized too small to present all the information.  These scroll bars are operated by a number of means, including:

  • moving the mouse to the slider in the middle of the scroll bar and holding down the left mouse button, and dragging it either up and down or left and right depending on whether it is a horizontal or vertical scroll bar.
  • moving the mouse to the area before or after the slider and clicking with the left mouse button, to advance the slider by a window width or height as the case may be.
  • moving the mouse to the arrows at either end of the scroll bar and either clicking or holding down the left mouse button to advance the slider towards the arrow in finer increments (usually corresponding to a line or column).
  • often the vertical scroll bars may be operated using the [PAGE UP], [PAGE DOWN], [CONTROL HOME], and [CONTROL END] keys to advance the slider up or down a page, or to the top or bottom of the file.  Often the horizontal scroll bars may be operated using the [CONTROL PAGE UP], [CONTROL PAGE DOWN], [HOME], and [END] keys, to advance the slider by a window width left or right, or to the extreme left or right.  However sometimes these keys serve other purposes for the windows and so are not available for this.  Other times there may be three or more scroll bars associated with a window, in many of these cases, there will be a horizontal and vertical scroll bar associated with one drawing area, and another pair associated with the second; in these cases the separate cursor and [HOME], [END], ...  keys can be used to control the scrollbars for the upper drawing area, and those on the numeric keypad can be used to control the other scrollbars.
  • often the scroll bars may be operated directly or indirectly with the cursor control keys.  These keys may manipulate the position of a cursor (or reverse video field in many cases, or a drawing background colour in some other cases), however as the cursor is, typically, moved past the edge of the window, the slider may be advanced by a row or column as the case may be.  If the scroll bars can not be operated by the cursor keys, due to their use for other purposes, try holding the CONTROL key down whilst operating the cursor keys.
  • if the mouse has a wheel, this can be used to operate the vertical scrollbar for the drawing area over which the mouse is positioned.  It is not necessary to click into the drawing area.  If it does not seem to operate, check where you have the mouse positioned.
  • if the mouse has a wheel, this can be used to operate the horizontal scrollbar for the drawing area over which the mouse is positioned, by holding the [SHIFT] key down while working the wheel.  It is not necessary to click into the drawing area.  If it does not seem to operate, check where you have the mouse positioned.

Data

All information is entered into the Movement Controller by typing characters into entry areas in dialogue windows, referred to herein as "fields".

When the focus falls upon a field, the current value is presented in the field shaded, indicating that the entire field's contents are "selected" and hence any character key you type is likely to replace this existing data.

If the field contents are not to be modified, the entry should be terminated appropriately, without typing any characters into the field.  [TAB] may always be used to terminate the entry, however other keys may also be used to terminate the entry, close the dialogue window, then direct subsequent actions. Refer to the section titled: "Set of Fields".

There is a "cursor" provided within the field with focus.  This is generally presented as a blinking vertical line between to characters within the field. When you type characters into a field, they will generally be entered at the cursor, moving the cursor one place to the right.  Had there been characters "selected" at the time you typed your character, those characters would have been deleted.

If the field contents are not to be modified, the entry should be terminated appropriately, without typing any characters into the field.  [RETURN] or [ENTER] may always be used to terminate the entry, however other keys may also be used to direct subsequent actions.  Refer to the section titled: "Set of Fields".

If a new entry is to be made, simply type the new entry, then terminate the entry appropriately.  Refer to the section titled: "Set of Fields".

The term "enter" is used throughout this document to imply typing in data then terminating the entry, usually with [RETURN] or [ENTER].

If the field contents are to be erased, type [GREY MINUS].

If the old entry is to be modified, type the [GREY PLUS] or [CONTROL Z], which moves the cursor to the end of the old entry, so that it may be altered.  Had you been editing this, the original field contents (those at the time the field received focus) will be restored.

The interpretation of the characters typed into these fields depends on the type of field.  Subsequent sections describe this interpretation for each of the field types.  These sections are intended as references for the subsequent sections.

Note: The window title is provided at the top of each window, and there is a single error line provided just below the main menu bar, usually located at the top left of the screen.

Moving the Cursor Through the Field

The [LEFT] and [RIGHT] keys may be used to move the cursor, backwards or forwards respectively, through the field to a position where you may wish to insert characters.

The [CONTROL LEFT] and [CONTROL RIGHT] keys may be used to move the cursor, backwards or forwards respectively, through the field, a word at a time, to a position where you may wish to insert characters.  In this context, a word is a contiguous sequence of alphabetic or numeric characters, all other characters are deemed space.

The [HOME] key can be used to move to the beginning of a field, while the [END] key can be used to move to the end of the field.

The cursor can also be placed at an artitary position in the field, by clicking there with the mouse.

Deleting Characters from the Field

Entries can then be edited by typing [BACKSPACE], to remove the portion to be reentered, then typing in the desired value.  Each time [BACKSPACE] is typed, it removes the character to the left of the cursor, moving the cursor one place left unless the cursor is at the beginning of the field, in which case, [BACKSPACE] has no effect.

After deleting the required characters, the replacement characters may be typed in, moving the cursor one place right, unless the cursor is at the end of the field, in which case the characters typed in have no effect.

The [CONTROL BACKSPACE] and [CONTROL DELETE] keys may be used to delete entire words from the cursor position, backwards or forwards respectively.  Again, in this context, a word is a contiguous sequence of alphabetic or numeric characters, all other characters are deemed space.

Select, Cut, and Paste

In modifying the field contents, you can make use of the "select, cut, and paste" function by first selecting a portion (or all) of the contents, then type a control character combination to either copy or cut it to the "clipboard".  The text copied to the clipboard can subsequently be pasted into another field, or, if you so desire, another application altogether such as an editor or word processor.

To do this, you need to, first, create a "selection".  A "selection" is a contiguous set of characters within the field, which you highlight to copy, delete or replace.

You can create a selection area within a field in a number of ways:

  • position the cursor at the start of the area, and hold down the [SHIFT] key while using any of a number of keys, to move the cursor to the end of the area,
  • double clicking with the mouse on a word to create a selection field about that word, or
  • position the mouse at the start of the area, and hold down the left mouse button as you move the mouse to the end of the area,

A selection area is shown using a blue rather than a white background.

Once the "selection" has been defined (i.e. a shaded area in the entry field exists with some or all of the field contents included), these characters can be "copied" or "cut" to the "clipboard", or deleted.  "Copying" leaves the exisiting field contents in tact, whilst "cutting" removes the selection from the field.  In both these cases, the characters in the selection are written to the "clipboard".  The clipboard is a system-wide location from where these characters can be later retrieved by this or any other application.  If, instead of copying or cutting the characters, you decide to delete the characters, the characters will be removed from the field, just as they are when cut, but they are not copied to the clipboard, and so can not be redeemed.  If you type any regular character key while a selection is in effect, the characters within the selection are replaced by the character typed.

To do any of these actions:

  • type [CONTROL C] to copy the contents of the selection area to a clipboard, for subseqent pasting elsewhere,
  • type [BACKSPACE] or [DELETE] to delete the contents of the selection area,
  • type any regular character key to delete the contents of the selection area and replace it with that character,
  • type [CONTROL X] to copy the contents of the selection area to a clipboard, and to delete its contents from the field being edited.

To use the characters you have copied to the clipboard, position the cursor within this field, or some other field (generally the corresponding field for another record within the same database), at the point at which you require the characters to be inserted.  You can then type [CONTROL V] to redeem these characters.

Name

A name field is one in which any string of characters, referred to herein as a "name", may be entered.

If the final character of the prompt is "a", "s" or "t" then the alphabetic characters entered will be conditionally capitalised.

If the final character is an "a" (for "all"), all alphabetic characters will be capitalised.

If the final character is an "s" (for "sentence"), only the first character, if alphabetic, will be capitalised.

If the final character is a "t" (for "title"), only the first character of each word, if alphabetic, is capitalised, unless the word is a "small word".  The "small words" are defined in a database.  Refer to the section titled: "Edit Databases", and its sub-section, "General" and its sub-section, "Small Words".

To defeat the capitalisation of the character you are about to type, precede the typing of the character with the typing of a "`", (the open single-quote, or acute symbol - just above the [TAB] on most keyboards).  To defeat the de-capitalisation of the first character of a "small word", after typing the word and before typing the subsequent [SPACE], type "`".

In some contexts the name is required to be unique.  In these cases, if the name typed in includes non-blank characters and has been used already then the message "Name already exists" will be displayed in the error line.

Character

Character fields contain a single character, being one of those presented in the list of the prompt for the field.  No other character can be entered into these fields.

Numeric

A numeric field is one in which a value is to be entered.

Once the value has been entered, it is interpreted as a value, so the entry is assumed to end on the first occurrence of a character that is neither a digit nor a decimal-point.

If the value entered is not in the inclusive range indicated in the prompt, the entry is not accepted.  The expression of the lower limit indicates the number of significant digits following the decimal-point, so any digits entered after these will be ignored.

If there is no range specified in the prompt, the value may range from 0 and should include no decimal places.

If the final character of the prompt is "x", "o" or "b" then the entry is to be made in hexadecimal, octal or binary notation, respectively.

If your entry begins with a "0", you will override the selection of the base. Instead the base will be hexidecimal if the character following the "0" is an "x", decimal if a "d", binary if a "b", or else octal.  There is just enough room in the field to type the value in the form expected, so if you use one of these base specifiers, the field may need to horizontally scroll as you type in extra characters.

You may also enter an arithmetic expression, using Allen-Bradley PLC ladder opcodes.  Among these are included addition, subtraction, multiplication, division, and parentheses, "(" and ")".  The usual symbols are associated with these operations except that Allen-Bradley use "|" in place of the more usual "/" for division, however, "/" will also be recognised in this context as division.

Once an expression is detected, the base, as designated by the final character of the prompt, is disregarded and all values are interpreted as decimal, unless they have a leading zero.  You may no longer use "0d" to specify decimal, and anyway it is now redundant.

Although the only operators you are likely to use are "+", "-", "*", "/", "(", and ")", for the record, the full list of operations, in order of precedence are:

  • Negate
    Symbols: ".NEG.".  Result: multiplies the left hand operand (or 1 if no such operand) by the negated value of the right hand operand. Example: ".NEG.25" returns -25.
  • Integer
    Symbols: ".INT.".  Result: multiplies the left hand operand (or 1 if no such operand) by the truncated integer part of the right hand operand. Example: ".INT.25.7" returns 25.
  • Sine
    Symbols: ".SIN.".  Result: multiplies the left hand operand (or 1 if no such operand) by the trigonometric sine of the right hand operand interpreted as a number of radians. Example: ".SIN.0.524" returns 0.5.
  • Cosine
    Symbols: ".COS.".  Result: multiplies the left hand operand (or 1 if no such operand) by the trigonometric cosine of the right hand operand interpreted as a number of radians. Example: ".COS.0.524" returns 0.866.
  • Tangent
    Symbols: ".TAN.".  Result: multiplies the left hand operand (or 1 if no such operand) by the trigonometric tangent of the right hand operand interpreted as a number of radians. Example: ".TAN.0.524" returns 0.578.
  • ArcSine
    Symbols: ".ASN.".  Result: multiplies the left hand operand (or 1 if no such operand) by the angle, in radians, whose trigonometric sine is the right hand operand. Example: ".ASN.0.500" returns 0.524.
  • ArcCosine
    Symbols: ".ACS.".  Result: multiplies the left hand operand (or 1 if no such operand) by the angle, in radians, whose trigonometric cosine is the right hand operand. Example: ".ACS.0.866" returns 0.524.
  • ArcTangent
    Symbols: ".ATN.".  Result: multiplies the left hand operand (or 1 if no such operand) by the angle, in radians, whose trigonometric tangent is the right hand operand. Example: ".ATN.0.578" returns 0.524.
  • ToDegrees
    Symbols: ".DEG.".  Result: multiplies the left hand operand (or 1 if no such operand) by the angle, in radians, represented by the right hand operand interpreted as a number of degrees. Example: ".DEG.0.524" returns 30.
  • ToRadians
    Symbols: ".RAD.".  Result: multiplies the left hand operand (or 1 if no such operand) by the angle, in degrees, represented by the right hand operand interpreted as a number of radians. Example: ".DEG.30" returns 0.524.
  • NaturalLog
    Symbols: ".LN.".  Result: multiplies the left hand operand (or 1 if no such operand) by the natural logarithm (base e) of the right hand operand. Example: ".LN.2.72" returns 1.
  • LogBase10
    Symbols: ".LOG.".  Result: multiplies the left hand operand (or 1 if no such operand) by the base 10 logarithm of the right hand operand. Example: ".LOG.10" returns 1.
  • SquareRoot
    Symbols: ".SQR.".  Result: multiplies the left hand operand (or 1 if no such operand) by the square root of the right hand operand. Example: "0.5.SQR.3" returns 0.866.
  • RaiseToPower
    Symbols: ".XPY." or "**".  Result: finds the value of the left hand operand raise to the power of the right hand operand.  Example: "2**3" returns 8.
  • Scale
    Symbols: ".SCL.".  Result: multiplies the left hand operand (or 1 if no such operand) by the first right hand operand, then divides the result by ten thousand then subtracts the second right hand operator. Example: "1270.SCL.500,20" returns (1270*500)/10000-20=43.5.
  • Multiply
    Symbols: ".MUL." or "*".  Result: multiplies the left hand operand (or 1 if no such operand) by the right hand operand. Example: "1270*500" returns 635000.
  • Divide
    Symbols: ".DIV." or "|" or "/".  Result: divides the left hand operand by the right hand operand (or by "1" if the right hand operand is "0"). Example: "635000/10000" returns 63.5.
  • Add
    Symbols: ".ADD." or "+".  Result: adds the left hand operand (or 0 if no such operand) by the right hand operand. Example: "43.5+20" returns 63.5.
  • Subtract
    Symbols: ".SUB." or "-".  Result: subtracts the right hand operand from the left hand operand (or 0 if no such operand). Example: "63.5-20" returns 43.5.
  • Complement
    Symbols: ".NOT." or "~".  Result: multiplies the left hand operand (or 1 if no such operand) by the one's (bit-wise) complement of the thirty-two bit value represented by the right hand operand. Example: "~0x55" returns 0xFFFFFFAA=a large number.
  • Mask
    Symbol: ".AND.".  Result: performs the bit-wise "and"ing if the left hand operand with the right hand operand. Example: "0xFF.AND.0xFFFFFF55" returns 0x55=85.
  • ExclusiveOr
    Symbol: ".XOR.".  Result: performs the bit-wise exclusive "or"ing if the left hand operand with the right hand operand. Example: "0xFFFFFF0B.AND.0xFFFFFF55" returns 0x5E=94.
  • Set
    Symbol: ".OR.".  Result: performs the bit-wise "or"ing if the left hand operand with the right hand operand. Example: "0xFFFFFF0B.AND.0xFFFFFF55" returns 0xFFFFFF5F=a large number.
  • LessThan
    Symbols: ".LES." or "<".  Result: rounds both the left and right operands to the nearest integer, then returns "1" if the left hand operand is less than the right or "0" otherwise. Example: "5.4<5.45" returns 0 as both round to "5" and are therefore equal.
  • GreaterThan
    Symbols: ".GRT." or ">".  Result: rounds both the left and right operands to the nearest integer, then returns "1" if the left hand operand is greater than the right or "0" otherwise. Example: "6>5" returns 1.
  • Limit
    Symbol: ".LIM.".  Result: rounds the left hand operand and both right hand operands to the nearest integer, then returns "1" if the first right hand operand is in the inclusive range of the other operands, or if the second right hand operand is less than the left hand operand, returns "1" if the first right hand operand is not in the exclusive range of the other operands.  Returns "0" otherwise. Examples: "4.LIM.5,6", "4.LIM.4,6", and "4.LIM.6,6" all return 1; "4.LIM.3,6", "4.LIM.7,6" both return 0; "6.LIM.3,4", "6.LIM.4,4", "6.LIM.6,4", and "6.LIM.7,4" all return 1; "6.LIM.5,4" returns 0.
  • MaskEqualTo
    Symbol: ".MEQ.".  Result: rounds the left hand operand and both right hand operands to the nearest integer, then exclusive "or"s the left hand operand with the second right hand operand, and "and"s this result with the first right hand operand, then returns "1" if this result is "0" and "0" otherwise. Example: "0x1234.MEQ.0x00F0,0x2131" returns 1;
  • EqualTo
    Symbols: ".EQU.", "=", or "==".  Result: rounds both the left and right operands to the nearest integer, then returns "1" if the left hand operand is equal to the right or "0" otherwise.  Example: "6.3=6.2" returns 1 as both are rounded to "6".
  • NotEqualTo
    Symbols: ".NEQ.", "<>", or "!=".  Result: rounds both the left and right operands to the nearest integer, then returns "1" if the left hand operand is not equal to the right or "0" otherwise.  Example: "6!=7" returns 1.
  • GreaterThanOrEqualTo
    Symbols: ".GEQ." or ">=".  Result: rounds both the left and right operands to the nearest integer, then returns "1" if the left hand operand is greater than or equal to the right or "0" otherwise. Example: "6>=5" returns 1.
  • LessThanOrEqualTo
    Symbols: ".LEQ." or "<=".  Result: rounds both the left and right operands to the nearest integer, then returns "1" if the left hand operand is less than or equal to the right or "0" otherwise. Example: "5<=6" returns 1.
  • Not
    Symbol: "!".  Result: returns "1" if the value is less than "0.5", or "0" otherwise, so the values returned by the above boolean expressions, "1" and "0" would be reversed. Example: "!5<=6" returns 0.
  • And
    Symbol: "&&".  Result: compares the left and right hand operands to "0.5", and returns "1" if both are greater than or equal to this value, or "0" otherwise. Example: "4<5&&5<=6" returns 1.
  • Or
    Symbol: "||".  Result: compares the left and right hand operands to "0.5", and returns "1" if either is greater than or equal to this value, or "0" otherwise. Example: "5<4&&5<=6" returns 1.

Also note that a value appearing before a left hand parenthesis, "(", will be multiplied by the result of the parenthesised expression.  For example: 25(2+3) returns 125.

When the value is entered, it is interpreted then rewritten into the field, right-justified.  The value "0" will be displayed as blank, however, to enter this value, type "0" so as to instruct the Movement Controller not to retain the old value.

In some contexts the value is required to be unique.  In these cases, if the value typed in is other than the lower limit and has been used already then the message "Value already exists" will be displayed in the error line.

Date

Date fields contain a date, expressed in the form "24-OCT-53". They may be altered as described in the section titled: "Data", with some differences.

[BACKSPACE] does not remove characters, it only moves the cursor.  If, by typing [BACKSPACE], the cursor would be left adjacent to a hyphen, then the cursor is moved an additional place left.

If, as characters are being typed, the cursor would be in the position of a hyphen, then the cursor is moved an additional place right.  When typing the replacement characters, colons, spaces and hyphens may be used to delimit sub-fields prior to typing the full sub-field, and all other characters are converted to either digits or upper case letters as appropriate.

The entry may be terminated while the cursor is in any position in the field.

Time

Time fields contain the time and date, expressed in the form "06:30:26 24-OCT-53".  They may be altered as described in the section titled: "Data", with some differences.

[BACKSPACE] does not remove characters, it only moves the cursor.  If, by typing [BACKSPACE], the cursor would be left adjacent to a colon, space or hyphen, then the cursor is moved an additional place left.

If, as characters are being typed, the cursor would be in the position of a colon, space or hyphen then the cursor is moved an additional place right.  When typing in the replacement characters, the colons, spaces, and hyphens may be used to delimit sub-fields prior to typing the full sub-field, and all other characters are converted to either digits or upper case letters as appropriate.

The entry may be terminated while the cursor is in any position in the field.

The number of seconds must be even or will be made so.

Symbolic Numeric

Symbolic numeric fields may contain only values from a previously defined set, or else must be blank. Presentation and editing is as described for "Numeric" fields. Refer to the section titled: "Numeric".

An alternative method of making this entry is to select the name from the previously defined set.  To do this click the arrow at the extreme right of the field and a drop-down (or up) menu is provided from which the desired number may be selected.  There may be a scroll bar associated with this menu, should the database be a large one.  To select a number, use the cursor keys to highlight, or click on it with the mouse, then press [ENTER] or double click on it with the mouse.

If an attempt is made to enter a non-existent value (no match can be found) then either the message, "No match found for this entry", or the message, "Unknown: If correct, confirm by pressing [SHIFT F11], - depending upon your privilege - will be displayed in the error line.

It is expected that the values to be entered into these fields be previously defined, however the provision to define these values at this point is provided if you have sufficient privilege.

For information on setting the privilege levels of users and the objects they are to use, please refer to the sections titled: "Modify List of Users", "Edit Databases", and its sub-sections "Menu Text and Security", "Database Privilege", and "Configuration Data".

To do this, after typing the value and encountering the message, "Unknown: If correct, confirm by pressing [SHIFT F11], press [SHIFT F11] This will open a window, through which the referenced database entity will be presented for editing.  It may also be accompanied by other fields had you been editing a "Key" field.  Refer also to the section titled: "Key".

Symbolic Name

Symbolic name fields may contain only names from a previously defined set, or else must be blank.

As characters are removed or typed in, the set of names is scanned for a match.  The remaining characters from the first match found are displayed from the cursor to the end of the field.  Typing [DOWN] will present the remaining characters of the next match, while typing [UP] will present the remaining characters of the previous match.

If the name presented is the desired name, typing [RIGHT] will save typing in the remaining characters, placing the cursor after the last character.  Alternatively, typing the [CONTROL RIGHT] will accept the remaining characters individually, moving the cursor one place right each time.

The [UP], [DOWN], and [RIGHT] keys only serve the above functions when the cursor is not in the left-most position. [CONTROL UP] and [CONTROL DOWN] can be used in place of [UP] and [DOWN] when the cursor is at the left-most position.

An alternative method of making this entry is to select the name from the previously defined set.  To do this click the arrow at the extreme right of the field and a drop-down (or up) menu is provided from which the desired name may be selected.  There may be a scroll bar associated with this menu, should the database be a large one.  To select a name, use the cursor keys to highlight, or click on it with the mouse, then press [ENTER] or double click on it with the mouse.

If a non-existent name is typed in (no match can be found) then either the message, "No match found for this entry", or the message, "Unknown: If correct, confirm by pressing [SHIFT F11], - depending upon your privilege - will be displayed in the error line.

It is expected that the names to be entered into these fields be previously defined, however the provision to define these names at this point is provided if you have sufficient privilege.

To do this, after typing the name and encountering the message, "Unknown: If correct, confirm by pressing [SHIFT F11], press [SHIFT F11] This will open a window, through which the referenced database entity will be presented for editing.  It may also be accompanied by other fields if you had been editing a "Key" field. Refer to the section titled: "Key".

Where

This presentation is used when entering an expression to restrict the presentation of database records.  For more details on viewing database records and restricting this view with an expression, please refer to the section titled: "Viewing Data" and its subsection "Records Satisfying an Expression".

Generally, the editing of these fields is as described earlier in the section titled: "Data", with some differences.

Note that, generally, any spaces entered will be ignored.

Some characters entered into this field have special significance as regards the editing.

The "[" and "]" delimit the database names.  The database names are listed as "Database name for "Where"" in the "Database Privilege" database.  This field is described in the section titled "Database Privilege".  Within the "[" and "]" characters the characters typed are treated as a symbolic reference to this field, and so the editing is as described in the previous section, "Symbolic Name".  Also, when you type "[", the "]" will also be entered ahead of the cursor, and when you type "]", instead of entering another "]", the cursor will be moved ahead of the next "]".  If you use [BACKSPACE] to delete the final "]", all text from the preceeding "[" up to and including the "]" will be removed, while using [DELETE] to remove the "[", will also remove all text from the "[" up to and including the following "]".  As text is typed between the brackets, the case will be adjusted to match a database name.

The double quotation marks (") delimit the text strings.  Normally, any spaces entered into this field will be ignored, except when between a pair of double quotation marks.  Also, when you type a double quotation mark, a second will also be entered ahead of the cursor, and when you type a double quotation mark from within a pair, instead of entering another double quotation mark, the cursor will be moved ahead of the next double quotation mark.  If you use [BACKSPACE] to delete the final double quotation mark, all text from the preceeding double quotation mark up to and including that double quotation mark will be removed, while using [DELETE] to remove the first double quotation mark, will also remove all text between and including the double quotation mark.

The dots ("."), when not within the specification of a number, can delimit operator names.  When you type a dot, a second will also be entered ahead of the cursor, and when you type a dot from within a pair, instead of entering another dot, the cursor will be moved ahead of the next dot.  All text between the pairs of dots will be capitalised.  If you preceed a dot with a number, it will be treated as a decimal point, however, if this is, then followed by a letter, then the second dot will be entered ahead of the letter that you typed.

The parentheses ("(" and ")") are used to override the normal order of operations.  When you type "(", the ")" will also be entered ahead of the cursor, and when you type ")", instead of entering another ")", the cursor will be moved ahead of the next ")".  If you use [BACKSPACE] to delete the final ")", the preceeding "(" will also be removed, while using [DELETE] to remove the "(", will also remove the following ")".

Also note that when the field is entered, it will be converted to a binary expression that is incomprehensible.  This binary expression may be presented briefly as the entry is made; please ignore this if you notice it.

Current Time

Current time fields present the current time and date, and by editing these fields the current time and date may be adjusted.

Presentation and editing is as described for "Time" fields. Refer to the section titled: "Time".

Password

Password fields are used to enter or set the passwords.

Presentation and editing is as described for "Name" fields except that when editing the password, the characters are echoed using spaces.  Refer to the section titled: "Name".

Screen Editing

These fields appear as "Name" fields.  However as an attempt is made to edit the field, a window is opened in the current window through which a number lines are displayed.

The first line corresponds to the database field initially presented, while the additional lines present the corresponding records from the subsequent database fields.

These lines may be edited using the cursor control keys and [RETURN], [ENTER], [BACKSPACE], [DELETE], [HOME], and [END] to provide their natural function, and using the character keys in insert mode. [RETURN] and [ENTER] provide for a carriage return and line feed but do not insert a blank line.

The cursor may be moved by clicking on the point to which it is to be moved.

Memo

These fields appear as "Name" fields. However as an attempt is made to edit the field, a window is opened through which a number lines are displayed.

The first line corresponds to the database field initially presented, while the additional lines present the remainder of the contents of a file.

The file name is comprised of three digits representing the database field number, followed by five digits representing the record number, followed by the file name extension ".MEM".  For example, the filename corresponding to record 1 of database field number 73 would be "07300001.MEM".  Please note that these files are outside the database and are therefore not backed up with the database; you will need to care for these explicitly.

The database field number is the option number given on the menu presented by the Edit Databases screen after selecting the final option from the first menu presented by this screen.  Refer to the section titled: "Edit Databases".

A special feature of these fields, is that, when you perform a "Match" (refer to the section titled: "Viewing Data"), not only is the database searched, but also the entire contents of the associated file.  This is could prove to be quite a powerful feature, but may also become slow as the number of files to be searched grows.

When you start to edit the file, it is loaded into the editor's memory and any edits you make are applied to this memory - not to the file itself. When you exit the editor, these changes will be written to the file, and the first line to the database field.

The format of this file is simple ASCII, except that new-lines (carriage returns and line feeds) are reserved for terminating a paragraph, so the lines are, typically, very long.

Key Assignments

The editor allows you to allocate upto three keys to each function and supports two modes of "select, cut and paste" in an attempt to allow the editor to be configured to roughly mimic your usual editor.

This section describes the method to display and set these assignments. While this may seem a rather esoteric point to embark on the description of the editor, we begin here so that you will be able to configure the editor to best match your previous experience, thereby reducing the level of learning required to use it.

If you press [F1], you will be presented with a list of the key assignments.

Below is a rough text-representation of this window:

Edit boolean file Enter 1c0d e00d Copy 4e2b Up 4800 48e0 Cut 4a2d Down 5000 50e0 Paste 5230 Left 4b00 4be0 Skip word forward 7400 74e0 Right 4d00 4de0 Skip word backward 7300 73e0 Page Up 4900 49e0 Learn 2600 4100 Page Down 5100 51e0 Terminate 1400 Beg Line/Screen/File 4700 47e0 Execute 2d00 4200 End Line/Screen/File 4f00 4fe0 Repeat 1300 Insert Overstrike 5200 52e0 Quit 1000 11b Delete This Char 5300 53e0 Edit Macro File 1200 Delete Previous Char e08 Set Up Keys 1f00 3b00 Delete To End Line 2500 Find 3f00 2100 Delete Entire Line 2000 1519 Find Next 5900 3100 Select 532e Find and Replace 4000 Select Up 4838 Edit Address Comment 1e00 Select Down 5032 Select Left 4b34 Select Right 4d36 Select Page Up 4939 Select Page Down 5133 Editing POCOLDMEine 1 Column 1 Insert

This displays the key assignments in two columns.  Each line of each column corresponds to one key function.  For each key function, the name of the function and the scan codes of upto three keys are displayed.  The three scan codes are displayed in three columns, with one scan code highlighted.

On the right of the fourth bottom line on the window, the scan code highlighted is explained.  In the above case, the highlighted scan code is 1c0d, with the text "Return" displayed in the lower right area of the window.

The cursor can be moved to each scan code position to present its translation or to change the key for the function.

If you are calling up this window for help rather than to alter the key assignments, you can have presented, next to each function description, one of the key descriptions for the function.  The key description presented will be dependent upon which column the highlighted scan code is in.  To call this up, type [F1] again.

Below is a rough text-representation of this window:

Edit boolean file Enter Return Copy Grey Plus Up 8/Up Cut Grey Minus Down 2/Down Paste SHIFT 0/Insert Left 4/Left Skip Word Forward CONTROL 6/Right Right 6/Right Skip Word Backward CONTROL 4/Left Page Up 9/Page Up Learn ALTERN' L Page Down 3/Page DownTerminate ALTERN' T Beg Line/Screen/File 7/Home Execute ALTERN' X End Line/Screen/File 1/End Repeat ALTERN' R Insert Overstrike 0/Insert Quit ALTERN' Q Delete This Char ./Delete Edit Macro File ALTERN' E Delete Previous Char BackSpace Set Up Keys ALTERN' S Delete To End Line ALTERN' K Find F5 Delete Entire Line ALTERN' D Find Next SHIFT F6 Select SHIFT ./Delete Find and Replace F6 Select Up SHIFT 8/Up Edit Address Comment ALTERN' A Select Down SHIFT 2/Down Select Left SHIFT 4/Left Select Right SHIFT 6/Right Select Page Up SHIFT 9/Page Up Select Page Down SHIFT 3/Page Down Editing POCOLDMEine 1 Column 1 Insert

To change the key assignment for a given function, move the highlight to the function, and across to the required scan code column, then type [ENTER], then type the key you wish to use for this function (or [SPACE] if you change your mind about wanting to change the key assignment).

Once you have finished interrogating or changing the key assignments, type [ESCAPE] to return to editing you file.

This function is the "Set Up Keys" function, which, according to the above screen dump, can be called up by typing [ALTERNATE S], whereas this section has instructed you to type the [F1] key to call up this function.  You will notice on the previous window that two scan codes were presented for this function, 1f00 and 3b00.  These scan codes correspond to [ALTERNATE S] and [F1] respectively.

Because of the flexibility of this editor, instructions for using it throughout the rest of the sections of the document will refer to the keys by their function.

Basic Editing

Most keys, when typed, result in their associated ASCII character being added to the file's buffer and the appropriate character being displayed on the window at the cursor position, moving the cursor one place to the right.

Cursor Movement

The cursor may be moved about the window using the specified keys for the "Up", "Down", "Left" and "Right" functions, in the natural manner.

Pressing any of the keys specified for the "Enter" function, will move the cursor to the start of the next line, possibly scrolling the window upwards.

The cursor may be moved to the beginning or end of the current line by typing a key specified for "Beg Line/Screen/File" or "End Line/Screen/File" function respectively when not at the beginning or end of the line respectively.

The cursor may be moved to the beginning or end of the window by typing a key specified for the "Beg Line/Screen/File" or "End Line/Screen/File" function respectively when at the beginning or end of the line respectively but not at the beginning or end of the window respectively.

The cursor may be moved to the beginning of the current string of characters (or if already there to the beginning of the previous string) by typing a key specified for the "Skip Word Backward".

The cursor may be moved to the beginning of the next string of characters by typing a key specified for the "Skip Word Forward".

Screen Movement

The window displays only a portion of the file.  The window can be made to view other portions of the file by typing any of the keys specified for the "Page Up" and "Page Down" functions to move the window a numner of lines up or down the file.

The window may be moved to the beginning or end of the file by typing a key specified for "Beg Line/Screen/File" or "End Line/Screen/File" function respectively when at the beginning of the first line on the window or at the end of the last line on the window respectively.

Find

A further means of cursor and window movement may be achieved using the find functions.

After typing any of the keys for the "Find" function, you will be prompted to enter the text you wish to find.  When you terminate this entry, an attempt will be made to find the specified text.

The search is conducted from the cursor position to the end of the file.  In matching the text to the file, the case of letters is ignored.

If the text is not found, a message to this effect will be presented, which you will be required to acknowledge by typing any key.

Had the text been found, the cursor and window will be relocated within the file to this text.

Once the text has been searched for once, a further search may be initiated by typing one of the keys for the "Find Next" function.

Find and Replace

You can ask the editor to replace one, several or all occurrences of a specified text string with another by typing one of the keys for the "Find and Replace" function.

In response, you will be prompted to enter the text you wish to find and then the text you wish to replace it with.  When you terminate the second entry (the replacement text), an attempt will be made to find the first specified text.

The search is conducted from the cursor position to the end of the file.  In matching the text to the file, the case of letters is ignored.

As each occurrence is found, the text will be highlighted and the prompt, "Replace/No/Global <R/N/G>", will be presented.  Enter "R" to replace the highlighted text, "N" to skip to the next occurrence or "G" to replace this and all subsequent occurrences.  Alternatively you can quit from the replace cycle by typing [ESCAPE].

Insert or Overtype Mode

Normally as characters are being typed and the cursor is moving to the right, the text previously at the cursor position is advanced with the cursor, inserting the new characters between it and the character that was previously to the left of the cursor.

Also, when typing one of the keys for the "Enter" function, before the cursor is relocated to the beginning of the next line, the lines below the cursor are moved down by one line and any characters to the right of the cursor will be relocated to the start of the new line.

In overtype mode, the character at the cursor position is replaced by the new character entered.  The cursor still moves one place to the right.

Also, when typing one of the keys for the "Enter" function, only the cursor is relocated; all the text remains where it is.

This mode is toggled between insert and overtype each time one of the keys corresponding to the "Insert Overtype" function is typed.  The current mode is displayed just left of the centre of the third last line on the window.

Deleting Text

The character at the cursor may be deleted by typing one of the keys for the "Delete This Char" function.  The cursor will be unmoved, and any text to the right of the cursor will be moved one place left.

The character to the left of the cursor may be deleted by typing one of the keys for the "Delete Previous Char" function.  The cursor will be moved to the left, and any text at or to the right of the cursor will be moved one place left.

The remainder of the line, from the character the cursor is at to the end of the line, may be deleted by typing one of the keys for the "Delete To End Line" function.  The cursor will be unmoved.

The line the cursor is on may be deleted by typing one of the keys for the "Delete Entire Line" function.  The cursor will be unmoved, and any lines below the cursor will be moved up by one line.

Select, Cut and Paste

There are two methods of "Select, Cut and Paste" employed.  Using the first method, you explicitly flag the beginning of the selection, using one of the keys for the "Select" function, then move the cursor/window to the point in the file at which you wish to end the selection. Refer the sections titled: "Cursor Movement", "Screen Movement", and "Find".

You can then either delete the selection (by typing one of the keys for the "Delete This Char" function), copy it to the "paste" buffer (by typing one of the keys for the "Copy" function), or cut it - copy it then delete it - to the "paste" buffer (by typing one of the keys for the "Cut" function).

Using this first method, you can cancel a selection by again typing one of the keys for the "Select" function.

Using the second method, you flag the beginning of the selection the first time you type a key corresponding to one of the following "Select and Move" functions to extend or reduce the selection:

  • Select Up       
    moves the end of the selection up by one line
  • Select Down     
    moves the end of the selection down by one line
  • Select Left     
    moves the end of the selection left by one character
  • Select Right    
    moves the end of the selection right by one character
  • Select Page Up  
    moves the end of the selection up by twenty-two lines
  • Select Page Down
    moves the end of the selection down by twenty-two lines

The selection can then be deleted, copied or cut as described for the first method.

Using this second method, you can cancel a selection by typing one of the keys for the "Cursor Movement" or "Screen Movement" functions. Refer the sections titled: "Cursor Movement", and "Screen Movement".

When using either method, the text within the selection will be highlighted.

After copying or cutting a selection to the "paste" buffer, you would normally move the cursor to another point in the file, then insert the copied or cut text at this point by typing one of the keys for the "Paste" function.

Key Sequence Macros - Learning

Sometimes it is necessary to repeat a given sequence of key strokes an inordinate number of times when editing a file.  To alleviate this, the editor may be instructed to remember these key strokes and to play them back time and time again.

To start the recording of key strokes, type one of the keys for the "Learn" function.  Then proceed to type the keys you wish recorded; as you do this the keys will be treated normally, resulting in the expected changes to the file and window.

During this phase, the text "Learning" will be displayed alongside the "Insert" or "Overstrike" text in the third bottom line of the window.

Once you have completed the sequence of key strokes, type one of the keys for the "Terminate" function.

You should take particular care of how you start and end the sequence, especially if you wish it to be executed a number of times in succession.

To replay this sequence, type one of the keys for the "Execute" function.

The sequence can be terminated and executed immediately by typing one of the keys for the "Execute" function in place of typing one of the keys for the "Terminate" function.

During the execution of the sequence, the text "Executing" will be displayed alongside the "Insert" or "Overstrike" text in the third bottom line of the window.

Repeating Key Strokes and Macros

The editor may be instructed to repeat any key stroke a given number of times by first typing one of the keys for the "Repeat" function, then entering the number of times the key stroke is to be repeated, then typing the key to be repeated.

The key to be repeated may be one of the keys for the "Execute" function, allowing you to execute the key-sequence macro a given number of times.

During the execution of the repeated key strokes, the number of iterations remaining is displayed further to the right of the "Insert" or "Overstrike" text than the "Learning" or "Executing" text on the third bottom line of the window.

Exiting from the Editor

To leave the editor, type one of the keys for the "Quit" function.  Any changes you have made will be written to both the file and the database.

Attribute

Attribute fields are used to alter the video attributes.  They consist of two hexadecimal digits, the first for the background and the second for the foreground.  If you enter a single digit it is assumed to be the foreground and will be presented in the second digit position.

Presentation and editing is as described for "Numeric" fields except that as the value is altered the associated attribute name is also presented in the attribute typed in and the two hexadecimal digits may be altered by positioning the cursor to the right of the digit in question and using the [UP] and [DOWN] keys to raise or lower its value.  Refer to the section titled: "Numeric".

Attribute fields are used to alter the video attributes, used by the GUI operator interface program when presenting database quantities. They consist of two values, a foreground value and a background value, presented as the foreground colour name, followed by "on" then the background colour name, such as "Black on Red".

All colours must be previous listed as a "Palette description".  Refer to the section titled: "Changing the Colours", and "Edit the Colour's Name".

As characters are removed or typed in, the list of "Palette descriptions" is scanned for a match.  The remaining characters from the first match found are displayed from the cursor to the end of the field.  Typing [DOWN] will present the remaining characters of the next match, while typing [UP] will present the remaining characters of the previous match.

If the name presented is the desired name, typing [RIGHT] will accept one more of the offered characters, moving the cursor one place right.

If non-matching characters are typed, they will be ignored.

Once sufficient characters have been typed to uniquely identify the colour, the cursor will be advanced to the beginning of the next sub-field (the background colour) or to the end of the field.

Miscellaneous Data

The miscellaneous data may be edited either as a numeric or a character field (as indicated by the presented prompt).  Refer to the sections titled: "Numeric", and "Character".

It may be noted that the prompt presented for the "Miscellaneous Data" is not the prompt associated with that database field but instead the data from the corresponding record of the "Miscellaneous Name" database field.  If this does not mean anything to you, let it pass.

When these fields are presented, specific records will present their data in a more explicit fashion.

Baud Rates

The baud rates for the various communications channels are presented and edited as "Symbolic Name" fields, except that the predefined set of names varies with the channel being described and the use of the channel. Refer to the section titled: "Symbolic Name".

If the channel is an asynchronous serial communications channel, the usual set of baud rates are used, however, if the channel is on the Allen-Bradley KTxD card, is set of baud rates is either that for the scanner mode, or the DH-485 mode depending upon which mode is selected for the channel.

Store Reference

The store reference fields are used to reference a location in the store.

References are expressed in the form "WW:RR-H-LLL-D" (example: "42:16-A-027-1"), where the first two characters ("WW") represent the warehouse (either 41 or 42) and is redundant with the rack, which consists of the first two characters ("RR") following the colon.  If the warehouse is "41", the rack must be in the range "05" to "10", otherwise the warehouse must be "42", and the rack must be in the range "11" to "16".  Rack "05" is the left hand side of crane "6", rack "06" is the right hand side of crane "6", rack "07" is the left hand side of crane "5", and so on to rack "16", which is the right hand side of crane "1".

This is probably presented more clearly in the following table:


          ╔═════════════════════════════╦═════════════════════════════╗
          ║   WAREHOUSE 41 "Freezer"    ║    WAREHOUSE 42 "Chiller"   ║
          ╟─────────╥─────────╥─────────╫─────────╥─────────╥─────────╢
          ║ Crane 6 ║ Crane 5 ║ Crane 4 ║ Crane 3 ║ Crane 2 ║ Crane 1 ║
          ╠════╦════╬════╦════╬════╦════╬════╦════╬════╦════╬════╦════╣
          ║ 05 ║ 06 ║ 07 ║ 08 ║ 09 ║ 10 ║ 11 ║ 12 ║ 13 ║ 14 ║ 15 ║ 16 ║
          ╚════╩════╩════╩════╩════╩════╩════╩════╩════╩════╩════╩════╝

The next character is always a hyphen, followed by a letter representing the hoist level ("H"), which uses "A" for level 1 to "H" for level 8, then "J" for level 9 to "M" for level 12.  This is followed again by a hyphen.  The next three characters ("LLL") represent the long travel position, the next character is always a hyphen and the final character ("D") represents the depth ("1" for the location near the crane, "2" for the location further from the crane).

These fields may be altered as described in the section titled: "Data", with some differences.

[BACKSPACE] does not remove characters, it only moves the cursor.  If, by typing [BACKSPACE], the cursor would be left adjacent to a character that can not contain an alternate value, then the cursor is moved an additional place left.

If, as characters are being typed, the cursor would be in a position that can contain only one possible character then the cursor is moved an additional place right.  When typing in the replacement characters, a colon, hyphen, space or period is ignored unless typed within the long travel specification where it delimits the long travel prior to typing all three digits.

The entry may be terminated while the cursor is in any position in the field.

When the store reference is entered, certain checks are performed.

If the warehouse number is other than 41 or 42, the following message will be produced: "WW Warehouse number out of range".

If the rack number is outside the range 5 to 16, the following message will be produced: "RR Rack number out of range".

If the warehouse and rack numbers are contradictory, the following message will be produced: "WW:RR Warehouse and rack numbers inconsistent".

If the hoist level is other than "A" to "H" and "J" to "M", the following message will be produced: "H Hoist out of range".

If the long travel position is outside the range 1 to 70, the following message will be produced: "LLL Long travel out of range".

If the depth is other than "1" or "2", the following message will be produced: "D Depth out of range".

Crane and Palletiser Alarms

The crane alarm and palletiser alarm fields list, by number, the cranes or palletisers that currently share the corresponding alarm.  This field appears as a sequence of digits.

These digits may be entered in any sequence, however they will be displayed in increasing order (from the left), with spaces in place of the missing digits.

These fields may be altered as described in the section titled: "Data".

Load Detection Indices

The load detection indices are used to tie a store location to a load detection system bit.  These indices represent the bit index from the start of the table of photocells or switches.

The start of these tables has been hard coded within the Movement Controller and removes the discontinuity between the photocell sub-tables for the main and remote systems.

The indices are expressed in hexadecimal to assist correlation with the load detection system.

These indices are expressed in the form "L:02A8" or "S:0003" depending whether the index is referencing the photocell or switch table respectively.

These fields may be altered as described in the section titled: "Data".

Photocell Arrangement

The photocell arrangement specifies that, for the given Heavy-Unit-Load Conveyor position, which of the six standard photocells (clear, stop and slow in the forward and reverse directions) are to be physically present on the conveyor position in question.

For background on this, please refer to the section titled: "System Definition".

Normally, during the generation of the Heavy-Unit-Load Conveyor PLC software, the photocell arrangement is established from knowledge of the transfers that need to be supported.  This arrangement is presented in the ".ain" file, which is generated at that stage.  In cases where the photocell arrangement is already set, or where peculiar transfers are required, you can nominate which photocells are available.  The transfer macros will pay attention to this arrangement, and will make the most of it that it can, even though it may not be the ideal arrangement.

There are six "sub-fields" within this field.  Each "sub-field" occupies four or five character positions, displaying "----" or "-----" to imply that there is no photocell at the corresponding location, and "Clear", "Stop", or "Slow" to imply that there is a photocell.

The first three sub-fields correspond to the "Clear", "Stop" and "Slow" photocells at the rear of the conveyor, and are separated from the second three (which represent the "Slow", "Stop" and "Clear" photocells at the front) by ">>>>>".  The first and last sub-fields represent the "Clear" photocells, the second and second last represent the "Stop" photocells, while the third and third last (fourth) represent the "Slow" photocells.

Each field is set with a single character keystroke, which then advances the cursor to the start of the next sub-field.  The keys "O", "0", "-", "_", and "N" sets the sub-field to dashes, while any other character key will set it to "Clear", "Stop", or "Slow" depending upon the sub-field in question.

In other respects, presentation and editing is as described for "Name" fields, except that the cursor will always be advaanced or backed up to a position corresponding to the start of a sub-field.  Please refer to the section titled: "Name".

Fault Assistance

This field is presented as a single line, however, as you begin to edit it, a window will be opened, presenting a number of lines.  These lines may be edited using the cursor control keys and [RETURN], [ENTER], [BACKSPACE], [DELETE], [HOME], and [END] to provide their natural function, and using the character keys in insert mode. [RETURN] and [ENTER] provide for a carriage return and line feed but do not insert a blank line.

When finished reading or modifying, type [ESCAPE] and the window will be closed, returning you to the database you had been editing.

Destination

The destination fields are either store reference fields or a symbolic name field referencing the conveyor names as the "previously defined" set of names.  The first character entered determines which type of field editing will be invoked.

Refer to the sections titled: "Store Reference", and "Symbolic Name".

Heavy-Unit-Load Conveyor Device Condition

When defining the devices to be implemented on the Heavy-Unit-Load Conveyor System, a number of inputs can be grouped together to select a graphic image to reflect the implied condition.  This group of inputs can be represented by a number of such images, depending upon which "condition" their state currently reflects.

For example, if three inputs are so grouped, there might be five conditions defined to reflect their various possible states:



  Input 3   Input 2  Input 1    Condition    Image
     0         0        0          000       IMAGE_1
     0         0        1          001       IMAGE_2
     0         1        0          010       IMAGE_3
     0         1        1          011       IMAGE_4
     1         0        0          1XX       IMAGE_5
     1         0        1          1XX       IMAGE_5
     1         1        0          1XX       IMAGE_5
     1         1        1          1XX       IMAGE_5

The valid characters for entry into the "condition" field are "0", "1" and "X".  If the "condition" bit corresponding to an input must either match it or be "X" for it to match.  If the "condition" matches all inputs, the corresponding graphic image will be displayed.

Heavy-Unit-Load Conveyor Device Character

When a device's condition is presented on the system overview, it is represented by a non-standard eight-by-sixteen bit character in the colour of your choice.  These fields may be altered as described in the section titled: "Screen Editing", with some differences.

You can only enter a space or a block or an "X" in any one position to indicate that the pixel is to be on or off, or irrelevant.  By typing a space or zero, you will effectively type a space, whilst any other regular character typed (say a one) will be interpreted as a block.

