Dematic equipment repairs - review of services from Fletcher Moorland

1. Creating a strong partnership for Customer Service Excellence Parts Repair Service for Dematic Sites

2. A brief background to our repair services for Dematic Many Dematic distribution sites have specialist pieces of control and automation equipment installed on cranes and sorters. When these fail it is critical to source a replacement or a repair. Traditionally OEM repair services have long turn-rounds This means sites have to keep a high inventory value to ensure replacement parts are available. When an OEM withdraws a product the support is usually withdrawn too. We identified products with long turn-round times and developed a repair service. We have managed to save time and money for distribution sites by providing this repair service.

4. Compact Drive Units (CDU’s) CDU units are fully repaired and tested in our electronics workshop, we rewind the motor to an enhanced ‘class H’ specification. The surface mount components on the control card are tested and replaced, the PSU section is repaired, the inverter unit is repaired and tested. The whole unit is re-programmed to site specific parameters and the connected to our test rig that performs a full load test. All digital, analogue and diagnostic information used by the sorter is checked and verified. Turnround – Typically less than 1 week Warranty – 12 months (whole unit)

5. Cell Servo Controllers (MDS 8 & DAC 8) Cell Servo Controllers (CSC’s) are repaired in our drives workshop. Usually a fault is detected by a driver channel not working. We identify which power channel has failed and replace the devices. We have developed a method of communicating with the specific communications card on the controller. By using this we are able to repair the control card and operate the CSC as the sorter would on site. Turnround – Typically less than 1 week Warranty – 12 months (whole unit)

6. KEB Inverter Drives (F4 & F5 series) KEB inverter drives are repaired in our drives workshop, We are able to fully test all aspects of these drives. We have the software to communicate with drive and program the parameters. During testing we operate the drives in a manner as would be seen on a high bay crane. Our test facility has 200 amp full load test capacity, well within the operating parameters of these drives Turnround – Typically less than 1 week Warranty – 12 months (whole unit)

7. Dematic Communication Controllers (RCM’s) RCM’s use a bespoke high voltage comms protocol to communicate to the sorter controller, we have developed a test method using the ‘Interbus S’ system to check for faults and verify our repair. We drive all the output channels in sequence by addressing the state controllers within the RCM unit. Turnround – Typically less than 1 week Warranty – 12 months (whole unit)

8. Revcon Power Controllers The Revcon power controllers are typically used as a DC supply to the main drive inverter for high bay cranes. We are able to diagnose all faults and repair these controllers. During testing we are able to verify the regen system using our 200 amp load rig. Turnround – Typically less than 1 week Warranty – 12 months (whole unit)

9. Indramat Drives & Motors (DKC & MKD series) Indramat drives and motors are an off the shelf servo system used in many industries. In sorter systems they are usually used in belt feed operations. Our servo workshop has the ability to fully test and repair these drives and motors including re-programming the drives and re-setting the motor feedback device. Both of these units are load tested on our specific servo load test rig. Turnround – Typically less than 1 week Warranty – 12 months (whole unit)

10. Power Supply Units (PSU’s) We have repaired various power supply units for Dematic sites. PSU’s from single output to multi voltage outputs can be repaired and fully load tested. Turnround – Typically less than 1 week Warranty – 12 months (whole unit)

11. Repair Benefits One of the main benefits of a repair service is the quick turnround, in most situations repairs are carried out within one week. We also operate an urgent repair service where repairs are completed within 24 – 48 hours. All our repairs are covered by a 12 month whole unit warranty. (In most situations this outlasts the OEM warranty term) Repairs cost less than the OEM. (Repairs can be as little as 20% of a new unit) Fixed price repairs enable simplified budgeting. Tracking of repairs is made simple using our bespoke on-line job tracking software (this is free of charge to Dematic sites) Obsolete equipment can be supported

12. Reliability of Repairs Distribution of repairs from Dematic and Siemens Postal Automation 2004 - 2009 * Improvements in test rig design has enabled a 100% right first time repair on these items since January 2009 Equipment Type No of Repairs Warranty Failures Right First Time % CDU Units 140 5 97.5 % * Cell Servo Controller 181 6 97.7 % * KEB F4 Units 48 1 96.0 % KEB F5 Units 10 0 100 % Dematic RCM Units 51 0 100 % Revcon Units 56 0 100 % Indramat Controllers 10 0 100 % Indramat Motors 184 2 99.0 % Various PSU’s 57 0 100 % Stober Motors 50 6 88.0 % *