Additional features include:

  • "F"
    the image will be flipped upside down.
  • "R"
    the image will be rotated 180 degrees.
  • "U"
    the upper half of the image will be rotated by 90 degrees.
  • "C"
    the centre half of the image will be rotated by 90 degrees.
  • "L"
    the lower half of the image will be rotated by 90 degrees.

The state of a bit (space or block) can be toggled by double clicking on it.

Heavy-Unit-Load Conveyor Device I/O Comments

When defining device types for the Heavy-Unit-Load Conveyor System, three of the five lines of the Allen-Bradley address comment may be specified generically, by typing this into a field containing three ten-character sub-fields.

These fields may be altered as described in the section titled: "Screen Editing".

The remaining two fields are used for the device specific symbol and description.

Heavy-Unit-Load Conveyor Device Pause Need

When defining device types for the Heavy-Unit-Load Conveyor System, you may wish to indicate that loads are to stop at the corresponding conveyor position.

When this field is presented, so is the following legend:



1: Load to pause at specified conveyor only
2: Also to pause at R/F in specified position
3: Also to pause at R/F on specified conveyor

By entering a "1", the load will only pause when it reaches the conveyor position for which the device is defined; bear in mind that a load on a rise-fall at this position is not in that conveyor position.

If you wish to also pause loads on the rise-fall at this position, you should enter "2", while, if you wish to pause loads on any rise-fall along the length of this conveyor, you should enter "3".

You would want to pause a load if you need to give the device, such as an alignment bar, a chance to operate.

Turn Peg Pattern

The turn peg pattern specifies for a particular row of a particular layer of a particular pattern, how many cartons are included and which cartons should be turned.  The format of this entry is the number of cartons, followed by a sequence of "T"s and/or underscores signifying whether the cartons are turned or not.

For example, the entry, "3TT_", would signify that there are three cartons in the row in question and that the first two should be turned.

When interpreting your entry, "T", "t", "1", "L", and "l" are all interpreted as "T", while any other character is interpreted as an underscore.

These fields may be altered as described in the section titled: "Data".

Layer Arrangement

The layer arrangement specifies that for the given product, certain layers are not to comply with the odd/even layer pattern sequencing.  This is a thirty-two bit value, allowing for pallet loads with up to thirty-two layers to be catered for.

Normally the entry would be "OEOEOEOEOEOEOEOEOEOEOEOEOEOEOEOE".  The first character corresponds to the first (bottom) layer, indicating - by the "O" that it is to use the odd layer pattern, while the next layer will use the even layer pattern and so on.

Presentation and editing is as described for "Name" fields, refer to the section titled: "Name".

If your entry does not contain thirty-two characters, the entry is interpreted as representing the start of the string; the remainder of the string is taken from the default shown above.

For example, if you were to simply enter "E", the result would be "EEOEOEOEOEOEOEOEOEOEOEOEOEOEOEOE".  This implies that the first two rows will be the same (column stacked), while the remainder will alternate.

You are expected to enter a sequence of "E"s and "O"s, however, if you type other characters, a "1", an "L" and an "I" are translated to an "E", anything with an ASCII code less than or equal to a space will cause the remainder of the string to be ignored, while any other character will be translated to an "O".

Phone Number

When entering a customer's phone number, the software references the town specified for this customer and from this references the town's STD code and the state specified for the town and from this references the country specified for the state and from this references the ISD code specified for this country.

The software also references the ISD and STD access codes.

Armed with this information, the software assists and supervises your entry of the phone number.  If you do not commence your entry with the ISD nor STD access codes, the software will provide the appropriate access and area codes, placing these ahead of your entry.

When you enter the phone number, the software checks it, and warns you if it does not agree with this information; you will be able to make the entry in spite of this warning by typing [F1] to confirm that the number is correct.

Post Code and Post Code Mask

When entering a town's post code, the software references the state specified for this town and from this references the country specified for the state and from this references the post code mask specified for this country.

The software uses this mask to control and interpret your entry.  The mask may appear similar to:



                      ###-###

This implies that you should enter three digits (in place of the cross-hatches) followed by a hyphen followed by another three digits.

In general you can enter any digit in a post code position corresponding to a cross-hatch ("#") in the post code mask, any letter in the position corresponding to a commercial-at ("@") and either a digit or a letter in the position corresponding to an asterisk ("*").  In any other position, the character specified in the mask must appear in the corresponding position in the post code.

[BACKSPACE] does not remove characters, it only moves the cursor.  If, by typing [BACKSPACE], the cursor would be left in a position corresponding to a character in the mask other than a cross-hatch, commercial-at or asterisk, then the cursor is moved an additional place left.

If, as characters are being typed, the cursor would be in a position corresponding to a character in the mask other than a cross-hatch, commercial-at or asterisk then the cursor is moved an additional place right.

The entry may be terminated while the cursor is in any position in the field.

Pick Area Reference

The pick area reference fields are used to reference a pick area.

References are expressed in the form "31:AA01", where the first two characters represent the zone to which the pick area belongs, the colon (':') delimits these from the remaining characters that uniquely identify the pick area within this zone.

These fields may be altered as described in the section titled: "Data", with some differences.

[BACKSPACE] does not remove characters, it only moves the cursor.  If, by typing [BACKSPACE], the cursor would be left adjacent to a colon, then the cursor is moved an additional place left.

If, as characters are being typed, the cursor would be in a position of the colon then the cursor is moved an additional place right.  When typing in the replacement characters, a colon delimits the zone name prior to typing both digits.

The entry may be terminated while the cursor is in any position in the field.

Pick Area Type Division's Address Offset

Each division within each pick area type must be given a unique address offset within that type.

The address offset consists of two numbers, separated by a period (full-stop, dot or ".").  The first, we will call the wire number and the second, the station number.

Your entry should consist of two digits (the wire number), followed by a period (full-stop, dot or ".") then another two digits (the station number).

The address offset may be edited as a numeric field.  Refer to the section titled: "Numeric".

Pick Area Address Patches

When defining the addresses of the pick area divisions using the harness wiring concept, you will need to specify links between the "wires" at the end of a chain of adjacent pick areas.

These "wires" are referred to by the pick area reference (refer to the section titled: "Pick Area Reference"), followed by a further colon then the wire address (refer to the section titled: "Pick Area Type Division's Address Offset").

Pick-to-Light Unit Internal Memory Address

When defining the descriptions for the bytes and bits within the pick-to-light unit's microprocessor memory, the reference for the byte or bit is specified by two hexadecimal digits, followed (if referring to a bit) by a slash ('/') and an octal digit specifying the bit number.

Presentation and editing is as described for "Name" fields, refer to the section titled: "Name".

Compartment References

To reference, via the database, a compartment within a pick area, you will need to enter a series of up to 12 ones and zeros.  As there is higher level software that provides you more natural access to these areas, you will not normally need to enter this reference.

When a pick area is divided into compartments, it is first divided into two compartments by the first division, then these may be divided in turn in two compartments by further divisions.

Should you need to enter the compartment reference, each digit you type indicates which side of the divisions the compartment lies.  The first digit refers to the first division made, the second to the first division within the compartment selected by the first digit, and so on.

For example, consider the following:



                   0                1
           ┌───────────────┬──────────────────┐
           │               │        10        │ 0
           │               ├─────┬────────────┤
        0  │       00      │     │            │
           │               │     │            │
           ├───────────────┤ 110 │  111       │ 1
           │               │     │            │
        1  │       01      │     │            │
           └───────────────┴─────┴────────────┘
                             0        1          

The above represents a pick area, first divided vertically, then both the left and right resulting compartments are divided horizontally then finally the lower right hand resulting compartment is divided vertically. The references to these compartments are shown within the compartments.

Pick Compartment Length and Width

These are entered as numeric fields, however as you enter these values, the software checks that the length is greater than the width before accepting you entries.

Response Codes

The response codes sent to the host_computer are single ASCII characters.  There are two sets of response codes, those used in the response messages to the hosts relocation requests and those used in the completion messages.

Unless the record is a response message, the response code will be interpreted as if it is a completion message.

The response code may be entered as a number in the range 0 to 255, or as an ASCII character prefixed by an apostrophe.  For example, the entries "65" and "'A" are equivalent.

When the response code is presented, if the value in the field matches a valid character in the appropriate set of response codes, the field will appear as the ASCII character, enclosed in apostrophes, and followed by text explaining its significance. For example, entries "65" or "'A" for completion response codes will be presented as "'A' Failed sizing ".

If no match can be found, the numeric value will be displayed.

These fields may be altered as described in the section titled: "Data".

TCP-IP Host

The TCP-IP host consists of four numbers separated by three periods (".").  Each must be in the range 0 to 255.  Bearing these restrictions and the two additional periods in mind, the value may be entered as described in the section titled: "Numeric".

TCP-IP Port

The TCP-IP port consists of two numbers separated by a comma. Each must be in the range 0 to 255.  Bearing these restrictions in mind, the value may be entered as described in the section titled: "Numeric".

Key

Certain fields, usually "Symbolic Name" fields and "Symbolic Numeric" fields, may reference a database (or "set of fields").  When the value/name has been entered into these fields, the data associated with this value/name is presented in a "Set of Fields" below the field.  Refer to the sections titled: "Set of Fields", "Symbolic Name", and "Symbolic Numeric".

This database will be displayed in the "Underline" attribute.  When editing a "Key" field, the referenced database may be edited by typing [SHIFT F11]. In response, the referenced database fields will be recoloured in the usual attributes, and may be edited.  Refer to the section titled: "Set of Fields".  For an understanding of the use of attributes, refer to the section titled: "Screen Attributes".

In several of these instances, the "Key" field is symbolic of the first field in the referenced database, so both will appear similar and may be presented at the same window position.  In this instance, when [SHIFT F11]is typed, the cursor will appear to be merely repositioned in the same field.

Set of Fields

A set of fields is a dialogue box that contains a number of pairs of prompts and editing fields arranged one beneath the other.

A set of fields will normally present the contents of a database record; that is, values from a given record number within a number of "Databases" that have been associated together in a "Record Set".  The database concepts are described in the section of the SOFTWARE MANUAL titled: "Database Structure".

The [TAB] and [SHIFT TAB] keys enable the cursor to be moved to next or previous field.  As you leave a field, using the [TAB] or [SHIFT TAB], any changes to the field contents are written away.  Had you made no change, then you will not alter the field; changes made to this field by the software or other people editing it after you have entered the field will not be affected by your editing of this field unless you had made a change.  Also, when you move into an editing field, its contents are refreshed from the database.

The [ENTER] key is used to close the set of fields dialogue box.  Had you been within an editing field at the time, any editing changes you made to that field will be written to the database.  [ENTER] is equivalent to clicking (with the mouse) the first of the buttons provided with this dialogue box.

Menus

There are three types of menus used throughout the software.  These are the horizontal menu bar, the drop-down menu that appears upon selection of an option from the horizontal menu bar, and the third type, the drop-down drawing area menu that presents its options, commonly with a scroll bar.

Selections may be made from all menus by clicking with the left mouse button on the desired option, however the drop-down drawing area menu requires a double click, or a single click to highlight the option and a subsequent pressing of [RETURN] or [ENTER].

Selections may also be made from a horizontal menu bar by typing the underlined first letter, or the key described by the capitalised portion of the option's description.

Selections may also be made from a horizontal menu bar, once one option is raised (i.e. presented as a raised button) by using the left and right cursor keys, then if the option does not correspond to a drop-down menu, typing [ENTER] or [RETURN].  I only know one way to raise the option and that is to click on it, which not only raises it but also executes it unless it corresponds to a drop down menu.  So to select from the horizontal bar using only the keyboard, first type the letter corresponding to an option with a drop down menu (which you will only know from experience) then use the cursor keys to move along the horizontal menu bar and down the drop-down menu as they appear, then type [ENTER] or [RETURN] on the desired option.

Selections may also be made from a drop-down menu, from the main horizontal menu bar, by typing the function key indicated at the right of the option's description.

Selections may also be made from a drop-down drawing area menu, using the [UP] and [DOWN] keys to highlight the desired option then pressing [RETURN] or [ENTER].

Additionally, when using some windows (those that do not use the function keys for their own purposes) the function keys will be available to select another window.

When Using the More DOS-Like Interface

If you have opted for the more DOS-like interface, once you have logged in, the window selection menu system will be presented in a window, rather than in the horizontal menu bar.  If you escape out of this window, you will be returned to the horizontal menu bar, from which you will need to make a selection before being again presented with the menu in this window.  For information on configuring a user for the more DOS-like interface and its impact, please refer to the section titled: "Modify List of Users".

If using the DOS-like interface selections from the window selection menu may be made by either moving the reverse/highlighted video line (using [UP] or [DOWN]) to the desired entry then typing "S", [RETURN] or [ENTER], or by typing the number corresponding to the option number then typing [RETURN] or [ENTER], or, if the desired window has been programmed into a function key ([F1] to [F9], and [F11]), by typing the function key corresponding the option.

Windows may also be selected from any one of the other window selection menus without the need to first call up the particular menu containing the option.  This selection may be made by typing the option number or by typing the function key programmed with this option.

The windows programmed into the function keys are listed at the bottom right of the window.

Setting Function Keys to Access the Menus

To do this, you will need to be familiar with the exact text of the window names that you wish to programme onto function keys, especially the first words in the names.

Then to programme a function key for the main horizontal menu bar's drop-down menu' options, having, first of all, logged in with sufficient privilege, activate "View" option from the main horizontal menu bar, then "Function keys" from the resulting menu.

A dialogue window will then be opened, presenting the ten function keys.  Move the highlight to the key of interest, either by using the [UP] and [DOWN] keys or by clicking with the mouse on the appropriate line.  Then select this key for change by typing "C", or [ENTER], or [RETURN] or by double clicking on the line or single clicking on "Change".

In response, another dialogue window will open, requesting that you enter the name of the window you wish programmed into this key.

You can start typing the name of the window, then when the rest of the name correctly appears, press [ENTER] or [RETURN] or click on "OK".

Alternatively, you should notice that there is a button to the right of this field that can be used to present a list of options to choose from.  Be warned that this list is quite extensive and is not restricted to windows applicable to site, so as a result it is possible to select a totally useless window by not recalling the exact name of the window you wish to programme.

For example, there might be an "Overhead crane commands and alarms" window, which deals with overhead cranes, and a "Crane status and control" window, which deals with stacker cranes.

Also, do not select any of the windows starting with the text "Emulate", they are for my use only.

To un-programme a function key, make a blank entry.  When you exit this dialogue, the site name will be presented against this function key.

Viewing Data

This section is best read when referred to from the "Specific Instructions" section.  It describes a generic form of window used extensively in two major ways:

  • Maintenance
    to select a particular set of configuration data to modify or delete, or to create a new set.
  • Reports    
    to print a report based on a selected portion of live or configuration data.

In all instances a file is presented to the window, with one record per line allowing you to manipulate the data in this file.  The following section describes the features common to all these instances, whereas the subsequent sections, describe the additional features corresponding to the "Maintenance Viewing Data", and "Report Viewing Data" usages.

General

The features offered by all these windows are:

  • moving the window across the records.
  • highlighting a particular record for individual attention.
  • highlighting a particular field for individual attention.
  • moving the window to other records of the file.
  • expanding/contracting the records.
  • restricting the records eligible for inclusion.
  • limiting the display to a range of consecutive records.

If the database in question is a "linked list", then there are operations that allow you to relocate or duplicate records, either within a list, or from one list to another.  The linked-list databases are indicated by the menu item "Group" in the menu bar.  Most of the databases automatically sequence the records according to a "key" field or fields or the record number occupied. With linked-lists, such as the menu structure, the records are sequenced and grouped.  Any menu item, for example, can appear on any sub-menu (a group) and in any position in the sub-menu.

Menu Bar

At the top of each of the windows is a legend that indicates which of the keys are active and what function they perform.  On all these windows, [RETURN] is equivalent to the first key listed. [ENTER] will behave similarly, however, when used to select a record [ENTER] will select the highlighted record directly, whereas [RETURN] will request the record designation from you, while offering the highlighted record as the default.  As well as being able to type the key, you may click the mouse on that part of the legend.

What's On the Display

The body of the window contains a number of lines of data, each line comprising a related set of data fields (known as a record).  There will be a horizontal scroll bar provided, in case the entire record is too long to fit on a window.  The [HOME] key will move the scroll bar to the extreme left, while [END] will move the scroll bar to the extreme right.

The lines of data are divided into fields, of varying widths.  If a given field width is sufficient, as many words from that field's prompt as will fit, will be presented at the top of the column as a heading.  The next paragraph throws light on how to interpret the data in the remaining columns.  If there is insufficient space to present the entire prompt in the column heading, you can move to mouse pointer to that column heading an a tooltip will be displayed that presents the full database prompt, along with, should your "Database" record set be defined to include the "Database name for "Where"" field, the database name for the "Where" field.  The "Where" field is described in the section titled: "Viewing Data" and its subsection "Records Satisfying an Expression".

If the display is restricted to records containing certain text (see "Given Text in Any Field ([CONTROL F])") or to those satisfying a given expression (see "Records Satisfying an Expression"), then the tooltip that is presented when the mouse pointer is positioned above the extreme left of the column heading (the horizontal scrollbar will need to be all the way left) will show either the first or the second of these restrictions instead of the details relating to the first field.  Generally, the details relating to the first field will still be available as a tooltip if you move the mouse a little further right.

One of the records will be shown differently to the rest and one of the fields of this record will be shown differently to the others in this record.  These are referred to as the "highlighted record" and the "highlighted field" respectively.  The prompt as well as the data associated with the highlighted field are displayed at the bottom of the window. [UP] and [DOWN] may be used to highlight the previous or next record respectively, while [LEFT] and [RIGHT] may be used to highlight the previous or next field respectively.

Moving the Window Around the File

The [PAGE UP] and [PAGE DOWN] may be used to move the window through the file in the indicated direction to view records that do not fit on one page. There will be a vertical scroll bar provided, and [CONTROL PAGE UP] may be used to return the window to the top of the file, while [CONTROL PAGE DOWN] may be used to move the window directly to the end of the file.

Expanding Record Details

If a field is a "Key" field, having a set of fields associated with it, these may, optionally, be shown as well.  Typing "E" will cause these associated fields, if not already displayed, to be displayed, or, if already displayed, not to be displayed. This is referred to as expanding or contracting the field.

When expanded, a symbolic field, if also a "Key" field, will be followed by the field it references.  This will appear as a duplication.  Refer to the section titled: "Key".

Restricting the Records Displayed

You can restrict the display, so that only certain records, which pass some criteria, will be presented.

Given Text in Any Field ([CONTROL F])

The crudest, but most straight-forward, method is to specify a pattern, which must be contained in at least one of the fields of the record for that record to be included.  You do this by typing [CONTROL F] then typing in the pattern.  The text you type in must be in the correct case for a match to be found, and is capitalised as if a "title" (see the section titled: "Name").  This text will be searched for in any of the "Name" fields making up the record, and in any "Name" field to which symbolic references are made from fields within the record.  For further detail on symbolic fields, please refer to the section titled: "Symbolic Name".

To remove this restriction, type [CONTROL F] a second time, and this time remove the field contents.

When this restriction is in force, and there is no restriction on the first field (see the next section, "Given Text in a Field (Restrict/Match)"), then the text "FIND: " followed by the text you are searching for (or as much of it as will fit), will be displayed above the records, in the first column, replacing the column title had there been one. In any case, the full description of the restriction will be presented in a tooltip, should you move the mouse pointer to the extreme left of the column heading (the horizontal scrollbar will need to be all the way left).

Given Text in a Field (Restrict/Match)

To restrict the records displayed to those with the same data in a given field, highlight the field where the restriction is to apply, then type "R". A dialogue window will open, with a single data entry field, loaded with the data from this field.  If this is the required data for the restriction, simply type [RETURN] or [ENTER], otherwise enter the required data.

When a restriction is in force, the restriction will be displayed above the records, in the appropriate column, replacing the column title had there been one.

To restrict the records displayed to those containing a given sequence of characters in a "Name" field, highlight the field where the restriction is to apply, then type "M". A dialogue window will open, with a single data entry field, loaded with the current restriction or sequence.  Type in the required sequence and type [RETURN] or [ENTER]. For editing instructions for this type of field, please refer to the section titled: "Name".

When a sequence is in force, the sequence will be displayed above the records, in the appropriate column, replacing the column title had there been one.

Restrictions and sequences can not be simultaneously in force for the same field.  The later specified will override the prior.

If the record has been expanded, take care to distinguish between the symbolic field and the following referenced field. Sequences may not be specified for "Symbolic Name" fields.

To remove a restriction or sequence, highlight the field where the sequence is to apply no longer, then type "R" or "M" followed [GREY MINUS] then [RETURN] or [ENTER].

All these restrictions, associated with the unexpanded resord set, may be edited within a single dialogue window.  To bring up this dialogue window, type [CONTROL R]. You may enter restrictions into any of the fields presented.  To enter a sequence, rather than a restriction, type [CONTROL A] after the sequence.

A Run of Records (First/Last)

For some sets of records, you may restrict the display to a range of consecutive records.  To do this, type "F" then enter the specification of the first record, then type "L" then enter the specification of the last record.

The specification in each of these cases will default to the highlighted record, so an alternative method is to highlight the first record to be included, then type "F", then [RETURN] sufficiently often to accept the default, then highlight the last record to be included, then type "L", then finally [RETURN] sufficiently often to accept the default (in some cases the specification of a record may require more than one entry).

If the file is a log file (i.e. its first database field is a time and date field), to limit the display to a range of consecutive records, move the highlight to first record to be included and type "F", then move highlight to the last record and type "L".  Subsequent typings of "F" and "L" will release the corresponding limitation.

A Given Group in Linked Lists

This applies to the "linked list" databases only.  These databases are indicated by the menu item "Group" in the menu bar.

These databases present their records with the name of the group to the left, sometimes followed by the designation of their position within the group, then the record porper, i.e. the fields that you can highlight, restrict upon, change, et cetera.  When a group restriction is in effect, the group designation may be removed from the presentation of the record, as all records displayed now belong to the one group.

To restrict the display to records from within a single group, type "G". A dialogue window will open, with a single data entry field, loaded with the group designation for the group to which the highlighted record belongs.  If this is the required group for the restriction, simply type [RETURN] or [ENTER], otherwise enter the required group designation.

To remove a restriction to a sigle group, type "G" followed [GREY MINUS] then [RETURN] or [ENTER].

Records Satisfying an Expression

This feature is only available to those sites where the "Database" record set has been defined to include the "Database name for "Where"" field.  This field is described in the section titled "Database Privilege".  You can refer to the "Database Privilege" database listing to obtain the field names for use in entering an expression.  Alternatively, if you move the mouse pointer to the column heading, a tooltip will be presented, which will present the full text of the field's prompt and, on its second line, the database name for "Where" experssion.

The editing of this expression is described in the section titled: "Where".

To restrict the records displayed to those that satisfy some explicit expression, click on "Where" in the menu bar or type "W".  A dialogue window will open, with a single data entry field, which would be blank unless you have already entered an expression.

Into this field, enter an expression.  An expression consists of a number of operands and operators.  A simple example is [DBWHERE]="DBPROMPT", which would restrict the presentation to those records for which "Database name for "Where"" field contains exactly DBPROMPT.  The result of each operation is either a text string, a floating-point number or an integer.  The final result of the entire expression should be an integer and if that integer is zero, the record will not be presented.  Floating-point numbers are rounded down towards zero, when converting to an integer.

The operands are either numeric values, text strings, database field names, or the special operand representing the record number.

Numeric values can be base-ten integers, floating-point numbers, or a number in base two, eight, or sixteen.  Base-ten integers must begin with one of the digits from "1" to "9", followed only by digits, unless the integer is zero, in which case it will consist of just the digit "0"; in other words, it can not start with "0" unless the integer is to be zero.  Floating-point numbers contain only digits and a single decimal point, followed by one or more digits. Base-two integers begin with the characters, "0b", followed by the digits "0" and "1", as required to represent the integer.  Base-eight integers begin with a "0", followed by the digits "0" and "7", as required to represent the integer.  Base-sixteen integers begin with the characters, "0x", followed by the digits "0" to "9", and the letters "a" to "f", as required to represent the integer.  Examples are 27, 27.0, 0b11011, 033, and 0x1b, which represent the value twenty-seven as a base-ten integer, a floating-point number, a base-two integer, a base-eight integer, and a base-sixteen integer, respectively.

Text strings begin with a double-quotation mark, followed by the required characters, and is terminated using a second double-quotation mark.  An example is "Text to be matched".  Most operators are arithmetic or logical, so, when a string is presented to one such operator, an attempt is made to convert the string to an integer (or, should the other operand be floating point, to a floating-point value) before applying the operator.  On the other hand, the .ADD. and .SUB. operators have a special meaning should both operands be text strings, or one a text string and the other a database value (which may have both numeric and text values).

The database field names are to be placed within open and close brackets.  An example is [DBWHERE].  References to database fields are replaced by the text or the integer contained within the corresponding record of the named field. In the case of interger values, both the raw integral value and the text that is used to present this raw value are kept.  In the case of integral fields, the text that represents raw value may differ from the raw value.  For example, should the corresponding database prompt end in a range specification, such as "<5-10>", then the raw value of zero will be stored in text as "5".  Which representation is used depends upon the operator that is applied to it and the other operand to which that operator is applied.  If text is required, then the text form will be used, and otherwise the raw integer value will be used.

The special operand representing the record number is "#".  References to the record's own number are replaced by both the integer representing the record number, and the string that is used to represent that record in the database. Which representation is used depends upon the operator that is applied to it and the other operand to which that operator is applied.  Consider, for example, a record within the product master database.  It has a physical position within the database (a position that is not subject to change as other records come and go), and this physical position is not displayed to the operator, unless the operator looks up the product code in the list that can be presented when you opt for "Field" rather than "Database" when using the "Edit Databases" screen (you may refer to the section titled: "Edit Databases").  When these records are presented as a database, they are identified using the product code, which must be unique.  So, the '#' operand is translated to both the integral record number and the textual presentation of the product code. Which is used depends upon whether an integer or a string is required.

The operators are executed according to their precedence.  This means that those with the lower precedence number (indicating a higher precedence) will be executed before those with a higher precedence number.  Those operators with the same precedence will be executed from left to right.  To override the order of execution of the operators, parentheses may be used.  For example 2+3*4 would result in 14, while (2+3)*4 would result in 20.  An exception to the rule of precedence occurs when there is no direct right-hand operand (that is, the right-hand operand is to be supplied as the result of the execution of the unary operator to its right).  In such cases, the execution of the operator without a right-hand operand is delayed until that operator is supplied.  For example, in executing .DEG..ARCSIN.[DATABASE], the .DEG. operator can not be executed until the .ARCSIN. operator has been executed, even though it has the higher precedence.

Some operators are unary, meaning that they operate only on the operand to their right.  Other operators are binary, meaning that they operate on two operands, the one to their right and the one to their left.  There are two ternary operators, which take three operands, the one to their left, the one to their right, and the one right of that, separated by a comma.  Also, there can be two names for some operators, with one consisting of two dots with a number of letters between them and the other consisting of one or two non-alphabetic, non-numeric characters.

The operators provided are, by and large, the same operators that are provided by the Allen-Bradley PLCs, which this software has needed to emulate. You might like to refer to the section titled "Precedence of Instructions". It is that set of operators that also forms the basis for the editing within "Numeric" fields (see the section titled: "Numeric").

Below are listed the operators available:

  • OPEN PARENTHESIS  
    ( Precedence:0 No operands
  • CLOSE PARENTHESIS 
    ) Precedence:0 No operands
  • REFERENCE         
    -> Precedence:1 Binary
  • RECORD NUMBER     
    # Precedence:1 No operands
  • RECORD STRING     
    .NO. Precedence:1 Unary
  • NEGATE            
    .NEG. Precedence:2 Unary
  • COMPLEMENT        
    .INV. & ~ Precedence:2 Unary
  • INTEGER           
    .INT. Precedence:2 Unary
  • TO DEGREES        
    .DEG. Precedence:2 Unary
  • TO RADIANS        
    .RAD. Precedence:2 Unary
  • SINE              
    .SIN. Precedence:3 Unary
  • COSINE            
    .COS. Precedence:3 Unary
  • TANGENT           
    .TAN. Precedence:3 Unary
  • INVERSE SINE      
    .ARCSIN. Precedence:3 Unary
  • INVERSE COSINE    
    .ARCCOS. Precedence:3 Unary
  • INVERSE TANGENT   
    .ARCTAN. Precedence:3 Unary
  • NATURAL LOGARITHM 
    .LN. Precedence:3 Unary
  • BASE 10 LOGARITHM 
    .LOG. Precedence:3 Unary
  • SQUARE ROOT       
    .SQRT. Precedence:3 Unary
  • TO BCD            
    .BCD. Precedence:3 Unary
  • TO BINARY         
    .BIN. Precedence:3 Unary
  • RAISE TO THE POWER
    .EXP. Precedence:4 Unary
  • MULTIPLY          
    .MUL. & * Precedence:4 Binary
  • DIVIDE            
    .DIV. & / Precedence:4 Binary
  • MODULUS           
    .MOD. & % Precedence:4 Binary
  • MASK              
    .MSK. & & Precedence:5 Binary
  • ADD               
    .ADD. & + Precedence:6 Binary
  • SUBTRACT          
    .SUB. & - Precedence:6 Binary
  • SET               
    .SET. & | Precedence:7 Binary
  • EXCLUSIVE OR      
    .XOR. & ^ Precedence:7 Binary
  • LESS THAN         
    .LT.  & < Precedence:8 Binary
  • GREATER THAN      
    .GT.  & > Precedence:8 Binary
  • LIMIT             
    .LIM. Precedence:8 Ternary
  • MASKED EQUAL TO   
    .MEQ. Precedence:8 Ternary
  • EQUAL TO          
    .EQU. & = Precedence:8 Binary
  • INCLUDES          
    .HAS. & } Precedence:8 Binary
  • NOT EQUAL TO      
    .NEQ. & <> Precedence:8 Binary
  • NOT LESS THAN     
    .GEQ. & >= Precedence:8 Binary
  • NOT GREATER THAN  
    .LEQ. & <= Precedence:8 Binary
  • LIKE              
    .LIKE. & : Precedence:9 Binary
  • NOT               
    .NOT. & ! Precedence:9 Unary
  • AND               
    .AND. & && Precedence:10 Binary
  • OR                
    .OR.  & || Precedence:11 Binary
  • ASSIGN            
    := Precedence:12 Binary
  • NEXT              
    .NEXT. & , Precedence:13 Binary

The use of these operators is:

  • OPEN PARENTHESIS
  • CLOSE PARENTHESIS
    These are used to override the normal order of operations.  For example 2+3*4 would result in 14, while (2+3)*4 would result in 20.
  • RECORD NUMBER
    This allows you to reference the actual physical record number.  It is anticipated that this would be of use in those circumstances where the record number relates to some extrinsic quantity, such as a racking location or an alarm number.  It requires no parameters.
  • RECORD STRING
    This allows you to reference the actual physical record number in the ASCII form that is used to present it to users.  It is anticipated that access to the record number would be of use in those circumstances where the record number relates to some extrinsic quantity, such as a racking location or an alarm number.  The ASCII representation is often just the ASCII representation of the actual number, but in some circumstances, such as in the case of racking locations, it is somewhat different.  In order for the system to know how to translate this value into ASCII, it needs to know which record set to reference because all non-standard representations of the record numbers are determined by the record set in question.  In order to identify this record set, you need to provide a reference to the first database (field) in that record set.  This is then used to scan through all record sets, looking for the first that has this database as its first field.  Should there be multiple record sets with this database as their first field, chances are that the record number representation scheme employed by each is the same.  If this is not the case and you particularly wanted to use the representation of a subsequent record set, then it is unfortunate. For example, ".NO.[RACKFILLED]" would present the record number in the form used to represent a racking location, "WW:RR-H-LLL-D" (such as: "42:16-A-027-1"), where the first two characters ("42") represent the warehouse (either 41 or 42) and is redundant with the rack, which consists of the first two characters, ("16") following the colon.  The character following the hyphen is the hoist level ("A").  The final digit, "1", represents the depth ("1" for the location near the crane, "2" for the location further from the crane). I have no idea what the corresponding record number would be, but the correspondence is fixed.
  • REFERENCE
    This allows you to reference a value in another database.  For example, if you were looking at the list of conveyor alarms and wanted to highlight those associated with any conveyor with, say, three active alarms, you could enter the expression, [CNACONVEYOR]->[CNNALARMS]=3.
  • NEGATE
    You can not enter a negative number, so should you require the value, -32, you could enter .NEG.3 (or use the binary subtract operator, with or without a left-hand operand: 0-3 or -3).
  • COMPLEMENT
    This allows you to take the binary complement of an integer.  For example, the value 27, which in binary is 11011, becomes, in binary, 111...11100100.
  • INTEGER
    This allows you convert a text string or floating-point number to an integer.  You can also use it to obtain the integral value corresponding to the presentation of a database field, rather than its raw value.  For example, if a database field contained the raw value zero, which happens to be presented to an operator as "5", the [DATABASE] would return 0, while .INT.[DATABASE] would return 5.
  • TO DEGREES
  • TO RADIANS
    Should you ever need to use the trigonometric functions, the operand needs to be specified in radians and the results of the corresponding inverse functions are in radians, so this pair of functions are provided to allow you to convert from degrees to radians.  For example, for the sine of 45 degrees, you would write .SIN..RAD.45 and to obtain the inverse sine of some database value you would write .DEG..ARCSIN.[DATABASE].
  • SINE
  • COSINE
  • TANGENT
    These trigonometric functions are provided because they were there.  Should you ever have need to use them, you'll need to specify the operand in radians.
  • INVERSE SINE
  • INVERSE COSINE
  • INVERSE TANGENT
    These inverse trigonometric functions are provided because they were there. Should you ever have need to use them, the results will be in radians.
  • NATURAL LOGARITHM
  • BASE 10 LOGARITHM
  • SQUARE ROOT
    This set of arithmetic functions are provided because they were there.
  • TO BCD
  • TO BINARY
    BCD is an alternate means of storing numbers in binary form, that is ideal for presentation on a numeric display.  For example, the number 123 would be stored, in binary as 1111011 or, in hexadecimal, as 0x7B.  When coded as BCD, the hexadecimal representation would be 0x123, which, in binary, is 100100011. That number, should it be interpreted as ordinary binary, would correspond to 291 in decimal, not 123.  This pair of functions are provided to convert between these alternate representations.  Examples are .BCD.123 would return 291, while .BIN.291 or .BIN.0x123 would return 123.
  • RAISE TO THE POWER
    This function raises the left-hand value to the power represented by the right-hand value.  For example, 2.EXP.3 would return 8.
  • MULTIPLY
    This function multiplies the left-hand value by the right-hand value.  For example, 2.MUL.3 would return 6.
  • DIVIDE
    This function divides the left-hand value by the right-hand value.  For example, 2.DIV.3 would return 0, while 2.0.DIV.3 or 2.DIV.3.0 would return 0.666667, or thereabouts.  If either operand is floating point, then floating-point arithmetic is used, otherwise, integer arithmetic is used.
  • MODULUS
    This function divides the left-hand value by the right-hand value and records the remainder.  For example, 5.MOD.3 would return 2.
  • MASK
    This function ANDs the left-hand and right-hand values together.  For example, 51.MSK.7 would return 3; 51 is 0b110011 and 7 is 0b000111, so ANDing these results in 0b000011, which is 3.
  • ADD
    This function add the left-hand and right-hand values together.  For example, 2.ADD.3 would return 5.  Should both operands be text strings, or one a text string and the other a database value (which may have both numeric and text values), this operator concatenates the strings.  So, if [DATABASE] has a raw value of zero and a text representation of "5", the expression, "Value is ".ADD.[DATABASE] would return "Value is 5".
  • SUBTRACT
    This function subtracts the right-hand value from the left-hand value.  For example, 3.SUB.2 would return 1.  Should both operands be text strings, or one a text string and the other a database value (which may have both numeric and text values), this operator removes the first occurrence of the right-hand operand from the left-hand operand.  So, if [DATABASE] has a raw value of zero and a text representation of "5", then the expression, "Value is 505".SUB.[DATABASE] would return "Value is 05".
  • SET
    This function ORs the left-hand and right-hand values together.  For example, 51.SET.7 would return 55; 51 is 0b110011 and 7 is 0b000111, so ORing these results in 0b110111, which is 55.
  • EXCLUSIVE OR
    This function exclusively ORs the left-hand and right-hand values together. in this operation the only bits that are set in the result are those that are set in one of the operands but not in both.  For example, 51.XOR.7 would return 52; 51 is 0b110011 and 7 is 0b000111, so exclusively ORing these results in 0b110100, which is 52.
  • LESS THAN
  • GREATER THAN
  • EQUAL TO
  • NOT EQUAL TO
  • NOT LESS THAN
  • NOT GREATER THAN
    These operators can be used on strings or integers or floating-point numbers.  In the case of strings, the two strings are compared, looking for the first character from the left that is different, and the comparison is then based on the relative ASCII values of those two characters.  If, one of the operands is a floating-point then the other will be converted to floating point prior to the comparison.  Otherwise, if one is an integer, the other will be converted to an integer before comparison.  A true result becomes the integer 1, while a false result becomes the integer 0.
  • LIKE
    This operator tests the left-hand operand to see if it satisfies the pattern that is contained in the right-hand operand.  If the pattern is satisfied, the result will be 1 and otherwise it will be 0.  The syntax for the pattern is based on the SQL syntax for its LIKE pattern.  Most characters in the pattern are used to match that same character in the left-hand operand.  The exceptions are the backslash character ('\'), the per-cent sign ('%'), the underscore ('_'), the open square-bracket ('['), the minus sign or hyphen ('-'), the circumflex ('^'), the close square-bracket (']'), and the asterisk ('*').  The backslash character is used to restore the literal meaning to the character that follows it, which is expected to be one of the exceptional characters just listed.  The backslash character is equivalent to the character nominated using the ESCAPE keyword in SQL.  The per-cent sign will match any number of characters, even zero characters.  It will match as many characters as needed to give the remainder of the pattern its maximum chance of matching the left-hand operand.  The underscore will match any one character, even a space; it is used to shift the focus in the left-hand operand along one place.  The open square-bracket introduces a range of characters so that the next character in the left-hand operand will be deemed as matching if it matches any one of those in the range specification.  The minus sign, circumflex, and close square-bracket only have special significance when the open square-bracket has been used to introduce the range of characters.  Under these conditions, the close square-bracket terminates the range specification.  The minus sign is used between two other characters to indicate that all the characters whose ASCII value lies between those of the two characters are also included in the range specification.  The circumflex, if it appears immediately after the open square-bracket, directs that the range specifies a list of unacceptable, rather than acceptable, characters.  Finally, the asterisk is used to modify the previous element of the pattern (usually a single character but sometimes a range specification if it follows a close square-bracket).  It states that the left-hand operand needn't match, but that if it does match, then the point of interest in the left-hand operand should be advanced to the first character that doesn't match the previous element of the pattern.  Unlike SQL, all comparisons are case sensitive, so "A" .LIKE. "a" will return 0.  I hope that that is all clear.  Examples: "The Quick Brown Fox Jumps" .LIKE. "%Quick%Fox%" will return 1, "5% of Nothing" .LIKE. "5\%%" will return 1, "5% of Nothing" .LIKE. "[0-9]\% of %" will return 1, "25% of Nothing" .LIKE. "[0-9]*\% of %" will return 1, as would "% of Nothing" .LIKE. "[0-9]*\% of %", and "[^8]*" would match any left-hand operand that did not have an "8" anywwhere in it. Note: the pattern "_*" will behave like the per-cent sign when it appears at the end of a pattern, but, should you follow the "_*" with anything at all, it matches nothing.  This operator can result in the use of considerable computer power, so please use with caution; try to restrict the number of candidate records using other means before applying this operator.  The computing involved on behalf of the per-cent character is particularly onerous, except when it appears at the end of the pattern.
  • NOT
    This operator compares the right-hand operand to 0.  If it is 0, then the result is 1.  Otherwise the result is 0.
  • LIMIT
    This operator only accepts integral operands.  An attempt will be made to convert the operands to integers.  The result is 1 if the second operand is within the inclusive range of the first and third, provided that the first is less than the third.  If the first is greater than the third, the result will be 1 if the second operand is not within the inclusive range of the third and first.  If the result is not 1, it will be 0.  For example, 2.LIM.3,5, would result in 1, as would any second operand in the set {2,3,4,5}.  Any other value in the second operand would result in 0.  A second example, 5.LIM.3,2, would result in 0, as would a second operand of value 4.  Any other value in the second operand would result in 1.
  • MASKED EQUAL TO
    This operator only accepts integral operands.  An attempt will be made to convert the operands to integers.  The first and third operands are bitwise anded with the second operand and the two results are compared for equality. For example, 0b11011.MEQ.0b01110,0b11111, would produce intermediate results of 0b01010 and 0b01110, which are not equal, while 0b11011.MEQ.0b01010,0b11111, would produce intermediate results of 0b01010 and 0b01010, which are equal.
  • INCLUDES
    This operator accepts text operands only.  If the right-hand operand is included, contiguously, within the left-hand operand, then the result is the integer value 1, rather than 0.  For example, "Text to be tested".HAS."be" will return 1, while "Text was tested".HAS."be" will return 0.
  • AND
    This operator returns 1 if both the left-hand and right-hand operands are other than 0.
  • OR
    This operator returns 1 if either of the left-hand and right-hand operands are other than 0.
  • ASSIGN
    This operator is only to be used in the "Set" expression, which will be described shortly.  This operator is only available for left-hand operands that are database names.  Since it has a very low precedence, it can only have a left-hand database operand if that operand is either the first or is preceeded by the NEXT operator, which is the only one with a lower precedence. Any use of this operator in a "Where" expression will be replaced by the "EQUAL TO" operator.  On the other hand, should you, when writing a "Set" expression, use the "EQUAL TO" operator where the left-hand operand is the first, or the first after the "NEXT" operator, and that operand is a database name, then it will be replaced by the "ASSIGN" operator.
  • NEXT
    This operator is used to enable the provision of a third parameter for the ternary operators, "LIMIT" and "MASKED EQUAL TO".  For example 0b11011.MEQ.0b01110,0b11111 or 0b11011.MEQ.0b01110.NEXT.0b11111.  It will also be used in the "Set" expression, which will be described shortly.

To remove this restriction, type "W" a second time, and this time remove the field contents.

When this restriction is in force, and there is no restriction on the first field (see the section, "Given Text in a Field (Restrict/Match)"), then the text "WHERE: " followed by the expression that you entered (or as much of it as will fit), will be displayed above the records, in the first column, replacing the column title had there been one. In any case, the full description of the restriction will be presented in a tooltip, should you move the mouse pointer to the extreme left of the column heading (the horizontal scrollbar will need to be all the way left).

This expression may accompany restrictions and sequences.  It is recommended that the listing be first restricted using the restrictions and sequences before entering the expression, as expressions take more computer time to implement.  Again, please refer to section, "Given Text in a Field (Restrict/Match)")

Modify All Satisfying Records

The "Where" dialogue window, if you have logged in with the highest privilege level, offers a "Set" button.  When this is clicked on, the "Where" expression is applied, just as it would have been had you clicked the "OK" button, but, additionally, a new dialogue window is presented allowing you to enter a second expression.  This second expression is to include assignments for one or more databases.

The editing of this expression is described in the section titled: "Where".

Only those records of the databases that satisfy the "Where" expression and any other restrictions that may be also in force, will be altered.  Each assignment should consist of a database field name, followed by the assignment operator (":="), then followed by an expression.  Should there be multiple assignments, then each should be separated from the previous assignment by the "NEXT" operator.

A simple example would be [DBWHERE]:=[DBWHERE]+"_NAME",[DBSEC]:=2, which would append "_NAME" to each member of the DBWHERE database that satisfies the restrictions and would also set the same records of the DBSEC database to the value 2.

After clicking on the "OK" button, you will be asked to confirm that you wish these alterations to be made before the statement will be executed.  Should you opt not to have the statement executed, it will still be kept, so that you can, subsequently, open the "Where" dialogue and then the "Set" dialogue to review the statement again, before considering whether or not to execute it.

Move Up/Down in Linked Lists

This applies to the "linked list" databases only.  These databases are indicated by the menu item "Group" in the menu bar.

The object here is to gather together records from within a single group within the linked-list database, into a "selection", and to relocate this "selection" within the group.  Subsequently, you can "copy" or "cut" the "selection" in order to "paste" it into another group; this will be covered in the next section titled: "Copy or Cut from Linked Lists".

It is important to understand the distinction between a "selection" of records, as described here, and a "collection" of records, as described in the section titled: "Multiple Record Editing (Kollecting)".  In each case, multiple records are highlighted, and the operation of the "Change" and "Select" for editing functions (see "Changing the Field Contents" and "Editing the Entire Record and Deleting") will serve to affect all records in either the selection or the collection.  The important difference is that including a record in a selection, reorders that record in the record set, whereas including a record in a collection does not affect its position in a record set.  You should be using this feature, primarily, if it is your intention to reorder the records.

In this section and the next, we will use the terms "select", "copy", "cut", and "paste".  These terms date from the earliest word processors, and were used to relate these electronic manipulations to the editing a paper document by cutting out words and pasting them elsewhere.

Before proceeding further, you must first restrict the display to a single "group" by typing "G" then entering the designation of that "group".  For further details, please refer to the section titled: "A Given Group in Linked Lists".

You can then define a "selection" by either highlighting a record and then typing [CONTROL M], or else you can hold down the [CONTROL] key as you click on a record.

Now that a "selection" is defined, it may be extended.  You can do this by holding down either the [SHIFT] or [CONTROL] key and clicking on other records from the same list.  You can also use the [UP] and [DOWN] keys to highlight other records, then hold down [SHIFT] or [CONTROL] while typing "M".

If you use the [SHIFT] key, and the record is above or below the "selection", then all intervening records will be added to the "selection".  If the record is at the bottom of the "selection", the "selection" will be disolved.  If the record is within or at the top of the "selection", the "selection" will be reduced to include only those records from the record to the top of the "selection".

If you use the [CONTROL] key, and the record is above or below the "selection", then the "selection" will be moved to the record and the record will be added to the bottom of the "selection".  If the record is at the top of the "selection", the "selection" will move its top down by one record, releasing the top record from the "selection".  If the record is within or at the bottom of the "selection", the record will be repositioned at the bottom of the "selection", then the bottom of the selection will be raised by one record, releasing this record from the "selection".

You can also create a "selection" by positioning on a record, and holding down the [SHIFT] key, as you click on another record.  In this instance, all records from the record positioned on initially, to the record you clicked on with the [SHIFT] key down, will be included in the "selection".

Also [CONTROL A] (for "add") is equivalent to [CONTROL M], and [CONTROL E] (for "extend") is equivalent to [SHIFT M].

Also, you can extend the "selection" by highlighting a record at one end of the "selection", then typing [SHIFT SEPARATE UP] or [SHIFT SEPARATE DOWN] to add its neighbour, in the corresponding direction, to the "selection".  If the direction is towards the inside of the "selection", then, highlighted record will be released from the "selection" and its neighbour is unaffected.  If you do not have sufficient privilege to create "collections" (see the section titled: "Multiple Record Editing (Kollecting)"), or a "copying" or "cutting" region is defined (see the section titled: "Copy or Cut from Linked Lists"), and no "collection" is defined, then these keystrokes can also be used to start the definition of a "selection".

Once the records to be moved are in the "selection", these records can be moved by clicking on another position within the list, without using either [SHIFT] nor [CONTROL].  If the position is above the "selection", the top of the "selection" will be moved to the position that record was occupying, and the record, and all below it, will be moved down to make room for it.  If the position is below the "selection", the bottom of the "selection" will be moved to the position that record was occupying, and the record, and all above it, will be moved up to make room for it.

Also, once a "selection" has been defined, the changing field contents and editing of entire record operations will be altered.  The data presented will be blank or zero, unless all records in the "selection" share the same value for a given field.  If a field is altered, you will be prompted, upon closing the dialogue, to confirm that all records in the "selection" are to have their corresponding field altered to this value.  Also upon closing the dialogue, any restrictions on the field that was the subject of the change, or all fields, if editing the entire record, will be removed.  Please note, that, unless all records agree with the value of a given field, that field can not be edited to blank or zero.

Please also bear in mind that, if the prompt specifies a range of numbers that does not begin at zero, zero will be presented as a non-zero number.  For example, the prompt, "How many in pack <1-4>" will present 0 as "1", 1 as "2", and so on, as zero corresponds to the lowest value in the range, in this case "1".  There might also be other data presentations where zero is not presented as a blank field.

After the move, the "selection" remains in place.  You will need to explicitly release the "selection".  This can be done as mentioned in passing earlier, or by right clicking, or by typing [CONTROL U].

Copy or Cut from Linked Lists

This applies to the "linked list" databases only.  These databases are indicated by the menu item "Group" in the menu bar.

The object here is to use the "selection" already defined, to be the basis for the creation of a duplicate set of records in this or another group of this linked-list database.  You must, therefore, first define a "selection". Please refer to the section titled: "Move Up/Down in Linked Lists".

Having defined a "selection", you can mark it as the base for "copying", by typing [CONTROL C], or for "cutting" by typing [CONTROL X].  Initially there is no difference between "copying" and "cutting", except that the records are presented in different colours.  When you later go to "paste" the records elsewhere, had they been marked for "copying", the original records will be left alone and copies of them made at the location of the "paste".  On the other hand, had they been marked for "cutting", the original records will be relocated to the location of the "paste".

Once a "copy" is defined, the records constituting it may be copied to other parts of this group or to other groups.  First, you will need to highlight the position at which you wish the records to be pasted.  If this location is within another group, you will need to switch to this group by typing "G" then entering the designation of that "group".  For further details, please refer to the section titled: "A Given Group in Linked Lists".

After highlighting the location at which you wish the records to be relocated or copied to, type [CONTROL V] to paste the records.  After the paste, the "copy" is released.  You may explicitly release the "copy", by right clicking, or by typing [CONTROL U].

Maintenance Viewing Data

These windows are presented to allow you to select a particular set of configuration data to modify or delete, or to create a new set.  The additional features offered by these windows are:

  • changing the contents of a field.
  • selecting a record to edit.
  • creating new records.

Changing the Field Contents

To change the contents of a particular field, highlight the target field of the target record then type "C", or click on the "Change" menu item, then enter the new contents.

If the record has been expanded, take care to distinguish between the symbolic field and the following referenced field. Changing the contents of the former selects a different referenced field and hence a different referenced "Set of Fields".

Changing the contents of the latter changes the contents of the referenced field leaving the symbolic field still referencing the same referenced "Set of Fields".  The change to the referenced field will be reflected as an apparent change to the symbolic field.

Editing the Entire Record and Deleting

To select a record for editing, type "S", or [RETURN], or click on the "Select" menu item, then enter the specification of the required record.  The specification will default to the highlighted record, so an alternative method is to highlight the required record, then type "S", then [ENTER], or [RETURN] sufficiently often to accept the default, or just double click on the record in question.

Once selected, a new dialogue window is opened, presenting this record as a "Set of Fields".  This data may now be modified as required.  Refer to the section titled: "Set of Fields".

While editing the "Set of Fields", [PAGE UP] and [PAGE DOWN] may be used to select the previous or next records, [DELETE] may be used in conjunction with [F1] to delete the record and [INSERT] may be used to create a new record.

Add New Records (Insert)

Back at the "Viewing Data" window, you can, by typing [INSERT] or "I" or clicking on the "Insert" menu item, select a data set containing wiped data. The wiped data sets are usually excluded from the "Viewing Data" windows automatically and so can not be selected using "S", [RETURN], [ENTER], or double-clicking.

As in the case of selecting a field using "S", a dialogue window is opened, presenting a record as a "Set of Fields", only this time they will be substantially blank.

Restrict to a Single Record

Back at the "Viewing Data" window, if you restrict display to those records that contain the given data in a field that is required to contain unique data, the will therefore specify a single record, which will be automatically selected for editing.  When you return to the "Viewing Data" window, the restriction will be removed.

Multiple Record Editing (Kollecting)

This function is only available if you have sufficient privilege.  This privilege level is specified in the "Configuration Data" record, titled "Level: kollect records".  Please refer to the section titled: "Configuration Data".

You may edit several records at once, by first defining a "collection". Subsequent to defining the "collection", any changing or editing will be applied to all records of the "collection".  You will be asked to confirm each field to be altered, but not each record to be affected, so you should make sure that only the desired records are collected.

In the case of "linked list" databases, it is important to understand the distinction between a "collection" of records, as described here, and a "selection" of records, as described in the section titled: "Move Up/Down in Linked Lists".  In each case, multiple records are highlighted, and the operation of the "Change" and "Select" for editing functions (see "Changing the Field Contents" and "Editing the Entire Record and Deleting") will serve to affect all records in either the selection or the collection.  The important difference is that including a record in a selection, reorders that record in the record set, whereas including a record in a collection does not affect its position in a record set.  You should be using a "selection", primarily, if it is your intention to reorder the records.  Otherwise, you are in the right place.

When records are included within a "collection" they will be displayed differently to the other records.

Throughout this section, several keystroke and mouse methods will be described. If you are dealing with a linked-list database, you are best to restrict your keystrokes to those that are not shared with the creation of "selections" (such as "k" and [SHIFT K]), and to avoid the mouse operations.  For information on "selections", please refer to the section titled: "Move Up/Down in Linked Lists".  The records of a "collection" will not only be coloured differently from regular records, they will also be coloured differently to records in "selections".

Now down to business.  The simplest approach is to highlight each record of interest and type "k" (or click on "Kollect").  If you type "k" for a record, that is already in the "collection", it will be removed from the "collection". If you type [SHIFT K], you will release all records from the "collection".

You can also select records for inclusion in a "collection", by highlighting one, then typing [SHIFT SEPARATE UP] or [SHIFT SEPARATE DOWN] to add the highlighted record, and its neighbour in the corresponding direction, to the "collection".  If the neighbouring record was already in the "collection", both records will be removed from the "collection".  When dealing with linked-lists, if a "selection" is defined, or a "copying" or "cutting" region is defined, then these keystrokes can not be used to start a "collection", as they will instead start or extend a "selection".  For more information on "selections" and the "copying" and "cutting" regions, please refer to the sections titled: "Move Up/Down in Linked Lists" and "Copy or Cut from Linked Lists".

Alternatively, unless using a linked-list database, you can highlight a record, then, while holding down [SHIFT], click on another record.  This causes the two records and all intervening records to be added in the "collection".  If, while holding down [CONTROL], you click on another record, only the record clicked on will be added to the "collection".  If in either of these operations, the record clicked upon was already within the "collection", the records involved will be removed from the "collection".  You can release all records from a "collection" by right clicking.

Once a "collection" has been defined, the changing field contents and editing of entire record operations will be altered.  The data presented will be blank or zero, unless all records in the "collection" share the same value for a given field.  If a field is altered, you will be prompted, upon closing the dialogue, to confirm that all records in the "collection" are to have their corresponding field altered to this value.  Also upon closing the dialogue, any restrictions on the field that was the subject of the change, or all fields, if editing the entire record, will be removed.  Please note, that, unless all records agree with the value of a given field, that field can not be edited to blank or zero.

Please also bear in mind that, if the prompt specifies a range of numbers that does not begin at zero, zero will be presented as a non-zero number.  For example, the prompt, "How many in pack <1-4>" will present 0 as "1", 1 as "2", and so on, as zero corresponds to the lowest value in the range, in this case "1".  There might also be other data presentations where zero is not presented as a blank field.

Refreshing the Display

The records that are presented in a "Maintenance Viewing Data" window are selected when the window is opened, and then, afterwards, as restrictions are applied, so as to include all records that satisfied those restrictions at that time.

Also, if you were to edit a record, then the selection of records would be reviewed in response to this.

It is possible, however, for there to be database changes by others or the Movement Controller itself, which would change the selection of records to be displayed. If this happens, you will find that the selection of records presented no longer satisfy the requirements for inclusion.

If you suspect that this has or might have happened, and want to present only those records that now qualify for inclusion, you should type "U" or click on the "Update" menu option.

Report Viewing Data

These windows are presented to allow you to apply restrictions prior to requesting a report.

Once any desired restrictions have been entered, typing "P", [RETURN], [ENTER], or clicking on the "Print" menu item terminates the restriction stage.  Before printing commences, further options may be presented, then finally you will be asked whether you wish to have the report

  • sent to the "Printer", or
  • sent to the "Viewer", or
  • written to a "Rich Text Format" or "RTF" file (suitable for viewing by most word-processing program such as Microsoft Word), or
  • written to a "Comma Separated Variable" or "CSV" file (suitable for importing into many database programs such as Microsoft Excel).

You can select "Printer" by typing "P" or by clicking on the "Printer" button.  You can select "Viewer" by typing "V", or by clicking on the "Viewer" button.  You can select "Rtf file" by typing "R", or by clicking on the "Rtf File" button.  You can select "Csv file" by typing "C", or by clicking on the "Csv File" button.

If you select "Printer" the report will be sent to the print spooler.  The report file may be configured to suit an IBM-PC printer or an HP PCL printer - see the "Using HP DeskJet" variable in the section titled: "Configuration Data"

If you select "Viewer", you will be presented with the report in a new dialogue window.  This window will have a vertical scroll bar, which you can use to scroll through the report.  The [PAGE DOWN], [PAGE UP], [DOWN], [UP], [CONTROL PAGE DOWN], and [CONTROL PAGE UP] keys may also be used to operate the scroll bar.  To quit viewing the report, type [ESCAPE].

The "Rich Text Format" is a standard format recognised by all common word processors.  These files have the extension ".rtf".  Had you specified that you wanted the files to go to the printer, the Movement Controller would have produced a temporary file that contained instructions for control of an IBM-PC style dot-matrix printer or an HP DeskJet or similar printer (depending upon database settings - see "Using HP DeskJet" variable in the section titled: "Configuration Data").  If you do not have one of these types of printers, then by producing an RTF file, you can use other word processors to print the report.  So, if you select "Rtf file", you will be asked to enter or select a filename to contain the report.  The file will not be automatically spooled to the printer; you'll need to do this yourself.

The "Comma Separated Variable" format is a standard format recognised by all common database and spreadsheet programs.  These files have the extension ".csv".  If you request files of this type, the column headings and column totals will be included, along with the bulk of the report, however, the report title and the report qualifying statements, usually included at the start of the report will be omitted, as these would not fit with the column format of the rest of the report.  If you select "Csv file", you will be asked to enter or select a filename to contain the report.

Help

Most of the windows provide the "Help" feature.  This feature, if active, is called up by typing [F12].

There is usually a "HELP" button or menu item that can also be pressed to call up the "Help" feature.

A quick aside for those reading this through the Movement Controller help windows: type [GREY PLUS] to advance the cursor to the topic of interest within the list presented below, then type [ENTER] to read the topic.  When done, type [BACKSPACE] to return to this section.

Display Format

In response to typing [F12], a window is opened in the current window, through which portions of this manual, the TECHNICAL MANUAL, and the SOFTWARE MANUAL may be displayed.  The section of the OPERATOR'S MANUAL (this manual), relevant to the window you are using will be displayed. Otherwise, a list of the major sections of this manual will be displayed.

The help window is normally divided into two parts, the header and the text sections.  There is also a vertical scroll bar and a menubar at the top of the display to provide, via the mouse, the features that are provided by the keyboard.

The header section is at the top of the window and shows the name of the major section of the manual that is currently open, and below this it shows the name of the section within this section that is currently open, and so on.

To the right of the final subsection is shown the page of this subsection that is being displayed.  Should the window be showing parts of two pages, the page number will reflect the first, and a plus sign ("+") will be appended to the page number.

In the text section is first presented the text from the indicated section of the manual (barring window dumps), followed by the list of sections subordinate to this section.  This text is presented in a number of colours. One colour is reserved for references to other sections of the manual and for the list of subordinate sections.

When no section is being displayed, there will be no division of the window; either the list of major sections or the list of manuals will be displayed in the undivided window.

Moving by Lines and Columns

There is a cursor, which is initially presented at the start of the first blank line in the text section.  This cursor may be moved throughout the text section using the cursor keys.

Attempts to move down past the bottom of the text section will result in the text scrolling upwards.  The page number will be advanced from "1" to "1+".  After continuing to scroll the text upwards, eventually you will reach page "2", given sufficient text.

Attempts to move up past the top of the text section will result in the text scrolling downwards until the start of the section is displayed.

The cursor may be moved to an arbitrary point on the help page by clicking there with the left mouse button.

Moving by Pages

The window may be moved through the section, page by page, by typing [PAGE DOWN] for the next page or [PAGE UP] for the previous page.

Attempts to page down past the last page of the section, will present the first page of the next section still subordinate to its encompassing section, or, if there is no such next section, the first page of the section next to the encompassing section, or, if there is no such next section, the first page of the section next to the section that encompasses the encompassing section, et cetera.

Attempts to page up past the first page of the section, will present the last page of the previous section still subordinate to its encompassing section, or, if there is no such previous section, the first page of the encompassing section.

The pages may be advanced using the scroll bar.

Moving to Beginnings and Ends

You can move to the beginning of the line, or, if at the beginning of the line, to the top of the window, or if at the top of the window, to the start of the section, by typing [HOME].

You can move to the end of the line, or, if at the end of the line, to the bottom of the window, or if at the bottom of the window, to the last page of the section, by typing [END].

Moving to References

You can relocate the cursor to the displayed references to other sections of the manual and to entries in the list of subordinate sections, by typing [GREY PLUS] to move forward, or [GREY MINUS] to move backwards.  These references and the entries in the list will be shown differently to the regular text.

Once the cursor has been relocated to a section reference or an entry in the list of subordinate sections, that section can be displayed by typing [ENTER].

The section may also be called up by double-clicking on it.

Moving to an Arbitrary Section

If you know the name of the section you wish to read, or some text you would expect to appear in its name, type [F1], "s", "S", "f", or "F".  In response, you will be asked to enter the text.

The text should be entered in lower case and will match names found in upper or lower case.

Once you enter the text, it will search the names of the major sections, then the names of the sections below these, then the names of the sections below these and so on, starting however at the section after the current section, and wrapping around till it again reaches this section.

Once it finds this text in a section name, it stops searching further and displays the corresponding section.  Should it fail to find the text at all, it will again display the current section.

Should the text you enter be expected to be found in several sections, you can display each of the matching sections in turn by typing [F2], "a", or "A".

Help on Using Help

If you type [F12] when already in Help, the "Help" section of the OPERATOR'S MANUAL will be displayed.  This provides help for using the help feature.

Moving Directly to the Encompassing Sections

The encompassing section may be reached, as described previously, by typing [PAGE UP] sufficiently often.  Alternatively, this encompassing section may be called up directly by typing "Z" or [BACKSPACE].

Once you have reached the major section, typing "Z" or [BACKSPACE] once more will result in a list of the major sections being presented as the list of subordinate sections to the manual.

Changing Manuals

To change manuals, you must first move out through the encompassing sections, by typing, "Z" or [BACKSPACE].  Once the list of major sections has been reached, the list of manuals can be reached by typing "Z" or [BACKSPACE] once more.

You may then move the cursor to the manual you wish to read, then type [ENTER].  In response, either the list of the major sections of the TECHNICAL MANUAL or the SOFTWARE MANUAL, or the section of the OPERATOR'S MANUAL relevant to the window you are using will be displayed.

Exitting

To exit from help, type [ESCAPE].  The original window will be restored.

Changing the Colours

On the main menu, under "View", are three options, "Fonts", "Colours", and "Function Keys".  The "Colours" option allows you access to the adjusting of the display colours.

This option is only provided if you have sufficient privilege.  The privilege level required is that that corresponds to the database field known, within the software, as "GraphicPaletteColour", which is usually presented with the prompt, "Palette description".

To change the colours, select this option. You will be requested to enter the colour purpose, a "Symbolic Name" field. For editing instructions for this type of field, please refer to the section titled: "Symbolic Name".

The software uses sixteen colours to display its information.  For some purposes, when it requires a particular colour to be presented, it will refer to this colour, using a number from one to sixteen.  More commonly, the software will refer to the purpose it wants the colour for, and retrieve the "colour number" - a number from one to sixteen - from a table.  The table has many more entries than the sixteen possible colours, however each entry in the table is confined to the range one to sixteen.  This is the "colour purpose" table.

The first sixteen colour purposes are the sixteen colours themselves.  This inclusion of the colours themselves among the colour purposes allows the definition of devices to select colours based on either their purpose, for example "photocell on", or colour, for example red and yellow for fire and grey for smoke.

If you wish to alter the shade of a colour, for example make the red a little darker, you would select one of the first sixteen colour purposes.  However, if you wish to use a different colour for a particular purpose, for example have the "Selected Backdrop" colour purpose use blue rather than dark green, you would select one of the colour purposes beyond the first sixteen.

Each of the sixteen possible colours has a single name, however, the shade corresponding to the colour can be set individually for each user.

Similarly, each of the colour purposes has a single name, however, the colour referenced by the colour purpose can be set individually for each user.

So the first step is to select the colour purpose.  As indicated already, this may either be one of the first sixteen, which coincide with the colours themselves, or more usually, one of the latter purposes.

Once the colour purpose is selected, there are four things that you can do:

  • select a different colour for the chosen purpose,
  • alter the shade of the colour that corresponds to the chosen purpose,
  • rename the colour that corresponds to the chosen purpose, and
  • rename the chosen purpose.

Select the Colour for the Chosen Purpose

Having selected a colour purpose (or one of the sixteen colours), you will be presented with a "Set of Fields" and a number of buttons.  The "Set of Fields" includes only the colour assigned to chosen purpose (a "Symbolic Name" field).  Refer to the sections titled "Set of Fields", and "Symbolic Name".

Do not alter the colour assigned to the first sixteen colour purposes, as the colour purpose "red" must always be assigned the colour "red" and so on.

The push-buttons allow you to alter

  • the shade of the colour,
  • the raw RGB components of the colour,
  • the name of the colour, and
  • the name of the colour's purpose,

Edit the Shade of the Colour

As well as being able to alter the colour assigned to the colour purpose, you may also edit the hue of the colour assigned to the chosen purpose, by pressing the "Edit palette" button.  In response, you will be presented with the "Color" dialogue window (featuring the usual american spelling mistakes).

When you enter this dialogue window, all of your colours are written to the "custom" colours in the set of squares at the lower left of this dialogue window.  You can now modify any or all of these colours.

You need first to select a colour into the "Color" square in the lower portion of the dialogue window, just right of centre.  This can be done a number of ways, but first of all you should click on the custom colour you wish to change.  In response the custom colour will be surrounded by a solid and a dotted square. Bear in mind, that each time you click on "Add to Custom Colors" (see below) this selection will change - the dotted square will be removed, and the solid square, even if it remains, will no longer ensure that this will be the custom colour to which the colour will be written.

The simplest way to set the colour in the "Color" square is by clicking on one of the "basic" colours.  This will move both the solid and dotted squares from the custom color, but leave it selected, at least until you click on "Add to Custom Colors" (see below).

Alternatively, you can create your own colour.  You will find the range of colours presented as a cube (or more correctly, an inverted triangular pyramid), represented by the base square (presenting a triangle of colours) and the "luminosity" column based on the selected point in the square.

To create your own colour, you can select a combination of hue and saturation, by clicking in the large square, just to the right of the "basic colors" boxes, then adjust the luminosity (brightness) of the colour by clicking in the vertical strip to the right of this square.  There is also a pointer that can be dragged to adjust the luminosity.

The square is coloured with increasing hue in the horizontal direction (from red, through green and then blue, and back to red again) and increasing saturation in the vertical direction.

As you move from a point at the top of the square towards the base, the "saturation" is decreased from 240 to 0.  This means that the quantities of red, green, and blue are uniformly increased so that they all reach their full value at the base.  At the base of the square the colour is grey (and hence the reference to a triangle rather than a square).

The "luminosity" column allows you to darken the colour selected from the square.  The "luminosity" ranges from 240 representing the colour at the selected point in the square, at full brightness, to 0 representing black (and hence the reference an inverted triangular pyramid rather than a triangular prism).

As you adjust the colour, a sample of the colour is presented in the rectangle titled "Color", just below the "hue-saturation" square.

There are two ways to specify a point in the three dimensional colour space. The first, and most obvious, is to specify the quantities of "red", "green", and "blue", in the range from 0 to 255.  The second is to specify the values for "hue", "saturation" and "luminosity" as described above.

In addition to being able to select a point in the "hue-saturation" square and a level on the "luminosity" column, any of the six dimensions, "hue", "saturation", "luminosity", "red", "green", and "blue" may be set directly using the numeric entry fields.  Note that as there are only three orthogonal dimensions, changes to any one of the first three are reflected by changes to the second three dimensions, and, conversely, changes to any one of the second three are reflected by changes to the first three dimensions.

By way of clarification, this is analogous to controlling your shower.  In this situation there are two orthogonal dimensions, which can be hot and cold (which most of us use).  Alternatively these orthogonal dimensions can be temperature and pressure, which would probably be more user-friendly and certainly more difficult to implement.

Having created a shade, you need to add it to the "custom" colours.  You do this by clicking on "Add to Custom Colors".  As well as adding this to the selected custom colour, it will advance the custom colour selection (without indication), so you should then click again on the custom colour of interest, to place the solid and dotted squares around it, before again clicking on "Add to Custom Colors".

Having done this you can now click on "OK" and have all the "custom" colours replace your current set of colours.  Should you not wish this to happen, click on "OK".

Should you so alter a colour, that its name no longer reflects its colour, you should change both its name and the name of the corresponding colour purpose from among the first sixteen colour purposes.  Bear in mind that as you change the colour, it only affects the presentation of that colour for the currently logged-in user, however, the name of the colour is common to all users, so you should try to reach a consensus with the other users before renaming the colour.  Refer to the sections titled: "Edit the Colour's Purpose".

Edit the Colour's Palette Directly

You may also edit the colour's Red, Green, and Blue components directly, by pressing the "Edit palette directly" button.  In response, you will be presented with a "Set of Fields".  The "Set of Fields" includes the three colour components assigned to the colour (all "Numeric" fields).  Refer to the sections titled "Set of Fields", and "Numeric".

Here the values for red, green, and blue are hexadecimal, ranging from 0 to FFFF (65535 in decimal).

When finished editing these details, press [ESCAPE] to return to editing the colour purpose details.

Edit the Colour's Name

You may also edit the colour's name, by pressing the "Edit colour name" button.  In response, you will be presented with a "Set of Fields".  The "Set of Fields" includes only the colour name (a unique "Name" field).  Refer to the sections titled: "Set of Fields", and "Name".

The main reason for calling up this "Set of Fields" is to rename the colour once the values have been so altered that the name no longer describes the colour.  Once you do this you should also alter the name of the corresponding colour purpose (one of the first sixteen).

Bear in mind that when you changed the colour, it only affected the presentation of that colour for the currently logged-in user, however, the name of the colour is common to all users, so you should try to reach a consensus with the other users before renaming the colour.

Edit the Colour's Purpose

This allows you to change the text used to describe this purpose, by pressing the "Edit colour purpose" button.  In response, you will be presented with a "Set of Fields".  The "Set of Fields" includes only the colour's purpose (a unique "Name" field).  Refer to the sections titled: "Set of Fields", and "Name".

Bear in mind when you changed the colour that was associated with this purpose, it only affected the presentation of that colour purpose for the currently logged-in user, however, the text used to describe the colour purpose is common to all users, so you should try to reach a consensus with the other users before changing the text that describes the colour purpose.

Finish Changing the Purpose

When done editing the colour purpose details, press [ESCAPE] to return to the selection of a colour purpose.

Finish Changing the Colours

When done, press [ESCAPE] to exit colour change mode.

Select the Font

There are three font uses within the Movement Controller software.

The first use employs a font derived from an IBM-PC BIOS.  This is required when characters outside the standard ASCII range are used, for the large character at the left of the uniform buttons on drawing areas, and for "character" primitives used in the graphical representation of user-defined devices.  No alternative font may be selected for this use, however you may edit this font.  This font is referred to as the "Button" font use.

The fonts for the second and third uses can be selected.

The second use requires a fixed-pitch (monospaced, typewriter) font and is employed within the drawing areas and text entry fields.  This font use is referred to as the "Fixed" font use.

The font, for the third use, may be a proportional font.  This font is employed in all other instances.  This font use is referred to as the "Proportional" font use.

On the main menu, under "View", are three options, "Fonts", "Colours", and "Function Keys".  The "Fonts" option allows you select fonts for the proportional and fixed uses in the displays, and to edit the font used for the large letter in buttons.

To select a different font for either the proportional and fixed font uses or to edit the font for the button use, select this option. If you have sufficient privilege to edit both font uses, you will be then requested to enter either an "F" for the "Fixed" font use or a "P" for the "Proportional" font use.  If you have only sufficient privilege to edit one of these uses, it will be assumed that this is the font use you will be editing.  Of course, if you didn't have sufficient privilege to edit either of these, the "FONT SELECT" would not have been displayed and typing "F" would have had no effect.

Once it has been determined whether you are editing the "Fixed" or the "Proportional" font use, the "Font Selection" dialogue window will be presented.

These options are only provided if you have sufficient privilege.  The privilege level required is that that corresponds to the database fields known, within the software, as "UserFixedPitchFont" and "UserProportionalFont", which are usually presented with the prompts, "User's font for fixed pitch", and "User's font for proportional" respectively.  The first of these sets the privilege level needed to obtain access to the fixed font, and the second for access to the proportional font.  You will need to have access to both of these in order to have access to the button font.

Edit Bitmap (Button) Font

This window presents all the characters in the font, arranged in ascii numerical order in sixteen rows of sixteen columns (with sixteen intervening blank columns).  The first sixteen characters are arranged from left to right along the forst row, and the second, similarly, along the second row, an so forth.

The cursor position is presented by the change in background colour at a character in the font (or between characters).  The cursor can be moved using the cursor keys or by clicking with the mouse.

To modify a character, move the cursor to the character of interest, then type "Z", or click on the "Zoom" menu option, or double-click on the character.

In response, the display will be repainted to present each pixel of the character as a full character, using "#" to represent pixels that are turned on and space to represent those that are turned off.  You can now edit the pixels of the character by positioning the cursor on the "#" representing an unwanted pixel, or on the space where you wish there to be a pixel, and then typing "T", or clicking on the "Toggle" menu option, or double-clicking on the "#".

Should you attempt to turn on a pixel that is between character positions, a message to this effect will be presented.

To return to the view of the complete font, type "Z", or click on the "Zoom" menu option.

Changes to the font will come into effect immediately, however, they will not be saved until you close this window.

Finish Selecting the Font

Irrespective of which page is presented, there are three buttons at the bottom of the dialogue window, "OK", "Cancel", and "HELP".

When done, click on the "OK" button to save your selection and exit the "Font Selection" dialogue window.

Should you wish to exit the "Font Selection" dialogue window without saving your selection, click on the "Cancel" button.

If you were sufficiently privileged to have had a choice between the "Fixed" and the "Proportional" font uses, you will be again be given the opportunity to make this choice, otherwise you will have exited from selecting the fonts.  When presented with the choice of font uses, you may exit from selecting the fonts by making a blank entry.

Specific Instructions

This section describes the operation of individual windows, using the Movement Controller's own screen and keyboard.

This section should be read in conjunction with operating the windows to which they relate.

References are made throughout this section to the subsections of the "General Instructions" section.  It should only be necessary to look these references up the first time they are encountered.

It is assumed that you are familiar with the subsections of "General Instructions" section titled:

As knowledge of the remaining subsections is required, these references are given.

The subsections within the "Specific Instructions" section are arranged as the options of the main menu and its sub-menus are arranged in the application.

Single Display Function Mode

There is an option to run the Movement Controller's operator interface in single display-function mode, as described in the section of the TECHNICAL MANUAL titled: "Operator Interface in Single Display Function Mode".

In this mode, when the Movement Controller's operator interface software is started, the main menu will not be presented.  Instead the nominated display-function will be presented, filling the display.

A dialogue box will also be opened, requiring that you enter your user name (a "Symbolic Name" field) and password (a "Password" field).  Please refer to the sections titled: "Symbolic Name", "Password", and "Modify List of Users".  You might also like to reference the section titled: "Log Off".

Should you choose not to enter your name and password, the operator interface will close.

Once you have entered your name and password, the dialogue box will close, and you will have access to the nominated display-function.

To exit the operator interface, type [ESCAPE] or [ALTERNATE F4].

Main Menu

The main menu will be presented when the Movement Controller's operator interface software is started.  The options presented will depend upon the privilege with which you have logged on, which before logging on will be minimal, and upon the configuration that has been created and may be altered by editing the database.

The main menu is contained in a horizontal menu bar presented at the top left of the screen.  Below is how the main menu would appear for the maximum configuration (which is assumed throughout this document).

If you have opted for the more DOS-like interface, once you have logged in, the main menu will be presented in a window, rather than in the horizontal menu bar.  If you escape out of this window, you will be returned to the horizontal menu bar, from which you will need to make a selection before being again presented with the menu in this window.  For information on configuring a user for the more DOS-like interface and its impact, please refer to the section titled: "Modify List of Users".

This menu window may be returned to from most windows by typing [ESCAPE] (or clicking on it) a sufficient number of times to wind back through windows and sub-menus.  In the default, maximum configuration (which is assumed throughout this document), the menu will appear, roughly, as shown below:

Movement Controller (C) Copyright 1998 to 2009 Woodgrove Digital Engineering File View ┌───────────────────────┐ │New User │ │Operations████████████>│ │Reports >│ │Communication reports >│ │Configuration >│ │Maintenance >│ │Definition >│ │Special Functions >│ │Exit │ └─-─────────────────────┘

This menu provides for the user to log off, or to choose between the major sub-menus, or to exit.

Log Off

This window is presented when the Log Off (or New User) option is selected from the main menu.

Below is a rough text-representation of this window:

New User keys usually active: ESCAPE : exit current display ALT-H : show help screen keys active when editing a record: MINUS : erase field PLUS : restore field HOME : move to first field END : move to last field PAGE UP : move to previous record PAGE DOWN : move to next record UP : previous field or symbol DOWN : next field or symbol LEFT : erase previous character RIGHT : accept one character ALT-Q : show function keys SHIFT F10 : force and edit symbol (function keys may be set by pressing CTRL-F1, CTRL-F2 etc.) keys active when viewing a file or menu: ENTER : same function as first entry in legend (reverse blue band at top) HOME : move to top of file END : move to bottom of file PAGE UP : move back 19 records PAGE DOWN : move forward 19 records UP : select previous record DOWN : select next record LEFT : select previous field RIGHT : select next_field CTRL-LEFT: display first fields CTRL-RIGHT: display last fields (these allow the display of fields which would not otherwise fit) WOODGROVE DIGITAL ENGINEERING NSW designed and written by W.D.E. P/L User t ███████████████████V Please enter password a ████████████████████

This window enables you to enter your user name (a "Symbolic Name" field) and password (a "Password" field).  Refer to the sections titled: "Symbolic Name", "Password", and "Modify List of Users".

The body of this window contains some abbreviated instructions for general control of the Movement Controller software.

There are four privilege levels, 0, 1, 2, and 3.  When you log in without entering a user name, you are given privilege level 0. This is intended to provide you with access to view the system but not to control it.

If you enter your user name and then password, you will be given the privilege level that has been assigned to you.

Privilege level 1 is intended to enable the ordinary control of the system.  Privilege level 2 is intended to enable access to certain configuration and maintenance functions.  Privilege level 3 should allow access to all functions.  For details on how to alter the security arrangements, refer to section titled: "Edit Databases", and its subsections "Menu Text and Security", "Database Privilege", "Crane Commands and Security", "Palletiser Commands", "Carton Conveyor Commands", and "Configuration Data".

There is provision for users with privilege levels of 2 or higher to be automatically logged out once a certain number of minutes have expired.  This is specified in the "Configuration Data" record, titled "Auto logout if >=2 (minutes)". Please refer to the section titled: "Configuration Data".

Operations

This menu provides access to the windows involved in the display of live data.

Below is a rough text-representation of this menu:

Movement Controller (C) Copyright 1998 to 2009 Woodgrove Digital Engineering File View ┌─-─────────────────────┐ │New User │ ┌─-────────────────────────────────┐ │Operations████████████>│ │Heavy-unit-load conveyors█████████│ │Reports >│ │Conveyor alarms │ │Communication reports >│ │Stores diagram │ │Configuration >│ │Crane status and control │ │Maintenance >│ │Retrieve from stores by location │ │Definition >│ │Store expected loads │ │Special Functions >│ │Store loads from part-load picking│ │Exit │ │Retrieve wanted loads │ └─-─────────────────────┘ │Start movements within the store │ │Review loads being retrieved │ │Enter orders for picking │ │Cartons within the conveyor system│ │Replenish the pick areas │ │Carton conveyor system │ │Palletiser status and commands │ │Machine status display │ └─-────────────────────────────────┘

Heavy-Unit-Load Conveyors

The Heavy-Unit-Load Conveyors diagram provides a back-drop representing the static features of the plant, against which the movement of loads is displayed.

The loads are presented as either squares, representing a load of cartons, with a thick edge of a different colour, representing the pallet on which they are supported, or as a circle, representing a roll of news print, a coil of steel, or a basket of cans, again with a thick edge of a different colour.  For instructions on selecting the presentation of loads, please refer to the section titled: "Presentation of Loads".

The window will appear as shown overleaf:

Heavy-Unit-Load Conveyors Diagram -- Overview

When the diagram has been zoomed in, the square loads are presented as a pallet with four boxes arranged within its perimeter.

The colours described in this and other sections of this manual, assume that you have kept the default colours.  If you have seen fit to change these colours, you will need to make allowance for this when reading.  For more information, please refer to the section titled: "Changing the Colours".

Push Buttons

There are "push buttons" presented at the top of this window. The purpose of these push buttons is indicated by the text within them.  The first letter of this text is larger and is to be typed to "press" the button. The button may also be clicked with the mouse.

If the button is grey, it is available.  If it is dark green with black text it is unavailable.  If it is light green, it is either available with there being some particular reason that you might wish to "press" it or it is "pressed".

There are also two operating-system-painted buttons.  One of which, "ESCAPE: exit", is for exiting from a "push button" selection or from the window completely if no such selection is active.  The other, "HELP", calls up the help feature, refer to the section titled: "Help".

Presentation of Loads

Loads in the Heavy-Unit-Load Conveyor System are shown in the positions indicated to Movement Controller by the Heavy-Unit-Load Conveyor System PLC.

The loads are coloured to indicate where they are destined.  In applications where the destination is not used, the colour may be used to indicate whether the load is empty, not-empty or fiddled-with.

Further detail is available concerning the loads in the "load details tablet" at the top left of the display.  Please refer to the section titled: "Control of Loads".

If the loads are in a "collection", they will be coloured to reflect this, and this condition will override all other colours.  Please refer to the section titled: "Modifying Several (KOLLECT TO EDIT)".

The representation of the loads can be set to resemble a pallet of cartons or a reel of paper, according to the setting of the "Configuration Data" record "Load square Circle/Big". Please refer to the section titled: "Configuration Data".

Presentation of the Plant

The Heavy-Unit-Load Conveyor System will be coloured to indicate whether it is in automatic (red), disabled (grey), enabled for manual (yellow), requested to run in the nominally east or south directions (green) or requested to run in the nominally west or north directions (light blue).

For some sites, there is a provision to disable groups of conveyors.  If a group has been disabled, and the conveyors are in automatic, they will be shown in the disabled colour (black).  The disabling and enabling of groups of conveyors is performed from the control mode of operation window.  Please refer to the section titled: "The Variables Intended to be Presented".

The immediate background of the conveyor is shown in mid-blue, unless the conveyor (or a device associated with it) is in alarm, in which case it will be shown in red, or is a destination for loads, in which case it will be coloured the same colour as the loads that are directed to it.

Other devices associated with the Heavy-Unit-Load Conveyor System are shown in their approximate relative positions and in a way that reflects their condition.  These devices may include: a pallet dispenser, alignment bars, a palletiser, the forklift floor loops, sizing stations, detierers, load stands, gates, doors, sirens, lights, load stops, miscellaneous photocells, emergency stops, the field supply and the MCR.

Details of Conveyor or Device

The status of a conveyor position or a device may be presented as text by placing the cursor on the conveyor position or device in question, then typing [SHIFT M] or right clicking the location with the mouse.

In response, the status of the plant item in question will be presented in a window, with three buttons, "OK", "HELP", and "ESCAPE".  To close this window, activate the "ESCAPE" button.

The first line in a window corresponding to a conveyor, presents the conveyor position name, while, for devices, the first line describes the device type and the second line indicates the conveyor position to which it is associated. The conveyor, with which a device is associated, needs to be set to manual before the device itself may be manually controlled.

The status includes, mostly, the states of processed inputs.  These inputs, if single bit, will generally directly reflect the physical input, though they may at times be inverted.  Some single bit inputs may refer to internal bits within the PLC, such as the colour bits for "fault lamps" that are only capable of a single colour.  Some single bit inputs may not, at times, reflect the physical input at all, if the PLC needs to override its true state so as to, for example, drive a load past its stop photocell into a squaring end stop.

Some "single bit inputs" are reflections of outputs rather than inputs.  For example, the status of a "fault lamp" is a reflection of the output turning it on.

The status of analogue inputs is commonly scaled from the raw input, and in some instances might reflect the result of a computation based on two or more physical analogue inputs.

Also included with the status is the manual control that is asserted at the terminal in question over the conveyor or device.

If the location corresponds to a rise-fall conveyor, the status of the base conveyor will be first presented, then upon activating the "OK" button, the status of the rise-fall conveyor will be presented, then upon pressing the "OK" button once more, the status of the rise-fall device (whether it is up or down) is presented.

If the location corresponds to a turntable or elevator, the status of the conveyor will be presented first, then upon activating the "OK" button, the status relating to its turning or elevating will be presented.

If the location corresponds to more than one device, or to a conveyor and one or more devices, then, if there is a conveyor position at this position, its status will be first presented, otherwise, the status of one of the devices.  Then upon subsequent activations of the "OK" button, the remaining devices will be presented in turn.

If a conveyor has been taken out of automatic by a terminal other than the one you are using, then the location of that terminal will be presented, if known.

If the plant item, on which you right click, has a special window for it (for example: a crane), then in response to right clicking on its representation, that window will be opened.

Devices for Americold

In addition to the standard photocells and rise-fall conveyors, the devices added to this Heavy-Unit-Load Conveyors diagram include:

  • Access gate status
  • Emergency stops
  • Sirens
  • Various lamps
  • Detierers and their doors and consoles
  • Fork lift detection loops
  • Sizing stations
  • Board checkers
  • Controlled doors
  • Alignment bars
  • Pallet stands
  • Crane fork detection and other guard photocells
  • Fire alarms
  • Smoke detectors
  • Scissor lifts
  • Start/stop push-buttons
  • Barcode readers
  • Hold on MCR
Access Gate Status

The gate status is shown as an unbroken line if the gate is closed, or as a broken line (resembling an open gate) if the gate is open and is coloured differently depending upon whether it is open or closed.

If any gate is open, the cranes will be instructed to stop, once they have completed their current operation, or sooner, if it is taking too long to complete.

Emergency Stops

This status is displayed only if an emergency stop is off, and would then be presented in the area corresponding to the location of the emergency stop in question.

On the overview, this status is represented by the small letters "ES", while, when zoomed in, it is represented by a large red "E" in a white circle.

Sirens

When a siren is operating, an image, intended to resemble a klaxon, is presented on both the overview and zoomed-in displays.

Various Lamps

This status is displayed only if the lamp is on.  There are several lamps about the conveyors system to indicate fault conditions or the presence of pallets at the various outfeeds.

Detierers, Their Doors & Consoles

An attempt is made to provide all the status from the detierer, apart from the state of its doors and console, within the area of the corresponding conveyor.  This is very crowded, and requires considerable experience to interpret.  As a result, I have provided this status via the "Machine Status" display, which can be conveniently reached from here by zooming in from the conveyor.  Please refer to the section titled: "Machine Status Display".

The detierer door status is shown as an unbroken line if the door is closed, or as a broken line (resembling an open door) if the door is open and is coloured differently depending upon whether it is open or closed.  The detierer doors are shown in the location on either side of the detierers.

The detierer console status is presented in the location next to the detierer, corresponding to where the physical console is with respect to the actual detierer.  The detierer console always shows whether the automatic/manual switch is in the automatic ("A") or manual ("M") position, whilst the states of the push-buttons are only shown for those that are pressed.

Fork lift Detection Loops

There are fork-lift detection loops at the infeed and outfeed conveyors M01A, M06A, M40A, M51A, M56A, and M89A.  These are presented on the overview and zoomed-in displays as rectangles, in the "Disabled" colour if inactive, and in the "Enabled" colour if active.

Sizing Stations

The sizing station status in only presented when zoomed-in.

All sizing station photocells and other optical devices are shown in the "Photocell On" colour when obstructed, and the "Photocell Off" colour when clear.

The sizing station consists of an optical plane (shown as a line across the conveyor position), the rear and front trigger photocells (shown using the standard photocell representation in the corresponding position along the conveyor), the height check (shown as a small rectangle across the middle of the conveyor), and the left and right side-check photocells, shown as small circles on the corresponding side of the conveyor.

Board Checkers

The board checker status in only presented when zoomed-in.

All board checker photocells are shown in the "Photocell On" colour when obstructed, and the "Photocell Off" colour when clear.

The board checker consists of a centre photocell (shown as a small rectangle across the middle of the conveyor), and the left and right check photocells, shown as small circles on the corresponding side of the conveyor.

Controlled Doors

The controlled doors are each shown, when closed, as an unbroken line across the conveyor and, when open, as two short lines at either edge of the conveyor.

Alignment Bars

The alignment bars are located at conveyors M03A and M53A, and each consist of two bars, which operate alternately.  The image shows, for each individual bar, whether it is back (a line along the corresponding side of the conveyor), fully extended (a line somewhat in from that side of the conveyor, with the rams showing), or in between.

Pallet Stands

The pallet stands are used to present pallets for pickup by the cranes or to receive pallets from the cranes.  If down they are not shown.  If up, they are shown, when zoomed-in, as two rectangles in the "Enabled" colour, or, when looking at the overview, as two rectangles in the "Other Device" colour (usually black).  If neither up nor down, they are shown, when zoomed-in, as two rectangles in the "Disabled" colour (usually grey), or, when looking at the overview, as two sets of dots in the "Disabled" colour.

Crane Fork Detection, Guard Photocells

There are photocells positioned so that they look along the side of the crane infeed and outfeed conveyors (and, for the other guard photocells, along or accross the corresponding conveyor) so as to detect the presence of the crane's forks (or other objects), and thereby prevent the conveyors from running under these circumstances.

These are presented on both the overview and the zoomed-in displays, in the "Photocell Off" colour when not blocked, and in the "Photocell On" colour when blocked.

Fire Alarms

If the fire alarm (which has never been commissioned) is active, it will be represented near conveyor M10C, by what is supposed to resemble flames.

Smoke Detectors

If a smoke detector is active, it will be represented near conveyor M36A or M86A, by what is supposed to resemble smoke.

Scissor Lifts

Scissor lifts are used at the conveyor infeeds and outfeeds (except where is interfaces to the cranes).  Their status is presented, using the text, "UP", if up, "DOWN" if down, and "BETWEEN" if neither up nor down.

Start/Stop Push-Buttons

There are two sets of start/stop push buttons.  Their images are shown when zoomed in.  This image comprises the depiction of two buttons, one with a red cap representing the stop and the other with a green cap representing the start.

The stop push-button breaks the circuit when pressed, whilst the start push-button makes the circuit when pressed.  This arrangement is shown in the image.

The start would be latched with a contact from the relay (not shown in the image), so for the system to be running, the start needs to be pressed, thereby energising the relay and latching the circuit on, and released, while the stop needs to be left alone.  Similarly, to stop the system, the stop needs to be pressed, thereby denergising the relay and unlatching the circuit, and released.

Barcode Readers

There are two barcode readers, one associated with conveyor M03A, and the other with M53A.  When the readers are asked to scan and you are zoomed-in, there will be a series of red lines shown across the conveyor, intended to depict the raster scan of the barcode readers.

The barcodes are relayed to Movement Controller via serial communications ports P7 and P8 (Com 12 and Com 13) for the chiller (M53A) and freezer (M03A) respectively. You can monitor this data transmission using the "Monitor Communications" window.  Please refer to the section titled: "Monitor Communications".

Hold on MCR

This output is used to prevent the fire doors from closing and the conveyor electrical system from shutting down, in the event of a fire, until the pallets are clear of the fire doors.

Anytime this output is energised, the text, "MCR HELD ON" will be presented on the zoomed-in display, near conveyor M40A.

Stacks of Pallets

Rather than the loads at conveyors M01A, M02A, M51A, and M53A representing single pallet loads, they, generally, represent stacks of pallets.  The number of pallets in these stacks are presented, in the "Disabled" colour, as a single digit, on both the overview and zoomed-in displays, placed alongside the corresponding conveyor position.

When zoomed-in, the load's sequence numbers for the first four pallets in each stack are printed over the single digit.

Control of Loads

The cursor may be moved around the Heavy-Unit-Load Conveyor System using the cursor keys, or using [GREY PLUS] and [GREY MINUS] to jump to conveyor positions that are in alarm. The cursor may also be moved by clicking the mouse on the desired location.

As it reaches each possible load position, the details associated with the position are displayed in the left hand portion of a grey rectangle that will be referred to as the "load details tablet".

These details, and others associated with the load, may be presented more explicitly and, if you have sufficient privilege, altered.  In either case you will, first need to present the details by, with the cursor on the load, either clicking on "MODIFY ..." button or double-clicking on the load or pressing "m" or [ENTER].

On some sites there may be a button commandeering the "m" for another purpose, so there will not be presented a "MODIFY ..." button.  If this is the case, you will need to either double-click on the load or, with the cursor on the load, type [ENTER].

Once selected, a "Set of Fields" is presented containing the load's details. If you are sufficiently privileged you will be asked to confirm that you wish to modify the details by pressing [F1].

The software may be configured so as to allow "generic" users.  The concept of "generic" users is discussed in the section titled: "Modify List of Users".  If you are logged in as a generic user, then, after pressing [F1] (as described above) you will be required to enter your specific name (a "Symbolic Name" field) and password (a "Password" field) before proceeding.  For editing instructions for these types of fields, please refer to the sections titled: "Symbolic Name", and "Password", while for more information on the "Users" database, please refer to the section titled: "Modify List of Users".

After pressing [F1] and, if asked for a reason and/or your name and password, entering those details, the "Set of Fields" will be presented in a dialogue box for editing.  After making the desired modifications, type [ESCAPE].  Please refer to the section titled: "Set of Fields".

Changing the load's destination field will result in the load being redirected, if possible, to this new destination.

Additional Details for Americold

For Americold, the load details displayed in the tablet also include the load's sequence number (the five character barcode).

Modifying Several (KOLLECT TO EDIT)

This button is only available if you have sufficient privilege.  This privilege level is specified in the "Configuration Data" record, titled "Level: kollect records".  Please refer to the section titled: "Configuration Data".

If you need to change one or more fields of several loads, you can make the task a little quicker by first gathering the loads into a "collection".  When you, subsequently, go to modify a load's details, you will, instead, modify the details of all loads in the collection.

The first step is to gather the loads into a "collection".  You can do this by moving the cursor to a load, then activating the "KOLLECT TO EDIT" button (by clicking on it or typing "k").  The "KOLLECT TO EDIT" button will be highlighted whenever there is at least one load in the collection.  Repeat this procedure for each other load you wish to include.  If you type "k" a second time for a given load, the load will be removed from the collection.

When a load is included in the collection, its colour will be changed to indicate this.

You can also achieve this using the [SHIFT] and the separate cursor keys.  If you hold down the [SHIFT] and type one of the separate cursor keys, the cursor will be moved in the usual way, however, the load moved away from and that moved to will both (if there are, indeed two) be added to the collection, unless the load moved to is already in the collection, in which case both loads will be removed from the collection.  If there is no load in the position moved to, then no action will occur.

You can also use the mouse to collect loads.  To do this, click on the first load to be included, and keeping the mouse button down, drag the mouse over each other load to be included in the collection.  Any load visited, in this manner, a second time, will be released from the collection.

Once the collection has been formed, when you attempt to edit a load contained in the collection (as described in the section titled: "Control of Loads"), you will be presented, instead, with the details common to all loads in the collection - all other fields will be set to blank or zero (note that zero is not always presented as blank).  Once you confirm that you intend to modify these details, and are presented with the fields in a dialogue window.  Any changes you make are recorded, so that when you close the dialogue window, you will be prompted to confirm that the change to each modified field was intentional.  Note that you get to confirm each field but not each load affected, so you will need to be sure that you have gathered the correct loads into the collection.

You can release all loads from the collection by typing [SHIFT K], or by right clicking on "KOLLECT TO EDIT" or by right clicking on any load within the collection.

Zoomed Display

The display may be zoomed into by typing "Z".  The window now displays fewer positions, (as many as will fit, given the size set for the window) along with the status or positions of the sensors and other devices along the Heavy-Unit-Load Conveyor System.

The window will appear as shown overleaf:

Heavy-Unit-Load Conveyors Diagram -- Zoomed

The Heavy-Unit-Load Conveyor System will now be coloured to indicate whether it is stopped in automatic (red), disabled (grey), enabled for manual (yellow), running in the nominally east or south directions (green) or running in the nominally west or north directions (light blue).

The immediate background of the conveyor is still shown in mid-blue, unless the conveyor (or a device associated with it) is in alarm, in which case it will be shown in red.

While in "zoomed" mode, the use of the cursor keys (and mouse) is altered. These are now used to pan and tilt the view of the Heavy-Unit-Load Conveyor System. The position at which the mouse is clicked will be shifted to the centre of the view.

The push-button advertising the "Z" key will be changed from "ZOOM" to "ZOOM OUT O'VIEW", indicating that a subsequent typing of the "Z" key will return you to the overview display.  However, provided that the Heavy-Unit-Load Conveyors diagram had been called up via the menu system (the usual way) and that it is not in push-button mode, when at the cranes and other nominated positions, the button will display the text, "ZOOM TO CRANES" or "ZOOM TO DISPLAY" respectively, indicating that a subsequent pressing of the "Z" key will result in the appropriate window being presented.  To return to the overview, in spite of the button not advertising "ZOOM OUT O/VIEW", type either [SHIFT Z] or [ESCAPE] or right click on the "ZOOM ..." button.

To assign conveyor positions to windows for this function refer to the section titled: "Conveyors from which to Zoom".

To return to the overview display, type "Z", unless the corresponding push-button no longer displays "ZOOM OUT O'VIEW", or [SHIFT Z] or [ESCAPE].

Push Button Control of the Plant: Overview

Push button control of the plant is restricted to those terminals listed in the set of terminal locations and, there, flagged as allowing manual control. Please refer to the section titled: "Terminal Locations".

To control the Heavy-Unit-Load Conveyor System via the "push buttons", it is necessary to first enter push-button mode by typing "P".  To exit from push-button mode, type "P" a second time.

This button is also only provided if you have sufficient privilege to activate it.  This privilege level is specified in the "Configuration Data" record, titled "Level: conveyor manual".  Please refer to the section titled: "Configuration Data".

Irrespective of whether the conveyor is in push-button or automatic mode, all the interlocks will continue to apply to the operation of conveyors and devices.  As a result, you may find that a conveyor or device refuses to respond to a push button.

When push-button control is enabled, the window will appear as shown overleaf:

Heavy-Unit-Load Conveyors Diagram -- Overview Push-Button Mode

The conveyors can be controlled via push buttons by moving the cursor to a load position on the Heavy-Unit-Load Conveyor System, then typing "E" to enable the conveyor, which includes this position, for push button operation, or typing "M" to deselect it from automatic operation.

The conveyors for which "E" was typed will be shown in yellow, whilst those for which "M" was typed will be shown in grey, leaving the remainder shown in red for automatic.  This assumes the system is running, otherwise all conveyors will be shown in grey and of course none may operate.

Once the conveyors you wish to run are enabled (shown in yellow) you may run these in one or more of the four orthogonal directions and in either slow or fast speed, by pressing one or more (sequentially) of the function keys [F1] to [F8].  The function of each of these keys is indicated by the diamond that replaced the load details tablet when push-button mode was entered.

Push buttons can be latching (meaning that you need to operate them once to turn them on and a second time to turn them off) or momentary action (meaning that they will remain on only so long as you hold them on).  Momentary action push buttons sport a circle to indicate that they need to be held down.

Whether the [F1] to [F8] keys are latching or momentary action can be toggled by typing the [F9] key, provided that you have sufficient privilege to use this key.  The latching/momentary-action setting is indicated by the text and colour of the triangle in the upper left corner left by the diamond; "LATCHING" on a grey background implies latching, while "HOLD ON" on a light green background implies momentary action.  If "F9: hold on" or "F9: latching" is presented beneath this, you have sufficient privilege to toggle this setting.  The latching/momentary-action setting is also indicated by the presence of the circles on the buttons corresponding to the [F1] to [F8] keys.

The requested motions will be reflected in the diamond by colouring the appropriate push buttons light green, and on the Heavy-Unit-Load Conveyor System by colouring the appropriate conveyors either blue or green (light or dark to distinguish between fast and slow speed respectively).

Pressing [SPACE] stops all push-button control.

To control the devices associated with the conveyors, the associated conveyor must first be set to manual (shown in light grey or yellow).  The cursor should then be moved to the device (which might not be on the conveyor).  When the cursor is in the position of a device, the buttons to control the device will appear.  If these buttons are shown in dark green with black text, the associated conveyor has not been selected for push button control.  The associated conveyor is in a straight line left, right, above or below the depiction of the device on the window.  You can right click on the depiction of the device to find out the name of the conveyor position with which it is associated.

Whether the push buttons for the device are latching or momentary action is configurable on a device type basis.  Please refer to the section titled: "Enter or Modify Device Types" and, in partiicular, its subsection titled: "Defining the Device Type's Output".

Control of Standard Devices

The standard devices are turntables, rise-fall (or transfer) conveyors, and elevators.

The control of turntables is via two push-buttons, usually marked "90 DEGREES" and "0 DEGREES".  Operating one of these will rotate the turntable one way, whilst operating the other will rotate it back the other way.  When neither is activated, the turntable will stop rotating.  When you return the conveyor to automatic, the turntable will be instructed to rotate to the position required by the automatic control.

The control of rise-fall conveyors and elevators is via two push-buttons, usually marked "UP" and "DOWN".  Operating "UP" will raise the conveyor, whilst operating the "DOWN" will lower it.  When neither is activated, the conveyor will stop rising or lowering.  When you return the conveyor to automatic, the conveyor will be instructed to rise or lower to the position required by the automatic control.

Controlling Devices for Americold

In addition to the standard rise-fall conveyors, the devices, which can be controlled from this Heavy-Unit-Load Conveyors diagram, include:

  • Sirens
  • Various lamps
  • Detierers
  • Controlled doors
  • Alignment bars
  • Pallet stands
  • Scissor lifts
  • Barcode readers
  • Hold on MCR
Sirens

The sirens are associated with conveyors M38 and M86 (which will need to be set to manual before you can operate the corresponding siren manually).  Once the conveyor has been set to manual, move the cursor to where the representation of the siren would be displayed, and the "SIREN ON" and "QUIET SIREN" buttons will be provided, allowing you to manually control the siren.

Various Lamps

These need to be enabled for manual, by setting their corresponding conveyor to manual.  Once this has been done, move the cursor to where the representation of the lamp would be displayed, and the push-buttons, "TURN ON LAMP" and "DOUSE LAMP" are presented, and may be operated to turn the lamp on or off.

Detierers

There is a local, physical, push-button console available for controlling the detierers in manual, however, to save you that walk, most of the functions provided by that console are also provided on this conveyor diagram display.  The operation of the conveyors has already been covered, so what follows are the remaining controls, i.e. the raising and lowering of the pegs and the inserting and withdrawing of them.

The detierers need to be enabled for manual, by setting their corresponding conveyor to manual.  Once this has been done, the push-buttons, "INSERT PEGS", "WITHDRAW PEGS", "RAISE DETIERR" and "LOWER DETIERR" are presented, and may be operated to work the detierer manually.

This can also be done using the "Machine Status" display, which can be conveniently reached from here by zooming in from the conveyor.  Please refer to the section titled: "Machine Status Display".

Of particular interest, is that, when the detierer's pegs are at the top and the physical console's conveyors reverse push-button is operated, the detierer resets itself, allowing you to recommence the detiering operation with a clean slate.

Controlled Doors

These need to be enabled for manual, by setting their corresponding conveyor to manual.  Once this has been done, the push-buttons, "OPEN DOOR", and "CLOSE DOOR" are presented, and may be operated to work the door manually.

Alignment Bars

These need to be enabled for manual, by setting their corresponding conveyor to manual.  Once this has been done, the push-buttons, "LEFT ALIGN", "RIGHT ALIGN", and "OFF AL.  BAR" are presented, and may be operated to work the bars manually.

Pallet Stands

These need to be enabled for manual, by setting their corresponding conveyor to manual.  Once this has been done, the push-buttons, "RAISE STAND", and "LOWER STAND" are presented, and may be operated to work the pallet stand manually.

Scissor Lifts

These need to be enabled for manual, by setting their corresponding conveyor to manual.  Once this has been done, the push-buttons, "UP", and "DOWN" are presented, and may be operated to work the lifts manually.

Barcode Readers

These need to be enabled for manual, by setting their corresponding conveyor to manual.  Once this has been done, the push-buttons, "BARCODE READ", and "QUASH READ" are presented, and may be operated to instruct the barcode reader to start or stop scanning.

The barcodes are relayed to Movement Controller via serial communications ports P7 and P8 (Com 12 and Com 13) for the chiller (M53A) and freezer (M03A) respectively. You can monitor this data transmission using the "Monitor Communications" window.  Please refer to the section titled: "Monitor Communications".

Hold on MCR

This need to be enabled for manual, by setting its corresponding conveyor (M40) to manual.  Once this has been done, move the cursor to where the representation of the output would be displayed, and the push-buttons, "HOLD MCR ON" and "RELEASE MCR" are presented, and may be operated to turn the output on or off.

Push Button Control of the Plant: Zoomed

Push-button control of the Heavy-Unit-Load Conveyor System is also available in the "zoomed" display mode.  You can achieve the zoomed push-button mode by either typing "Z" when in push-button mode, or by typing "P" when in the "zoomed" display mode.

To exit from the zoomed push-button mode and return to the normal "zoomed" display mode, type "P", or click on "P-BUTTON CONTROL" again.  Alternatively, to exit from the zoomed push-button mode and return to the overview push-button mode, type [SHIFT Z], [ESCAPE] or click on "ESCAPE: exit", or right-click on the "ZOOM..." button.  In most cases, you can also type "Z" or click on "ZOOM OUT O'VIEW", however, in certain positions this button changes its text and function allowing you to open a window associated with the device presented at this position.

Irrespective of whether the conveyor is in push-button or automatic mode, all the interlocks will continue to apply to the operation of conveyors and devices.  As a result, you may find that a conveyor or device refuses to respond to a push button.

When zoomed push-button control is enabled, the window will appear as shown overleaf:

Heavy-Unit-Load Conveyors Diagram -- Zoomed Push-Button Mode

Once in zoomed push-button mode, the cursor will be represented by "telescope cross hairs", which remain in the centre of the view; the Heavy-Unit-Load Conveyor System is moved rather than the cursor.  Therefore the use of the cursor keys (and mouse) is altered.  These are now used to pan and tilt the view of the Heavy-Unit-Load Conveyor System.  The position at which the mouse is clicked is shifted to the centre of the view.

The conveyors can be controlled via push buttons by moving the cursor to a load position on the Heavy-Unit-Load Conveyor System, then typing "E" to enable the conveyor, which includes this position, for push button operation, or typing "M" to deselect it from automatic operation.

The conveyors for which "E" was typed will be shown in yellow, whilst those for which "M" was typed will be shown in grey, leaving the remainder shown in red for automatic.  This assumes the system is running, otherwise all conveyors will be shown in grey and of course none may operate.

Once the conveyors you wish to run are enabled (shown in yellow) you may run these in one or more of the four orthogonal directions and in either slow or fast speed, by pressing one or more (sequentially) of the function keys [F1] to [F8].  The function of each of these keys is indicated by the diamond displayed to the left of the push buttons at the top of the window.

Push buttons can be latching (meaning that you need to operate them once to turn them on and a second time to turn them off) or momentary action (meaning that they will remain on only so long as you hold them on).  Momentary action push buttons sport a circle to indicate that they need to be held down.

Whether the [F1] to [F8] keys are latching or momentary action can be toggled by typing the [F9] key, provided that you have sufficient privilege to use this key.  The latching/momentary-action setting is indicated by the text and colour of the triangle in the upper left corner left by the diamond; "LATCHING/hold on" on a grey background implies latching, while "latching/HOLD ON" on a light green background implies momentary action.  If "F9" is presented beneath this, you have sufficient privilege to toggle this setting.  The latching/momentary-action setting is also indicated by the presence of the circles on the buttons corresponding to the [F1] to [F8] keys.

The requested motions will be reflected in the diamond by colouring the appropriate push buttons light green.  The requested motions are not reflected by the conveyors in zoomed push button mode; instead the actual running status is shown by colouring the appropriate conveyors either blue or green (light or dark to distinguish between fast and slow speed respectively).

Typing [SPACE] stops all push-button control.

To control the devices associated with the conveyors, the associated conveyor must first be set to manual (shown in light grey or yellow).  The cursor should then be moved to the device (which might not be on the conveyor).  When the cursor is in the position of a device, the buttons to control the device will appear.  If these buttons are shown in dark green with black text, the associated conveyor has not been selected for push button control.  The associated conveyor is in a straight line left, right, above or below the depiction of the device on the window.

Deleting and Creating Loads

A load may be deleted or created by moving the cursor to the position and typing "D" or [DELETE] or "I" or [INSERT] respectively and confirming with [F1].

The software may be configured so as to allow "generic" users.  The concept of "generic" users is discussed in the section titled: "Modify List of Users".  If you are logged in as a generic user, then, after pressing [F1] (as described above) you will be required to enter your specific name (a "Symbolic Name" field) and password (a "Password" field) before proceeding.  For editing instructions for these types of fields, please refer to the sections titled: "Symbolic Name", and "Password", while for more information on the "Users" database, please refer to the section titled: "Modify List of Users".

When a load is deleted it is moved from the location into a special logical location referred to as "Deleted".  This special location is displayed in the load details tablet.

When the next load is deleted, it replaces the load that was previously in the "Deleted" location, that load is now "really deleted".  The load in the "Deleted" location can also be deleted by the standard means, thereby "really deleting" it.

When a load is inserted into the Heavy-Unit-Load Conveyor System or onto a crane or a trolley or into the stores diagram (refer to the section titled: "Stores Diagram"), if the "Deleted" location contains a load, that load will be moved to the position where the load is being inserted.  If the "Deleted" location does not contain a load, a load will be created at the position.

Using the "Deleted" location, a load may be moved from one position to another by first deleting the load from the first position (moving it to the "Deleted" location) and then inserting it at the second location (moving it from the "Deleted" location).

When moving a load, by deleting and inserting it, it is most important that you stop the Heavy-Unit-Load Conveyor System to prevent other loads, reacting to the deletion of the load in question, driving into it, or rise-fall conveyors operating, or another load transferring to the position into which you intend to reinsert the load in question.

If a number of loads need to be relocated, they should be moved one at a time; deleting the first and reinserting it then deleting the second and so forth.

Deleting Loads Unknown to the System

When deleting loads, the Movement Controller first finds the load at the designated conveyor position within its database.  If it fails to do this the load within the Heavy-Unit-Load Conveyor System is considered to be a "ghost" load, since it does not correspond to any information on loads within the database.  In these circumstances it is harder for the Movement Controller to delete the load, since it can not check that the load being deleted is the load on which the operator had clicked (since the Heavy-Unit-Load Conveyor System is moving loads about).

Under these circumstances, the Movement Controller will delete any load tag that it finds at this conveyor position within the conveyor PLC.

Prior to deleting a "ghost" load, you will be advised of this, and should only proceed if you are satisified that the load is not likely to move while the deletion attempt is being made.

Presentation of the Cranes

A crane will be shown at either the crane pickup/deposit position, or away from it.  It will show whether the crane is in alarm or not and whether it is enabled for automatic or retrievals by the colour of the crane body (blinking red/blue implies alarm, black implies that automatic is disabled, blue that retrievals are disabled, and orange implies no alarm) and whether it is in automatic, manual or out of service by the colour of the forks or the border of the load (red implies automatic, yellow implies manual, and grey implies out of service, but not in manual).  For details on turning on and off automatic or just retrievals, please refer to the sections titled: "Turning Off and On Automatic Commands", and "Turning Off and On Retrieval Commands".

The crane is deemed to be in alarm if it reports an alarm, or it is idle and its loaded status is not as expected by the Movement Controller.

The crane must not only be in automatic but must also be communicating for it to be presented as in automatic.

When zoomed in, it will also show the state of its load sensing, load off-centre, bin occupied and height check photocells and the extension of its forks and, if the forks are not centred, whether at high stop or not; if at high stop, a load will be shown at the forks extension, otherwise the forks will be shown.

If the forks are centred, the crane will instead show whether the computer's inventory has it holding a load.

Also, when zoomed in, the colour of the forks (or the border of the load) will be red if in automatic, yellow if in manual or grey if otherwise out of service.

Keep No-Reads at Scanner (HOLD NO READ)

Normally, if a load has failed barcode scanning, it will proceed through sizing and then be diverted down the reject lane.  After the load has been scanned, and before it proceeds to the sizing station, it is in a convenient position for its sequence number to be read.

So, you have the option to have loads that either failed scanning, or were found to have a barcode that has not been supplied to the Movement Controller from the host_computer, to wait at the barcode scanning location for manual entry of the details.

If the "HOLD NO READ" button is presented in the "Unavailable" colouring (dark green with black text), then this feature is disabled, however, contrary to standard button behaviour, this button can still be operated (by typing "H") to enable this feature.  After operating this button in this condition, you will be asked to confirm that you wish the feature enabled by pressing the [F1] key. Because this button is "unavailable", you will not be able to use the mouse to operate this button whilst in this state.

If the "HOLD NO READ" button is presented in the "Available" colouring (grey), then the feature is enabled, however there are no loads waiting at barcode readers.  If you operate the button in this situation you will be asked to confirm that you want the feature disabled by pressing the [F2] key.

If, on the other hand, the "HOLD NO READ" button is coloured light green, then you will find that there is a load waiting at a barcode reader, and, in fact, the text of the button will have changed to "HOLDING NO READ".  If you operate the button at this time, you will be advised of the situation - whether there is a load waiting at the chiller or the freezer or both, and whether the problem is that the barcode could not be read or that the barcode read has not been supplied to the Movement Controller.

If there are bad barcode reads at both the chiller and freezer, then you will be asked, first of all, to nominate which load you wish to deal with.  When presented with this dialogue window, you should select either "Chiller" or "Freezer".

If there was only the one load, or you have selected the load with which to deal, then you will be presented with two or, in the case of a no-read, three options.  These options are:

  • "Modify load":   
    You will be presented with a dialogue window, into which you must enter a barcode and a destination, and, in order to keep Americold happy, a load number.
  • "Reject load":   
    There is no further dialogue required; the load will proceed to the corresponding reject.
  • "Select barcode":
    This option is provided only if the barcode could not be read and barcodes have been supplied for the detierer in question.  These barcodes are listed in this dialogue window, so you can tell immediately whether it would be worthwhile selecting this option.  If you do select this option, you will be then asked to select the barcode, by activating the corresponding button.

Retrieve Empty Pallets (FETCH EMPTIES)

There are regular means to retrieve empty pallets from the pickface, as described in the section titled: "Retrieve from Stores by Location (new)". However, this feature is intended to make this operation more convenient.

This button is enabled by setting the "Configuration Data" record, titled "Fetch empty ok/auto", to "O" meaning that the operator is required to OK the preparation of a schedule for the retrieval of the empty pallets from the pickface.  Please refer to the section titled: "Configuration Data".

You also need to be logged on in order for this button to be presented.

If the racking photocells report that there is something in a location that is used for the return of empty pallets from the pickface for a particular crane, and there is no manual retrieval schedule, referencing such locations on that crane, then this button will be highlighted.

On the other hand, should there be no cranes satisfying this condition, then if there are cranes for which there are manual retrieval schedules that reference such locations, then this button will be lit (differently highlighted) to indicate that such retrievals are underway.

Otherwise the button will be shown as disabled.

Anytime the button is highlighted (showing that there are stacks of empty pallets that need attention), then the button can be operated (by typing "F" or clicking on it).  In response, you will be advised which cranes have such stacks and be given the options of:

  • No cranes
    Do nothing about it.
  • Chiller cranes
    Having a manual retrieval schedule created (if necessary) to retrieve from all such locations in the chiller.
  • Freezer cranes
    Having a manual retrieval schedule created (if necessary) to retrieve from all such locations in the freezer.
  • Select cranes
    Having manual retrieval schedules created (if necessary) to retrieve from all such locations in each of the cranes that are then nominated.  In response to selecting this option, you will be asked to nominate the cranes that the schedule(s) are to cover.  You will need to specify the cranes as described in the section titled: "Crane and Palletiser Alarms".
  • All cranes
    Having manual retrieval schedules created (if necessary) to retrieve from all such locations in both the chiller and the freezer.

Once schedules have been created, they can be monitored, modified, or deleted using the "Retrieve from Stores by Location (new)" window, as described in the section titled: "Retrieve from Stores by Location (new)".

Reject Control (1/2 REJECT FREEZER/CHILLER)

These buttons are enabled by setting the "Configuration Data" record, titled "No reject automatically", to "N" for "No reject".  Please refer to the section titled: "Configuration Data".

If this record has been so set, then when pallets arrive at the reject junction, they will wait, and the appropriate one of these buttons will be highlighted.

In response to activating one of these buttons, you will be presented with a dialogue window, detailing the reasons for rejecting the pallet, and allowing you to elect to infeed or reject the pallet.

Fast Putaway (GO ANY-WHERE)

When infeeding, and all loads are destined to a single crane, the system will be not utilised to its full capacity, since this one crane becomes a bottle-neck.

You can relieve this situation, in either the freezer or chiller conveyors by operating the "GO ANY-WHERE" button.  When the "go anywhere" function is in force, any pallets that are destined for regular store locations (not flow-through locations) will be redirected to a crane that is less snowed under.

After typing "G", or clicking on the button, you will be asked whether you wish to enable or disable this function for the freezer or chiller cranes.  You must first click of "Freezer" (or type "F") to select the freezer, or click of "Chiller" (or type "C") to select the chiller.  You will then be asked whether you wish this turned on or off.

If this function is in force for either the chiller or freezer, the button will be lit.  The second line of text on the button will change to indicate whether it is the chiller, freezer, or both that have this function enabled.

Trunk Line Purge (TRUNK PURGE)

When the arrangement of loads along the inside trunk line has become confused, you may, rather than attempt to correct the situation by deleting and inserting loads, send all these loads to the outfeed.

Prior to invoking this function, you should ensure that all loads along this trunk line and out to the outfeed are either completely on the conveyors in this path, or clear of them. Failure to check this will cause loads to twist and collide, damaging the product and the Heavy-Unit-Load Conveyor System.

Once you have done this, you need to type "T" to turn on the "TRUNK PURGE" push-button.  In response, the system will advise you of your responsibility to check the trunk line and request that you type "F" or "C" to confirm whether you wish to purge the freezer or the chiller, or to type [ESCAPE] otherwise.

All conveyors will need to run for a couple of minutes, however as conveyors need to stop as the loads are being taken from the outfeed, the time for the purge to run to completion will be considerably longer than this couple of minutes.

Once this period has expired, the Heavy-Unit-Load Conveyor System will return automatically to its normal operation.

Outfeeding Loads (OUTFEED LOAD)

A load may be redirected by the operator to any location within the store, or to the reject or outfeed.  As the outfeed is a common destination for the operator to direct the load to, a push-button has been provided for this.

First, position the cursor on the load to be redirected, then type "O" to turn on the "OUTFEED LOAD" push-button, then confirm your intention (as you will be prompted to do) by pressing [F1].

Multilevel Conveyor Systems (LEVEL CHANGE)

For multilevel Heavy-Unit-Load Conveyor Systems, the upper levels may be displayed by typing "L" (turning on the "LEVEL CHANGE" button).  This results in the lower levels being shown in orange.  To return to the lower level display, type [SHIFT L], or "L" sufficiently often to cycle around to it.

There are options that can be set to cause the Heavy-Unit-Load Conveyor System to be presented as though it were a single level (sensible where there is no interaction - such as elevators - between the various levels), or to allow the "LEVEL CHANGE" button to cycle around to a summarising position.

The text of the "LEVEL CHANGE" button will be "LEVEL 1 CHANGE" when the button is selecting level 1 (off), "LEVEL 2 CHANGE", when selecting level 2, "LEVEL 3 CHANGE" when selecting level 3, and so on, and, finally, "LEVEL * CHANGE" when selecting the summary.

This option can be set via the "Configuration Data" record, titled "Flat/Extra conv level".  Please refer to the section titled: "Configuration Data".

Displaying Conveyor Alarms (ALARM LIST)

From the overview display, you may enter the conveyor alarms window by typing "A".  The push button advertising this will be in flashing if there is an alarm.

If the cursor is positioned at a conveyor position that is shown to be in alarm at the time you type "A", the conveyor alarms window will be restricted to displaying only those alarms associated with this conveyor position.

When you exit the conveyor alarms window, you will be returned here.

Changing the Appearance (EDIT DIAGRAM)

The conveyors and the load details tablet on the overview may be moved by typing "E" to enter edit mode (turning on the "EDIT DIAGRAM" button, and renaming it "END EDIT DIAGRAM"), then moving the cursor to the conveyor to be moved (or the tablet), then using [CONTROL UP], [CONTROL DOWN], [CONTROL LEFT], and [CONTROL RIGHT] to relocate the selected item.  Type "E" to exit edit mode.

The overview (non-zoomed) can be expanded in the "X" and "Y" directions by typing "X" or "Y" respectively.  Similarly, the overview can be contracted by typing [SHIFT X] or [SHIFT Y] respectively.

Additionally, finer adjustments to the expansion in the "X" and "Y" directions can be achieved, simultaneously for both directions, by typing [CONTROL X] to expand, in both directions, slightly or [CONTROL Y] to contract slightly.

The overview and zoomed displays may be rotated in 90 degree increments by typing "R" for one direction and [SHIFT R] for the other.

The zoomed conveyors can be shown as either roller or chain conveyors.  To change this option for a given conveyor position, first enter the zoomed display, then enter edit mode by typing "E", then locate the cross hairs on the conveyor position to be changed, then type "R" for rollers or "C" for chains.

To change the colours, refer to the section titled: "Changing the Colours".

To change the fonts, refer to the section titled: "Select the Font".

Conveyor Mode (CONVEYOR MODE)

Typing "C" when at the overview display (turning on the "CONVEYOR MODE" button) will replace the load details tablet with a description of the conveyor's operating mode.  The push button advertising this will be shown in light green if the Heavy-Unit-Load Conveyor System is not in full-automatic mode.

To return to the Heavy-Unit-Load Conveyors diagram, press any key other than "Z" and keys such as [SHIFT], [CONTROL], [ALTERNATE] et cetera.

Provided that the Heavy-Unit-Load Conveyors diagram had been called up via the menu system (the usual way), the "Z" button will be highlighted and display the text, "ZOOM TO CONTROL", indicating that by pressing the "Z" key will result in the control mode of operation window being displayed.  Refer to the section titled: "Control Mode of Operation".

Archive Log Files (FLOPPY ARCHIVE)

This function may be disabled, and the "FLOPPY ARCHIVE" button removed from the display by setting the"Configuration Data" record, titled "No floppy archive". Please refer to the section titled: "Configuration Data".

Typing "F" when at the overview display (turning on the "FLOPPY ARCHIVE" button) will replace the load details tablet with a list of files requiring archiving.  If some of these files are about to lose un-archived data the push button advertising this will be shown in light green.

In response, the load details tablet will be replaced by another presenting the list of log files, each accompanied by an asterisk.  The asterisk will be highlighted if there is something to be archived, whilst the text will only be highlighted if the log file is more than 80% full.

You can archive a log file by moving the cursor to one of the highlighted asterisks and typing either [RETURN] or [ENTER]. You may also double-click the mouse on the desired asterisk to archive the log file.

This will present you with the appropriate archive window, such as "Archive List of Events to Floppy Disc".  Refer to the sections titled: "Archive List of Events to Floppy Disc" et cetera.

It is not mandatory that the log files be archived; this is a decision that can be made depending upon the anticipated benefit these archives may have.  You may decide only to archive certain log files or only to archive a log file during some troublesome period.

Pick Face Loads Not Seen

As a load is placed in a pick face location, by a crane, the Movement Controller waits to see that the load has rolled forward sufficiently to be seen by the pallet detection system photocells (PDS).  The photocells should be adjusted so that they can see the pallet as soon as it is placed in the pick back location, or else the pallet is expected to roll forward so that it can be seen by the photocell.

Once the crane has completed its deposit into the back location of a pick face, the load is allowed ten seconds to be detected by the PDS.  This ten seconds is adjustable via the database variable, "Secs for PDS to see"; please refer to the section titled: "Configuration Data".  When one or more loads have failed to have been detected by the PDS, then a dialogue box will be opened, presenting the operator with a list of locations where the load has failed to be detected by the PDS.

In addition to this message being presented, an entry will be made in the event log file for each such location.  Please refer to the section titled: "Event Log Historic Report".

Checking the Linked Lists

This check is performed automatically upon selection of the Heavy-Unit-Load Conveyors diagram from the menu.  Normally all you might notice would be a flicker before the window appears, unless problems are found, in which case it will present a message corresponding to the list in which it found problems, along with a request that you note what you have been doing and contact Greg Wood.

If you have sufficient privilege, you will be asked whether you wish the Movement Controller to attempt to correct the problem.  It is probably prudent to first stop the crane and the conveyors, then exit all software and save a copy of the database.  Once you have done this, run the software, call up this window and enter "Y" in reply to the question.

Then check that everything appears to be correct before restarting the system.

Checking the Communications Ports

This check is performed automatically upon selection of the Heavy-Unit-Load Conveyors diagram from the menu.  It checks that the communications ports needed to present the information on this diagram have been opened and that they are still accessible.

If all is as it should be, there will be no report, however, should it find something wrong, a dialogue box will be presented, indicating that this has happened.

For these ports not to be open or accessible, would be a rare occurrence with communications ports that have been installed directly into the computer.

On the other hand, if these ports are presented to the software via a terminal server, from some remote location, then there is a real possibility that, due primarily to network problems, one of the channels of the terminal server might be out of action.

When you encounter this problem, it will usually be necessary to cycle the power to the terminal server, and to stop the main Movement Controller application and restart it.  For information on stopping and restarting the main Movement Controller application, please refer to the section of the TECHNICAL MANUAL titled: "Installing and Running the Software".

This check is also performed from other windows, when opened or switched to a device on a different communications port, to check the communications ports needed for those windows as well.

Conveyor Alarms

After selecting "Conveyor Alarms" from the Operation Menu, the Heavy-Unit-Load Conveyor System alarms window will be presented.

Below is a rough text-representation of this window:

Computer system alarms Select Change Restrict Where Match Expand Insert Kollect First Last Conveyor Alarm Alarm # Old 94|Turntable T11 to T12 transfer watchdog |T11 |A| 2| 1^ 161|Conveyor A2 indexing forward transfer watchdog |A2-5|A| 2| 1█ 272|Turntable T1 conveyor motor isolated |T1 |A| 2| 1█ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Conveyor Alarms Conveyor alarm s Turntable T11 to T12 transfer watchdog

This window shows the currently active Heavy-Unit-Load Conveyor System alarms, arranged one alarm per line.  This window shows one alarm per line, presenting, at least, the following information:

  • the alarm number, which is used by the PLC and computer software,
  • the description assigned to it by the computer (a unique "Name" field),
  • the individual conveyor to which it has been assigned (a "Symbolic Name" field),
  • whether it is in alarm (a "Character" field),
  • the number of times this alarm has occurred in the current and previous reporting periods ("Numeric" fields, also refer to: "Conveyor Alarm Summary Report"),
  • the fault category (a "Symbolic Name" field - also refer to: "Fault Assistance" ), and
  • whether this alarm has been enabled or not (a "Character" field),
  • whether occurences of this alarm are to be recorded in the event log and summary reports (a "Character" field) (not all sites),
  • whether this alarm may be reset by an operator (a "Character" field) (not all sites).

For editing instructions for these types of fields, please refer to the sections titled: "Name", "Numeric", "Symbolic Name", and "Character".

The window is restricted to active alarms, however, if alarms deactivate they will remain displayed (in a different colour) until the window is repainted, in response to you typing "U" or clicking on "Update".  If alarms occur while observing the window, they will not be written to the window until you cause it to be repainted.

All features provided by the "Maintenance Viewing Data" windows except editing an alarm, are active.  These features are:

  • moving the window across the records.
  • highlighting a particular alarm for individual attention.
  • highlighting a particular field for individual attention.
  • expanding/contracting the records.
  • restricting the alarms eligible for inclusion.
  • changing the contents of a field.

Refer to the sections titled: "Viewing Data", and "Maintenance Viewing Data".

If you have sufficient privilege, these alarms may be cleared manually, by highlighting the appropriate line and typing [ENTER] or by double clicking on the appropriate line, in order to select the alarm, then typing the [DELETE] key, in order to clear the alarm.

When the alarm is selected, a generic explanation may be presented along with the alarm, explaining the sorts of things that are likely to have caused the alarm, and whether there is any use in resetting the alarm.  This should be read before pressing the [DELETE] key.

Below is a rough text-representation of this window:

Reset conveyor alarm Transfer watchdog alarms occur when a load fails to reach the next photocell in time. The possible causes include: 1. Motor failing to operate - either jammed or stalled or failure of a control relay or contactor. 2. Load jammed - not moving with the conveyor. 3. Photocell failing to see load - rare unless stretch wrap used. The cause should be established then the alarm may be reset allowing a further attempt to be made to advance the load. ╒══════════════════════════════════════════════════════════════════════════════╕ │Conveyor alarm s Load transferring from S3-5 was not detected in t│ │Alarm conveyor a S3-5 │ │Conveyor alarm state <A>a A │ │# conveyor alarms <0-999> │ │Old # conveyor alarms<0-999> │ │Fault category s Transfer watchdog │ │Conveyor alarm logging <N>a │ ╘══════════════════════════════════════════════════════════════════════════════╛ ╔══════════════════╗┌──────────────────┐┌──────────────────┐┌──────────────────┐ ║ OK ║│ HELP ││ ESCAPE: exit ││DELETE:reset alarm│ ╚══════════════════╝└──────────────────┘└──────────────────┘└──────────────────┘

Conveyor system alarms can be broadly grouped into either motion watchdog alarms or status alarms.

A motion watchdog alarm is latched when an action has not completed in the allowed time and prevents the Heavy-Unit-Load Conveyor System from continuing with that action until the alarm has been reset.  Examples of motion watchdog alarms are the transferring of a load from one location to another and the feedback of a motor contactor.

A status alarm is active while a PLC input remains in an unexpected state for normal operation.  The alarm will be removed once the PLC input agrees with the expectation of the PLC. Examples of status alarms are photocell conflicts and emergency stops.  If a photocell is blocked when it should not be or is clear when it should not be, the alarm is raised.  Such an alarm can be cleared by removing the obstruction, advancing the load under manual control to the photocell, or adjusting the inventory of the Heavy-Unit-Load Conveyor System.  There is no point in clearing alarms of this sort.

A common alarm is the failure of the system to transfer a load from one position to another.  To transfer a load the system attempts to run the conveyor, from which the load is to be moved, and the conveyor, to which the load is to be moved. Typically, the transfer is deemed to be completed when the photocell at the position, from which it is to be moved (the source), is cleared and the photocell at the position, to which it is to reach (the destination), is blocked.

In this instance, a transfer alarm will result if either the source photocell remains blocked or the destination remains clear after the transfer has been running sufficiently long to expect that the load has transferred.

So when this alarm results, the status of the photocells should be checked, to see the situation through the eyes of the Heavy-Unit-Load Conveyor System, and the physical situation should be checked.  Look for stretch wrap hanging from the load, cartons fallen from the load, loose boards on the pallet, photocells out of alignment or damaged et cetera.  Should you be unable to ascertain the cause of the alarm, remain and watch the transfer as you have someone reset the alarm.

Communications Failure Alarms

As well as the Heavy-Unit-Load Conveyor System alarms, this display presents whole-system-related alarms, such as the failure of the Movement Controller to successfully communicate to a remote device, such as a PLC.  There is no point in resetting alarms of this sort.

The text of these alarms is set by the communications logic, so, should you decide to edit this text, your edits may be lost when the alarm is raised.

If the device connected to this port is not responding at all, then the text of the alarm will be something like "Failed to communicate to communications port ...".  If it succeeded in communicating to a DataHighway modem, but that modem failed to communicate to the end device, then the text of the alarm will show the diagnostic data that is being returned by the modem.  Finally, if there is no problem with the communications, but there is a bad indication being presented in the PLC's status data file, then that condition will be described. In the last instance, the system may still be fully operational.

In the cases where those PLCs are Allen-Bradley PLC5 or SLC-500, then those alarms are also used to present bad status from the corresponding PLC.  When these alarms report bad status from the PLC, rather than an actual communications failure, the text of the alarm will be altered to reflect this.

Some of the status that is reported, in this fashion, are the PLC's minor faults.  When these are presented, the individual minor faults may be acknowledged by resetting the alarm.  Once the minor fault has been acknowledged, the alarm will be removed until it is needed to present an actual communications failure or another status failing needs to be reported.  Once the minor fault is removed, it will be automatically unacknowledged, so that the next time it occurs, an alarm will be raised.

The minor fault acknowledgements are stored on an individual PLC basis in the database fields, "Minor fault word 1" and "Minor fault word 2".  These may be edited directly, via the PLC setup database - see "PLC Setup".

Task Killed Alarms

All communications to a specific PLC is expected to originated by the task that is dedicated to that PLC.  Mostly each PLC has its own serial channel.  In some cases, however, several PLCs can be accessed through the one serial channel, which connects to a DataHighway modem, which, in turn, connects to each of the remote PLCs on the DataHighway.  In this situation, there is a task dedicated to the DataHighway serial channel, and all tasks wanting to communicate to any of those PLCs, do so by queueing their requests to the DataHighway task.  In this way, there should be a single task corresponding to each serial channel.

There is a check that the task that first uses a serial communications channel is the only one that ever uses that channel.  Should another task, subsequently, attempt to use that channel, it will be killed and this alarm will be raised and its text will indicate which task has been killed.

This check has, in the past, killed a crane task, which used a function from within the conveyor task to remove a load tag, for a load in a specific conveyor position, from the database.  This was normally harmless enough, but, in the event that the tag in question appeared in multiple conveyor positions, the function would read the tags directly from the conveyor PLC, thereby causing the crane task to access the conveyor PLC's serial channel.  This first occurred five years after the check was installed, in the wake of a crash of the virtual crane server hosting the Movement Controller.  It was not immediately apparent, then, what the cause of their problem was, so this alarm was added to the system, in place of the event log that had, previously, noted this problem. Also, that bug has been rectified.  More details on the indicent are provided in the SOFTWARE MANUAL titled: "Change Log" for Change 427.

Stores Diagram

After selecting "Stores Diagram" from the Operation Menu, the layout of the near (if double-deep racking) right-most rack will be displayed.

Below is a rough text-representation of this window:

Stores diagram Select Change Restrict Where Match Expand Insert Delete Fast movers Kollect G Number of loads: 370 Empty locations: 729 ^ ┌───┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬───┐█ │■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪■▪▪▪▪■▪▪▪■■■■▪▪■■▪▪■■■■■▪■■▪■■■■■■■■▪■■│█ │▪▪▪▪■▪■▪▪▪▪■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪▪▪■■▪▪▪▪▪■■▪▪▪■■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪│█ │■■■■■■■■■■■■■■■■■■■■■■■▪■■■■■■■■■■■■■■■■■■■■▪■■■■■■■■■■■■■■■■■■■■■▪■■■■■│█ │▪■■■▪▪■▪■■■▪■■■■■■■■■■■■▪■▪■■■■■■■■■■■■■■▪■■■■■■■■■■■■■■■▪■■■■■■■■■■■▪■■│█ │■■▪■■■▪■■■■■▪▪■■■■■■■■■■■■■▪■■■■■▪■■■■■■▪■■■■■■■▪■■■■■■■■■■■■■■■■■■■■■■■│█ │▪▪▪▪▪■■■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪■■▪▪▪▪▪▪▪▪▪▪▪▪▪■▪■▪│█ │▪▪■▪▪■■▪▪▪▪▪■▪■▪▪▪▪■▪▪▪▪▪■▪▪▪▪▪▪▪▪▪■■■▪■▪▪▪▪▪▪▪▪▪■▪▪■▪▪■■▪▪■▪▪■▪■▪▪■■▪▪■│█ │▪▪▪▪■■▪▪▪■■▪▪■▪■▪■■▪■■■▪■■▪■▪▪▪■▪▪▪▪▪▪▪■■▪▪▪▪■■▪■▪■■■▪▪▪▪■■■■▪■▪▪▪▪▪▪▪▪■│█ │▪▪▪▪▪▪▪▪■▪▪■▪▪▪▪▪▪▪▪▪■▪▪■▪▪■▪▪▪▪▪■▪▪■▪▪▪▪▪■▪▪▪▪▪▪▪▪■▪▪▪▪▪▪▪▪▪■▪▪■■▪▪■▪▪■│█ │▪▪▪▪▪▪▪▪▪■▪▪■▪▪▪▪■▪▪▪▪▪■▪▪▪▪▪▪▪▪■■▪▪▪▪▪■▪■■■▪■■▪■■▪▪▪▪▪▪▪■▪▪▪■▪▪▪▪■■■■▪■│█ │▓▓■▪▪▪▪ ▪▪▪■▪▪▪▪▪▪▪▪■▪▪▪▪■■▪■▪▪▪▪▪▪▪▪ ▪▪▪▪■▪▪■■▪■▪■■■■■■■▪■■▪■■■▪▪▪■▪■▪■│█ └───┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴───┘█ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> 1002010|O| | | | | |207680|593100720030023457| Rack slot inhibited <I/S/R>a Rack Rack Rack SSCC <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Rack slot occupied <O>a O

At the top of the window is a legend that indicates which of the keys are active and what function they perform.  The [RETURN] and [ENTER] keys are equivalent to the first key listed in the legend. As well as being able to type the key, you may click the mouse on that part of the legend.

Graphical Representation

Towards the top of the window, is the graphical representation of the store layout.

Presentation of the Locations

In this description, references to colours will be made using the name used to describe its purpose, as the actual colour used to present the condition in question may be altered as described in the section titled: "Changing the Colours".

The window shows loads using a drawing of a load, on a pallet, on supports to show occupied locations, or just the supports to show vacant locations. There are also other special characters used for specific conditions.

Full and Part Loads

The loads are shown in the "Full Load" colour.  If the database has knowledge of the product on the pallet, then it will be able to determine whether it is a full load or not, and will alter its presentation of the load accordingly, including showing the load in the "Part Load" colour (which may not differ from the "Full Load" colour, if we prefer to rely on the shape of the load to present this information).

Total Numbers of Loads & Vacancies

The total number of loads and the total number of empty locations, in the rack face displayed, is shown at the top of the window.

Presenting Vacant, Disabled, Etc

Non-existent locations are shown containing a space, disabled locations are shown containing a cross, and vacant locations are shown containing a drawing of the pallet supports in the "Vacant" colour (initially set to "Blue").

Pallet Detection System

If the location is supported by load detection photocells, the state of the photocell rather than the occupancy record is used to determine whether a load will be presented in that location or not. Generally, under these circumstances, I would use the "Part Load" colour to present these loads, leaving the load shape to distinguish between the full and part pallets.

Bad Configuration Data

There is the possibility for some sites that the data associated with a location be inconsistent.  If such is detected, the load image will be replaced, on a flashing basis, with a full block in the alarm colour.  When presented as a full block in the alarm colour, it will be included in the tally of neither loads nor vacancies.  Hence, when a rack face is presented, if there are any such locations included, the first thing to look for is to see whether the total number of loads or vacancies is alternating (as it will on that same flashing basis).

Movement Class and Product Group

There may be options, depending upon the software requirements for this site, to present the movement class or product group to which the product in the location belongs or, if the location is empty, that to which the location is dedicated, instead of the above described occupancy.  The movement class display is presented in response to typing "F" or clicking on "Fast movers", while the product group display is presented in response to typing "F" or clicking on "Fast movers" a second time, while typing or clicking a third time will return you to the occupancy display.  In response, the pallet representations will be replaced by the first character of the description of the corresponding movement class or product group of the pallet in the location, or, if there is none, of the location itself.  The colour of the character will reflect the occupancy status.

Presentation of the Crane

The position of the crane is indicated by a rectangle, occupying the whole area dedicated to the location that the crane is in front of, and the locations neighbouring it.  If the crane is loaded, there will be a smaller rectangle (occupying the single location that the crane is in front of), representing the load, painted on top of the rectangle representing the crane.

The colour used for the crane's rectangle, is:

  • Alarm/Conveyor
    flashing if in alarm,
  • Crane/Conveyor
    flashing if loading or unloading,
  • Shadow        
    if automatic is disabled,
  • Conveyor      
    if retrievals are disabled,
  • Automatic     
    if in service, or
  • Disabled      
    if out of service.

The colour used for the load's rectangle, is:

  • Destination 1 
    if in service, or
  • Disabled/Dest1
    flashing if out of service.

This presentation is painted behind the presentation of the location, so the information relating to the location can still be read when the crane is at that location.

Moving the Window About the Store

A pair of scroll bars are provided in case the rack layout is too large for the window.  The horizontal scroll bar may be controlled using the [CONTROL SEPARATE RIGHT], [CONTROL SEPARATE LEFT], [CONTROL SEPARATE HOME], and [CONTROL SEPARATE END] keys.  The vertical scroll bar may be controlled using the [CONTROL UP], [CONTROL DOWN], [CONTROL PAGE UP], and [CONTROL PAGE DOWN] keys.

Note that not all the keyboard keys, normally available to manipulate the scroll bars, can be used for this because the [SEPARATE LEFT], [SEPARATE RIGHT], [UP], [DOWN], [PAGE UP], [PAGE DOWN], [HOME], and [END] keys are used for controlling graphical representation of the stores, while the [NUMERIC LEFT], [NUMERIC RIGHT], [CONTROL NUMERIC RIGHT], [CONTROL NUMERIC LEFT], [CONTROL NUMERIC HOME], and [CONTROL NUMERIC END] keys are used for controlling the display of location details.

Moving the Cursor About the Store

The cursor is initially positioned in the bottom right hand corner of the layout.  The cursor control keys (those not part of the numeric key-pad) may be used to move from location to location within the store.  The cursor may also be moved by clicking the mouse on the desired location.

Use [PAGE UP] and [PAGE DOWN] to move through the depths, sides and aisles in the logically implied direction and use [END] to move to the left, far (if double-deep racking), side of the left most aisle and [HOME] to move back to the right, near (if double-deep racking), side of the right-most aisle.

To move directly to an arbitrary aisle, side, long travel and hoist level, type in the address in the standard form. This is described more fully in the section titled: "Store Reference". Once you have typed the leading digit, a dialogue window will be opened, with the digit in place. You may also activate this function by typing "G" then entering the address into the field provided.

If you have accessed this window from the "Retrieve from Stores by Location" window, the location addressed in this way will be selected for the retrieval schedule.  Refer to the section titled: "Retrieve from Stores by Location".

Examining and Modifying Location

The details of the location at the cursor are presented in the lower portion of the window.  These details include the occupancy status, the type of racking (storage, pickup/deposit or flow through), the enabled/disabled status and the existent/non-existent status, (all "Character" fields).

For editing instructions for these types of fields, please refer to the sections titled: "Character".

In addition, there are details specific to this site: the barcode of the pallet label (a "Name" field), the location the pallet was originally destined for (a "Destination" field), whether the location is reserved for use by the Movement Controller (a "Character" field), indexes into the load-detection data (a "Load Detection Indices" field), the number of times the load has been moved (regular locations) or the number of times the crane has found the location full (pickface locations) (a "Numeric" field).

For editing instructions for these types of fields, please refer to the sections titled: "Character", "Destination", "Numeric", and "Load Detection Indices".

Immediately below the location details, the restriction details are presented.

A horizontal scroll bar is provided in case the details extend beyond the width of the window.  This horizontal scroll bar may be controlled using the [CONTROL NUMERIC RIGHT], [CONTROL NUMERIC LEFT], [CONTROL NUMERIC HOME], and [CONTROL NUMERIC END] keys.

One of the details will be shown in reverse video.  This is referred to as the "highlighted field".

The prompt as well as the data associated with the highlighted field are displayed at the top of the window.  The [LEFT] and [RIGHT] keys from the numeric key pad may be used to highlight the previous or next detail respectively.

Displaying the Full Location Details

The details of a load may be displayed in full by positioning cursor at the load (using the cursor keys), then typing [ENTER].  You can also achieve this by double clicking on the location.

Once selected, the stores window is partially replaced with a "Set of Fields" containing the details.

If you are sufficiently privileged, this window will include a button labelled, "F1: modify".  If you have sufficient privilege, the corresponding function can also be activated without first displaying the location details in full.  To activate the function without presenting this window, move the cursor there and type [SHIFT F1].

For some sites, there might be additional buttons provided, with the first sporting a label starting with "F2:".  If there is such a button, the corresponding function can also be activated without first displaying the location details in full.  To activate the function without presenting this window, either right click on the location in question or move the cursor there and type [SHIFT F2].

Pallet Coming to Location

Having selected to display the location details, if there is a pallet on its way to this location or scheduled to be brought here, the barcode of the pallet and, if still only scheduled, its priority and, in any case, where it currently is, will be presented above the location details themselves.

Modifying the Location Details

Having selected to display the location details, if you are sufficiently privileged you will be asked to confirm that you wish to modify the details by pressing [F1].

The software may be configured so as to allow "generic" users.  The concept of "generic" users is discussed in the section titled: "Modify List of Users".  If you are logged in as a generic user, then, after pressing [F1] (as described above) you will be required to enter your specific name (a "Symbolic Name" field) and password (a "Password" field) before proceeding.  For editing instructions for these types of fields, please refer to the sections titled: "Symbolic Name", and "Password", while for more information on the "Users" database, please refer to the section titled: "Modify List of Users".

After making the desired modifications, type [ESCAPE].  The stores diagram will be returned.  Refer to the section titled: "Set of Fields".

The "Set of Fields" includes the location's occupancy status, its enabled/disabled status and its existent/non-existent status (all "Character" fields).  For editing instructions for this type of field, please refer to the sections titled: "Character".

Prioritising Replenishment

If there is no pallet on its way, but there is one scheduled, then an extra button will be presented, which will allow you to alter the priority of this movement.  This button will advertise the [F2] key, indicating that, rather than clicking on the button, you can, instead, press that key.

Modifying Several Locations At Once

This function is also only available if you have sufficient privilege.  This privilege level is specified in the "Configuration Data" record, titled "Level: kollect records".  Please refer to the section titled: "Configuration Data".

If you need to change one or more fields of several locations, you can make the task a little quicker by first gathering the locations into a "collection".  When you, subsequently, go to modify a location's details, you will, instead, modify the details of all locations in the collection.

The first step is to gather the locations into a "collection".  You can do this by moving the cursor to a location, then activating the "Kollect" menu item (by clicking on it or typing "k").  Repeat this procedure for each other location you wish to include.  If you type "k" a second time for a given location, the location will be removed from the collection.

You can also achieve this using the [SHIFT] and the separate cursor keys.  If you hold down the [SHIFT] and type one of the separate cursor keys, the cursor will be moved in the usual way, however, the location moved away from and that moved to will both (if there are, indeed two) be added to the collection, unless the location moved to is already in the collection, in which case both locations will be removed from the collection.  If there is no location in the position moved to, then no action will occur.

When a location is included in the collection, its colour will be changed to indicate this.

You can also use the mouse to collect locations.  To do this, click on the first location to be included, and keeping the mouse button down, drag the mouse over each other location to be included in the collection.  Any location visited, in this manner, a second time, will be released from the collection.

Once the collection has been formed, when you attempt to edit the location details of a location contained in the collection (as described in the section titled: "Examining and Modifying Location"), you will be presented, instead, with the details common to all locations in the collection - all other fields will be set to zero (though zero is not always blank).  Once you confirm that you intend to modify these details, and are presented with the fields in a dialogue window.  Any changes you make are recorded, so that when you close the dialogue window, you will be prompted to confirm that the change to each modified field was intentional.  Note that you get to confirm each field but not each location affected, so you will need to be sure that you have gathered the correct locations into the collection.

You can release all locations from the collection by typing [SHIFT K] or by right clicking on any location within the collection.

Deleting and Inserting Loads

If you are privileged, a load may be added to or removed from a location by positioning cursor there (using the cursor keys), then typing [INSERT] or [DELETE] respectively.  You will be requested to confirm that it is your intention to delete a load, by typing [F1].

As with the modification of a location (described above), you may find that you are required to enter a reason for adding or removing a load from the location, before the requested action is performed.

When a load is deleted it is moved from the location into a special logical location referred to as "Deleted".

This special location is displayed in the load details tablet on the Heavy-Unit-Load Conveyors diagram.  Please refer to the section titled: "Heavy-Unit-Load Conveyors".

When the next load is deleted, it replaces the load that was previously in the "Deleted" location, that load is now "really deleted". The load in the "Deleted" location can be explicitly deleted, via the Heavy-Unit-Load Conveyors diagram.

When a load is inserted into the racking or into the Heavy-Unit-Load Conveyors (refer to the section titled: "Heavy-Unit-Load Conveyors"), if the "Deleted" location contains a load, that load will be moved to the position where the load is being inserted.  If the "Deleted" location does not contain a load, a load will be created at the position.

Using the "Deleted" location, a load may be moved from one position to another by first deleting the load from the first position (moving it to the "Deleted" location) and then inserting it at the second location (moving it from the "Deleted" location).

If a number of loads need to be relocated, they should be moved one at a time; deleting the first and reinserting it then deleting the second and so forth.

Inhibited Locations

Should the crane, while attempting to deposit a load to the store, find its photocells reporting the location as occupied, the location will be automatically flagged as "Inhibited".

Should the crane, after attempting to pickup a load, find itself unloaded on high stop, the location will be flagged as "Inhibited".

Locations flagged as inhibited should be inspected regularly.

In cases where the inventory shows the location to be vacant, should the location be found to be clear of loads, the "Inhibited" status should be removed.  Should a load be found in the location, the inventory should be updated and the "Inhibited" status should be removed.  Should there be a problem with the location, such as cartons fallen from a neighbouring location, the location should be rectified before the "Inhibited" status is removed.

Should a large number of locations on one particular rack be found to be "Inhibited" you should check the adjustment of the appropriate rack occupied photocell on board the crane.

In cases where the inventory shows the location to be occupied, should the location be found to be clear of loads, the inventory should be corrected and then the "Inhibited" status removed. Should a load be found there, in good order, the "Inhibited" status should be removed.  Otherwise, you will need to rectify the problem, then possibly adjust the inventory and then remove the "Inhibited" status.

Changing the Appearance

The presentation of the stores can be expanded in the "X" and "Y" directions by typing "X" or "Y" respectively.  Similarly, the overview can be contracted by typing [SHIFT X] or [SHIFT Y] respectively.

Additionally, finer adjustments to the expansion in the "X" and "Y" directions can be achieved, simultaneously for both directions, by typing [CONTROL X] to expand, in both directions, slightly or [CONTROL Y] to contract slightly.

Select Loads for Retrieval

If this window had been called up from the location retrieval window, you have only to type in the address in the standard form (refer to the section titled: "Store Reference"), for the location to be added to the schedule.  Once you have typed the leading digit, a field, with a prompt will be presented at the top of the window with the digit in place.

The "S", [RETURN] and [ENTER] keys may be used to select and deselect loads at the cursor to be included in the retrieval. Had this window not been called up from the location retrieval window, the "S", [RETURN] and [ENTER] keys would have served to modify the location details. You may also double-click the mouse on the desired load to select or deselect it.

The loads will be shown in the "Highlight" colour if available to be selected, in the "Basic Colour" colour if the retrieval of this load is either under way or complete, in the "Selected Full Load" colour when part of this schedule and in the "Reverse" colour when part of another schedule.

For an understanding of the use of colours, refer to the section titled: "Changing the Colours".

Restricting the Display

The locations displayed within the layout, may be restricted to those whose details satisfy certain requirements.  These requirements may be that the locations be occupied.  Locations that do not satisfy all requirements will be displayed as a space.

All features provided by the "Maintenance Viewing Data" windows (except that the [LEFT] and [RIGHT] keys used to highlight a field must be those on the numeric key-pad) are active.  These features are:

  • moving the window across the records.
  • highlighting a particular field for individual attention.
  • expanding/contracting the records.
  • restricting the locations eligible for inclusion.
  • changing the contents of a field.
  • selecting a location to edit.

Refer to the sections titled: "Viewing Data", and "Maintenance Viewing Data".

Any number of restrictions may coexist.

Crane Commands and Alarms

After selecting "Crane Commands and Alarms" from the Operation Menu, the crane status and control window will be presented.

Below is a rough text-representation of this window:

Crane status and control Select crane Automatic on/off Retrieval on/off Put in service Commands HELP Crane 1 Status Alarms ░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░ LT out of position ░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░ HL out of position ░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░ Forks are centred ░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░ Next: Deposit 42:16-B-003-2 Current: Pickup 42:16-A-001-1 Position: 42:16-A-001-1 Command: Store Stage: Waiting to issue pickup

This window shows the commands, status and alarms relating to the crane 1, and provides a list of commands that the operator may send to the crane.  The blanked out section in the upper left quarter of the screen is a graphical representation of the crane, showing the position of its forks and the condition of its photocells.

To present this window for other cranes, select the "Select crane" item from the menu bar.  This opens a dialogue window, allowing you to enter the desired crane number.  Alternatively, you can use the [PAGE DOWN] and [PAGE UP] keys to move from one crane to the next, or back again.

Status List

The crane states appear beneath the heading, "Status", in the middle of the window.

If you right-click on a status line in this window, you will be presented with the help page relating to that status - one of the following subsections.

LT in/out of position

This status is always present and indicates whether the crane is positioned on a long travel screen.

HL in low/in high/out of position

This status is always present and indicates whether the crane is positioned on a hoist level screen.

Forks position

This status is always present and indicates the current position of the forks to a resolution of about 3% of full extension.

Manual

This is set when the crane is has been switched to manual or is in remote manual.  This should be off for automatic operation.

Out Of Service

This is set when an alarm occurs, the MCR drops out, the crane is switched to manual or it has been set out of service by Movement Controller.  If an alarm has occurred the fault must be rectified and the alarm reset.  If the MCR had dropped out, the cause must be rectified and the MCR must be energised.  If the crane has been switched to manual it should be returned to automatic.  Once the corrective action has been taken, the crane may be set in service.

Light Curtain

This bit indicates that a light curtain on the infeed or outfeed of the Heavy-Unit-Load Conveyor System has been entered, so there is no power provided to the crane. You would expect the crane to be not communicating under these circumstances.

Conveyor Alarm

This bit indicates that an alarm from the Heavy-Unit-Load Conveyor System that inhibits the operation of the crane is active.

Alarm change

This bit toggles on and then off to register each change in the alarm state.  It should only be on for a short duration unless communications has failed or the processor has faulted.

Loaded Status

A load has been detected on the crane forks.  If the crane is idle and this status is inconsistent with the inventory state of the crane, this state's text (or the text "Not loaded") will be highlighted.

MCR deenergised

The Master control relay is off.

LT no speed enable

The crane is in a long-travel speed restricted region.

HL no speed enable

The crane is in a hoisting speed restricted region.

Key switch manual

This is set when the crane has been switched to manual. This should be off for automatic operation.

Correction limit

The crane is permitted to travel with the load not centred, provided that a second, wider, forks-not-centred switch is still made.  This is an electrical interlock.  If this interlock is wired into the PLC, this status will reflect that it is no longer made.  Otherwise, the PLC will attempt to simulate the likely state of this switch by counting pulses from the centre, setting this status accordingly.

It is expected that this status should be shown during fork cycles, but not during travel.

Catching dev bypass

When the catching device is tripped, no motion is permitted by the crane PLC, unless this switch is set.  If this switch is set, automatic operation is not permitted, however, you are allowed to raise the hoist in manual, from the controls on board the crane.

Off-centre to left

This is set when the load has broken the left side off-centre photocell.  An alarm is not generated immediately, as the crane will try to rectify the problem by shifting the load to fit between the photocells.  Once it has failed to do this, it will then generate an alarm.  This alarm is latched and will remain even if the status is cleared.

Off-centre to right

This is set when the load has broken the right side off-centre photocell.  An alarm is not generated immediately, as the crane will try to rectify the problem by shifting the load to fit between the photocells.  Once it has failed to do this, it will then generate an alarm.  This alarm is latched and will remain even if the status is cleared.

Bin occupied left

This state may be used in conjunction with the Bin Occupied or Empty alarms to provide more detail.

Bin occupied right

This state may be used in conjunction with the Bin Occupied or Empty alarms to provide more detail.

Bin occ'd far left

This state may be used in conjunction with the Bin Occupied or Empty alarms to provide more detail.

Bin occ'd far right

This state may be used in conjunction with the Bin Occupied or Empty alarms to provide more detail.

Hoist down stop

This indicates that the hoist has tripped the down stop magnetic switch.  It should be accompanied by an alarm to this effect.

Hoist up stop

This indicates that the hoist has tripped the up stop magnetic switch.  It should be accompanied by an alarm to this effect.

LT reverse stop

This indicates that the long travel has tripped the reverse stop magnetic switch.  It should be accompanied by an alarm to this effect.

LT forward stop

This indicates that the long travel has tripped the forward stop magnetic switch.  It should be accompanied by an alarm to this effect.

LT drive failure

This state summarises the circuit breaker, thermal overload and drive fault indications for the long-travel motor.  It should be accompanied by an alarm that will be latched and provide indication of the actual fault.

HL drive failure

This state summarises the circuit breaker, thermal overload and drive fault indications for the hoist motor.  It should be accompanied by an alarm that will be latched and provide indication of the actual fault.

Forks drive failure

This state summarises the circuit breaker, thermal overload and drive fault indications for the forks motor.  It should be accompanied by an alarm that will be latched and provide indication of the actual fault.

Hoist safety fault

This state summarises the hoist safety inputs, such as slack rope and catching device.  It should be accompanied by an alarm that will be latched and provide indication of the actual fault.

MCC 24V Power Fail

Loss of DC Power.

24V supply failure

Loss of DC Power.

No conveyor system

This status is a reflection of the state sent to the crane from the computer indicating that either the gate into the crane area is open (as reported by the Heavy-Unit-Load Conveyor System) or the Heavy-Unit-Load Conveyor System is not capable of reporting.  This should be accompanied by a gate open alarm, a Heavy-Unit-Load Conveyor System alarm.

Communications fail

This state is set by the computer and indicates that either it can not communicate with the crane, or that the toggling with the crane has not completed or that there is something in the PLC's status data file that is indicating a problem.  This will be highlighted.

This is to be expected when the key to the communications switch has been removed.

If the communications switch is turned on, first of all, check the "Computer system alarms" window (as described in the section titled: "Conveyor Alarms").  Towards the bottom of the list of alarms, the communications alarms will be found.  If this "Communications fail" is a result of a condition that is reported as a computer system alarm, then the text of that alarm will give a further indication of what the problem is.  If the crane is not responding at all, the text of the alarm will be something like "Failed to communicate to communications port ...".  If it succeeded in communicating to a DataHighway modem, but that modem failed to communicate to the crane (note that we never use such an arrangement to communicate with cranes), then the text of the alarm will indicate what status is being returned by the modem.  Finally, if there is no problem with the communications, but there is a bad indication being presented in the PLC's status file, then that condition will be described.  Some of these causes for the "Communication fail" alarm will leave the system still operational.  If there is no communications alarm among the computer system alarms, then the problem must be that the toggle has stopped.  Normally, such a condition would be expected to be accompanied by a bad indication within the PLC's status file.

Had there been an accompanying computer system alarm with the text of the alarm starting with something like "Failed to communicate to communications port ...", then check that power is available to the crane, that the Infrared Serial Devices (ISD) are not obstructed, that they are correctly aligned and that the crane PLC is in run.  If all this is so, have an electrician check the wiring and power supplies to these devices.

Cabinet too cold

This alarm is relevent to cranes operating in freezer conditions, where it is necessary to regulate the temperature of the electrical cabinet.  This status, if it persists, may indicate that the regulation of the cabinet temperature has failed, or that someone has left the door open.

Cabinet too warm

This alarm is relevent to cranes operating in freezer conditions, where it is necessary to regulate the temperature of the electrical cabinet.  This status, if it persists, may indicate that the regulation of the cabinet temperature has failed.

Full current bypass

This indicates that the full current bypass switch is turned on.  This should only be turned on to allow the hoist to be lowered after the full current switch itself has been tripped.  It must be off to allow automatic operation.

Cabin position

If the cabin is one that moves, its position (up, down, or in between) will always be present.  The cabin must be up to allow the hoist to lower to the lowest level and down to allow the hoist to raise to the highest level.

Over-height 1

This indicates that the first (lowest) height check photocell is currently blocked.  If the crane is given an automatic command to put the load away where it will not fit, the "High load automatic" alarm will be raised.  If the crane is in manual and the driver attempts to place the load where it will not fit, then "High load manual" alarm will be raised.

Over-height 2

This indicates that the second height check photocell is currently blocked.  If the crane is given an automatic command to put the load away where it will not fit, the "High load automatic" alarm will be raised.  If the crane is in manual and the driver attempts to place the load where it will not fit, then "High load manual" alarm will be raised.

Over-height 3

This indicates that the third height check photocell is currently blocked.  If the crane is given an automatic command to put the load away where it will not fit, the "High load automatic" alarm will be raised.  If the crane is in manual and the driver attempts to place the load where it will not fit, then "High load manual" alarm will be raised.

Over-height 4

This indicates that the fourth height check photocell is currently blocked.  If the crane is given an automatic command to put the load away where it will not fit, the "High load automatic" alarm will be raised.  If the crane is in manual and the driver attempts to place the load where it will not fit, then "High load manual" alarm will be raised.

Over-height 5

This indicates that the fifth height check photocell is currently blocked.  If the crane is given an automatic command to put the load away where it will not fit, the "High load automatic" alarm will be raised.  If the crane is in manual and the driver attempts to place the load where it will not fit, then "High load manual" alarm will be raised.

Over-height 6

This indicates that the sixth height check photocell is currently blocked.  If the crane is given an automatic command to put the load away where it will not fit, the "High load automatic" alarm will be raised.  If the crane is in manual and the driver attempts to place the load where it will not fit, then "High load manual" alarm will be raised.

Over-height 7

This indicates that the seventh height check photocell is currently blocked.  If the crane is given an automatic command to put the load away where it will not fit, the "High load automatic" alarm will be raised.  If the crane is in manual and the driver attempts to place the load where it will not fit, then "High load manual" alarm will be raised.

Over-height 8

This indicates that the eighth height check photocell is currently blocked.  If the crane is given an automatic command to put the load away where it will not fit, the "High load automatic" alarm will be raised.  If the crane is in manual and the driver attempts to place the load where it will not fit, then "High load manual" alarm will be raised.

Long Travel Motion

This indicates whether there is any long travel motion, and in which direction and at what speed that motion is supposed to be taking place.  Should a long travel screen be over shot, the word "oops!" will be displayed.  Should the long travel find itself off a screen and stopped, the crane will enter the "lost!" state for the long travel and display that text.

Hoist Motion

This indicates whether there is any hoist motion, and in which direction and at what speed that motion is supposed to be taking place.  Should a hoist screen be over shot, the word "oops!" will be displayed.  Should the hoist find itself off a screen and stopped, the crane will enter the "lost!" state for the hoist and display that text.

Forks Motion

This indicates whether there is any fork motion, and in which direction and at what speed that motion is supposed to be taking place.  Should the crane be set back in service while the forks are extended, its first operation will be to centre its forks; while doing this it will display "lost!" against the forks.  If, during travel, the crane finds the load is off-centre, it will try to correct, and displays "fix OC" while attempting this.

Graphical Status

To the left of the list of status conditions is shown a diagram of the crane, showing the state of its load sensing, load off-centre, bin occupied and height check photocells and the extension of its forks and, if the forks are not centred, whether at high stop or not; if at high stop, a load will be shown at the forks extension, otherwise the forks will be shown.

If the forks are not centred, the crane will instead show whether the computer's inventory has it holding a load.

The colour of the forks, or the colour of the border around the load will be red if the crane is in automatic, yellow if in manual or grey if otherwise out of service.

The body of the crane will be shown in orange if healthy, or red if in alarm.

Alarms

The crane alarms appear beneath the heading, "Alarms" towards the right of the window.

Please bear in mind that all these alarms are based on the PLC's view of the system and may therefore be the result of a failure in the sensing mechanisms and/or circuitry or in the control mechanisms and/or circuitry.  This is not reiterated in the following discussions of the individual alarms.

The sensing mechanisms include limit switches, relay contacts, proximity switches, and photocells, while the sensing circuitry includes wiring, terminations, PLC inputs, the field input power supply, and circuit breakers.

The control mechanisms include motors and associated gearboxes, sprockets, chains, drums, and cables, while the control circuitry includes circuit breakers, the field output power supply, PLC outputs, relays, motor contactors, variable speed drives, motor circuit breakers, thermal overloads, and motor isolators.  In particular, check that the motor isolators are turned on.

Typically, after an alarm has been encountered, investigated and the cause removed, the alarms reset, the MCR will need to be energised, and the crane set back into service.

Bear in mind, that when rectifying problems on the crane, using manual controls, the crane PLC is watching, trying to determine what has happened to the load.  Therefore, if you centre the forks with the load left in the racking then pickup the load, the load will be assumed to be left in the racking (as indicated by your first action) and, when back in service, the next load to be picked up is likely to generate a "Pickup but loaded" alarm, which, if you abort that pickup, will lead the system to believe this second load to have been picked up by the crane, rather than the first causing considerable confusion.

The assumptions made by the system when a cycle has been completed while the crane is in alarm, are entered into the event log and should be checked to determine whether they are correct.

If you right-click on an alarm in this window, you will be presented with the help page relating to that alarm - one of the following subsections.

For some sites, there is referenced, for each of these alarms, another alarm from this list, which, if active, is considered as the prime cause of the fault, while the referencing alarm is considered to be parasitic.  Such alarms, though active, will be suppressed from being presented in this list.  For more information on defining the parasitic nature of certain alarms, please refer to the section titled: "Enter or Modify the Crane Alarms".

MCR is off

The main control relay had dropped out.  The MCR is released by the PLC program when the crane enters alarm state, under which conditions it will be accompanied by that alarm.

24VDC is off

The 24VDC field power supply had been lost.

This will result normally when someone accesses the crane via security gates that are wired to drop the power to the crane.  You should only be concerned about this alarm should it occur at other tmes.

In particular, bear in mind that if this alarm does occur, it may be accompanied by parasitic false alarms.  Although we do not suppress the reporting of parasitic alarms, there is a data file within the crane PLC that has a bit associated with each alarm that the crane can raise.  If this bit is set for a given alarm, then, should the field power supply recover, that alarm will be automatically cleared.  We have tried to list, in this data file, each of the alarms that would be dependent upon the field power supply.  Hence, a momentary failure of the field power supply would latch this field power supply alarm but it would cause the parasitic alarms to be cleared when that moment passes.

Should this alarm occur at times when the security gate has been opened or when you know that power has been disrupted to the crane, you should refer this fault to an electrician.

HL circuit breaker

The hoist motor circuit breaker had tripped.

Please refer this fault to an electrician.

LT circuit breaker

The long travel motor circuit breaker had tripped.

Please refer this fault to an electrician.

Forks circuit b'ker

The fork motor circuit breaker had tripped.

Please refer this fault to an electrician.

HL drive fault

The hoist motor's drive had reported a fault.

Please refer this fault to an electrician.

LT drive fault

The long travel motor's drive had reported a fault.

Please refer this fault to an electrician.

Forks drive fault

The fork motor's drive had reported a fault.

Please refer this fault to an electrician.

HL thermal overload

The hoist motor's drive or brake had experienced a thermal overload.

Please refer this fault to an electrician.

LT thermal overload

The long travel motor's drive or brake had experienced a thermal overload.

Please refer this fault to an electrician.

Forks thermal O/L

The fork motor's drive or brake had experienced a thermal overload.

Please refer this fault to an electrician.

HL thermistor trip

The hoist motor's drive or brake had experienced a thermistor trip.

Please refer this fault to an electrician.

LT thermistor trip

The long travel motor's drive or brake had experienced a thermistor trip.

Please refer this fault to an electrician.

Forks thermistor tr

The fork motor's drive or brake had experienced a thermistor trip.

Please refer this fault to an electrician.

Cabin too cold

The PLC cabinet had become too cold.

Cabin too warm

The PLC cabinet had become too warm.

Load Off Centre

Either the crane was unable to centre its load without extending its forks unacceptably far ("Load Off Centre"), or it has spent too much time attempting to centre its load ("Load correct'n fail"), or both off-centre photocells were blocked at once ("Load seems too wide"), or one of the off-centre photocells was blocked while the crane was unloaded ("Off-centre fouled").

There are a multitude of causes for these alarms, such as badly stacked loads, badly stacked empty loads, rubbish hanging from the loads, rubbish or loads protruding from the racking, the crane attempting to pickup from double deep while the single deep is occupied, the crane attempting to pickup an incorrectly positioned load, et cetera.

This fault will require that you inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

Load correct'n fail

Either the crane was unable to centre its load without extending its forks unacceptably far ("Load Off Centre"), or it has spent too much time attempting to centre its load ("Load correct'n fail"), or both off-centre photocells were blocked at once ("Load seems too wide"), or one of the off-centre photocells was blocked while the crane was unloaded ("Off-centre fouled").

There are a multitude of causes for these alarms, such as badly stacked loads, badly stacked empty loads, rubbish hanging from the loads, rubbish or loads protruding from the racking, the crane attempting to pickup from double deep while the single deep is occupied, the crane attempting to pickup an incorrectly positioned load, et cetera.

This fault will require that you inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

Off-centre fouled

Either the crane was unable to centre its load without extending its forks unacceptably far ("Load Off Centre"), or it has spent too much time attempting to centre its load ("Load correct'n fail"), or both off-centre photocells were blocked at once ("Load seems too wide"), or one of the off-centre photocells was blocked while the crane was unloaded ("Off-centre fouled").

There are a multitude of causes for these alarms, such as badly stacked loads, badly stacked empty loads, rubbish hanging from the loads, rubbish or loads protruding from the racking, the crane attempting to pickup from double deep while the single deep is occupied, the crane attempting to pickup an incorrectly positioned load, et cetera.

This fault will require that you inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

Load seems too wide

Either the crane was unable to centre its load without extending its forks unacceptably far ("Load Off Centre"), or it has spent too much time attempting to centre its load ("Load correct'n fail"), or both off-centre photocells were blocked at once ("Load seems too wide"), or one of the off-centre photocells was blocked while the crane was unloaded ("Off-centre fouled").

There are a multitude of causes for these alarms, such as badly stacked loads, badly stacked empty loads, rubbish hanging from the loads, rubbish or loads protruding from the racking, the crane attempting to pickup from double deep while the single deep is occupied, the crane attempting to pickup an incorrectly positioned load, et cetera.

This fault will require that you inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

Catch block set

The "Catch Block" hoist safety device had tripped.

Please refer this fault to a crane maintenance person.

Slack rope

The "Slack Rope" hoist safety device had tripped.

Please refer this fault to a crane maintenance person.

Rope overload

The "Rope Overload" hoist safety device had tripped.

Please refer this fault to a crane maintenance person.

Hoist over-speed

The "Hoist Over-Speed" hoist safety device had tripped.

Please refer this fault to a crane maintenance person.

Speed govenor trip

The "Speed Governor" hoist safety device had tripped.

Please refer this fault to a crane maintenance person.

Hoist whole current

The "Whole Current" hoist safety device had tripped.

Please refer this fault to a crane maintenance person.

Hoist too slow

The crane has taken too long to reach the destination Hoist screen, possibly because the destination screen is missing.

This fault will require that you inspect the situation and position the hoist and long travel on a screen appropriately by using the manual controls at the electrical cabinet or from the cabin.

HL hunting too slow

The crane has taken too long to position on the destination Hoist screen.

This fault will require that you inspect the situation and position the hoist and long travel on a screen appropriately by using the manual controls at the electrical cabinet or from the cabin.

LT too slow

The crane has taken too long to reach the destination Long Travel screen, possibly because the destination screen is missing.

This fault will require that you inspect the situation and position the hoist and long travel on a screen appropriately by using the manual controls at the electrical cabinet or from the cabin.

LT hunting too slow

The crane has taken too long to position on the destination Long Travel screen.

This fault will require that you inspect the situation and position the hoist and long travel on a screen appropriately by using the manual controls at the electrical cabinet or from the cabin.

Forks 2 slow left

The forks took too long to reach the limit switch for either single or double deep or the centre switch.

This could be a result of the forks trying to extend into another load, the load on the forks fouling the racking, cartons coming loose from the load an obstructing the progress of the forks, the clutch being set too light or mechanical problems with the forks.

This fault will require that you inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

Forks 2 slow right

The forks took too long to reach the limit switch for either single or double deep or the centre switch.

This could be a result of the forks trying to extend into another load, the load on the forks fouling the racking, cartons coming loose from the load an obstructing the progress of the forks, the clutch being set too light or mechanical problems with the forks.

This fault will require that you inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

Hoist too high

The magnetic switch to detect the limit of travel has tripped.

This fault will require that you inspect the situation and position the hoist on a screen appropriately by using the manual controls at the electrical cabinet or from the cabin.

Hoist too low

The magnetic switch to detect the limit of travel has tripped.

This fault will require that you inspect the situation and position the hoist on a screen appropriately by using the manual controls at the electrical cabinet or from the cabin.

LT overrun

The magnetic switch to detect the limit of travel has tripped.  A common cause of "LT overrun", in cold stores, is a build up of ice on the rail.

This fault will require that you inspect the situation and position the long travel on a screen appropriately by using the manual controls at the electrical cabinet or from the cabin.

Cabin door open

Either the cabin door or one of its windows had been opened. You will need to close the offending door or window.

Gate is open

The computer had informed it that its access gate had been opened or that it could not rely on the Heavy-Unit-Load Conveyor System to report the gate's condition.

Trolley problems

Either the communications with the trolley PLC has failed (this would produce this alarm on all cranes at once) or the trolley PLC reports that the trolley is not at the crane position, while the crane is attempting to pickup or deposit a load at the trolley.

Communications bad

The crane had detected a prolonged loss of communications. This alarm is raised only if the crane is idle or at the end of a cycle.

This alarm can only be raised once the communications has been restored.  You need only to energise the main contactor, reset the alarm, and set it back in service.  This is most common after the key has been restored to the communications switch.

Pickup got nothing

The 'Loaded' photocell was not blocked at the completion of a pickup cycle.  This is usually an indication that the location in question is vacant, however, this can also result from leaving the crane unloaded and on high stop after correcting an earlier problem.  You should leave the crane on low stop if unloaded and high stop if loaded.

If the "Crane to find vacancy" is set, the computer will handle this alarm on its own, inhibiting the location, provided it did not occur at the crane infeed.

Deposit still loaded

The 'Loaded' photocell was blocked at the completion of a deposit cycle.

This is expected to be rare and must be inspected.

Pickup but loaded

The 'Loaded' photocell was blocked at the commencement of a pickup cycle.

The command must be aborted, however, this is likely to result in the Movement Controller becoming confused about the actual locations of the loads in question.  After aborting the command and before resetting the alarm and setting the crane back in service, you should check the inventory in the areas likely to be affected.

Deposit but no load

The 'Loaded' photocell was not blocked at the commencement of a deposit cycle.

The command must be aborted, however, this is likely to be the result of the Movement Controller becoming confused about the actual locations of the loads in question.  After aborting the command and before resetting the alarm and setting the crane back in service, you should check the inventory in the areas likely to be affected.

Forbidden slot

An attempt was made to extend the forks into a location where there is no racking.  Note that the forks are allowed into non-existent single depth locations if there are existent locations behind them.

Bad command

An automatic command requested the crane to access a location where there is no racking.  Note that the forks are allowed into non-existent single depth locations if there are existent locations behind them.

This should be rare unless the command was issued by the operator.  You may need to use the "Modify Current Command" to provide an alternate destination for the load.

LT location bad

An automatic command requested the crane to move to a long travel position that is out of range of the crane.

This should not occur.

HL location bad

An automatic command requested the crane to move to a hoist level position that is out of range of the crane.

This should not occur.

Empty or blocked

An automatic command requested the crane to pickup a load from a location in which it could not see a load, or from a double deep location while it could see a load in front. If the "Crane to find vacancy" is set, or there are pickface linkages set for that location, the computer will handle these alarms on its own, provided it did not occur at the crane infeed.

If the computer does not handle it automatically, you should abort the current command.

Location empty

An automatic command requested the crane to pickup a load from a location in which it could not see a load, or from a double deep location while it could see a load in front. If the "Crane to find vacancy" is set, or there are pickface linkages set for that location, the computer will handle these alarms on its own, provided it did not occur at the crane infeed.

If the computer does not handle it automatically, you should abort the current command.

Location full

An automatic command requested the crane to deposit a load into a location in which it could already see a load. If the "Crane to find vacancy" is set, the computer will handle these alarms on its own, provided it did not occur at the crane outfeed.

If the computer does not handle it automatically, you should use the "Modify Current Command" to issue a deposit to an alternate location.

HL bad screen

After positioning on a screen, the reader found the screen not to have the correct number of tabs.

The screen the crane is positioned at may need to be replaced, or rubbish may need to be removed from the reader, or the reader may need repair.

LT bad screen

After positioning on a screen, the reader found the screen not to have the correct number of tabs.

The screen the crane is positioned at may need to be replaced, or rubbish may need to be removed from the reader, or the reader may need repair.

HL stalled

This alarm reflects the situation where the crane has asked for hoist motion and has seen no evidence of this.  There are a number of possible causes, including the motors being isolated, and failure of hoist position reader.

In this case, you will need to inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

LT stalled

This alarm reflects the situation where the crane has asked for long travel motion and has seen no evidence of this.  There are a number of possible causes, including the motors being isolated, and failure of long travel position reader. In cranes where the forks off-centre switch is not wired into the PLC, the most common cause of "LT stalled", is the forks being slightly off centre resulting in the relay logic, unbeknown to the crane, preventing long travel motion.

In this case, you will need to inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

LT stalled/centred?

This alarm reflects the situation where the crane has asked for long travel motion and has seen no evidence of this.  There are a number of possible causes, including the motors being isolated, failure of long travel position reader. In cranes where the forks off-centre switch is not wired into the PLC, the most common cause of "LT stalled", is the forks being slightly off centre resulting in the relay logic, unbeknown to the crane, preventing long travel motion.

In this case, you will need to inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

Lost fork limit sw.

This indicates that the forks have travelled past the target limit switch.  This is likely to result from the forks failing to slow down beforehand.  This in turn can be caused by the fork centre proximity being falsely triggered away from centre or by the fork counter photocell either not operating or else not operating correctly.

To correct the situation, position the forks on the appropriate limit switch, using the manual controls at the electrical cabinet or from the cabin.  It may assist to recentre the forks first, then extend the forks to the limit switch, where it should either pause (if single deep) or stop (if double deep).  Had you centred the forks, you should use the "Modify Current Command", specifying the same command so as to start the command again from scratch.

Forks switch lost

This indicates that the forks have travelled past the target limit switch.  This is likely to result from the forks failing to slow down beforehand.  This in turn can be caused by the fork centre proximity being falsely triggered away from centre or by the fork counter photocell either not operating or else not operating correctly.

To correct the situation, position the forks on the appropriate limit switch, using the manual controls at the electrical cabinet or from the cabin.  It may assist to recentre the forks first, then extend the forks to the limit switch, where it should either pause (if single deep) or stop (if double deep).  Had you centred the forks, you should use the "Modify Current Command", specifying the same command so as to start the command again from scratch.

Overall Watchdog

This indicates that the crane failed to complete its command within a reasonable time.  Its probable cause is that the crane has entered a looping mode switching from one state to another and back again without triggering the associated watchdogs within these states.  The cause for this is likely to be associated with physical problems, such as rubbish in the long travel or hoist readers, missing screens or the T1 and/or T2 photocells being incorrectly adjusted.

It can also be caused by conflicting readings from its inputs such as having the double deep left switch activated at the same time as the forks centred switch.

The quick fix is to check the readers for rubbish then position the hoist and long travel on the appropriate screen by using the manual controls at the electrical cabinet or from the cabin.

High load manual

An attempt was made to extend the forks into a location that can not accommodate a load of this load's apparent height.

High load automatic

An automatic command requested the crane to access a location that can not accommodate a load of this load's apparent height.

You may need to use the "Modify Current Command" to provide an alternate destination for the load.

Cabin too slow down

The crane has taken too long to lower the cabin. This implies that either the cabin has not moved fast enough or has not been seen to move fast enough.

If it has failed to move, check for obstructions.

If it has not been seen to move, check the adjustment of the proximity switches.

This fault will require that you inspect the situation and position the hoist and long travel on a screen appropriately by using the manual controls at the electrical cabinet or from the cabin.  Raising the hoist above the third top level causes the cabin to lower, while lowering it below the fourth top level causes the cabin to rise.

Pickup not going

The crane is in its pickup cycle (B18/11) but has been spending too long waiting for conditions to be appropriate for the next phase of the pickup cycle to commence (B18/14 - extend left, B18/24 retract from left, B18/15 - extend right, or B18/25 - return from right).

This is a type of catch-all alarm that is here because insufficient care has been taken to report the actual problem that has lead to the situation that prevents this operation from continuing.

Possible causes include the load-on-forks photocell being blocked, or, else, with the forks off the centre sensor, having one of the load-off-centre photocells obstructed.

Empty Pallet in Way

This alarm was originally designated "Deposit not going" and has been renamed in honour of its most common cause.

The crane is in its deposit cycle (B19/11) but has been spending too long waiting for conditions to be appropriate for the next phase of the deposit cycle to commence (B19/14 - extend left, B19/24 retract from left, B19/15 - extend right, or B19/25 - return from right).

This is a type of catch-all alarm that is here because insufficient care has been taken to report the actual problem that has lead to the situation that prevents this operation from continuing.

We have found that, generally, this is a result of an empty pallet being left in the pickface after all product has been picked from it.

Cabin too slow up

The crane has taken too long to raise the cabin. This implies that either the cabin has not moved fast enough or has not been seen to move fast enough.

If it has failed to move, check for obstructions.

If it has not been seen to move, check the adjustment of the proximity switches.

This fault will require that you inspect the situation and position the hoist and long travel on a screen appropriately by using the manual controls at the electrical cabinet or from the cabin.  Raising the hoist above the third top level causes the cabin to lower, while lowering it below the fourth top level causes the cabin to rise.

Pickup not centred

Once the photocells indicate that conditions are safe to pickup a load, then, provided that the forks are centred, the forks cycle will start.  Had the forks not been centred, this alarm will be raised.  This is not expected to be a common event; most likely resulting from the crane being left, after manual intervention, with its forks off centre.

Deposit not centred

Once the photocells indicate that conditions are safe to deposit a load, then, provided that the forks are centred, the forks cycle will start.  Had the forks not been centred, this alarm will be raised.  This is not expected to be a common event; most likely resulting from the crane being left, after manual intervention, with its forks off centre.

LT wrong card

The long travel axis has counted its way to the screen, then when its photocells had settled on the screen, it found that it was on the wrong place.  Had the location been sufficiently close to the intended target, the crane would have had a second attempt to find the correct screen before raising this alarm.

This alarm can result from rubbish in the aisle blocking the reader, causing it to miscount the screens, an incorrectly placed or programmed screen, a damaged screen, or a fault with the reader box.

Hoist wrong card

The hoist axis has counted its way to the screen, then when its photocells had settled on the screen, it found that it was on the wrong place.  Had the location been sufficiently close to the intended target, the crane would have had a second attempt to find the correct screen before raising this alarm.

This alarm can result from rubbish in the aisle blocking the reader, causing it to miscount the screens, an incorrectly placed or programmed screen, a damaged screen, or a fault with the reader box.

Can't centre forks

After the crane is set in service, it first tries to centre its forks. If it fails to do so within a reasonable period of time, this alarm is raised.

The most likely cause is that the crane was between high and low stop, or came off high or low stop during forking, preventing this operation from taking place.

Other causes include, the load on the forks fouling the racking, cartons coming loose from the load an obstructing the progress of the forks, the clutch being set too light or mechanical problems with the forks.

This fault will require that you inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

Fork recovery fail

After the crane is set in service, it first tries to centre its forks. If it fails to do so within a reasonable period of time, this alarm is raised.

The most likely cause is that the crane was between high and low stop, or came off high or low stop during forking, preventing this operation from taking place.

Other causes include, the load on the forks fouling the racking, cartons coming loose from the load an obstructing the progress of the forks, the clutch being set too light or mechanical problems with the forks.

This fault will require that you inspect the situation and adjust the load physically or by using the manual controls at the electrical cabinet or from the cabin.

Off LT when forking

This alarm is produced if the crane is no longer on the screen during the forking operation (picking up or depositing).  The degree to which this is policed, is settable, and if set loosely, will allow the forking to continue so long as the crane is partially on the screen.

This fault will require you to centre the forks, then set the crane correctly on the long travel screen, then reset the alarms and set it back in service.

Off HL when forking

This alarm is produced if the crane is no longer on the screen during the forking operation (picking up or depositing).  The degree to which this is policed, is settable.  It may be set so that the crane must remain on high stop or low stop (as the case may be), see either T1 or T2 tab for the appropriate position, or see T1 or T2 for either position.

This fault will require you to centre the forks, then set the crane correctly on the hoist screen, then reset the alarms and set it back in service.

LT reader blocked

The long travel screen reader box found that at least one of its location or parity photocells was blocked when both its T1 and T2 photocells were clear.

This alarm can result from rubbish in the aisle, or caught up in the reader, blocking the reader, or grime on or damage to the body of the screen causing either the T1 or T2 photocell not to be reflected or blocked (depending upon the method used).  If this alarm can be reset, without needing to attend to the crane's reader box, it implies that the cause was, most likely, grime on or damage to a screen.  This grime or damage should be corrected as it will also impact on the crane's positioning performance.

HL reader blocked

The hoist screen reader box found that at least one of its location or parity photocells was blocked when both its T1 and T2 photocells were clear.

This alarm can result from rubbish in the aisle, or caught up in the reader, blocking the reader, or grime on or damage to the body of the screen causing either the T1 or T2 photocell not to be reflected or blocked (depending upon the method used).  If this alarm can be reset, without needing to attend to the crane's reader box, it implies that the cause was, most likely, grime on or damage to a screen.  This grime or damage should be corrected as it will also impact on the crane's positioning performance.

LT brake release on

The LT brake release is used to release the brake, to allow the crane to be pushed when the motor has failed.  While the brake is released, neither manual nor automatic operation can not take place.

If this has been left on erroneously, have an electrician correct it.

Buffer shifted back

This indicates that the crane has gone beyond the end stop (in the reverse direction) and has thereby shifted its buffer.

Depending on the type of buffer used, it may be sufficient to move the crane back off the buffer.  Other types of buffers need to be mechanically reset.

Buffer shifted fwd.

This indicates that the crane has gone beyond the end stop (in the forward direction) and has thereby shifted its buffer.

Depending on the type of buffer used, it may be sufficient to move the crane back off the buffer.  Other types of buffers need to be mechanically reset.

Emergency stop

An emergency stop has been operated.  The reason for pressing the stop should be established, then, when safe to do so, the stop should be released, allowing the operation of the system to continue.

LT at both ends

The long travel forward and reverse end inputs have indicated that the crane is at both ends at once - an impossible state.

This could be due to failure of one of the switches involved, a fault in the cabling, or badly adjusted magnets.

HL at both ends

The hoist high and low inputs have indicated that the crane is towards the top of its travel and the bottom of its travel at once - an impossible state.

This could be due to failure of one of the switches involved, a fault in the cabling up the mast, or badly adjusted magnets.

Cabin up and down

The cabin up and down inputs have indicated that the crane's cabin is both up and down at once - an impossible state.

This could be due to failure of one of the switches involved, a fault in the cabling up the mast, or badly adjusted magnets.

HL at low & hi stop

All the hoist reader box's "T" photocells are blocked, indicating that it is simultaneously in both high and low stop.

This alarm can result from rubbish in the aisle, or caught up in the reader, blocking the reader, or grime on or damage to the body of the screen causing either the T1 or T2 photocell not to be reflected or blocked (depending upon the method used).  If this alarm can be reset, without needing to attend to the crane's reader box, it implies that the cause was, most likely, grime on or damage to a screen.  This grime or damage should be corrected as it will also impact on the crane's positioning performance.

HL wrong for magnet

The hoist axis has encountered a magnet where it should not be, or else has not encountered a magnet where it had expected one to be.

This is either because it failed to read the magnet, or else has miscounted a screen.  The miscount could have resulted from rubbish in the aisle blocking the reader, an incorrectly placed or programmed screen, a damaged screen, or a fault with the reader box.

LT wrong for magnet

The long travel axis has encountered a magnet where it should not be, or else has not encountered a magnet where it had expected one to be.

This is either because it failed to read the magnet, or else has miscounted a screen.  The miscount could have resulted from rubbish in the aisle blocking the reader, an incorrectly placed or programmed screen, a damaged screen, or a fault with the reader box.

Automatic Command Queue

At the bottom of the window are the two motion commands currently written into the crane's PLC - the current command below the pending command.  Below these again is the done command that should appear briefly at the completion of a command.  When the done command is not shown, the current position of the crane is shown instead.

Beneath this is the "governing command", when one is present.  If present, the governing command is shown next to the text "Command:", if it does not correspond to a single crane command, the stage, at which the governing command is up to, will be presented below the governing command.

If either all-automatic-commands or just-automatic-retrievals are turned off, then, when there is no governing command, a message to this effect will be presented in place of the governing command.  For instructions for disabling automatic commands or just retrievals, refer to the sections titled: "Turning Off and On Automatic Commands", and "Turning Off and On Retrieval Commands".

If the Movement Controller is attempting to issue a command, which the Movement Controller's checking software is deeming to be unwise, a message to this effect will be presented beneath the governing command and in place of the automatic-commands-off message.  For more detail on these messages, please refer to the section titled: "Checking Software Messages".

Command Presentation Format

The formats of the two motion commands and the done command or position, are all the same.

The first field in each command indicates whether the command is a travel, pickup or deposit command by displaying the text "Travel", "Pickup", or "Deposit" respectively.  If there is no command this field will be blank.

The second field presents the store slot coordinates to which the command refers, or, in the case of the "done command or position" when there is no done command, the slot nearest the crane.

Governing Command

Most of the commands issued to the crane are issued so as to move a pallet from one location to another.  This is referred to as the governing command.  The governing command, usually a "Store", "Retrieve", or "Relocate" is presented below the command queue, along with the stage it is at, for example, "Waiting to issue pickup".

Associated with a governing commands may be a number of crane commands, such as pickup from the racking, and deposit to the outfeed.

Once the deposit command has been written to the crane, the governing command is finished, and a new governing command may start.  This new governing command may be at the stage "Waiting to issue pickup", while it waits for the deposit command, from the previous governing command, to be shifted into the current command position.  The point to bear in mind here is that the governing command presented at any time does not necessarily have anything to do with what the crane is currently doing, or about to do, as the crane might still be following the instructions from the last governing command.

You might regard the governing command as an indication of what's coming up.

Checking Software Messages

The messages you are likely to see, which can impact upon what the crane is wanting to do, include:

  • PAUSED
    At certain sites, the Movement Controller may find it necessary, in, say, the event of fire, to instruct the crane to pause its operations, in order to allow people to evacuate the warehouse, via the passages that cross the crane aisles.  This might also result from someone requesting access to the warehouse.
  • NOT PERMITTED TO TRAVEL
    At certain sites, the Movement Controller may determine that it is not safe for the crane to travel (long travel or hoisting) due to, say, the detection of an obstruction in the aisle.  When this status is set, the crane will be allowed to complete its fork cycles, but not to move to another position.
  • TRYING TO PICKUP FROM OUTFEED
  • TRYING TO DEPOSIT TO INFEED
    Somehow, the Movement Controller has found itself trying to issue an illegal command to a crane.  This would usually require some investigation, however, in the end, you'll probably need to abort commands so as to allow the crane to resume its normal operations.

Turning Off and On Automatic Commands

This menu option is only presented if you have sufficient privilege to use it. This privilege level is specified in the "Configuration Data" record, titled "Level: crane auto off".  Please refer to the section titled: "Configuration Data".

The Movement Controller issues governing commands to the crane to move pallets about the warehouse as it thinks fit.  If you wish to issue these governing commands yourself, using the commands, "Store a load", "Retrieve a load", and "Relocate a load in the rack" (discussed in the next section), then you might wish to disable the Movement Controller from issuing these commands itself.

To do this, click on the menu bar item, "Automatic on/off", or type "A", then click on "Off" or type "O".

In response the text, "AUTOMATIC ISSUING OF COMMANDS IS OFF", will be displayed in place of the governing command.  Disabling of the automatic issuing of commands has no effect on any governing command that may already be in place.

To allow the system to again issue governing commands automatically, click on the menu bar item, "Automatic on/off", or type "A", then click on "Automatic on" or type "A".

Inhibiting the Crane

There is a provision to let the host_computer know that a crane is out of action.  Once you turn off the automatic issuing of crane commands, you will be asked whether you wish to inform the host_computer of this.

Informing the host_computer of the crane being down will result in it not issuing further requests for this crane, and to have its existing requests cancelled.

You should only do this if you are intending that the crane be left out of automatic operation for some time.

To inform the host_computer of this, enter a reason for the crane being down.  The reason is a "Symbolic Name" field that references the "Crane Down Reasons" database.  For editing instructions for this type of field, please refer to the section titled: "Symbolic Name".

The host_computer will be informed of the crane being again available once you have turned automatic commands back on.

The reason the crane is down will be presented alongside the text, "AUTOMATIC ISSUING OF COMMANDS IS OFF".

Turning Off and On Retrieval Commands

This menu option is only presented if you have sufficient privilege to use it.  This privilege level is specified in the "Configuration Data" record, titled "Level: crane auto off".  Please refer to the section titled: "Configuration Data".

The Movement Controller issues governing commands to the crane to retrieve loads from the warehouse in accordance with the retrieval schedules.  Please refer to the section titled: "Retrieve from Stores by Location".

If you wish to suspend the retrieval of loads, without deleting the schedules themselves, then you can do this using this function.

To do this, click on the menu bar item, "Retrieval on/off", or type "R", then click on "Off" or type "O".

In response the text, "AUTOMATIC RETRIEVAL OF ... IS OFF", will be displayed in place of the governing command.  Disabling of the automatic issuing of retrieval commands has no effect on any governing command that may already be in place, and the message, , will only be displayed if there is no governing command, and if you have not also disabled all automatic commands as well. Please refer to the section titled: "Turning Off and On Automatic Commands".

To allow the system to again issue retrieval commands automatically, click on the menu bar item, "Retrieval on/off", or type "R", then click on "Retrieval on" or type "R".

Putting the Crane Back Service

This menu option is only presented if you have sufficient privilege to use it.  This privilege level is specified in the "Configuration Data" record, titled "Level: crane auto off".  Please refer to the section titled: "Configuration Data".

Additionally, certain sites have a restriction upon which terminals allow an operator to use this command.  If this is one of these sites, this function is restricted to those terminals listed in the set of terminal locations and, there, flagged as allowing crane control.  Please refer to the section titled: "Terminal Locations".

If you do not have sufficient privilege to use this command, you will need to issue the individual, non-motion commands, "Reset Alarms", "Energise Main Contactor", and "Set in Service", via the "Command" menu bar item.  Please refer to the section titled: "Operator Commands".

When the crane encounters an alarm, as well as raising the alarm, it may drop its main contactor, and will always set itself out of service.  To get it back into service, you need to reset its alarms, energise its main contactor and set it back into service.  This command performs these three functions.

To do this, click on the menu bar item, "Put in service", or type "P", then click on "Put in service" or type "P" a second time.

For some sites, there may be required further dialogue, in order to obtain a reason for the action and/or to obtain the identity of the person putting the crane back in service.

In response, you should see the crane's status gradually change so that first its main contactor is energised, then its alarms are reset, and finally it is set back into service.

Operator Commands

There are several operator commands, however, depending upon you privilege level, you may not be allowed access to all or any of these.  Please refer to the section titled: "Crane Commands and Security",

Additionally, certain sites have a restriction upon which terminals allow an operator to use the crane commands.  If this is one of these sites, this function is restricted to those terminals listed in the set of terminal locations and, there, flagged as allowing crane control.  Please refer to the section titled: "Terminal Locations".

Of the many commands, which an operator may issue to a crane, the first six are non-motion commands.  The next group of commands are either individual instances of the two motion commands or higher level (governing) commands requiring two or more motion commands.

The remaining commands allow the modification of the current crane command, without upsetting the next command, the killing of the governing command (which does not directly involve communications with the crane), and manual control of the crane (which may not be supported by the crane's manufacturer).

Commands may be sent by clicking on the "Commands" menu item or typing [ALTERNATE C], then selecting the command from the resulting drop-down menu then filling in the required parameters for the command, then typing [ENTER] or clicking on the "DO IT" button.

Alternatively, there is a list of commands shown to the right of the window. Associated with each command in this list is a number, and one of these commands is highlighted.  Any command can be selected by either typing the corresponding number and pressing [ENTER], or by moving the highlight, using the [UP], [DOWN], [HOME], and [END] keys, to the desired command and typing [ENTER], or by clicking the desired command with the mouse and typing [ENTER], or by double clicking the command with the mouse.  However you selected the command, you will then be required to fill in the required parameters, just as if you had selected it via the "Command" menu item, and confirm by typing [ENTER] or clicking on the "DO IT" button.

If you right-click on a command in the list at the right of the window, you will be presented with the help page relating to that command.

Sometimes you might be warned that it might not be a good idea to do what you have chosen to do - if you get such a message you should review what you are about to do.

In particular, the Movement Controller prefers the crane to be idle before you issue relocation-style commands, as this helps to ensure that it has correct stack height data available.  If you are issuing relocation-style commands, it might be best to first turn off the automatic issuing of commands to the crane.

For some sites, there may be required further dialogue, for one or more of the commands, in order to obtain a reason for the action and/or to obtain the identity of the person issuing the command.

For many of the commands, it is a good idea to be familiar with how the commands are sent to the crane.  For a discussion of this procedure, please refer to the section titled: "Automatic Command Queue".

Non-Motion Commands

The Movement Controller has six non-motion commands that it may send to the crane and three motion commands.

Reset alarms

Used to unlatch the alarms in the crane PLC after the faults have been rectified.

Energise main contactor

Used to energise the main contactor after the cause of its deenergisation has been rectified.

Set out of service

Prevents Movement Controller from issuing further commands to the crane and the PLC from executing those it has.

Set in service

Allows the automatic control of the crane to recommence. A crane can be set out of service due to a blockage to the aisle-clear scanners.  If this is the case, you will not be able to set the crane back into service.  Once the scanners are clear, you will still not be able to set the crane back in service until confirming that you have checked that the obstruction is now clear.  You may be asked to provide your login before you may make such a confirmation (this is set by the "Configuration Data" record "Get password: clear crane" - see "Configuration Data").

Abort current cycle

Kills the currently executing command in the PLC.  May only be issued when the crane is out of service.

Kill next cycle

Kills the pending command in the PLC.  This may result in another command replacing the pending command.  It too may be killed by repeating this command.

Motion Commands

The motion commands are:

  • Movement test cycle
    Sends the crane to a given long travel and hoist level.
  • Pickup test cycle
    Sends the crane to a given long travel and hoist level to pickup a load.
  • Deposit test cycle
    Sends the crane to a given long travel and hoist level to deposit a load.

The motion commands that an operator may send to a crane are either specific instances of the above, or combinations of two or more of these commands.

Movement test cycle

Sends the crane to a given long travel and hoist level.

Pickup test cycle

Sends the crane to a given long travel and hoist level to pickup a load.

Deposit test cycle

Sends the crane to a given long travel and hoist level to deposit a load.

Goto crane infeed

Issues a test travel command specifying the coordinates of the infeed station.

Goto crane outfeed

Issues a test travel command specifying the coordinates of the outfeed station.

Park at Maintenance Bay

This command is offered for several sites.  It allows you to issue a test travel command, specifying the coordinates of the maintenance bay.

Store a load

Issues a pickup half cycle specifying the infeed station then a deposit half cycle specifying the given store location.

Retrieve a load

Issues a pickup half cycle specifying the given store location then a deposit half cycle specifying the outfeed station (or the given outfeed station, if more than one exists).  The ultimate destination is also entered and assigned to the load when it is picked up.

Deposit the load on board

Issues a deposit half cycle specifying the given store location.

Relocate a load in the rack

Issues a pickup half cycle specifying the given store location then a deposit half cycle specifying another given store location.

Run test cycles

Issues a series of test cycles ultimately sending the crane to every store location.  It is stopped by issuing another of these eleven commands.

Modify Current Command

The next command, "Modify current command", allows the modification of the current command in the crane PLC to allow an alternate location to be specified.

You would typically use this command if a deposit command fails due to a problem with the destination.  Had you used the "Abort" command, there may have been a pickup command, corresponding to the next governing command, in the crane's next command position, which would also need to be killed, along with its governing command.  This command allows you to leave the next command and its associated governing command in place, while you instruct the crane to unload itself elsewhere.

You should also take the opportunity to disable this location so that the Movement Controller does not attempt to place another load here until the problem has been rectified.

Kill Governing Command

The command, "Kill governing command", allows you to kill the governing command, which is responsible to the issuance of the individual crane commands.

You would typically need to do this if you have made an adjustment to the inventory and so you need to have the Movement Controller work out its next move based on this new data - the previous governing command could be in error as it was constructed based on erroneous data.

Please bear in mind that the Movement Controller considers a load to have been delivered to an outfeed once it has put the corresponding governing command in place, so if you kill one of these commands you may find that you do not receive the number of loads you had asked for.

Remote Manual Crane Control

The remote manual commands should only be used to rectify crane faults once the physical situation has been checked.

Typically, if you have returned from fixing the crane and found you had left it so that the "Hoist too low" or "LT overrun" alarms resulted, you could raise or reverse the crane until the "In Position" lamps flash, then position the crane on these lamps.  Similarly had you failed to centre the forks, You could use these controls to centre the forks.

After selecting manual control, the window will appear as shown overleaf:

Crane Commands and Alarms -- Manual Control

This window presents "push buttons" for long travel forward and reverse, slow and fast, hoist up and down, slow and fast, and forks left and right.  The rim of one push button is highlighted and several of the push buttons advertise a function key.

The highlighted rim can be moved about the "push buttons" using the cursor control keys.  The push button with the highlighted rim can be "pressed" by pressing on the space bar, while those advertising function keys may be "pressed" by pressing the advertised function key. The mouse may be used to push a push button, however it does not relocate the highlighted rim.

The window also provides several "lamps", which show whether the crane is in high stop, low stop, long travel position and whether it has a load off-centre to the left or right.

In the top right corner of the window is shown a diagram of the crane, showing the state of its load sensing, load off-centre, bin occupied and height check photocells and the extension of its forks and, if the forks are not centred, whether at high stop or not; if at high stop, a load will be shown at the forks extension, otherwise the forks will be shown.

If the forks are not centred, the crane will instead show whether the computer's inventory has it holding a load.

The colour of the forks, or the colour of the border around the load will be red if the crane is in automatic, yellow if in manual or grey if otherwise out of service.

The body of the crane will be shown in orange if healthy, or red if in alarm.

Initialise Crane PLC

If you are working with the current version of the crane PLC code, there will be an option enabling you to write the racking data to the crane.  This option draws on the information contained within the stores diagram - the non-existent locations and the slot heights - to initialise the corresponding data files within the crane PLC. Refer to the section titled: "Stores Diagram".

This is normally performed using "Save and Restore Crane PLC Configuration" window, please refer to the section titled: "Save and Restore Crane PLC Configuration".

Save Crane PLC Configuration

If you are working with the current version of the crane PLC code, there may be an option enabling you to save the current configuration of this crane to a file on the hard disc.  This is normally performed using "Save and Restore Crane PLC Configuration" window, please refer to the section titled: "Save and Restore Crane PLC Configuration".

Restore Crane PLC Configur'n

If you are working with the current version of the crane PLC code, there may be an option enabling you to restore the previously saved configuration of this crane from a file on the hard disc.  This is normally performed using "Save and Restore Crane PLC Configuration" window, please refer to the section titled: "Save and Restore Crane PLC Configuration".

Retrieve from Stores by Location (new)

This window allows the operator to create and review location retrieval schedules.

There are four methods of retrieving loads.

The first of these methods we call "Stores".  This method allows you to select loads to retrieve by moving about the stores diagram, pressing [ENTER] or double-clicking as you go.  This is the traditional method offered by the Movement Controller.  The remaining three methods have been written specifically for Americold to assist them in the way that they enter retrievals.

The second method (the first of the three written specifically for Americold) we call "Replenishment".  This method allows you to specify movements from within the store to the pick-face, more conveniently.

The third method we call "Outfeed".  This method allows you to specify movements from several store locations to the appropriate outfeed.

The fourth and final method we call "Empties".  This method creates a schedule to retrieve all empty pallets, allowing you to delete any you do not want to retrieve, before submitting the schedule.

So when you first enter the screen, you will be presented with a dialogue box allowing you to select one of these four methods.  You need to type "S" or click on "Stores" to select the first method (as described in the dialogue box). Similarly, you need to type "R" or click on "Replenishment" to select the second method, type "O" or click on "Outfeed" to select the third method, and type "E" or click on "Empties" to select the fourth method.

Had you selected the first method, you would proceed as described for the traditional method in the section titled: "Retrieve from Stores by Location".

The remaining three methods are very different to the traditional method, but very similar to one another.  So the instructions that follow will refer to all three of these remaining methods, indicating the differences between them when necessary.

After selecting one of the three remaining methods, you will be presented with a window in which the records corresponding to each retrieve request are listed.  Each retrieve request consists of a barcode, a source location, a destination, and the priority.

This is a "Maintenance Viewing Data" screen, so the features shared by all such screens will not be described here; for these, please refer to the sections titled: "Viewing Data", and "Maintenance Viewing Data".

Initially these screens will be substantially blank, except in the case of "Empties", where it will be populated by retrieval requests for each empty pallet stack location that the PDS system shows to be loaded, provided that the location has not been inhibited.

Creating Retrieval Requests

To get started (or if using the "Empties" yet still needing to add requests), press [INSERT].  In response you will be presented with a dialogue window.

For the "Replenishment" method, there will be two fields to fill in, namely the source location (which should be an occupied regular storage location), and the destination (which should be a vacant pick-face location).  After typing in the source location, press the [TAB] key and commence to type in the destination location.  After typing in the destination, you should type [ENTER] or [RETURN].

For the "Outfeed" method, you will only need to fill in the source location, which should be an occupied regular storage location.  After typing in the source location, you should type [ENTER] or [RETURN].  The destination will be automatically set to either "M89A", or "M40A" depending upon which is appropriate.

For the "Empties" method, you will only need to fill in the source location, which should be an empty pallet location, which the PDS system is reporting as occupied.  Unlike the other methods, which will offer blank fields, this will provide the reference to the next empty pallet stack location, irrespective of whether the stack can be seen or the location is inhibited.  The "next" refers to the first location after that specified in the highlighted retrieve request. After typing in the source location, you should type [ENTER] or [RETURN].  The destination will be automatically set to either "M89A", or "M40A" depending upon which is appropriate.

In all cases, the priority will be set to 0 or blank, indicating the highest priority.  Don't concern yourself with the priority at this stage.  Should you need to alter the priority, you may do so, on an individual record basis, when you have returned to the "Maintenance Viewing Data" screen.  The altering of priorities is described in the section titled: ""Prioritise, Modify, or Delete".

In response to typing [ENTER] or [RETURN], certain checks are made of your entry.  If your entry fails one of these checks, you will be informed of this. If the failure is due to a location being inhibited, you will be given the opportunity to clear the inhibited status.  Certain, of the other possible causes for the failure of these checks, may also be overridden.

If your entry passes these checks, the dialogue box will be presented again, allowing you to immediately enter the next request.  In the case of the "Replenishments" and "Outfeeds", the dialogue box will provide you with the barcode corresponding to the request that you had just entered, allowing you to check that you had entered the correct source location.

Once you have entered all the requests that you need to, either press [ENTER] or [RETURN] with blank entries, or press [ESCAPE].  If you press [ESCAPE], then anything that had been entered into the fields in the current dialogue box will be discarded.  In either case, you will be returned to the "Maintenance Viewing Data" screen, now including your new requests.  These will not, yet, be acted upon.

Deleting Retrieval Requests

To remove a request, simply highlight the request in question, then type "D" twice.  The first "D" invokes the menu bar option "Delete", whilst the second confirms the deletion request by activating the "Delete" button in the resulting dialogue box.

Prioritise, Modify, or Delete

The difference between this window and a standard "Maintenance Viewing Data" window is that, as well as modifying a load, the operator has the option to conveniently adjust the priority of the load.

When selecting a record, if "U" or [RETURN] is used, you will be asked, after specifying the record, whether you wish to prioritise (type "U" or click on "Urgency"), modify (type "M" or click on "Modify"), or delete the load (type "D" or click on "Delete").

On the other hand, had you used [ENTER] to select the record, it will be assumed that you wish to prioritise the load. Double-clicking the mouse on the desired load is equivalent to typing [ENTER].

Had you opted to prioritise the load, you will be presented with the prompt, "Please enter new urgency for the load, Urgent 0:most 10:stop <0-10>".  Enter the desired priority.

Submitting the Schedule

When happy with the schedule, you can submit it by exiting the screen.  In response, these requests will be transfered to the "Waiting" queue.  You can monitor the requests from this point by using the "Review Loads Being Retrieved" screen.  Please refer to the sections titled: "Review Loads Being Retrieved".

Retrieve from Stores by Location

This window allows the operator to create and review location retrieval schedules.

This screen will appear substantially blank unless some retrieval requests have been entered.  Once this has been done, each schedule will be represented by a box at the bottom of the screen, arranged in the order in which they are created, with the first at the left.

Below is a rough text-representation of this window:

Retrieve loads by location Select Change Restrict Where Match Expand Insert First Last Number of loads 370 ^ ┌───┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬───┐█ │■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪■▪▪▪▪■▪▪▪■■■■▪▪■■▪▪■■■■■▪■■▪■■■■■■■■▪■■│█ │▪▪▪▪■▪■▪▪▪▪■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪▪▪■■▪▪▪▪▪■■▪▪▪■■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪│█ │■■■■■■■■■■■■■■■■■■■■■■■▪■■■■■■■■■■■■■■■■■■■■▪■■■■■■■■■■■■■■■■■■■■■▪■■■■■│█ │▪■■■▪▪■▪■■■▪■■■■■■■■■■■■▪■▪■■■■■■■■■■■■■■▪■■■■■■■■■■■■■■■▪■■■■■■■■■■■▪■■│█ │■■▪■■■▪■■■■■▪▪■■■■■■■■■■■■■▪■■■■■▪■■■■■■▪■■■■■■■▪■■■■■■■■■■■■■■■■■■■■■■■│█ │▪▪▪▪▪■■■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪■■▪▪▪▪▪▪▪▪▪▪▪▪▪■▪■▪│█ │▪▪■▪▪■■▪▪▪▪▪■▪■▪▪▪▪■▪▪▪▪▪■▪▪▪▪▪▪▪▪▪■■■▪■▪▪▪▪▪▪▪▪▪■▪▪■▪▪■■▪▪■▪▪■▪■▪▪■■▪▪■│█ │▪▪▪▪■■▪▪▪■■▪▪■▪■▪■■▪■■■▪■■▪■▪▪▪■▪▪▪▪▪▪▪■■▪▪▪▪■■▪■▪■■■▪▪▪▪■■■■▪■▪▪▪▪▪▪▪▪■│█ │▪▪▪▪▪▪▪▪■▪▪■▪▪▪▪▪▪▪▪▪■▪▪■▪▪■▪▪▪▪▪■▪▪■▪▪▪▪▪■▪▪▪▪▪▪▪▪■▪▪▪▪▪▪▪▪▪■▪▪■■▪▪■▪▪■│█ │▪▪▪▪▪▪▪▪▪■▪▪■▪▪▪▪■▪▪▪▪▪■▪▪▪▪▪▪▪▪■■▪▪▪▪▪■▪■■■▪■■▪■■▪▪▪▪▪▪▪■▪▪▪■▪▪▪▪■■■■▪■│█ │▓▓■▪▪▪▪ ▪▪▪■▪▪▪▪▪▪▪▪■▪▪▪▪■■▪■▪▪▪▪▪▪▪▪ ▪▪▪▪■▪▪■■▪■▪■■■■■■■▪■■▪■■■▪▪▪■▪■▪■│█ └───┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴───┘█ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> 1002010|O| | | | | |207680|593100720030023457| Rack slot inhibited <I/S/R>a Rack Rack Rack SSCC <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> ■■■■ <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░>

If the schedule is in the extreme left position, it is being executed.

When the schedule has been completed, it is removed from the window and the string of schedules is shifted one place left.

Reading Schedules

As the cursor is moved (using the [SEPARATE LEFT] and [SEPARATE RIGHT] keys, or clicking with the mouse) among the schedules, the box will be shown open, and its contents are displayed in the rack face display.

There will also be a horizontal scroll bar, in case the window is not large enough to present the maximum number of schedules.  This scroll bar can only be operated using the mouse - this is the fourth scroll bar on this window, so all the usual keys have been otherwise used.

As the commands to retrieve a load are issued, the box representing its location in the rack face display, is darkened.

Creation of Schedules

A schedule may be created by typing [INSERT].  The cursor will be moved to the "Set of Fields", this data may now be set as required.  Refer to the section titled: "Set of Fields".

This "Set of Fields" typically includes the destination (a "Destination" field) and a load number (a "Numeric" field). For editing instructions for these types of fields, please refer to the sections titled: "Numeric", and "Destination".

After setting the destination and load number, the cursor will be relocated into the rack face display.  The normal functions associated with this display are available.  Refer to the section titled: "Stores Diagram", and in particular, its subsection titled: "Select Loads for Retrieval".  In the rack face display, selecting a location allows you to edit the database details associated with the location, but, in this case, selecting a location will, instead, add it to the schedule (or, should it already be on the schedule, remove it from the schedule).

When all required locations have been selected, type [ESCAPE].

At the bottom of the window, each schedule is represented by a box.  As you create more schedules these will be arranged in the order in which they are created and will be executed, with the first at the left.

Modification of Schedules

A schedule may be modified by moving the cursor to that schedule then typing the "S", [RETURN] or [ENTER] key.  The cursor will return to the "Set of Fields".

Proceed from here as you did to create the schedule.  Refer to the section titled: "Creation of Schedules".

Sequencing Schedules

If the order of the schedules requires modification, move the cursor to the schedule that needs to be repositioned, then type the [SEPARATE UP] key.  The schedule is then positioned one line above its current position, and if possible the cursor is moved one position left. Clicking on the schedule at the cursor will alternately raise and lower it, leaving the cursor at the schedule.

By using the [SEPARATE LEFT] and [SEPARATE RIGHT] keys this schedule may be moved along the string, one place to the right of the cursor whenever possible, while the contents of the schedule at the cursor position are displayed.  When its new location has been found type [SEPARATE DOWN].  The schedule will be lowered into position and the cursor moved back to it. The schedule may also be moved to a given place in the queue by clicking the mouse on the schedule currently in that location.  This moves the schedule into this position, moving the other schedules left or right to fill the vacancy left, while placing the cursor one position to the left of the schedule if possible.

Deleting Schedules

Any schedule may be deleted by moving the cursor to that schedule then typing [DELETE].  If you type [DELETE] you will be prompted to confirm your intention by typing [F1].

Review Loads Being Retrieved

This window allows the operator to create or modify requests for loads to be retrieved from the high-rise.  These loads are entered into this area as they are requested to be retrieved, either by the operator or via a message from the host_computer, and will remain here until the crane is commanded to retrieve the load.

The operator may need to alter the priority of the loads on this list.  A priority of "0" is the highest, and "9" is the lowest.  A priority of "10", prevents the load from being retrieved.  The default priority is "9".

This is a "Maintenance Viewing Data" window that lists each of the loads to be retrieved.

Below is a rough text-representation of this window:

Review loads to be retrieved Urgency Change Restrict Where Match Expand Insert Loads to be retrieved |51-3-046|23987|88654|137| 9|'0' ^ Loads to be retrieved |52-3-121| 2997|88651| 23| 9|'0' █ Loads to be retrieved |54-5-023| 68|88649| 34|10|'0' █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Details of Loads Load's origin 51-3-046

All features provided by the "Maintenance Viewing Data" windows are active.  These features are:

  • creating, modifying, and deleting records.
  • moving the window across the records.
  • highlighting a particular alarm for individual attention.
  • highlighting a particular field for individual attention.
  • expanding/contracting the records.
  • restricting the alarms eligible for inclusion.
  • changing the contents of a field.

Refer to the sections titled: "Viewing Data", and "Maintenance Viewing Data".

Prioritise, Modify, or Delete

The difference between this window and a standard "Maintenance Viewing Data" window is that, as well as modifying a load, the operator has the option to conveniently adjust the priority of the load.

When selecting a record, if "U" or [RETURN] is used, you will be asked, after specifying the record, whether you wish to prioritise (type "U" or click on "Urgency"), modify (type "M" or click on "Modify"), or delete the load (type "D" or click on "Delete").

On the other hand, had you used [ENTER] to select the record, it will be assumed that you wish to prioritise the load. Double-clicking the mouse on the desired load is equivalent to typing [ENTER].

Had you opted to prioritise the load, you will be presented with the prompt, "Please enter new urgency for the load, Urgent 0:most 10:stop <0-10>".  Enter the desired priority.

Enter Orders for Picking

This window allows the operator to enter orders for picking cartons. Corresponding to each order, a barcode is printed, which is to be fixed to a carton.  Should the carton become filled, the packer is to press the "split case" button, calling for an additional barcode to be printed and fixed to a fresh carton.

This window will appear substantially blank unless some orders have already been entered locally or down loaded from the host_computer.  Once this has been done, each schedule will be represented by a box at the bottom of the window, arranged in the order in which they are created (if created locally) or received (if created on behalf of the host_computer), with the first at the left.

Below is a rough text-representation of this window:

Enter orders for picking CODE ORDERED ISSUED QUANTITY GEFFEN GEFD-24612 |Judy Collins 5 100 ^ FIE! RECORDS FIE9115 |Guy Evans and Peter Hammill 5 450 █ EMI CDP 7 46605 2 |Animals, The 5 60 █ DEMON FIEND CD 704 |Beausoleil 5 85 █ CAPITOL CDP 7 46069 2 |Band, The 5 95 █ BLUE NOTE CDP724385548420|Jacky Terrasson & Cassandra 5 450 █ ATLANTIC 7 82526-2 DISC 9|Led Zeppelin 5 █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> ■■■ ■■ <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░>

The cursor will be positioned initially at the first of the boxes at the bottom left of the window.  These characters each represent a customer's order.  The boxes at the bottom right hand side of the window represent templates for schedules.  More about templates later.

Reading Schedules

As the cursor is moved (using the [LEFT] and [RIGHT] keys or clicking on the schedule with the mouse) among the schedules, the box will be shown open, and the details of the schedule will be displayed.

There will also be a horizontal scroll bar, in case the window is not large enough to present the maximum number of schedules.  This scroll bar can only be operated using the mouse - this is the fourth scroll bar on this window, so all the usual keys have been otherwise used.

At the top of the window is displayed the order's customer, while in the main body of the window are the requirements of the order.  Each requirement consists of the product code and description and the quantity required.

Creation of Schedules

To create a schedule, press [INSERT].  You will be presented with a "Set of Fields" for you to edit.

Below is a rough text-representation of this window:

Enter orders for picking Order's customer t P & O Cold Storage Customer address t 69 Mandoon Road Customer town or suburb t Girraween Town in state/province t N.S.W. State in country t Australia Country's ISD (NZ=64) a Zip mask (Canada: ###-###) a #### Town or suburb post code a 2145 Town STD (Melb=3) a Customer's phone number a 96362666 Customer's facsimile no. a 96882610 Customer's delivery notes s Order number a 111111 Special instructions a Order destination lane a 81 ■ ■■■ ■■ <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░>

This data may now be set as required.  Refer to the section titled: "Set of Fields".

This "Set of Fields" includes the customer (a "Symbolic Name" field), the customer's order number and any special delivery instructions - additional or overriding the customer's standard instructions - (both "Name" fields) and a destination pick area zone (a "Symbolic Name" field). For editing instructions for these types of fields, please refer to the sections titled: "Symbolic Name", and "Name".

Once you have entered this "Set of Fields", you will be presented with a substantially blank window on which the entries of the schedule will be displayed as they are entered.  To create an entry in the schedule, type [INSERT], then enter a product code and then the number required.  Repeat this for each product the order specifies.

Below is a rough text-representation of this window:

Enter orders for picking CODE ORDERED ISSUED QUANTITY GEFFEN GEFD-24612 |Judy Collins 5 100 ^ FIE! RECORDS FIE9115 |Guy Evans and Peter Hammill 5 450 █ EMI CDP 7 46605 2 |Animals, The 5 60 █ DEMON FIEND CD 704 |Beausoleil 5 85 █ CAPITOL CDP 7 46069 2 |Band, The 5 95 █ BLUE NOTE CDP724385548420|Jacky Terrasson & Cassandra 5 450 █ ATLANTIC 7 82526-2 DISC 9|Led Zeppelin 5 █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> ■■■ ■■ <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░>

The lines will be presented in the order (with the latest at the top) they are entered until you delete a line.  Once a line has been deleted, the next entry will fill its place.

To modify an entry, highlight the line, then type [RETURN] or [ENTER].  Then in response to being presented with the product code, you must press [RETURN] or [ENTER] again; if, instead, you enter a different product code you will create a fresh entry.  You may now change the number required.  If you set this number to zero, you will delete the entry.

To delete an entry, refer to the previous paragraph.

If you make an entry requesting a product code that is not in stock, the entry will not be displayed but will remain.  Once you exit from the creation process, these entries will be displayed.

The above discussion has assumed that the window has been set to show only ordered and stocked product codes.

If you wish to show all product codes that are not stocked, enter "QU", if you wish to display product codes irrespective of whether they are stocked or not, enter "QA", and if you wish to return to displaying only stocked product codes, enter "QS".  This selection will be remembered only until you exit from the creation of this schedule. You may also click on the menu item "Quantity", then click on either the "Unstocked", "Stocked" or "All" button.

If you wish to show all stocked (or unstocked - refer previous paragraph) product codes, enter "OA", and if you wish to return to displaying only ordered product codes, enter "OO".  This selection will be remembered for the user until the software is next rebooted. You may also click on the menu item "Ordered picked", then click on either the "Ordered" or "All" button.

In this mode (showing all product codes - not only those ordered), each product code is shown in alphabetical order.

Once you have made all entries, type [ESCAPE].  The original display will again be presented, with the new schedule positioned at the end of the queue of boxes.

Modification of Schedules

To modify a schedule, use the [LEFT] and [RIGHT] keys to move the cursor to the schedule you wish to modify. the cursor may also be moved to a schedule by clicking the mouse on the desired schedule. Then type [ENTER] or [RETURN].

Once selected, a "Set of Fields" is presented containing the schedule's details. If you are sufficiently privileged you will be asked to confirm that you wish to modify the details by pressing [F1].  You will, then, be presented with a "Set of Fields" in a window, for you to edit.

From this point, proceed as described for the creation of schedules.  Refer to the section titled: "Creation of Schedules".

Sequencing Schedules

The first schedule (or order/carton) to be executed will be the one corresponding to the box at the extreme left of the window. The order of execution of the schedules may be changed.

This reordering is conducted by picking up a schedule, moving it to a new position in the queue and then lowering it into this position.  Use the [LEFT] and [RIGHT] keys to move the cursor to a schedule, then the [UP] key to pick it up, then again the [LEFT] and [RIGHT] keys to move it to its new position and, finally, the [DOWN] key to lower the schedule into this position. Clicking on the schedule at the cursor will alternately raise and lower it, leaving the cursor at the schedule.

When the schedule is first picked up, the cursor remains beneath it.  The Movement Controller takes its first opportunity to separate the cursor and schedule, keeping the cursor one position to the left of the schedule, when you first type [LEFT] or [RIGHT].  As a result the first time you type the [LEFT] key only the cursor is moved or the first time you type the [RIGHT] key only the schedule is moved. The schedule may also be moved to a given place in the queue by clicking the mouse on the schedule currently in that location, placing the cursor one position to the left of the schedule if possible.

The cursor is kept one position left of the schedule to show you the contents of the schedule currently in front of the raised schedule.  The cursor is not initially moved automatically left because you may wish the cursor to remain beneath the schedule in order to copy it to the templates (or to the schedules if working with the templates).  More about templates later.

Using Templates

The only differences between the schedules and the templates are that the schedules appear at the left whilst the templates are on the right and that the schedules are being executed whilst the templates are not.

You can switch from side to side by typing [CONTROL RIGHT] to move to the template side and [CONTROL LEFT] to return.  If at the time you switch to the templates, the schedule at the cursor is raised, a template will be created identical to the schedule; the schedule will be unaffected. You can switch to or from the template side by merely clicking on that side with the mouse.

If at the time you switch back to the schedules, the template at the cursor is raised, you will be presented with a "Set of Fields" for you to edit.

From this point, proceed as described for the creation of schedules.  Refer to the section titled: "Creation of Schedules".

Once you have completed any modifications you might wish to make to the new schedule, and have pressed [ESCAPE], The original display will again be presented, with the new schedule positioned at the end of the queue of boxes.  The original template will still exist and will be unaffected by the changes made when creating the schedule based on it.

Replenish the Pick Areas

This window allows the operator to define the contents for cartons containing the replenishment for the pick areas.  Corresponding to each replenishment carton, a barcode is printed, which is to be fixed to a carton with the specified contents.

This window will appear substantially blank unless some replenishments have already been entered locally or down loaded from the host_computer.  Once this has been done, each schedule will be represented by a box at the bottom of the window, arranged in the order in which they are created (if created locally) or received (if created on behalf of the host_computer), with the first at the left.

Below is a rough text-representation of this window:

Replenish the pick areas Select Change Restrict Where Match Expand First Last On hand stored Quantity ATLANTIC 7 82526-2 DISC 2|Led Zeppelin 100 480 ^ HANNIBAL HNCD 1326 |Danny Thompson 100 20 █ GEFFEN GEFD-24612 |Judy Collins 100 100 █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> ■■■ ■■ <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░>

The cursor will be positioned initially at the first of the boxes at the bottom left of the window.  These characters each represent a replenishment schedule.  The boxes at the bottom right hand side of the window represent templates for schedules.  More about templates later.

Reading Schedules

As the cursor is moved (using the [LEFT] and [RIGHT] keys or clicking the mouse on the desired schedule) among the schedules, the box will be shown open, and the details of the schedule will be displayed.

There will also be a horizontal scroll bar, in case the window is not large enough to present the maximum number of schedules.  This scroll bar can only be operated using the mouse - this is the fourth scroll bar on this window, so all the usual keys have been otherwise used.

The top line of the window will be blank, while in the main body of the window are the contents of the replenishment carton.  Each replenishment consists of the product code and description and the quantity contained.

Creation of Schedules

To create a schedule, press [INSERT].  You will be presented with a substantially blank window on which the entries of the schedule will be displayed as they are entered.  To create an entry in the schedule, type [INSERT], then enter a product code and then the number contained in the replenishment carton.  Repeat this for each product in the carton.

Below, once you have made a number of entries in the schedule, is a rough text-representation of this window:

Replenish the pick areas CODE ON HAND ISSUED QUANTITY ATLANTIC 7 82526-2 DISC 2|Led Zeppelin 100 480 ^ HANNIBAL HNCD 1326 |Danny Thompson 100 20 █ GEFFEN GEFD-24612 |Judy Collins 100 100 █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> ■ ■ <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░>

The lines will be presented in the order (with the latest at the top) they are entered until you delete a line.  Once a line has been deleted, the next entry will fill its place.

To modify an entry, highlight the line, then type [RETURN] or [ENTER].  Then in response to being presented with the product code, you must press [RETURN] or [ENTER] again; if, instead, you enter a different product code you will create a fresh entry.  You may now change the number of items on hand.  If you set this number to zero, you will delete the entry.

To delete an entry, refer to the previous paragraph.

If you make an entry for a product code that is completely out of stock, the entry will not be displayed but will remain.  Once you exit from the creation process, these entries will be displayed.

The above discussion has assumed that the window has been set to show only on-hand and stocked product codes.

If you wish to show all product codes that are not stocked, type "QN"[ENTER], if you wish to display product codes irrespective of whether they are stocked or not, type "Q"[SPACE][ENTER], and if you wish to return to displaying only stocked product codes, type "QS"[ENTER].  This selection will be remembered only until you exit from the creation of this schedule. You may also click on the menu item "Quantity", then enter "N", "S" or a [SPACE] into the field provided.

If you wish to show all stocked (or unstocked - refer previous paragraph) product codes, type "O"[SPACE][ENTER], and if you wish to return to displaying only product codes on hand, type "OO"[ENTER].  This selection will be remembered for the user until the software is next rebooted. You may also click on the menu item "Ordered picked", then enter "O" or a [SPACE] into the field provided.

In this mode (showing all product codes - not only those on hand), each product code is shown in alphabetical order.

Once you have made all entries, type [ESCAPE].  The original display will again be presented, with the new schedule positioned at the end of the queue of boxes.

Modification of Schedules

To modify a schedule, use the [LEFT] and [RIGHT] keys to move the cursor to the schedule you wish to modify. The cursor may also be moved to a schedule by clicking the mouse on the desired schedule. Once at the desired schedule, type [ENTER] or [RETURN].

Once selected, a "Set of Fields" is presented containing the schedule's details. If you are sufficiently privileged you will be asked to confirm that you wish to modify the details by pressing [F1].  You will, then, be presented with a "Set of Fields" in a window, for you to edit.

From this point, proceed as described for the creation of schedules.  Refer to the section titled: "Creation of Schedules".

Sequencing Schedules

The first schedule (or replenishment carton) to be executed will be the one corresponding to the box at the extreme left of the window. The order of execution of the schedules may be changed.

This reordering is conducted by picking up a schedule, moving it to a new position in the queue and then lowering it into this position.  Use the [LEFT] and [RIGHT] keys to move the cursor to a schedule, then the [UP] key to pick it up, then again the [LEFT] and [RIGHT] keys to move it to its new position and, finally, the [DOWN] key to lower the schedule into this position. Clicking on the schedule at the cursor will alternately raise and lower it, leaving the cursor at the schedule.

When the schedule is first picked up, the cursor remains beneath it.  The Movement Controller takes its first opportunity to separate the cursor and schedule, keeping the cursor one position to the left of the schedule, when you first type [LEFT] or [RIGHT].  As a result the first time you type the [LEFT] key only the cursor is moved or the first time you type the [RIGHT] key only the schedule is moved. The schedule may also be moved to a given place in the queue by clicking the mouse on the schedule currently in that location, placing the cursor one position to the left of the schedule if possible.

The cursor is kept one position left of the schedule to show you the contents of the schedule currently in front of the raised schedule.  The cursor is not moved automatically left because you may wish the cursor to remain beneath the schedule in order to copy it to the templates (or to the schedules if working with the templates).  More about templates later.

Using Templates

The only differences between schedules and the templates are that the schedules appear at the left whilst the templates are on the right and that the schedules are being executed whilst the templates are not.

You can switch from side to side by typing [CONTROL RIGHT] to move to the template side and [CONTROL LEFT] to return.  If at the time you switch to the templates, the schedule at the cursor is raised, a template will be created identical to the schedule; the schedule will be unaffected. You can switch from side to side by simply clicking on the side with the mouse.

If at the time you switch back to the schedules, the template at the cursor is raised, you will be presented with a "Set of Fields" for you to edit.

From this point, proceed as described for the creation of schedules.  Refer to the section titled: "Creation of Schedules".

Once you have completed any modifications you might wish to make to the new schedule, and have pressed [ESCAPE], The original display will again be presented, with the new schedule positioned at the end of the queue of boxes.  The original template will still exist and will be unaffected by the changes made when creating the schedule based on it.

Cartons Within the Conveyor System

This window allows the operator to view, modify, delete or add cartons to the carton conveyor system.  These cartons may correspond to either orders for picking or replenishment cartons for the pick areas.

This window will appear substantially blank unless some cartons are in the carton conveyor system.

The details for these cartons are normally entered via the Enter Orders for Picking and Replenish the Pick Areas windows. The schedules corresponding to these cartons are transferred to this window once the cartons are scanned on the carton conveyor system.

The ability to add cartons to the carton conveyor system (logically) is also provided by this window.

Once there are cartons on the carton conveyor system, the corresponding schedules will be represented by a boxes at the bottom of the window, arranged in the order in which they are scanned into the carton conveyor system.

Below is a rough text-representation of this window:

Cartons within the conveyor system CODE ORDERED ISSUED QUANTITY GEFFEN GEFD-24612 |Judy Collins 5 100 ^ FIE! RECORDS FIE9115 |Guy Evans and Peter Hammill 5 450 █ EMI CDP 7 46605 2 |Animals, The 5 60 █ DEMON FIEND CD 704 |Beausoleil 5 85 █ CAPITOL CDP 7 46069 2 |Band, The 5 95 █ BLUE NOTE CDP724385548420|Jacky Terrasson & Cassandra 5 450 █ ATLANTIC 7 82526-2 DISC 9|Led Zeppelin 5 █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> ■■■ ■■ <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░>

The cursor will be positioned initially at the first of the boxes at the bottom left of the window.  These characters each represent a carton on the carton conveyor system.

Reading Schedules

As the cursor is moved (using the [LEFT] and [RIGHT] keys or clicking on the desired schedule) among the schedules, the box will be shown open, and the details of the schedule will be displayed.

There will also be a horizontal scroll bar, in case the window is not large enough to present the maximum number of schedules.  This scroll bar can only be operated using the mouse - this is the fourth scroll bar on this window, so all the usual keys have been otherwise used.

If the schedule corresponds to a customer's order, at the top of the window is displayed the order's customer, while in the main body of the window are the requirements of the order.  Each requirement consists of the product code and description and the quantity required.

If the schedule corresponds to a replenishment carton, the top line of the window will be blank, while in the main body of the window are the contents of the replenishment carton.  Each replenishment consists of the product code and description and the quantity contained.

Creation of Schedules

This is not a normal activity, as these schedules are not usually created here but transferred here from the Enter Orders for Picking and Replenish the Pick Areas windows as cartons are scanned onto the conveyor system.

However, to create a schedule, press [INSERT].  You will be presented with a "Set of Fields" for you to edit.

Below is a rough text-representation of this window:

Cartons within the conveyor system Order's customer t P & O Cold Storage Customer address t 69 Mandoon Road Customer town or suburb t Girraween Town in state/province t N.S.W. State in country t Australia Country's ISD (NZ=64) a Zip mask (Canada: ###-###) a #### Town or suburb post code a 2145 Town STD (Melb=3) a Customer's phone number a 96362666 Customer's facsimile no. a 96882610 Customer's delivery notes s Order number a 111111 Special instructions a Order destination lane a 81 ■ ■■■ ■■ <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░>

This data may now be set as required.  However if you are entering the details for a replenishment carton, these details should be left blank, indicating that it is a replenishment.  Refer to the section titled: "Set of Fields".

This "Set of Fields" includes the customer (a "Symbolic Name" field), the customer's order number and any special delivery instructions - additional or overriding the customer's standard instructions - (both "Name" fields) and a destination pick area zone (a "Symbolic Name" field). For editing instructions for these types of fields, please refer to the sections titled: "Symbolic Name", and "Name".

Once you have entered this "Set of Fields", you will be presented with a substantially blank window on which the entries of the schedule will be displayed as they are entered.  To create an entry in the schedule, type [INSERT], then enter a product code and then the number required.  Repeat this for each product the order specifies.

Below, once you have made a number of entries in the schedule, is a rough text-representation of this window:

Cartons within the conveyor system Select Change Restrict Where Match Expand First Last Ordered picked Quantity GEFFEN GEFD-24612 |Judy Collins 5 100 ^ FIE! RECORDS FIE9115 |Guy Evans and Peter Hammill 5 450 █ EMI CDP 7 46605 2 |Animals, The 5 60 █ DEMON FIEND CD 704 |Beausoleil 5 85 █ CAPITOL CDP 7 46069 2 |Band, The 5 95 █ BLUE NOTE CDP724385548420|Jacky Terrasson & Cassandra 5 450 █ ATLANTIC 7 82526-2 DISC 9|Led Zeppelin 5 █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> ■■■ ■■ <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░>

To proceed from here please refer the sections titled: "Creation of Schedules", and "Creation of Schedules".

Modification of Schedules

To modify a schedule, use the [LEFT] and [RIGHT] keys to move the cursor to the schedule you wish to modify. The cursor may also be moved to a schedule by clicking the mouse on the desired schedule. Once at the desired schedule, type [ENTER] or [RETURN].

Once selected, a "Set of Fields" is presented containing the schedule's details. If you are sufficiently privileged you will be asked to confirm that you wish to modify the details by pressing [F1].  You will, then, be presented with a "Set of Fields" in a window, for you to edit.

From this point, proceed as described for the creation of schedules.  Refer to the section titled: "Creation of Schedules".

Sequencing Schedules

There is no control purpose served by reordering the schedules in this list, however you may wish to do this so as to arrange schedules corresponding to cartons of particular interest towards the front of the list for ease of reference.

This reordering is conducted by picking up a schedule, moving it to a new position in the queue and then lowering it into this position.  Use the [LEFT] and [RIGHT] keys to move the cursor to a schedule, then the [UP] key to pick it up, then again the [LEFT] and [RIGHT] keys to move it to its new position and, finally, the [DOWN] key to lower the schedule into this position. Clicking on the schedule at the cursor will alternately raise and lower it, leaving the cursor at the schedule.

When the schedule is first picked up, the cursor remains beneath it.  The Movement Controller takes its first opportunity to separate the cursor and schedule, keeping the cursor one position to the left of the schedule, when you first type [LEFT] or [RIGHT].  As a result the first time you type the [LEFT] key only the cursor is moved or the first time you type the [RIGHT] key only the schedule is moved. The schedule may also be moved to a given place in the queue by clicking the mouse on the schedule currently in that location, placing the cursor one position to the left of the schedule if possible.

The cursor is kept one position left of the schedule to show you the contents of the schedule currently in front of the raised schedule.

Carton Conveyor System

The carton conveyor diagram shows the status of the carton conveyors and their associated devices, the status of the pick-to-light system, the occupancy of the shelving and the progress of the picking.

The window will appear as shown overleaf:

Carton Conveyor System

All graphics on this window are shown to scale.

Push Buttons

There are "push buttons" presented at the foot of this window. The purpose of these push buttons is indicated by the text within them.  The first letter of this text is larger and is to be typed to "press" the button. The button may also be clicked with the mouse.

There are also two operating-system-painted buttons.  One of which, "ESCAPE: exit", is for exiting from a "push button" selection or from the window completely if no such selection is active.  The other, "HELP", calls up the help feature, refer to the section titled: "Help".

If the button is grey, it is available.  If it is dark green with black text it is unavailable.  If it is light green, it is either available with there being some particular reason that you might wish to "press" it or it is "pressed".

In response to activating certain push-buttons, the mode of control changes. This is reflected by a change in the push-buttons available.

Carton Conveyor System Status

Running conveyors are shown in green, stopped in yellow and those in alarm in red.

Clear photocells, undiverted diverters and deflated air-bags are shown dark, whereas those blocked, diverted or inflated are shown in blue.

Any alarms in the carton conveyor system are presented in the bottom right hand corner of the window.

Alarms

This section discusses each alarm that can be raised by the carton conveyor PLC.

Please bear in mind that all these alarms are based on the PLC's view of the system and may therefore be the result of a failure in the sensing mechanisms and/or circuitry or in the control mechanisms and/or circuitry.  This is not reiterated in the following discussions of the individual alarms.

The sensing mechanisms include reed switches, relay contacts, proximity switches and photocells, while the sensing circuitry includes wiring, terminations, PLC inputs, the field input power supply and circuit breakers.

The control mechanisms include cylinders and associated gates and levers, motors and associated gearboxes, belts et cetera, while the control circuitry includes circuit breakers, the field output power supply, PLC outputs, relays, solenoids, motor contactors, variable speed drives, motor circuit breakers, thermal overloads and motor isolators.  In particular, check that the motor isolators are turned on.

The following alarms may be reported:

  • Emergency stop     

    An emergency stop has been operated.  The reason for pressing the stop should be established, then, when safe to do so, the stop should be released, allowing the operation of the system to continue.

  • PLC battery flat   

    This is an alarm reported to the PLC program by the PLC. For further refer to the appropriate Allen-Bradley SLC-500 manual.

  • CI Tect DH+ link off

    There is a flag within the PLC that is set to zero by the CiTect system.  The PLC is continually setting this flag.  If the CiTect system fails to zero the flag within a given time, this alarms will be raised.

    This alarm, therefore, indicates that the CiTect system is unable to communicate or is not functioning correctly.

  • Field power lost

    The power supply for the inputs and outputs from the PLC is monitored.  If this fails, this alarm will be raised.  While this alarm is present, any other alarm should be ignored as it is very likely to be parasitic.

  • Main power lost

    The main power supply for conveyor motors, et cetera, is monitored.  If this fails, this alarm will be raised.

  • Air pressure low

    This indicates that the air pressure is low.  Any alarms associated with the actions of cylinders (such as the diverter) should be attributed to this cause.

  • Conveyor didn't start

    There are a series of these alarms, one for each conveyor. There is contactor feedback for each conveyor.  If this feedback is not seen within a given time of requesting the conveyor to run or is removed while the request is still in force, this alarm will be raised.  You should have an electrician investigate the cause.

  • Conveyor didn't stop

    There are a series of these alarms, one for each conveyor. There is contactor feedback for each conveyor.  If this feedback is not removed within a given time of requesting the conveyor to stop or is asserted while there is no request, this alarm will be raised.  This is not expected to be at all common.  You should have an electrician investigate the cause.

  • VSD not running

    There are a series of these alarms, one for each variable speed drive.  There is a signal from each variable speed drive indicating whether it is running.  If this signal is not seen within a given time of requesting the drive to power up or is removed while the request is still in force, this alarm will be raised.  You should have an electrician investigate the cause.

  • Conveyor case jam

    There are a series of these alarms, one for each conveyor.  As cases are seen to move onto a conveyor, the case is recorded on the conveyor, and as it is removed from the conveyor, this record is removed.  Each case is allowed a given time to reach the end of the conveyor, if it fails to do so within this time, then this alarm will be raised.

    This could be the result of the case being caught, or the PLC failing to distinguish the gap between the cases and, therefore, failing to remove its record of the case.

    Resetting the alarm allows the case more time to reach the end of the conveyor.  If the problem is that the PLC failed to see the gap, then the record will need to be removed from the PLC.  Please refer to the section titled: "Conveyor Mode".

  • Diverter failed

    The diverter has failed to operate within the time expected. This could be because the diverter has not moved, or has not been seen to move.

    If it has failed to move, check for obstructions, especially cases caught.

    If it has not been seen to move, check the adjustment of the proximity switches.

Certain alarms within the carton conveyor system are "latched". These alarms are usually associated with an action not completing within a reasonable amount of time.  Once these alarms are corrected, it is necessary to reset them before normal operation may recommence.  To reset these alarms type 'A'.

Other alarms, such as emergency stops, need no resetting, once the stop has been released.

Tally of Cases

In the place where the alarms are normally displayed, the tally of cases produced on the two lines may be displayed by typing "T", or, after noting the tallies, the alarms may be again displayed by typing "T" a second time.

Conveyor Mode

Conveyor mode is entered for more information or more control over the conveyors.  This is achieved by typing "C".  In response a new set of push buttons is presented, along with a list of the conveyors with the estimated number of cases on each.

The list may be scrolled using [UP] and [DOWN], [PAGE UP] and [PAGE DOWN].  These keys no longer perform vertical scrolling of the carton conveyor diagram.

One conveyor in the list will be highlighted and the border of that conveyor in the diagram will be shown in white.

You may simultaneously enter "Conveyor Mode" and select a conveyor by clicking on the conveyor.

The colour of the conveyors will be as before, except that, should the conveyor be in automatic, it will be shown in red. The devices will all be shown in grey, indicating that they are irrelevant to what you are currently about.

Each conveyor can be set to automatic, by typing "A", manually stopped by typing "M" or manually running by typing "G". Subsequent typings of "G" will switch the conveyor between manually stopped and running.

The inventory for each conveyor may be zeroed by typing "K".

The contents of each conveyor may be displayed by typing "C" (for case listing).  In response, the list of conveyors will be replaced by a list of cartons on the highlighted conveyor.  In this mode, individual cartons may be deleted by typing "D".  To return to the conveyor mode type [ESCAPE].

You may call up the contents of a conveyor by double clicking on the conveyor.

To exit conveyor mode type [ESCAPE].

Device Mode

Device mode is entered for more information or more control over the devices.  This is achieved by typing "D".  In response a new set of push buttons is presented, along with a list of the device types.

It is first necessary to select a type of device to view or control.  Once done, this list is replaced by a list of the devices of that type.

The lists may be scrolled using [UP] and [DOWN], [PAGE UP] and [PAGE DOWN].  These keys no longer perform vertical scrolling of the carton conveyor diagram.  A selection of device type is made by pressing [ENTER] once the desired entry has been highlighted - the devices do not need to be selected, only highlighted.

One device in the list will be highlighted and that device in the diagram will be shown in yellow.

You may simultaneously enter "Device Mode", and select a device type, and select an individual device by clicking on the device.

The colour of the devices will be as before, except that, should the device be in automatic, it will be shown in red.  The conveyors will all be shown in grey, indicating that they are irrelevant to what you are currently about.

Each device can be set to automatic, by typing "A", manually deactivated by typing "M" or manually activated by typing "G". Subsequent typings of "G" will switch the device between manually deactivated and activated.

A different type of device may be chosen by typing "T" then making a new selection.

To exit device mode type [ESCAPE].

Setting Case Lengths

The carton conveyor PLC is informed by others as to what product it is conveying from each cartoner.  For it to make intelligent use of this data it needs to know the case lengths and number of cases per pallet load for this product.

This information is contained within the Movement Controller and can be modified. Refer to the sections titled: "Enter or Modify Palletiser Product Data", and "Enter or Modify Palletiser Patterns".

Anytime this information is changed or added to it should be written to the carton conveyor system.  This is done by typing "S".

Pick-To-Light System Status

Each pick area is displayed as a blue rectangle, representing a unit of shelving viewed from above, with black lines around three of its sides, leaving no such border on the side from which the picking will occur.

A unit of shelving may consist of several shelves, with each shelf consisting of several compartments arranged across the shelf.  Less orthodox arrangements may also be configured.

In the centre of this rectangle is a small circle, which will be coloured to reflect the state of the pick-to-light system within this unit of shelving.  These colours (in order of precedence) are:

  • YELLOW
    The pick area is being picked.
  • RED   
    The pick area has a problem.
  • GREY  
    The pick area has stock.
  • BLACK 
    The pick area contains no stock.

Pick Area Mode

Pick area mode is entered for more detailed information or to adjust the data associated with individual pick areas or to access the pick-to-light units.  This is achieved by typing "P". In response a new set of push buttons is presented, along with a list of the picking zones.

A picking zone corresponds to a carton stopping position, where the carton is expected to be loaded.  These tie the carton stopping positions to a group of pick areas.

It is first necessary to select a zone (i.e. a group of pick areas) to view or adjust.  Once done, this list is replaced by a list of the pick areas in that zone.

The lists may be scrolled using [UP] and [DOWN], [PAGE UP] and [PAGE DOWN].  These keys no longer perform vertical scrolling of the carton conveyor diagram.  A selection is made by pressing [ENTER] once the desired entry has been highlighted.

One picking zone in the list will be highlighted and that zone in the diagram will be shown normally; the others will be grey.

One pick area in the list will be highlighted and that pick area in the diagram will be shown in light blue.

You may simultaneously enter "Pick Area Mode", and select a zone, and select a pick area by clicking on the pick area.

After selecting a zone and before examining a pick area, all pick areas may be enabled by typing "A".  This resets the "Shelf Disabled" status for all divisions of all pick areas of all zones.  This is particularly convenient when a communications link has been restored, having caused a large number of pick areas to be disabled.

A different zone may be chosen, at this time, by typing "S" then making a new selection.

To exit pick area mode, type [ESCAPE].

Examining a Pick Area

To examine a pick area, first highlight the desired pick area (as described above) then type "E".  Once a pick area has been selected for examination, the window is replaced with a face view of the selected pick area shown within a yellow border, with its neighbouring pick areas shown alongside it.

You may examine a pick area by double clicking on the pick area.

The window will appear as shown overleaf:

Carton Conveyor System - Examining a Pick Area

The pick area selected may be changed, without returning to the pick area selection window, by pressing [PAGE DOWN] for its right hand neighbour or [PAGE UP] for its left hand neighbour.

The top-left division will be shown in light blue and its details (contents and whether disabled) will be shown below the depiction of the pick areas.  Other divisions may be alternatively highlighted by using the cursor keys.  In addition, the [END] key moves you to the bottom-right division, while the [HOME] key returns you to the top-left division.

Within each division is shown the number of items to be picked, or if there is no picking, the number of items on-hand in the division.  This number will be coloured to reflect the status of the division.  These colours (in order of precedence) are:

  • YELLOW
    The pick area division is being picked.
  • RED   
    The pick area division has a problem.
  • GREY  
    The pick area division has stock.

A new set of push buttons are now provided, primarily to manipulate the data of these divisions.

The contents of the division shown in light blue may be manipulated by pressing:

  • "I"
    to modify the details.
  • "D"
    to delete/destroy/wipe the details.
  • "Z"
    to zoom-into/expand the details.
  • "C"
    to copy the details to memory/scrap-buffer/clip-board.
  • "G"
    to get the details from memory/scrap-buffer/clip-board.
  • "S"
    to swap the details with memory/scrap-buffer/clip-board.

The expanded details include the shelf pick-to-light address, the quantity to be picked, whether picking is in progress, and the reason the division is disabled.

The expansion of these details may be at the expense of the pick area window.  Once expanded, you may return to the non-expanded mode by pressing "Z" a second time.

The division could be disabled either because it could not be communicated with, or because it reported a fault with its display.  If the fault is with its display, the offending digit and segment is indicated, otherwise the text "Separate LED" is displayed.

When the memory (scrap buffer or clip-board equivalent) is set its details will be shown alongside the division's details.

The remaining push buttons allow you to access the pick-to-light unit's memory (by pressing "M") or to exit this window (by pressing [ESCAPE] or "E").

Monitor Memory

This option should only be used by people with knowledge of the hardware and software of the pick-to-light system, or under the guidance of someone who has this knowledge.

The window is now substantially green.  Within this green area is displayed the memory of the selected division.

The window will appear as shown overleaf:

Carton Conveyor System - Examining a Pick Area -- Monitor Memory

In the top left of the green, following the text "PTL Address:" is the address of this division (a pick-to-light unit) - its communications address or station number, not its memory address. This will not change as you page through the memory - it will only change if you select another division.

This is followed by the text "READ/WRITE".  Alternatively, you may access the division's program memory by pressing "P".  In response the text "READ/WRITE" will be replaced with "PROGRAM". To return to the display of the division's read-write memory, press "R".

Below this the memory is displayed twice.  The first time in decimal and the second in hexadecimal.  The memory is displayed as eight-bit bytes in five rows of sixteen columns.  The row starting addresses are shown at the left of the rows in hexadecimal and the column offsets from these addresses are shown as a single hexadecimal digit above the columns.

An asterisk (star) is shown in the hexadecimal memory area to the right of the memory location currently being interrogated.

In both the decimal and hexadecimal memory areas, one location is displayed in reverse video.  The address of this location is shown below the hexadecimal area at the right, followed by a colon, then the binary representation of the value, followed, usually, by a less-than ("<") sign then, if read-write memory and known, the description of the byte.

The reverse video may be moved using the cursor keys. The cursor may also be moved by clicking on the desired memory location.

Some individual bits within the read-write memory have descriptions.  These may be presented by typing [CONTROL LEFT] or [CONTROL RIGHT] to move through the bits.  In response:

  • The less-than sign is removed and a circumflex ("^") is presented beneath the corresponding bit.
  • The bit number is appended to the byte address.
  • The byte description is replaced with the bit description.
  • The [LEFT] and [RIGHT] move through bits not bytes, until you move beyond the last bit.

A bit can also be selected by clicking on the bit.

At the bottom of the green is presented the base address of the memory being displayed, in hexadecimal.

The base address may be increased or reduced by 50 hex by typing [PAGE DOWN] or [PAGE UP] respectively.  Alternatively, the base address may be set to an arbitrary value by typing "A" then entering the desired address.

Alternate divisions may be interrogated by typing in the pick-to-light address of the division.

To exit monitor memory mode, type [ESCAPE].

Read-Write

These features are only available when the read-write memory is selected.

The memory location highlighted in reverse video may be altered in a variety of ways.  You can set the value of the byte to a given decimal number by pressing "C" then entering the new value, or you can set the value of the byte to a given hexadecimal number by pressing "H" then entering the new value, or you can invoke the circumflex and move it to an individual bit of the byte and toggle this bit by pressing "T".

You can double click on the location rather than move the cursor there and type "C".

Any changes made to the read-write memory will be lost whenever power is removed from the device.  Upon restoration of power, part of this memory is restored from EEROM.  If you make changes to this part of the memory, you can have these changes secured to EEROM by pressing "S".

In addition, you can specify that the changes and the securing you are about to perform are to apply to all divisions by pressing "G".  In response the "GLOBAL WRITING" push button will be illuminated indicating that the changes you are making are global.

Changing the Appearance

The diagram can be scrolled (panned and tilted), rotated, and zoomed.

The [LEFT], [RIGHT], [CONTROL LEFT], [CONTROL RIGHT], [HOME], [END], [CONTROL PAGE UP], and [CONTROL PAGE DOWN] keys are used to horizontally scroll (pan) the view past the conveyors, with the [LEFT], [CONTROL PAGE UP], and [HOME] keys moving the view left while the [RIGHT], [CONTROL PAGE DOWN], and [END] keys moving the view right.  The [HOME] and [END] keys scroll to the ends while the [CONTROL PAGE UP] and [CONTROL PAGE DOWN] keys scroll by larger increments than do the [LEFT] and [RIGHT] keys.  The [CONTROL LEFT] and [CONTROL RIGHT] keys do the same as the [LEFT] and [RIGHT] keys, respectively.

The [UP], [DOWN], [PAGE UP], [PAGE DOWN], [CONTROL HOME], and [CONTROL END] keys are used to vertically scroll (tilt) the view past the conveyors, with the [UP], [PAGE UP], and [CONTROL PAGE UP] keys moving the view "higher".  The [CONTROL HOME] and [CONTROL END] keys scroll to the ends, while the [PAGE UP] and [PAGE DOWN] keys scroll by larger increments, than do the [UP] and [DOWN] keys.  The [CONTROL UP] and [CONTROL DOWN] keys do the same as the [UP] and [DOWN] keys, respectively.

By typing "R" or [SHIFT R] the display may be rotated or rotated back in 15 degree increments. [CONTROL R] will rotate the display in 1 degree increments in the reverse direction to the last "R" or [SHIFT R] key.  [ALTERNATE R] will reverse the direction for future typings of [CONTROL R].  Clicking on the "ROTATE SH.: CCW" button, with the left button, rotates the display clockwise while clicking, with the right button, rotates the display counter-clockwise.

By typing "Z" or [SHIFT Z] the display may be zoomed in or out.  [CONTROL Z] will zoom by a finer amount in the opposite direction to the last "Z" or [SHIFT Z] key. [ALTERNATE Z] will reverse the direction for future typings of [CONTROL Z].  Clicking on the "ZOOM IN SH.: OUT" button, with the left button, zooms the display in while clicking, with the right button, zooms the display out.

These changes can be made permanent for this terminal by pressing "W" to store them.  To return to the settings last made permanent, press "L".

Defining Views of the Conveyor System

This window is entered from the first by pressing "V".  When you wish to examine a portion of the conveyor system you can pan, tilt, rotate and zoom the diagram as described previously.  Alternatively, these settings may be stored and recalled as "views".

When you enter this window, the carton conveyor diagram will be returned to the settings last made permanent.  The pan, tilt, rotate and zoom functions are disabled.

A view is defined by providing it with a name, the coordinates of its centre in millimetres, the rotation in degrees and the scale in millimetres per pixel.  All these parameters, except for the name, can be set interactively and explicitly; the name must be set explicitly.

To add a view, you need to press "A" or [INSERT].  You will be then prompted to pan, tilt, rotate and zoom the window to create the desired view, then to type "D" when done.  These functions are now enabled.  Refer to the section titled: "Changing the Appearance".  Once you are satisfied with the appearance of the system for this view, type "D".  In response, you will be presented with a set of fields.  You will need to set the name of the view and may, optionally, make adjustments to the other parameters, which have been set from the pan, tilt, rotate and zoom operations you have just completed.

This set of fields includes the view's name (a unique "Name" field), the x and y coordinates of the centre of the view, the angle of rotation, and the scaling (all "Numeric" fields).  For editing instructions for these types of fields, please refer to the sections titled: "Name", and "Numeric".

As views are defined, they will be listed to the right of the push buttons, with one entry highlighted.  The highlight may be moved to other entries using the following keys:

  • [UP]               
    Move the highlight up one line
  • [DOWN]             
    Move the highlight down one line
  • [PAGE UP]          
    Move the highlight up seven lines
  • [PAGE DOWN]        
    Move the highlight down seven lines
  • [CONTROL PAGE UP]  
    Move the highlight to the first line
  • [CONTROL PAGE DOWN]
    Move the highlight to the last line

These views are also presented on the carton conveyor diagram as thin rectangles.  The rectangles will be coloured black, except for the rectangle corresponding to the highlighted entry, which will be coloured yellow.

A view may be highlighted by clicking within the corresponding thin rectangle.

The highlighted entry may be modified by pressing "M".  In response, the carton conveyor diagram will be panned, tilted, rotated and zoomed in accordance with the selected view.  You will be then prompted to pan, tilt, rotate and zoom the window to create the desired view, then to type "D" when done, as was the case when adding a new type. After typing "D", you will not be required to enter a name for the view as it already has one, however, the name and the other parameters may now be edited explicitly if so desired.

It is desirable to be able to set the parameters explicitly if creating a series of views that you wish to be same in all respects except for, say, the x coordinate.

The highlighted entry may be deleted by pressing "D" or [DELETE].

Finally, the highlighted view may be selected as the current view, by typing "S" or [ENTER].  In response, the carton conveyor diagram will be panned, tilted, rotated and zoomed in accordance with the selected view and you will be returned to the first carton conveyor diagram window.

A view may be selected by double clicking within the corresponding thin rectangle.

To return to the first carton conveyor diagram window, without selecting a view, press [ESCAPE].

To cancel a view, when back at the first carton conveyor diagram window, type "L" to return to the settings last made permanent.

Palletiser Status and Commands

This window shows the states of all the devices making up the palletiser, along with the expected positions of the cartons on the palletiser.

The window will appear as shown overleaf:

Palletiser Status and Commands

Blocked photocells and proximity switches are shown in yellow, while clear photocells are shown in grey.  Risen gates are shown in blue, while lowered gates are shown in a dark colour.  Running conveyors are shown in green, while stopped are shown in red for automatic or yellow for manual.  If the palletiser is off, these are shown in grey.

Light barriers are shown in yellow if in tact or grey otherwise. Pilot lamps are shown in a variety of colours if on, or dark if off.

The lift chains are shown in green if the lift is rising and in blue if lowering.  The position of the lift is estimated from knowledge of the load and the states of the sensors.

Any alarms associated with the palletiser are shown in the top right hand corner of the window.  When there are no alarms to display, one of the following messages will be displayed:

  • I'm happy, check the pallet conveyors
    if an alarm is present in the Heavy-Unit-Load Conveyor System.  This should be accompanied by the push button advertising the Heavy-Unit-Load Conveyors diagram being lit in light green.
  • I'm happy, check the infeed conveyors
    if an alarm is present in the carton conveyor system.  This should be accompanied by the push button advertising the carton conveyors diagram being lit in light green.
  • I'm happy, what's your problem
    if unaware of any alarm.

Push Buttons

There are "push buttons" presented at the lower right hand side of this window.  The purpose of these push buttons is indicated by the text within them.  The first letter of this text is larger and is to be typed to "press" the button. The button may also be clicked with the mouse.

There are also three operating-system-painted buttons.  One of which, "Palletiser select", can be used to select another palletiser.  The "ESCAPE: exit" button is for exiting from a "push button" selection or from the window completely if no such selection is active.  The "HELP" button calls up the help feature, refer to the section titled: "Help".

If the button is grey, it is available.  If it is dark green with black text it is unavailable.  If it is light green, it is either available with there being some particular reason that you might wish to "press" it or it is "pressed".

In response to activating certain push-buttons, the mode of control changes. This is reflected by a change in the push-buttons available.

Alarms

This section discusses each alarm that can be raised by the palletiser PLC.

Please bear in mind that all these alarms are based on the PLC's view of the system and may therefore be the result of a failure in the sensing mechanisms and/or circuitry or in the control mechanisms and/or circuitry.  This is not reiterated in the following discussions of the individual alarms.

The sensing mechanisms include reed switches, relay contacts, proximity switches, photocells, fork lift detection loops and light curtains, while the sensing circuitry includes wiring, terminations, PLC inputs, the field input power supply and circuit breakers.

The control mechanisms include cylinders and associated gates and levers, motors and associated gearboxes, sprockets, chains, pulleys, belts et cetera, while the control circuitry includes circuit breakers, the field output power supply, PLC outputs, relays, solenoids, motor contactors, variable speed drives, motor circuit breakers, thermal overloads and motor isolators. In particular, check that the motor isolators are turned on.

There are two classes of palletiser alarms: alarms that stop the palletiser, alarms that advise that an operator action is required.

The following alarms belong to this first class:

  • Open case flap
  • Open or no barcode

    There are three photocells at the metering belt.  Depending on the product believed to be at this position, one of these photocells, at least, will be expected to be clear.  If this photocell is blocked, either because a case flap is open or the carton is not of the expected product, the metering belt will stop and this alarm will be raised.

    Had there been a no-read from the barcode scanner in the last five seconds, there is an increased chance that the cause is that the carton is not of the expected product, being falsely assumed to be the same as the previous carton as a result of a no-read.  Under these circumstances, the second of these alarms is raised instead.

    To clear this alarm, you will need either to reseal the flap or amend the expected cartons.

  • Infeed guide fault

    The infeed guide's reed switches did not indicate that the guide had moved to the intended position within the time allowed.  This could result from insufficient air pressure, an obstruction (such as a carton in the wrong orientation or of the wrong product) or badly adjusted reed switches on the cylinders.

  • Meter belt PE
  • Turn peg PE
  • Row entry PE
  • Row gate A PE
  • Row gate B PE
  • Row gate C PE
  • Row gate D PE
  • Row gate E PE
  • Row gate F PE
  • Glue spray PE

    The nominated photocell has been blocked for too long while the belt or rollers have been running.  This could indicate that the photocell is out of adjustment, there is a carton stuck at this position or two or more cartons passed without the photocell seeing a gap.

  • Row sweep intrusion

    The row sweep intrusion photocell is just beyond the row sweep bar.  This photocell must be clear for a row sweep to be able to run.  If this photocell is blocked at this time, then this alarm is latched.

    Generally you will find a carton in front of this photocell that will need to be relocated according to the arrangement of cartons shown on the window.

  • Row sweep failed

    This indicates that the row sweep bar failed to travel out and back within the expected time.  Check for cartons (or other items) blocking its progress.

  • Layer exit gate flt

    This indicates that the layer exit gate failed to lower in the time expected.  Check the air pressure and then the reed switch adjustment.

  • Layer side fault
  • Apron side fault
  • Apron end fault

    This indicates that the corresponding compression operation failed to either extend or retract in the time expected. Check the air pressure and then the reed switch adjustment.

  • Layer transfer fail

    There is a photocell just beyond the layer exit gate.  This is expected to be clear before the layer transfer is deemed to be complete.  Check that cartons are not straggling behind and that the photocell is correctly aligned.

  • Layer VSD fault
  • Apron VSD fault
  • Lift VSD fault

    These faults indicate that the corresponding variable speed drive has signaled that it has a fault.  You should refer to the drive's display for further details.  To reset the fault, you can cycle the power to the drive by dropping the master control relay.  This is accomplished by hitting any emergency stop associated with this system.

  • Apron open/close fl

    The apron has failed to open or close within the time expected.  This could be because the apron has not moved, or has not been seen to move.

    If it has failed to move, check for obstructions.  Should you need to enter the lift to do this you should follow the isolation procedure.

    If it has not been seen to move, the apron is likely to have overrun the proximity.  Check the adjustment of the proximity switches.

  • Pallet part in lift

    This implies that either the photocell at the rear of the lift or the photocell beyond the load stop is blocked while the Heavy-Unit-Load Conveyor System has deemed the transfers into and out of the lift to have been completed.

    This could result from problems with the Heavy-Unit-Load Conveyor system transfers.  For more details on these problems, refer to the section of the TECHNICAL MANUAL titled: "Transferring Loads".

    To correct the problem, you will need to relocate the loads on the Heavy-Unit-Load Conveyor System to the positions shown on the Heavy-Unit-Load Conveyors diagram.  This can be achieved using the "push button control" via the Heavy-Unit-Load Conveyors diagram.  Please refer to the section titled: "Control of Loads".

  • Lift gone too high

    There is an overrun proximity at the top of the permitted lift travel.  If the lift contains a good pallet, of the correct dimensions, the lift should have stopped a short time after the first of the six photocells below the curtain have been blocked.

    The most common cause is the lift not having a pallet on board, however other causes include the proximity switch or slow down photocells being out of adjustment and the variable speed drive not reacting fast enough (incorrect settings).

    The alarm can not be reset until the lift is lowered; this must be done in manual.  If you intend to reject the load, return to automatic mode on the window and type "R", before resetting the alarm, so that the system does not immediately attempt to raise the load again.

  • Lift up PE when down

    One of the six photocells under the apron is blocked while the lift is down.  This should indicate a photocell that is out of adjustment, or that a piece or cardboard has been left behind blocking one of these photocells.

    Another cause could be the palletiser attempting to load too many layers on the pallet.

  • Lift up PE disagree

    The lift rises until the first of the six photocells under the apron is blocked, then travels for a little longer expecting the remaining photocells to become blocked in this time.  If this fails to happen, this alarm is raised.

    Typical causes include bad pallets, cartons not sitting down, carton flaps sticking up, or photocells out of adjustment.

  • Lift up/down failed

    The lift is allowed a certain amount to time to travel from the down proximity to the overrun proximity (and reverse).  If it did not complete within this time, this alarm is raised.

    This could be because the lift has not moved, or has not been seen to move.

    If it has failed to move, check for obstructions.

    If it has not been seen to move, the lift is likely to have overrun the proximity.  Check the adjustment of the proximity switches.

  • PLC battery flat

    This is an alarm reported to the PLC program by the PLC. For further refer to the appropriate Allen-Bradley SLC-500 manual.

  • Lower light curtain
  • Upper light curtain

    There is or was an obstruction to the light curtain.  This obstruction should be removed and the appropriate light curtain reset push button operated before the alarm can be reset.

    Should the alarm remain, the alignment of the light curtain should be checked and adjusted.  Otherwise there may be a fault with the unit.

    Please note that the light curtains appear to have a "bug filter", allowing them to be automatically reset after a momentary violation.  There is no corresponding filter in the PLC software, so it is possible that these alarms may be set while the light curtain appears not to have been interrupted.

  • No case @ turn peg
  • No case @ row entry

    These alarms arise when a carton is expected at these locations but has either failed to arrive or pass within a reasonable time.  The problem could be that the machine has failed to count correctly at an earlier photocell, or that the carton was delayed in its travels.

    You should relocate the cartons to reflect the arrangement shown on the window.

The following alarms belong to the second class (advice):

  • Stopped:Press start

    This is a reminder that the system will not run until the start button is pressed.

  • No empty pallets

    This is a reminder to load some more pallets at the heavy-unit-load conveyor infeed.

  • Outfeed chockers

    This is a request to remove the loads from the outfeed so that the system may continue to operate.

  • Many barcodes late

    The barcode reader is expected to return a barcode within a given time after the carton has passed the photocell.

    This alarm indicates that, recently, the number of missed barcodes is excessive.

    To be more explicit, if a barcode is not received in time, a tally is incremented.  If a barcode is received, the tally is decremented.  If the tally reaches 5, this alarm is raised, whereas if it makes it back to 0, this alarm is cleared.

    If the rate exceeds 50% eventually the alarm will be raised, whereas if the rate is below 50% eventually the alarm will be cleared.  There is no point resetting this alarm.

  • Many barcode noread

    The barcode reader should report for every carton, with either a barcode or a no-read.

    This alarm indicates that, recently, the number of no-reads is excessive.

    To be more explicit, if a no-read is reported, a tally is incremented.  If a barcode is reported, the tally is decremented.  If the tally reaches 5, this alarm is raised, whereas if it makes it back to 0, this alarm is cleared.

    If the rate exceeds 50% eventually the alarm will be raised, whereas if the rate is below 50% eventually the alarm will be cleared.  There is no point resetting this alarm.

Most alarms within the palletiser are "latched".  These alarms are latched either because they are associated with an action not completing within a reasonable amount of time, or so that the alarm, if possibly fleeting or intermittent, is captured. Once these alarms are corrected, it is necessary to reset them before normal operation may recommence.  To reset these alarms type 'A'.

Other alarms, such as emergency stops, need no resetting, once the stop has been released.

Tally of Cases

In the place where the push buttons are normally displayed, the tally of cases produced on the two lines feeding the palletiser may be displayed by typing "C".  After noting the tallies, the push buttons may be again displayed by typing any key.

Finish Load

This function causes all cartons known to the palletiser to be gathered onto the pallet, without waiting for the complete load. This would typically be done when shutting down.  Type "F" to invoke this function.

Reject Pallet

This function causes the pallet in the lift to be lowered and transferred from the lift.  This would typically be done when you are dissatisfied with the pallet in the lift.  Type "R" to invoke this function.

Palletiser Semi-Automatic

In automatic, the PLC decides when to perform its various cycles and controls a number of devices to achieve each cycle.  In semi-automatic, you leave the coordination of the devices to the PLC but take over the decision as to when each cycle is to be performed.  Type "S" to enter this mode.  Once you do so the PLC will cease to start any new cycles.

The push buttons will be replaced with a new set listing the keys that control the semi_automatic operations.

If one of these buttons is grey, there is no outstanding action. If it is light green, it has requested the PLC to perform a semi-automatic operation and has not yet been informed by the PLC of its compliance. If it is dark green, it has been informed by the PLC that it has started/completed (depending on how the PLC handles the operation) the requested operation and has removed its request.  Once the PLC acknowledges that it has seen the request removed, the button will be returned to grey.

The semi-automatic cycles are:

  • "C"
    Release a case from the metering belt
  • "R"
    Sweep a row onto the layer area
  • "T"
    Transfer a layer onto the apron
  • "A"
    Release the layer onto the lift
  • "D"
    Discharge the load on the lift

Type [ESCAPE] to exit semi-automatic mode.  The palletiser will immediately resume automatic operation.

Palletiser Manual Mode

In automatic, the PLC decides when to perform its various cycles and controls a number of devices to achieve each cycle.  In manual, you take over all these responsibilities.  Type "M" to enter this mode.  Once you do so, the PLC will stop all motors it controls and will freeze all other outputs until you instruct it otherwise.

The push buttons will be replaced with a new set listing the keys that control the manual operation for most of the devices.

If one of these buttons is grey, it is untouched.  If it is light green, it is turned on.  If it is dark green with black text it is turned off.

The manual control keys are:

  • "S"
    corresponds to the enabling/disabling of the glue spray unit.
  • "I"
    corresponds to the operation of the infeed guide.
  • "T"
    corresponds to the operation of the turn peg (off = turn).
  • "M"
    corresponds to the running of the metering belt.
  • "W"
    corresponds to the running of the wider infeed rollers.
  • "R"
    corresponds to the running of the row form area rollers.
  • "N"
    corresponds to the running of the row sweep arm.
  • "L"
    corresponds to the running of the layer area rollers.
  • "H"
    corresponds to the selection of speed for the layer area rollers.
  • "A"
    corresponds to the running of the apron rollers.
  • "O"
    corresponds to the running of the apron open or close.
  • "U"
    corresponds to the running of the lift up.
  • "D"
    corresponds to the running of the lift down.

In addition, the keys "C", "G" and "P" allow you to enter the sub-manual modes to control the compressing of the loads, the gates and the pilot lamps respectively.  These sub-modes may be exited by typing [ESCAPE].

Type [ESCAPE] to exit manual mode.  The palletiser will immediately resume automatic operation.

Motors Versus Solenoids

To control a motor, the key corresponding to a push button must remain pushed for it to run, as distinct to controlling a solenoid, where the state of the solenoid is switched with each alternate key press.  Do not hold on keys corresponding to the manual control of solenoids.

When controlling a solenoid, the corresponding push button becomes illuminated light green when turned on or dark green when turned off.

When controlling a motor, the corresponding push button becomes illuminated light green when on and reverts to grey when off.

The infeed guide push button relates to several cylinders and will cycle through the positions with alternate presses.

High speed push buttons behave as the solenoid push buttons, as the actual control of the motor is handled by another button.

Palletiser Gates

There are many gate controls, each corresponding to one of the possible gates within a palletiser.  Initially, the manual control of these devices will cause them to remain in the state they were left in by the automatic control.

These controls allow the user to raise then lower each gate individually.

The main row entry gate is controlled by pressing "R", while the remaining row entry gates are controlled by pressing "!", "@", "#" and "$".  These correspond to [SHIFT 1], [SHIFT 2], [SHIFT 3] and [SHIFT 4] and refer to the first, second, third and fourth gates prior to the main row entry gate.

The row form area gates are referred to as "A" to "F" and are controlled by pressing the corresponding keys.  These gates are usually allocated starting from the gate nearest the main row entry, however, gates may be added later in the design and may therefore not fit this pattern.  You are best to refer to the drawings.

The end stop, though not actually a gate, is controlled by pressing "S".

The layer gates are referred to as "1" to "4" and are operated by pressing the corresponding key.

The layer exit gate is controlled by pressing "L".

The state of these controls will toggle each time the corresponding key is pressed.  As the state toggles, the corresponding push button becomes illuminated light green when compressing or dark green when retracting.

To return to the main manual control functions, press "M" or [ESCAPE].

Palletiser Compress

There are three compress controls.  Initially, the manual control of these devices will cause them to remain in the state they were left in by the automatic control.

The three controls relate to the side compression of the layer area ("L"), and the side ("S") and end ("E") compression of the apron area.

The state of these controls will toggle each time the corresponding letter is pressed.  As the state toggles, the corresponding push button becomes illuminated light green when compressing or dark green when retracting.

To return to the main manual control functions, press "M" or [ESCAPE].

Palletiser Pilot Lamps

There are several pilot lamps.  Initially, the manual control of these devices will cause them to reflect the status they were designed to reflect.

These controls allow the user to exercise these lamps.

The pilot lamp manual control keys are:

  • "D"
    corresponds to the main dome lamp.
  • "U"
    corresponds to the upper light curtain pilot lamp.
  • "L"
    corresponds to the lower light curtain pilot lamp.
  • "M"
    corresponds to the manual mode pilot lamp.
  • "A"
    corresponds to the automatic mode pilot lamp.
  • "S"
    corresponds to the stopped mode pilot lamp.

The state of these controls will toggle each time the corresponding key is pressed.  As the state toggles, the corresponding push button becomes illuminated light green when turned on or dark green when turned off.

To return to the main manual control functions, press "E" or [ESCAPE].

Edit Cartons

When the palletiser's knowledge of the position of cases is in error, it is usually simplest to rearrange the cases as shown on the window.

If this is impractical, you may clear up the situation using the semi-automatic commands, then zero the case counters.  This is done by typing "E" to enter the edit cartons mode, then typing "Z" to zero the counters.  The load in the lift is then discharged.

Alternatively, you may, should you be of sterner stuff, attempt to correct the palletiser's view of the cartons by editing this data.  The data at the glue spray, the metering belt, the turn peg, the row entry, the layer form, the apron and the lift are presented in the top centre of the window.

Each line of data consists of the product code (accompanied by the pattern name), followed by the coordinates of the next carton expected at these locations.  When editing these, horizontal and vertical pointers are provided to indicate which datum is to be edited.  Once the pointers are positioned using the cursor keys or clicking on the location, type [ENTER] then enter the new value.

This is further complicated should the end of a load occur. Here a single line may contain two sets of data, one black relating to the end of the load and the other indicating how far into the next load we have progressed.  In these circumstances, after editing one line vertically scroll to the next and edit it as well.

Once happy, press [ESCAPE] to exit and see how it goes.

Running Without a Barcode Reader

Should the barcode reader fail, it can be disabled by typing "B" followed by entering the product code of the expected cartons. It is then necessary to type "B" again and enter the product code each time the line is cleared for a new product.

When disabled the push button advertising this will be coloured light green.

To bring the barcode reader back into service type "B" and enter a blank product code.

Disabling the Glue Spray

The operation of the glue spray is determined on a pattern and product basis.  Refer to the sections titled: "Enter or Modify Palletiser Patterns", and "Enter or Modify Palletiser Product Data".

If however, contrary to these settings you require the current batch not to be glued, type "G".

When disabled the push button advertising this will be coloured light green.

To bring the glue spray back into operation type "G" a second time.

Writing Pattern Data

The palletiser PLC is informed by its barcode reader of the product it is receiving.  For it to make intelligent use of this data it needs to know the product code to which the barcode relates, the pattern to be used for this product et cetera.

This information is contained within the Movement Controller and can be modified. Refer to the sections titled: "Enter or Modify Palletiser Product Data", "Enter or Modify Palletiser Patterns", and "Enter or Modify the Palletisers".

Anytime this information is changed or added to it should be written to the palletiser.  This is done by typing "W".  The palletiser is switched to manual while the transfer takes place.

Accessing the Pallet Conveyor System

You can call up the Heavy-Unit-Load Conveyors diagram from this window by typing "P".  Subsequently, when you exit the Heavy-Unit-Load Conveyors diagram, you will be returned here.

Accessing the Carton Conveyor System

You can call up the carton conveyors diagram from this window by typing "I".  Subsequently, when you exit the carton conveyor diagram, you will be returned here.

Machine Status Display

A "machine" is a mechanism that requires more status monitoring than is afforded by the definition of devices within the Heavy-Unit-Load Conveyor System and has not had explicit software developed for it (as in the case of cranes and palletisers).

The window will appear as shown overleaf:

Machine Status Display

Alternative machines may be selected by activating the "Machine" option from this window's horizontal menu bar. In response a dialogue window will appear with a "Symbolic Name" field that should be used to select the desired machine. Refer to the section titled: "Symbolic Name". You can also page through the different machines using [PAGE UP] and [PAGE DOWN], or by clicking on "PAGE-UP" and "PAGE-DOWN" in the window's menu.

In the top left corner of the window is the name of the machine, while the status and alarms, active in the machine at this point in time, are shown in dedicated areas of the window.  There may also be an area dedicated to push-buttons to control the machine.

The status is also displayed graphically.

Push-buttons may be presented in a number of colours.  These colours are:

  • Off     
    indicating that the button is off but able to be pushed.
  • On      
    indicating that the button is on.
  • Disabled
    indicating that nothing can happen by pressing it.
  • Alarm   
    indicating a abnormal condition is associated with it.

Push-buttons may be activated by either typing the first, enlarged, character presented in the button, or by clicking on it.  The button will change colour to indicate that it is in operation.

Most of these buttons are latched; do not hold them down, but rather, in the case of manual operations, be prepared to reactivate them to toggle them off and, thereby, stop the operation.

If, however, the button is presented with an etched circle, then the button is active only while it is being held down.  You hold the button down by either holding down the corresponding key, or pressing the mouse button down while the mouse is over the button and keeping it down.  If the mouse moves off the button while the button is held down, the button is not released.

What is actually presented is determined by the definition of the machines.  For details on defining these machines, please refer to the sections titled: "Enter or Modify Machine States", "Enter or Modify Machine Alarms", "Enter or Modify Machine Controls", and "Enter or Modify Machine Definition".

Configuration for Americold

There are two "machines", the "Freezer Detierer", and the "Chiller Detierer".

These windows allow you to, more conveniently than via the conveyor diagram, observe the state of a detierer and to control it manually.

These windows provide buttons that can be used to set the corresponding conveyor (M02A or M52A) to manual or automatic.  The corresponding conveyor must be set to manual before the manual control buttons can be used.

When these conveyors are set to manual in this way, they must be set back to automatic in the same way, though any terminal on the network can be used to do this.  If you right click on the conveyor on the conveyor diagram, while it is set to manual via this window, it will show the controlling location to be "Indirect", rather than a specific terminal; this is intended to tell you that it is held in manual via the machine status window.

These windows present their status, graphically, in the following areas:

  • Elevation
  • Plan view

Below these areas are the control buttons, while to the right is presented the status in text form.

In the "Elevation" area, it presents the entry and exit height photocells, the photocells that look to find the gap in a pallet and that to see below the pallet, and the vertical position of the forks.

In the "Plan view" area, it presents the too-far left and right exit photocells and whether the forks (or pegs) are back, extended, or fully inserted into a pallet.

Controls

Firstly, at the right, are the push-buttons to set the corresponding conveyor to manual or automatic ("MANUAL MODE" and "AUTO MODE").

The remaining buttons are only operable when the conveyor is in manual and allow you to raise and lower the detierer's forks, and to extend or withdraw them.

Produce Reports

This menu provides access to the windows required to generate the reports (other than the communications reports).

The physical printing of a file is handled by the MS-DOS batch file "prnqueue.bat".  If you wish the reports to be sent to a network printer, you should modify this file, replacing "/D:\\.\LPT1" with the suitable description for the network printer you wish to use, such as: "/D:\\server\printer", where "server" is the machine name (which might be an IP address), and "printer" is the name of the printer on that machine (which might be something like "HPLaserJ").

The reports can be produced for the old style IBM printers, or those emulating the Hewlett-Packard PCL language.  You may make this selection and alter other parameters controlling the formatting of the report on a page by setting the "Using HP DeskJet", "Print wide reports A4", "Print wide in landscape", "Lines in portrait", and "Lines in landscape" records of the "Configuration Data" database.  Please refer to the section titled: "Configuration Data".

Below is a rough text-representation of this menu:

Movement Controller (C) Copyright 1998 to 2009 Woodgrove Digital Engineering File View ┌─-─────────────────────┐ │New User │ │Operations >│ ┌─-─────────────────────────────────────┐ │Reports███████████████>│ │Produce report listing events │ │Communication reports >│ │Produce report listing load movements │ │Configuration >│ │Produce conveyor alarm summary │ │Maintenance >│ │Produce report listing store occupancy │ │Definition >│ │Produce report showing store matrix │ │Special Functions >│ │Produce crane alarm summary │ │Exit │ └─-─────────────────────────────────────┘ └─-─────────────────────┘

Most of the report windows are "Report Viewing Data" windows. For these refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Event Log Historic Report

This "Report Viewing Data" window is used to set up the restrictions, then produce a report listing each of the event logs, with time and date of the event and the description. For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Below is a rough text-representation of this window:

Event log historic report Print Restrict Match Expand First Last 19:52:59 19-JAN-99|ALARM 1000 Standby computer is not responding ^ 19:47:49 19-JAN-99|Graham Moore at Console has logged on █ 19:47:49 19-JAN-99|Clear 999 Crane communications failure █ 19:40:49 19-JAN-99|Clear 998 Conveyor communications failure █ 19:40:49 19-JAN-99|ALARM 999 Crane communications failure █ 19:40:49 19-JAN-99|ALARM 998 Conveyor communications failure █ 16:55:56 19-JAN-99|Software started █ 19:11:19 19-JAN-99|ALARM 1000 Standby computer is not responding █ 18:03:08 19-JAN-99|Graham Moore at Console has logged on █ 18:03:08 19-JAN-99|Clear 999 Crane communications failure █ 17:35:37 19-JAN-99|Clear 998 Conveyor communications failure █ 17:03:07 19-JAN-99|ALARM 999 Crane communications failure █ 17:00:07 19-JAN-99|ALARM 998 Conveyor communications failure █ 17:00:07 19-JAN-99|Software started █ 17:00:07 19-JAN-99|Des Hindes at Console : Set Inhibit shuttle S2█ 16:59:56 19-JAN-99|Des Hindes at Console : Issued a manual shuttl█ 16:58:56 19-JAN-99|Des Hindes at Console : Crane command - Set Cr█ 16:57:56 19-JAN-99|Clear 7 Crane: Loaded low vac hd 2 █ 16:56:56 19-JAN-99|Des Hindes at Console : Crane command - Reset V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Event log Event: Time 19:52:59 19-JAN-99

Load Log Historic Report

This "Report Viewing Data" window is used to set up the restrictions, then produce a report listing each of the load movement logs, with time and date of the movement log, the load details, the location to which it has moved and whether it has completed the journey at that point. For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Below is a rough text-representation of this window:

Produce report listing load movements Print Restrict Match Expand First Last 19:53:58 19-JAN-99|400345001|41:16-H-023-2|A|BB8P9 ^ 19:47:46 19-JAN-99|M01AC | |C| █ 19:42:46 19-JAN-99|400345013|41:13-M-018-2|A|BBQWE █ 19:42:44 19-JAN-99|400345001|41:15-A-001-1|C|BB8P9 █ 19:40:12 19-JAN-99|400345022|41:05-B-045-2|A|BBSRT █ 19:12:12 19-JAN-99|400345013|41:13-A-001-1|A|BBQWE █ 18:13:10 19-JAN-99|400345001|M53AC |C|BB8P9 █ 18:10:04 19-JAN-99|400345001|41:06-A-001-1|C|BBSRT █ 18:09:08 19-JAN-99|400345013|41:16-A-001-1|A|BBQWE █ 18:05:54 19-JAN-99|M52AC | |C| █ 17:53:42 19-JAN-99|400345013|41:16-B-065-1|A|BBQWE █ 17:49:48 19-JAN-99|400345022|M03AC |C|BBSRT █ 17:44:42 19-JAN-99|M51AC | |C| █ 17:43:42 19-JAN-99|400345011|41:10-L-051-2|A|BBRTG █ 17:42:34 19-JAN-99|M52AC | |C| █ 17:39:36 19-JAN-99|400345001|M02AC |C|BB8P9 █ 17:36:34 19-JAN-99|400345011|41:10-A-001-2|A|BBRTG █ 17:35:38 19-JAN-99|M51AC █ 17:32:26 19-JAN-99|M01AC V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Movement log Movement: Time 19:53:59 19-JAN-99

The load movement log logs the significant moves made by each load.  A move is significant if it causes the Movement Controller to adjust its inventory to show the load in a new location.

Conveyor Alarm Summary Report

This "Report Viewing Data" window is used to set up the restrictions, then produce a report listing each of the conveyor alarms with the number of instances of these alarms during the reporting period. For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Below is a rough text-representation of this window:

Produce conveyor alarm summary Print Restrict Match Expand First Last 1|Transfer C202 to C205 failed to complete in the time allowed|C202A| |Tran^ 2|Index C205B to C205A failed to complete in the time allowed |C205B| |Tran█ 3|Transfer C205 to CR05 failed to complete in the time allowed|C205A| |Tran█ 4|Transfer C203 to C204 failed to complete in the time allowed|C203A| |Tran█ 5|Index C204B to C204A failed to complete in the time allowed |C204B| |Tran█ 6|Transfer C204 to CR04 failed to complete in the time allowed|C204A| |Tran█ 7|Transfer C209 to C210 failed to complete in the time allowed|C209A| |Tran█ 8|Transfer C210 to C211 failed to complete in the time allowed|C210A| |Tran█ 9|Transfer C211 to C212 failed to complete in the time allowed|C211A| |Tran█ 10|Transfer C212 to C213 failed to complete in the time allowed|C212A| |Tran█ 11|Transfer C213 to C214 failed to complete in the time allowed|C213A| |Tran█ 12|Transfer C214 to C215 failed to complete in the time allowed|C214A| |Tran█ 13|Transfer C215 to CR16 failed to complete in the time allowed|C215A| |Tran█ 14|Transfer C218 to C219 failed to complete in the time allowed|C218A| |Tran█ 15|Transfer C219 to C220 failed to complete in the time allowed|C219A| |Tran█ 16|Transfer C220 to C221 failed to complete in the time allowed|C220A| |Tran█ 17|Transfer C221 to C222 failed to complete in the time allowed|C221A| |Tran█ 18|Transfer C222 to C223 failed to complete in the time allowed|C222A| |Tran█ 19|Transfer C223 to C224 failed to complete in the time allowed|C223A| |TranV <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Conveyor alarms Conveyor alarm Transfer C202 to C205 failed to complete in the time

After terminating the restrictions, you will be asked whether you wish "All tallies" to be listed, or the "Non-zero only", allowing you to get a report covering all alarms, even those which have not been active during the reporting period, or, as is more normal, a report listing only those alarms that have been active during the reporting period.

Upon answering this question, you will be asked whether you wish to print tallies fo the "Current period" or the "Last period", allowing you to request either the completed period (the "last" period) or the current, incomplete period to report on.

In order to adjust the alarm reporting period, refer to the section titled: "Control Mode of Operation" and, in particular, its subsection titled: "Alarm Summary Period".

Produce Report Listing Store Occupancy

This "Report Viewing Data" window is used to set up the restrictions, then produce a report listing each of the store locations (a "Store Reference" field), with its occupancy status, whether it exists, its enable/inhinit status, and storage type - storage, flow-through or pickup/deposit to conveyor - (all "Character" fields).

This is then followed by the barcode, whether its available for use by the Movement Controller when it needs to relocate a front load and its index into the load detection system.

For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Below is a rough text-representation of this window:

Product report listing store occupancy Print Restrict Match Expand First Last 42:16-A-024-1|O|F| L:0400 ^ 42:16-A-048-1|O|F| L:0900 █ 42:15-C-010-1|O|F| L:0008 █ 42:15-E-010-1|O|F| L:0028 █ 42:15-G-010-1|O|F| L:0048 █ 42:15-J-010-1|O|F| L:0068 █ 42:15-C-027-1|O|F| L:0019 █ 42:15-E-027-1|O|F| L:0039 █ 42:15-G-027-1|O|F| L:0059 █ 42:15-J-027-1|O|F| L:0079 █ 42:15-C-045-1|O|F| L:0487 █ 42:15-E-045-1|O|F| L:0507 █ 42:15-G-045-1|O|F| L:0587 █ 42:15-J-045-1|O|F| L:0607 █ 42:15-C-062-1|O|F| L:0498 █ 42:15-E-062-1|O|F| L:0518 █ 42:15-G-062-1|O|F| L:0598 █ 42:15-J-062-1|O|F| L:0618 █ 42:15-C-037-1|O|S| S:0000 V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Rack locations Store Occupied<O>a O

Having made any restrictions, and asking to print the report, you will be asked to nominate whether you wish the report to include "All" locations, or only the "Occupied" locations.

For editing instructions for this type of field, please refer to the section titled: "Character".

Produce Report Showing Store Matrix

This report produces a store map showing locations of loads.

This window first presents a store layout, to allow the restriction of the report.

Below is a rough text-representation of this window:

Produce report showing store matrix Select Change Restrict Where Match Expand Insert First Last Number of loads 370 ^ ┌───┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬────┬───┐█ │■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪■▪▪▪▪■▪▪▪■■■■▪▪■■▪▪■■■■■▪■■▪■■■■■■■■▪■■│█ │▪▪▪▪■▪■▪▪▪▪■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪▪▪■■▪▪▪▪▪■■▪▪▪■■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪│█ │■■■■■■■■■■■■■■■■■■■■■■■▪■■■■■■■■■■■■■■■■■■■■▪■■■■■■■■■■■■■■■■■■■■■▪■■■■■│█ │▪■■■▪▪■▪■■■▪■■■■■■■■■■■■▪■▪■■■■■■■■■■■■■■▪■■■■■■■■■■■■■■■▪■■■■■■■■■■■▪■■│█ │■■▪■■■▪■■■■■▪▪■■■■■■■■■■■■■▪■■■■■▪■■■■■■▪■■■■■■■▪■■■■■■■■■■■■■■■■■■■■■■■│█ │▪▪▪▪▪■■■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪▪▪▪▪▪▪▪■▪▪▪▪▪▪▪▪▪▪▪▪▪▪▪■▪■■▪▪▪▪▪▪▪▪▪▪▪▪▪■▪■▪│█ │▪▪■▪▪■■▪▪▪▪▪■▪■▪▪▪▪■▪▪▪▪▪■▪▪▪▪▪▪▪▪▪■■■▪■▪▪▪▪▪▪▪▪▪■▪▪■▪▪■■▪▪■▪▪■▪■▪▪■■▪▪■│█ │▪▪▪▪■■▪▪▪■■▪▪■▪■▪■■▪■■■▪■■▪■▪▪▪■▪▪▪▪▪▪▪■■▪▪▪▪■■▪■▪■■■▪▪▪▪■■■■▪■▪▪▪▪▪▪▪▪■│█ │▪▪▪▪▪▪▪▪■▪▪■▪▪▪▪▪▪▪▪▪■▪▪■▪▪■▪▪▪▪▪■▪▪■▪▪▪▪▪■▪▪▪▪▪▪▪▪■▪▪▪▪▪▪▪▪▪■▪▪■■▪▪■▪▪■│█ │▪▪▪▪▪▪▪▪▪■▪▪■▪▪▪▪■▪▪▪▪▪■▪▪▪▪▪▪▪▪■■▪▪▪▪▪■▪■■■▪■■▪■■▪▪▪▪▪▪▪■▪▪▪■▪▪▪▪■■■■▪■│█ │▓▓■▪▪▪▪ ▪▪▪■▪▪▪▪▪▪▪▪■▪▪▪▪■■▪■▪▪▪▪▪▪▪▪ ▪▪▪▪■▪▪■■▪■▪■■■■■■■▪■■▪■■■▪▪▪■▪■▪■│█ └───┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴────┴───┘█ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> 1002010|O| | | | | |207680|593100720030023457| Rack slot inhibited <I/S/R>a Rack Rack Rack SSCC <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Rack slot occupied <O>a O

The normal functions associated with this window are available. Refer to the section titled: "Stores Diagram".

Once you have made any desired restrictions, type "P" or click on "Print" menu item.  You will be presented with a dialogue window allowing you to further modify the report. The question, "Crane (0 = all) <0-8>" (please refer to the section titled: "Numeric") allows you to restrict the printout to a single crane.

You will then be presented with the "Viewer/Printer/Rtf file/Csv file" options. Please refer to the section titled: "Report Viewing Data".

Crane Alarm Summary Report

This "Report Viewing Data" window is used to set up the restrictions, then produce a report listing each of the crane alarms with the number of instances of these alarms for each crane during the reporting period. For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Below is a rough text-representation of this window:

Produce crane alarm summary Print Restrict Match Expand First Last 1|MCR is off ^ 2|24VDC is off █ 3|HL circuit breaker █ 4|LT circuit breaker █ 5|Forks circuit breaker █ 6|HL drive fault █ 7|LT drive fault █ 8|Forks drive fault █ 9|HL thermal overload █ 10|LT thermal overload █ 11|Cabin too cold █ 12|Cabin too warm █ 13|Load off centre █ 14|Catch block set █ 15|Slack rope █ 16|Rope overload █ 17|Hoist over-speed █ 18|Speed govenor fault █ 19|Hoist whole current V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Crane alarms Crane alarm MCR is off

After terminating the restrictions, you will be asked whether you wish "All tallies" to be listed, or the "Non-zero only", allowing you to get a report covering all alarms, even those that have not been active during the reporting period, or, as is more normal, a report listing only those alarms that have been active during the reporting period.

Upon answering this question, you will be asked whether you wish to print tallies fo the "Current period" or the "Last period", allowing you to request either the completed period (the "last" period) or the current, incomplete period to report on.

In order to adjust the alarm reporting period, refer to the section titled: "Control Mode of Operation" and, in particular, its subsection titled: "Alarm Summary Period".

For some sites, there is referenced, for each of these alarms, another alarm from this list, which, if active, is considered as the prime cause of the fault, while the referencing alarm is considered to be parasitic.  For such alarms, efforts are made to not include the count of their occurrences that occurred while the referenced is or becomes active. For more information on defining the parasitic nature of certain alarms, please refer to the section titled: "Enter or Modify the Crane Alarms".

Crane Movement Tally Report

This report provides a tally of the number of moves each crane has made in the current hour, day, week, and month, along with the number of moves made in the previous five hours, days, weeks, and months, along with the totals across all cranes.

This report has no window; once selected, you will be immediately presented with the "Viewer/Printer/Rtf file/Csv file" options.  Please refer to the section titled: "Report Viewing Data".

Crane Cycle Log Report

This "Report Viewing Data" window is used to set up the restrictions, then produce a report listing all load movements performed by the six stacker cranes. For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Below is a rough text-representation of this window:

Redirected loads Print Restrict Where Match Expand First Last Update HELP ESCAPE:exit 20:02:14 02-JUL-09|1|42:15-J-042-1|42:16-A-001-1|42:16-A-001-1| 0'41"| 0'41"|^ 20:02:54 02-JUL-09|2|42:13-M-013-1|42:14-A-001-1|42:14-A-001-1| 2'32"| 2'32"|█ 20:02:26 02-JUL-09|4|41:09-D-025-1|41:10-A-001-1|41:10-A-001-1| 1'55"| 1'55"|█ 20:02:06 02-JUL-09|3|42:11-C-052-1|42:12-A-001-1|42:12-A-001-1| 0'44"| 0'44"|█ 20:01:56 02-JUL-09|6|41:05-F-061-1|41:06-A-001-1|41:06-A-001-1| 1'27"| 1'27"|█ 20:01:28 02-JUL-09|5|41:07-A-042-1|41:08-A-001-1|41:08-A-001-1| 2'13"| 2'13"|█ 20:01:02 02-JUL-09|2|42:13-G-038-1|42:14-A-001-1|42:14-A-001-1| 2'47"| 2'47"|█ 20:00:44 02-JUL-09|1|42:15-M-017-1|42:16-A-001-1|42:16-A-001-1| 1'58"| 1'58"|█ 20:00:32 02-JUL-09|2|42:13-H-025-1|42:14-A-001-1|42:14-A-001-1| 1'22"| 1'22"|█ 20:00:04 02-JUL-09|3|42:11-J-054-1|42:12-A-001-1|42:12-A-001-1| 0'19"| 0'19"|█ 19:59:54 02-JUL-09|4|41:09-K-038-1|41:10-A-001-1|41:10-A-001-1| 1'46"| 1'46"|█ 19:59:34 02-JUL-09|5|41:07-D-020-1|41:08-A-001-1|41:08-A-001-1| 2'30"| 2'30"|█ 19:59:12 02-JUL-09|1|42:15-C-052-1|42:16-A-001-1|42:16-A-001-1| 1'23"| 1'23"|█ 19:58:44 02-JUL-09|6|41:05-A-023-1|41:06-A-001-1|41:06-A-001-1| 0'25"| 0'25"|█ 19:58:12 02-JUL-09|2|42:13-J-061-1|42:14-A-001-1|42:14-A-001-1| 1'34"| 1'34"|█ 19:57:58 02-JUL-09|3|42:11-M-034-1|42:12-A-001-1|42:12-A-001-1| 1'41"| 1'41"|█ 19:57:16 02-JUL-09|4|41:09-F-018-1|41:10-A-001-1|41:10-A-001-1| 2'56"| 2'56"|█ 19:56:40 02-JUL-09|5|41:07-G-024-1|41:08-A-001-1|41:08-A-001-1| 1'09"| 1'09"|█ 19:56:28 02-JUL-09|6|41:05-B-051-1|41:06-A-001-1|41:06-A-001-1| 0'12"| 0'12"|V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Crane cycle log Crane cycle log: Src a 42:15-J-042-1

The records consist of the time and date that the load relocation was completed, the crane involved, the source location, the destination to which it was taken, the destination that it was asked to be taken, the time it took excluding down time, the time it took including down time, the number of extra locations that it had to be taken to, and the number of times that it stopped because of faults.

These same fields are included in the subsequent report.

Once the restrictions are in place, type "P", or click on the "Print" menu item. You will be asked where to send the report.  You may select "Printer", "Viewer", "Rtf file", or "Csv file".

Communication Reports

This menu provides access to the windows required to generate the communications reports.

The physical printing of a file is handled by the MS-DOS batch file "prnqueue.bat".  If you wish the reports to be sent to a network printer, you should modify this file, replacing "/D:\\.\LPT1" with the suitable description for the network printer you wish to use, such as: "/D:\\server\printer", where "server" is the machine name (which might be an IP address), and "printer" is the name of the printer on that machine (which might be something like "HPLaserJ").

Below is a rough text-representation of this menu:

Movement Controller (C) Copyright 1998 to 2009 Woodgrove Digital Engineering File View ┌─-─────────────────────┐ │New User │ │Operations >│ │Reports >│ ┌─-─────────────────────────────────────┐ │Communication reports█>│ │Produce report of PLC communications │ │Configuration >│ │Produce report of pick-to-light comm's │ │Maintenance >│ │Produce report of barcode scanner comm'│ │Definition >│ │Produce report of TCP-IP communications│ │Special Functions >│ └─-─────────────────────────────────────┘ │Exit │ └─-─────────────────────┘

These report windows are "Report Viewing Data" windows.  For these refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Each of these windows show the recent communications between the Movement Controller and some remote equipment or computer system.  This history is presented as records of a database.  The first field of these records are the time and date, followed by a field providing the originator of the message, and, possibly, another providing the channel number.  The final field will provide the message contents.  The message contents, for non-ASCII protocols, will be converted to hexadecimal.

Opening a Communications Report Window

If logging is currently enabled on the communications link corresponding to the window you select from this menu, then upon entry into the window you will be asked whether you wish to "Continue logging" or to "Suspend logging" as you examine the log.

If do not you wish to suspend logging, you need only type [RETURN] or [ENTER] or type "C" or click on "Continue logging" to accept the offered default.  Otherwise enter type "S" or click on "Suspend logging".  It is an advantage to suspend logging if you want to capture the information already gathered (i.e. prevent it from being overwritten) or to enable simpler control of the file.

Leaving a Communications Report Window

When the you leave the window, you will be asked whether you want to

  • a)
    Leave as it was (i.e. continue logging with whatever restrictions might have been in place previously),
  • b)
    Enable and restrict (i.e. continue or start logging but apply the restrictions that were just imposed), or
  • c)
    Stop logging.

The "Leave as it was" option will be default, and so can be selected by typing [RETURN] or [ENTER].  Alternatively you can click on your desired option or type the first letter of the corresponding button, "L", "E", or "S".

Help with the Protocol

For some channels, a terse explanation of the protocol used by the channel can be obtained by pressing "H" or clicking on "Help on protocol". If further pages of explanation are available, these will be available by pressing "H" or clicking on "Help on protocol" subsequently.

PLC Communications Report

This "Report Viewing Data" window is used to set up the restrictions, then produce a report listing each of the messages communicated between the Movement Controller and PLCs, with time and date of the message, the PLC, the originator and message contents. For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Instructions related to entering and exiting this window are given in the section titled: "Communication Reports".

The message contents begin with a file number, then the address within the file, then a colon, then the contents of each address being written or read within the file.

Below is a rough text-representation of this window:

Produce report of PLC communications Print Restrict Match Expand First Last 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000^ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Palletiser 4 |O|07 0020:0000,0000,0000,0000,463C,0000,000█ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|O|07 0020:0000,0000,0000,0000,463C,0000,000█ 19:53:59 19-JAN-99|Palletiser 4 |I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Palletiser 4 |I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|O|07 0020:0000,0000,0000,0000,463C,0000,000█ 19:53:59 19-JAN-99|Palletiser 4 |I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Palletiser 4 |I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000█ 19:53:59 19-JAN-99|Carton conveyors|I|07 0000:0000,0000,0000,0000,C901,C900,000V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: A-B DH Communications A-B DH message: Time 19:53:59 19-JAN-99

For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Produce Report of Pick-to-Light Comm's

This "Report Viewing Data" window is used to set up the restrictions, then produce a report listing each of the messages communicated between the Movement Controller and pick-to-light units, with time and date of the message, the channel number, the originator and message contents. For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Instructions related to entering and exiting this window are given in the section titled: "Communication Reports".

The message contents begin with a four-digit unit address, the flag (message type) and then the three-digit data field.

Below is a rough text-representation of this window:

Produce report of Pick-to-Light comm's Print Restrict Match Expand First Last 19:53:59 19-JAN-99| 1|M|0266700 ^ 19:53:59 19-JAN-99| 1|L|02c4715 █ 19:53:59 19-JAN-99| 1|M|02c4700 █ 19:53:59 19-JAN-99| 1|L|02b7755 █ 19:53:59 19-JAN-99| 1|M|02b7700 █ 19:53:59 19-JAN-99| 1|L|0266705 █ 19:53:59 19-JAN-99| 1|M|0266700 █ 19:53:59 19-JAN-99| 1|L|02c4715 █ 19:53:59 19-JAN-99| 1|M|02c4700 █ 19:53:59 19-JAN-99| 1|L|02b7755 █ 19:53:59 19-JAN-99| 1|M|02b7700 █ 19:53:59 19-JAN-99| 1|L|0266705 █ 19:53:59 19-JAN-99| 1|M|0266700 █ 19:53:59 19-JAN-99| 1|L|02c4715 █ 19:53:59 19-JAN-99| 1|M|02c4700 █ 19:53:59 19-JAN-99| 1|L|02b7755 █ 19:53:59 19-JAN-99| 1|M|02b7700 █ 19:53:59 19-JAN-99| 1|L|0266705 █ 19:53:59 19-JAN-99| 1|M|0266700 V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Pick to light comms PTL message: Time 19:53:59 19-JAN-99

Produce Report of Barcode Scanner Comm's

This "Report Viewing Data" window is used to set up the restrictions, then produce a report listing each of the messages communicated between the Movement Controller and barcode scanners, with time and date of the message, the channel number, the originator and message contents. For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Instructions related to entering and exiting this window are given in the section titled: "Communication Reports".

Below is a rough text-representation of this window:

Produce report of Barcode Scanner comm's Print Restrict Match Expand First Last 19:53:59 19-JAN-99| 2|B|BMG60 ^ 19:53:59 19-JAN-99| 2|B|BMG6V █ 19:53:59 19-JAN-99| 2|B|BMG6M █ 19:53:59 19-JAN-99| 2|B|BMG6R █ 19:53:59 19-JAN-99| 2|B|BMG6P █ 19:53:59 19-JAN-99| 3|B|BMF9N █ 19:53:59 19-JAN-99| 2|B|BMG61 █ 19:53:59 19-JAN-99| 3|B|BMG9M █ 19:53:59 19-JAN-99| 2|B|BMG6T █ 19:53:59 19-JAN-99| 2|B|BMG6X █ 19:53:59 19-JAN-99| 2|B|BMGYG █ 19:53:59 19-JAN-99| 3|B|BMG8G █ 19:53:59 19-JAN-99| 2|B|BMG67 █ 19:53:59 19-JAN-99| 2|B|BMG61 █ 19:53:59 19-JAN-99| 3|B|BMG8F █ 19:53:59 19-JAN-99| 3|B|BMG8H █ 19:53:59 19-JAN-99| 2|B|BMG6Y █ 19:53:59 19-JAN-99| 3|B|BMG8J █ 19:53:59 19-JAN-99| 2|B|BMGLP V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Barcode scanner comms Barcode message: Time 19:53:59 19-JAN-99

Produce Report of TCP-IP Communications

This "Report Viewing Data" window is used to set up the restrictions, then produce a report listing each of the messages communicated between the Movement Controller and the host_computer over the FTP control and data channels of the TCP/IP interface, with time and date of the message the originator and message contents.  For further general instructions on using this type of window, please refer to the sections titled: "Viewing Data", and "Report Viewing Data".

Additionally, TELNET control channel messages are also included.

Instructions related to entering and exiting this window are given in the section titled: "Communication Reports".

Below is a rough text-representation of this window:

Produce report of TCP-IP communications Print Restrict Match Expand First Last 10:52:50 18-JAN-95|O|QUIT!! ^ 10:48:40 18-JAN-95|I|226 Transfer complete.!! █ 10:48:40 18-JAN-95|I|150 Opening data connection for 18019500.INV (165.69.72.22█ 10:48:40 18-JAN-95|O|STOR 18019500.INV!! █ 10:48:40 18-JAN-95|I|200 PORT command okay.!! █ 10:48:40 18-JAN-95|O|PORT 165,69,72,22,254,275!! █ 10:48:40 18-JAN-95|I|502 Unimplemented MODE type.!! █ 10:48:40 18-JAN-95|O|MODE B!! █ 10:29:20 18-JAN-95|I|226 Transfer complete.!! █ 10:29:20 18-JAN-95|I|150 Opening data connection for 18019500.SHP (165.69.72.22█ 10:29:20 18-JAN-95|O|STOR 18019500.SHP!! █ 10:29:20 18-JAN-95|I|200 PORT command okay.!! █ 10:29:20 18-JAN-95|O|PORT 165,69,72,22,254,275!! █ 10:29:20 18-JAN-95|I|502 Unimplemented MODE type.!! █ 10:29:20 18-JAN-95|O|MODE B!! █ 10:29:20 18-JAN-95|I|226 Transfer complete.!! █ 10:29:20 18-JAN-95|I|150 Opening data connection for 18019500.STK (165.69.72.22█ 10:29:20 18-JAN-95|O|STOR 18019500.STK!! █ 10:29:20 18-JAN-95|I|200 PORT command okay.!! V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: TCP-IP communications Host message: Time 10:52:50 20-FEB-97

The exclamation marks in the above window diagram represent the non-printing ASCII codes within the messages.

If communications between the host_computer and the Movement Controller use directories rather than the Movement Controller's native FTP, then the directories themselves can be looked into in order to establish what has and has not been communicated.  However, the contents of these files will be logged in this communications report, as though they had come via TCP-IP direct to the Movement Controller.

Configuration

This menu provides access to the windows required to maintain the configuration data.

Below is a rough text-representation of this menu:

Movement Controller (C) Copyright 1998 to 2009 Woodgrove Digital Engineering File View ┌─-─────────────────────┐ │New User │ │Operations >│ │Reports >│ │Communication reports >│ ┌─-───────────────────────────────────────┐ │Configuration█████████>│ │Control mode of operation │ │Maintenance >│ │Enter or modify conveyor alarms │ │Definition >│ │Enter or modify products for loads │ │Special Functions >│ │Enter or modify the crane alarms │ │Exit │ │Enter or modify the crane states │ └─-─────────────────────┘ │Enter or modify the countries │ │Enter or modify the states/provinces │ │Enter or modify the towns/suburbs/cities │ │Enter or modify the customers │ │Enter or modify the products │ │Enter or modify the pick area shelving │ │Enter or modify palletiser alarms │ │Enter or modify palletiser patterns │ │Enter or modify palletiser product data │ │Enter or modify machine states & alarms │ └─-───────────────────────────────────────┘

Many of the configuration windows are "Maintenance Viewing Data" windows.  For these refer to the sections titled: "Viewing Data", and "Maintenance Viewing Data".

Control Mode of Operation

This screen allows you to alter certain configuration variables in a straight-forward manner:

  • find the line describing the quantity you wish to change,
  • double click on this line, and,
  • when the dialogue window opens, enter the new value.

Full Description of this Window

This is a very limited version of the "Maintenance Viewing Data" window that lists certain records from the "Configuration Data" database.  The [LEFT] and [RIGHT] keys are still effective for setting restrictions (should you want to) however their action is not visible on the window and has no effect on the operation of the "C" key used to change the contents of a field.  Instead, the "C" key always refers to the setting of the miscellaneous data and never its description.  Also typing the "S", [ENTER] or [RETURN] key has the same effect as typing "C". You may also double click the line.

The "Configuration Data" database includes the "Miscellaneous Name" field (a unique "Name" field), "Miscellaneous Data" field (a "Miscellaneous Data" field) and the "Initial/Run/Network <I/R/N>a" field (a "Character" field). For editing instructions for these types of fields, please refer to the sections titled: "Name", "Character", and "Miscellaneous Data".

Only those records of the "Configuration Data" with the "Initial/Run/Network <I/R/N>a" field set to "R" will be included on this window. Please refer to the section titled: "Configuration Data". You should also refer to that section of the manual for more information about the meaning of the records presented here.

The miscellaneous data field is also coloured to highlight those fields not containing 0 and therefore likely to be in the abnormal state.

The records from the "Configuration Data" database chosen for inclusion on this window are those records that are most likely to be altered after the commissioning of the system is complete.

Below is a rough text-representation of this window:

Control mode of operation Select Change Restrict Where Match Expand Insert First Last 1-nine Seconds before screen save 600 ^ Product Code <0-999999> █ Crane to find vacancy <V>a █ Crane 1 Ret:Sto <R/2/F/1/S>a store always █ Crane 2 Ret:Sto <R/2/F/1/S>a store always █ Crane 3 Ret:Sto <R/2/F/1/S>a store always █ Crane 4 Ret:Sto <R/2/F/1/S>a store always █ Start of Alarm Report Period 00:00:00 21-JAN-99 █ Alarm Report Period (days) 7 █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Configuration Data Retrieve:Store <R/1/F/2/S>a retrieve always

The Variables Intended to be Presented

As was described in the section titled: "Full Description of this Window", which variables are included in this window may be altered by yourself, from the set of variables contained in the "Configuration Data" record set.

The variables that are included in this window by default are described in the following sub-sections.

Override Palletiser Barcode Scanner

The "Product number" if set, disables the palletiser barcode reader, and indicates to the system that all future product will be of this type.

Stacker Crane To Find Vacancy

The "Crane to find vacancy" if set ('V') allows the crane to recover from "Location full" and "Pickup got nothing" alarms automatically (provided the problem was encountered away from the infeed or outfeed) relocating the load to another location within the crane aisle.

Stacker Crane Store:Retrieve Ratio

The "Retrieve:Store" ratios allow you to control the arbitration between the crane servicing its infeed and retrieving or replenishing.

Irrespective of this setting, if it has no infeeding, it will retrieve or replenish and if it has no retrievals or replenishments it will infeed.

Otherwise: if the ratio is set to "store always" infeeding will be done whenever there is infeeding to do, if set to "retrieve always", retrieval or replenishment will be done whenever there is one to do, if set to "retrieve 2:store 1" an infeed will be done once two retrieval or replenishments have been done, if set to "fifty/fifty" an infeed will be done once a retrieval or replenishment has been done, if set to "retrieve 1:store 2" a retrieval or replenishment will be done once two infeeds have been done.

If it is set to "store always", then crane, when idle, will move to the infeed position.

High Level Crane Inhibiting

The variables, "No automatic crane commands" and "Suspend crane retrievals", allow you to stop the Movement Controller from sending, automatically, any new jobs or any new retrieval jobs, respectively, to the crane.

Alarm Summary Period

The "Start of Alarm Report Period" and the "Alarm Report Period" values are used together to define the periods, over which the crane and conveyor alarms are summarised. Please refer to the sections titled: "Crane Alarm Summary Report", and "Conveyor Alarm Summary Report".

When the time passes the "Start of Alarm Report Period" plus the "Alarm Report Period" number of days, the currently aggregating counts will be captured as the "last" period counts and then be reset to zero.  The "Alarm Report Period" number of days will then be added to the "Start of Alarm Report Period".

Enter or Modify the Conveyor Alarms

This is a "Maintenance Viewing Data" window that lists each of the conveyor alarms.  These are defined to associate text with the alarms raised.

Below is a rough text-representation of this window:

Enter or modify the conveyor alarms Select Change Restrict Where Match Expand Insert First Last 1-nine 1|Transfer C202 to C205 failed to complete in the time allowed|C202A |Tran^ 2|Index C205B to C205A failed to complete in the time allowed |C205B |Tran█ 3|Transfer C205 to CR05 failed to complete in the time allowed|C205A |Tran█ 4|Transfer C203 to C204 failed to complete in the time allowed|C203A |Tran█ 5|Index C204B to C204A failed to complete in the time allowed |C204B |Tran█ 6|Transfer C204 to CR04 failed to complete in the time allowed|C204A |Tran█ 7|Transfer C209 to C210 failed to complete in the time allowed|C209A |Tran█ 8|Transfer C210 to C211 failed to complete in the time allowed|C210A |Tran█ 9|Transfer C211 to C212 failed to complete in the time allowed|C211A |Tran█ 10|Transfer C212 to C213 failed to complete in the time allowed|C212A |Tran█ 11|Transfer C213 to C214 failed to complete in the time allowed|C213A |Tran█ 12|Transfer C214 to C215 failed to complete in the time allowed|C214A |Tran█ 13|Transfer C215 to CR16 failed to complete in the time allowed|C215A |Tran█ 14|Transfer C218 to C219 failed to complete in the time allowed|C218A |Tran█ 15|Transfer C219 to C220 failed to complete in the time allowed|C219A |Tran█ 16|Transfer C220 to C221 failed to complete in the time allowed|C220A |Tran█ 17|Transfer C221 to C222 failed to complete in the time allowed|C221A |Tran█ 18|Transfer C222 to C223 failed to complete in the time allowed|C222A |Tran█ 19|Transfer C223 to C224 failed to complete in the time allowed|C223A |TranV <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Conveyor alarms Conveyor alarm s Transfer C202 to C205 failed to complete in the time

Refer to the section titled: "Viewing Data", and its subsection "Maintenance Viewing Data".

The "Set of Fields" includes the alarm description (a unique "Name" field), the conveyor associated with the alarm (a "Symbolic Name" field), the state of the alarm (a "Character" field) the fault category (a "Symbolic Name" field), whether this alarm has been enabled or not (a "Character" field), and, for some sites, whether occurences of this alarm are to be recorded in the event log and summary reports (a "Character" field) and whether this alarm may be reset by an operator (a "Character" field).  Refer to the sections titled: "Name", "Symbolic Name", and "Character".

Below, once a set of fields has been selected for editing, is a rough text-representation of this window:

Conveyor alarms - 1 Conveyor alarm s Transfer C202 to C205 failed to complete in the time Alarm conveyor a C202A Conveyor alarm <A>a Fault category s Transfer watchdog ╔════════════════════════╗┌────────────────────────┐┌────────────────────────┐ ║ OK ║│ DELETE ││ HELP │ ╚════════════════════════╝└────────────────────────┘└────────────────────────┘

If the option to prevent the operator from resetting specific alarms is provided, then this flag must be clear for the alarm in question as well as for, if there is a fault category, the fault category to which it is assigned. So, if it does belong to a fault category, you would normally want to leave the flag clear for the specific alarms that belong to the fault category, and use the fault category to control whether an operator has the right to reset an alarm.  For further information on fault categories, please refer to the section titled: "Fault Assistance".

Enter or Modify Products

This is a "Maintenance Viewing Data" window that lists each of the products expected in the warehouse.  These are defined to associate a description with product code and to provide other details such as the number of packages comprising a full load.

Below is a rough text-representation of this window:

Enter or modify products on loads Select Change Restrict Where Match Expand Insert First Last 000034|PETERS DRUMSTICKS 24 L/P |144 ^ 000035|PETERS TRUMPETS 24 L/P |144 █ 000136|CADBURY PICNIC 24 L/P | 80 █ 000137|CADBURY CRAVE 24 L/P | 80 █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Products Product code 000034

Refer to the section titled: "Viewing Data", and its subsection "Maintenance Viewing Data".

The "Set of Fields" includes the product code, product description (both unique "Name" fields) and the number of packages on a full load (a "Numeric" field). For editing instructions for these types of fields, please refer to the sections titled: "Name", and "Numeric".

Enter or Modify the Crane Alarms

This is a "Maintenance Viewing Data" window that lists each of the crane alarms.  These are defined to associate text with the alarms raised by the cranes.

Below is a rough text-representation of this window:

Enter or modify crane alarms Select Change Restrict Where Match Expand Insert First Last 1-nine 1|MCR is off ^ 2|24VDC is off █ 3|HL circuit breaker █ 4|LT circuit breaker █ 5|Forks circuit breaker █ 6|HL drive fault █ 7|LT drive fault █ 8|Forks drive fault █ 9|HL thermal overload █ 10|LT thermal overload █ 11|Cabin too cold █ 12|Cabin too warm █ 13|Load off centre █ 14|Catch block set █ 15|Slack rope █ 16|Rope overload █ 17|Hoist over-speed █ 18|Speed govenor fault █ 19|Hoist whole current V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Crane alarms Crane alarm MCR is off

Refer to the section titled: "Viewing Data", and its subsection "Maintenance Viewing Data".

The "Set of Fields" includes the alarm description (a unique "Name" field), whether to record alarms of this sort in the event log and the alarm summary (a "Character" field), for some sites there is a reference to another alarm which, if active, would be deemed to have caused this alarm (a "Symbolic Name" field), and the crane alarms field (a "Crane and Palletiser Alarms" field).  For editing instructions for these types of fields, please refer to the sections titled: "Name", "Character", "Symbolic Name", and "Crane and Palletiser Alarms".

Be warned, that if you change the text, the software may fail to correlate the alarm with the text in the manual, by which the alarm is described.  As a result, it will not be able to call up the correct page of the help in response to the right-click request (for details on this "request", please refer to the section titled: "Alarms").

Below, once a set of fields has been selected for editing, is a rough text-representation of this window:

Crane alarms - 1 Crane Alarm Names s MCR is off Don't log crane alarm <D>a Crane Alarms ╔════════════════════════╗┌────────────────────────┐┌────────────────────────┐ ║ OK ║│ DELETE ││ HELP │ ╚════════════════════════╝└────────────────────────┘└────────────────────────┘

Enter or Modify the Crane States

This is a "Maintenance Viewing Data" window that lists each of the crane states.  These are defined to associate text with the states reported by the cranes.

Below is a rough text-representation of this window:

Enter or modify crane states Select Change Restrict Where Match Expand Insert First Last 1-nine 1|LT in position ^ 2|HL in low position █ 3|HL in high position █ 4|Forks position bt 0 █ 5|Forks position bt 1 █ 6|Forks position bt 2 █ 7|Forks position bt 3 █ 8|Forks position bt 4 █ 9|Manual █ 10|Out of service █ 11|Alarm change █ 12|Loaded █ 13|MCR deenergised █ 14|LT speed enable █ 15|HL speed enable █ 16|Key switch manual █ 17|Too high on left █ 18|Too high on right █ 19|Off-centre to left V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Crane states Crane State Names In Automatic

Refer to the section titled: "Viewing Data", and its subsection "Maintenance Viewing Data".

The "Set of Fields" includes only the state description (a unique "Name" field). For editing instructions for this type of field, please refer to the section titled: "Name".

Be warned, that if you change the text, the software may fail to correlate the state with the text in the manual, by which the state is described.  As a result, it will not be able to call up the correct page of the help in response to the right-click request (for details on this "request", please refer to the section titled: "Status List").

The "Crane Commands and Alarms" window takes some liberties with the text entered here.

  • If the "LT in position" bit is not set, the text "LT out of position" is displayed; this is hard-coded.
  • If neither the "HL in low position" nor the "HL in high position" bit is set, the text "HL out of position" is displayed; this is hard-coded.
  • If both the "HL in low position" and the "HL in high position" bit is set, the text "HL in low position" is displayed.
  • If neither the "Cabin up position" nor the "Cabin down position" bit is set, and the crane has a movable cabin, the text "Cabin in between" is displayed; this is hard-coded.
  • The text for the forks status bits, "Forks position bt 0" et cetera, is completely ignored; the forks status is hard-coded.

Below, once a set of fields has been selected for editing, is a rough text-representation of this window:

Crane states - 1 Crane State Names s HL in low position ╔════════════════════════╗┌────────────────────────┐┌────────────────────────┐ ║ OK ║│ DELETE ││ HELP │ ╚════════════════════════╝└────────────────────────┘└────────────────────────┘

Enter or Modify the Countries

This is a "Maintenance Viewing Data" window that lists each of the countries.  These are defined to assist in the entry of address of customers, providing, not only the full country name but also the ISD code and the format of the post (or "zip") code for that country.

Below is a rough text-representation of this window:

Enter or modify the countries Select Change Restrict Where Match Expand Insert First Last Australia |#### ^ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Countries Country's name Australia

Refer to the section titled: "Viewing Data", and its subsection "Maintenance Viewing Data".

The "Set of Fields" includes the name of the country, its ISD code (both unique "Name" fields), and its post code mask (a "Post Code Mask" field). For editing instructions for these types of fields, please refer to the sections titled: "Name", and "Post Code and Post Code Mask".

Below, once a set of fields has been selected for editing, is a rough text-representation of this window:

Countries - Australia Country's name t Australia Country's ISD (NZ=64) a Zip mask (Canada: ###-###) a #### ╔════════════════════════╗┌────────────────────────┐┌────────────────────────┐ ║ OK ║│ DELETE ││ HELP │ ╚════════════════════════╝└────────────────────────┘└────────────────────────┘

The ISD code, along with the STD code for the customer's town, is provided to assist in the entry of the customer's phone number. For editing instructions for this type of field, please refer to the section titled: "Phone Number".

Enter or Modify the States/Provinces

This is a "Maintenance Viewing Data" window that lists each of the states or provinces.  These are defined to assist in the entry of addresses of customers, providing, not only the full state's or province's name but also the country for that state or province, and thereby the ISD code and the format of the post (or "zip") code for that country.

Below is a rough text-representation of this window:

Enter or modify the states/provinces Select Change Restrict Where Match Expand Insert First Last N.S.W. |Australia ^ Victoria |Australia █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: States and provinces State/province name N.S.W.

Refer to the section titled: "Viewing Data", and its subsection "Maintenance Viewing Data".

The "Set of Fields" includes the name of the state or province (a unique "Name" field) and the country (a "Symbolic Name" field). For editing instructions for these types of fields, please refer to the sections titled: "Name", and "Symbolic Name".

If the name of a state or province should be used by more than one country, you should make the subsequent name unique by adding to the name the vertical line character ("|") followed some indication of the country. When printing the customer's delivery instructions, or in other reports on the customer, characters in the state or province name from the vertical line character onwards will not be printed.

Below, once a set of fields has been selected for editing, is a rough text-representation of this window:

State/province - N.S.W. State/province name t N.S.W. State in country t Australia Country's ISD (NZ=64) a Zip mask (Canada: ###-###) a #### ╔════════════════════════╗┌────────────────────────┐┌────────────────────────┐ ║ OK ║│ DELETE ││ HELP │ ╚════════════════════════╝└────────────────────────┘└────────────────────────┘

Enter or Modify the Towns/Suburbs/Cities

This is a "Maintenance Viewing Data" window that lists each of the towns or suburbs.  These are defined to assist in the entry of addresses of customers, providing, not only the full town, suburb or city name, along with the post (or "zip") code and STD code, but also the state's or province's name, along with the country for that state or province, and thereby the ISD code and the format of the post (or "zip") code for that country.

Below is a rough text-representation of this window:

Enter or modify the towns/suburbs/cities Select Change Restrict Where Match Expand Insert First Last Campbellfield |Victoria |3047 |3 ^ Girraween |N.S.W. |2145 █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Towns and Suburbs Town or suburb name Campbellfield

Refer to the section titled: "Viewing Data", and its subsection "Maintenance Viewing Data".

The "Set of Fields" includes the name of the town or suburb (a unique "Name" field) the state or province (a "Symbolic Name" field) and the post code (a "Post Code" field) and the STD code (a "Name" field). For editing instructions for these types of fields, please refer to the sections titled: "Name", "Symbolic Name", and "Post Code and Post Code Mask".

If the name of a town or suburb should be used by more than one state or province, you should make the subsequent name unique by adding to the name the vertical line character ("|") followed some indication of the state or province. When printing the customer's delivery instructions, or in other reports on the customer, characters in the town or suburb name from the vertical line character onwards will not be printed.

Below, once a set of fields has been selected for editing, is a rough text-representation of this window:

Town or suburb - Campbellfield Town or suburb name t Campbellfield Town in state/province t Victoria State in country t Australia Country's ISD (NZ=64) a Zip mask (Canada: ###-###) a #### Town or suburb post code a 3047 Town STD (Melb=3) a 3 ╔════════════════════════╗┌────────────────────────┐┌────────────────────────┐ ║ OK ║│ DELETE ││ HELP │ ╚════════════════════════╝└────────────────────────┘└────────────────────────┘

The STD code, along with the ISD code for the corresponding country is provided to assist in the entry of the customer's phone number. For editing instructions for this type of field, please refer to the section titled: "Phone Number".

Enter or Modify the Customers

This is a "Maintenance Viewing Data" window that lists each of the customers.  These provide the customer's street address, town or suburb, telephone and facsimile numbers and standard delivery instructions.

Below is a rough text-representation of this window:

Enter or modify the customers Select Change Restrict Where Match Expand Insert First Last P & O Cold Storage |69 Mandoon Road |Girraween ^ W & D Engineering Pty Limited |25 Glenbarry Road |Campbellfiel█ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ █ V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Customers Customer name P & O Cold Storage

Refer to the section titled: "Viewing Data", and its subsection "Maintenance Viewing Data".

The "Set of Fields" includes the customer's name (a unique "Name" field), the street address (a "Name" field), the town or suburb (a "Symbolic Name" field), the telephone and facsimile numbers (both "Phone Number" fields) and the standard delivery instructions (a "Name" field). For editing instructions for these types of fields, please refer to the sections titled: "Name", "Symbolic Name", and "Phone Number".

The standard delivery instructions will be printed followed by any order specific instructions entered in the order specification.

Below, once a set of fields has been selected for editing, is a rough text-representation of this window:

Customer - P & O Cold Storage Customer name t P & O Cold Storage Customer address t 69 Mandoon Road Customer town or suburb t Girraween Town in state/province t N.S.W. State in country t Australia Country's ISD (NZ=64) a Zip mask (Canada: ###-###) a #### Town or suburb post code a 2145 Town STD (Melb=3) a Customer's phone number a 96362666 Customer's facsimile no. a 96882610 Customer's delivery notes s ╔════════════════════════╗┌────────────────────────┐┌────────────────────────┐ ║ OK ║│ DELETE ││ HELP │ ╚════════════════════════╝└────────────────────────┘└────────────────────────┘

Enter or Modify the Products

This is a "Maintenance Viewing Data" window that lists each of products for the pick areas.  In this case each product definition includes a catalogue number, recording artist and the recording's title.

Below is a rough text-representation of this window:

Enter or modify the products Select Change Restrict Where Match Expand Insert First Last A&M 393601-2 |Carpenters ^ A&M 393614-2 |Joan Baez █ A&M 540 728-2 |Phil Ochs █ A&M CD 4257 |Fairport Convention █ ABC COUNTRY/EMI 4796522 |_Miscellaneous █ ABC JAZZ/EMI 4796232 |James Morrison █ ABKCO 820 140-2 |Rolling Stones, The █ AHS 5-1 |Glenn Miller █ ALBERT 465396 2 |Easybeats, The █ ALTRAX 595 |Dave Swarbrick █ AMERICAN 9 43104-2 |Donovan █ ARIO 883 948|HYCD 200 128|Bert Jansch █ ARISTA ACD2-8634 |Grateful Dead █ ARISTA ARCD-8575 |Grateful Dead █ ARISTA ARCD-8643 |Yes █ ARISTA ARCD85-90126 |Anderson, Bruford, Wakeman, Howe █ ARISTA VPCD 7528 |Sky █ ARISTA/BMG 74321-13697-2 |David Bowie █ ARISTA/BMG 74321-17004-2 |David Bowie V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Recordings Item's catalogue number A&M 393601-2

Refer to the section titled: "Viewing Data", and its subsection "Maintenance Viewing Data".

The "Set of Fields" includes, in this instance the catalogue number (a unique "Name" field) and the recording artist and recording's title (both "Name" fields). For editing instructions for this type of field, please refer to the section titled: "Name".

Below, once a set of fields has been selected for editing, is a rough text-representation of this window:

Recording - ARIO 883 948|HYCD 200 128 Item's catalogue number a ARIO 883 948|HYCD 200 128 Item's recording artist t Bert Jansch Item's recording title t From the Outside ╔════════════════════════╗┌────────────────────────┐┌────────────────────────┐ ║ OK ║│ DELETE ││ HELP │ ╚════════════════════════╝└────────────────────────┘└────────────────────────┘

Enter or Modify Palletiser Alarms

This is a "Maintenance Viewing Data" window that lists each of the palletiser alarms.  These are defined to associate text with the alarms raised.

Below is a rough text-representation of this window:

Enter or modify palletiser alarms Select Change Restrict Where Match Expand Insert First Last 1-nine 1|Open case flap ^ 2|Infeed guide fault 1 4 █ 3|Meter belt PE █ 4|Turn peg PE █ 5|Row entry PE █ 6|Row gate A PE █ 7|Row gate B PE █ 8|Row gate C PE █ 9|Row gate D PE █ 10|Row gate E PE █ 11|Row gate F PE █ 12|Row sweep intrusion █ 13|Row sweep failed █ 14|Layer exit gate flt █ 15|Layer side fault █ 16|Layer transfer fail █ 17|Layer VSD fault █ 18|Apron side fault █ 19|Apron end fault V <████████████████████████████████████░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░░> Database: Palletiser alarms Palletiser alarm name Open case flap

Refer to the section titled: "Viewing Data", and its subsection "Maintenance Viewing Data".

The "Set of Fields" includes the palletiser alarm description (a unique "Name" field) and the palletisers that share this alarm (a "Crane or Palletiser Alarm" field). For editing instructions for these types of fields, please refer to the sections titled: "Name", and "Crane and Palletiser Alarms".

Below, once a set of fields has been selected for editing, is a rough text-representation of this window:

Palletiser alarm - 2 Palletiser alarm name s Infeed guide fault Palletiser alarms 1 4 ╔════════════════════════╗┌────────────────────────┐┌────────────────────────┐ ║ OK ║│ DELETE ││ HELP │ ╚════════════════════════╝└────────────────────────┘└────────────────────────┘

Enter or Modify Palletiser Patterns

This is a "Maintenance Viewing Data" window that lists each of the palletiser patterns.  These are defined to direct the operation of the palletiser and are also used by the Movement Controller to display the palletiser status.

Below is a rough text-representation of this window:

Enter or modify palletiser patterns Select Restrict Change Match Expand Insert First Last Pattern rows View 6U2 |1| 8| 3| G ^ 8S1 |1| 4| 3| G █ 9D1 |2| 4| 3| G █ █ █ █ █ █ █ █ █ █ █