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Operator instructions for
Flat Sort Machine

Flat sort machine installation FS1
CARRY
Poznan, Poland

EQ-P-CPO.128
Prepared by: Equinox MHE BV

Version: 1.0
Date: 10-05-2010

Equinox MHE bv Document : EQ-MAN-CPO.128-OP
Pastoorslaan 57 Flat Sort machine Version : 1.0
2182 BW Hillegom Date : 10-05-2010
The Netherlands
Operator instructions Page :2

Document history
Revision Date By Remark

1.0 10-05-2010 F. Methorst Final

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PROPRIETARY and CONFIDENTIAL
Equinox MHE bv - Iban NL.28 INGB0665430477 - K.v.K. 28100151 Leiden - BTW NL 812989314.B.01

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EQUINOX M.H.E. BV (“EQUINOX”)
PROPRIETARY AND CONFIDENTIAL INFORMATION
The information contained herein is the PROPRIETARY and CONFIDENTIAL property of EQUINOX
and may not be disclosed, reproduced or transmitted in any form or by any means, electronic or
mechanical, for any purpose, without the express prior written permission of EQUINOX.

EQUINOX may have patents or pending patent applications, trademarks, copyrights or other
intellectual property rights covering subject matter in this document.

The furnishing of this document does not give you license to these patents, trademarks, copyrights or
other intellectual property except as expressly provided in a written license agreement from
EQUINOX.

COPYRIGHT
The copyright for these operating instructions remains with Equinox MHE BV.
The operating instructions contain technical regulations and drawings which may not be reproduced
partially or in full, transmitted by any means, utilized without permission for competitive purposes or
disclosed to third parties.

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Table of content
TABLE OF CONTENT........................................................................................................................................4
1 SORT MACHINE OVERVIEW........................................................................................................................5
1.1 TOTAL OVERVIEW...............................................................................................................................................5
1.1.1 Platform 1...............................................................................................................................................6
1.2 PRIOR TO EACH OPERATION..................................................................................................................................7
1.3 PROCEDURE FOR ACCIDENTS OR MALFUNCTIONING...................................................................................................7
2 SAFETY...............................................................................................................................................................8
2.1 BASIC SAFETY INSTRUCTIONS...............................................................................................................................8
2.2 INTENDED USE...................................................................................................................................................8
2.3 INCORRECT USE..................................................................................................................................................8
2.4 SPECIALISTS......................................................................................................................................................8
2.5 DANGERS..........................................................................................................................................................8
2.6 INTERFACES TO OTHER DEVICES............................................................................................................................9
2.7 SORT MACHINE SAFETY LIGHT SYSTEM...................................................................................................................9
3 PRODUCT SPECIFICATIONS......................................................................................................................11
3.1 SORT OF PRODUCTS..........................................................................................................................................11
3.2 PRODUCT DIMENSIONS.......................................................................................................................................11
4 INDUCTING PRODUCTS...............................................................................................................................12
4.1 INDUCTION STATION..........................................................................................................................................12
4.1.1 Induction screen / monitor...................................................................................................................12
4.1.2 Cash desk scanner................................................................................................................................12
4.1.3 Start and stop button............................................................................................................................12
4.1.4 Emergency stop....................................................................................................................................12
4.2 SCANNING THE PRODUCT BY HAND......................................................................................................................12
4.3 INDUCTING PRODUCTS.......................................................................................................................................12
4.4 HOW TO SAFELY INDUCT ITEMS INTO THE SORTING SYSTEM....................................................................................14
4.5 PROHIBITED!!!!...............................................................................................................................................16
5 ASSIGNING CLIENT BOX............................................................................................................................17
5.1 ASSIGN A BOX TO THE SORT MACHINE SYSTEM......................................................................................................17
5.2 FULL BOX.......................................................................................................................................................17
6 AVAILABLE FUNCTIONS ON THE DROP STATIONS...........................................................................18
6.1.1 Light on drop station:...........................................................................................................................18
6.1.2 Drop station suspend/release:..............................................................................................................18
6.1.3 Carton Cut-off :....................................................................................................................................18
6.1.4 Carton Assign :.....................................................................................................................................18
7 ERROR MESSAGES ON SORT MACHINE CONTROL PC SCREEN...................................................19
8 COMPANY INFORMATION.........................................................................................................................23
8.1 ABOUT US.......................................................................................................................................................23
8.2 CONTACT INFORMATION....................................................................................................................................23

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1 Sort machine overview
1.1 Total overview
PLATFORM A

PLATFORM B

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1.1.1 Platform 1

I1 I2 I3 I4

SD

CS1

CS2

SD

I8 I7 I6 I5

I1 = Induction station 1
CS1 = Scanner system 1
CS2 = Scanner system 2

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1.2 Prior to each operation
• Check the sort machine for visible damage. Pay particular attention to the closing stations,
carriers and protective equipment;
• Ensure that all safety equipment and emergency stops are functioning correctly;
• Make sure that only authorized persons are in the sort machines work area;
• Always remove materials and objects which are not required from the work area;
• Provide instructions about and monitor correct loading of the sort machine system.

1.3 Procedure for accidents or malfunctioning
In case of an accident
• Stop the device and ensure that it cannot be started accidentally;
• If necessary, apply first aid treatment and make an emergency call;
• Inform a specialist to check the machine;
• Only restart the device after it has been deemed safe and released by a specialist.
In case of malfunctioning
• Operators are only allowed to eliminate faults which are clearly related to an operator error!
The danger zones of the sort machine system are covered by guards and protective
equipment;
• Stop the device immediately and ensure that it cannot be started accidentally;
• In case of stuck material: Remove the material and check equipment;
• Always make sure that nobody can be injured before restarting the sort machine.

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2 Safety
2.1 Basic safety instructions
The sort machine meets the highest technical specifications and is safe to operate after correct
installation.

Nevertheless, dangers may still arise during utilization:
• Danger of death or personal injury to operators and others;
• Adverse effects on the sort machine and other areas.
Read these operating instructions carefully and adhere to the information contained herein to ensure
safe conveyor operation.

Important!
Non-adherence to the information in these operating instructions can result in life-threatening injuries!

2.2 Intended use
The sort machine is intended for use in industrial environments and should only be applied for sorting
sort able goods, e. g. parcels, letters, clothing, books, handbags.
The sort machine is intended for certain application areas only, its defined capacity limits must not be
exceeded during operation. Any other use is not permitted.

Users are not permitted to carry out alterations or modifications which will have an adverse effect on
safety.

2.3 Incorrect use
The sort machine system is not intended for transporting people, bulk goods, small parts, rolling parts
(e. g. bottles), barrel-shaped parts and dimensionally instable parts.

2.4 Specialists
Specialists are personnel who have the knowledge to read and understand the operating instructions
and the ability to carry out work professionally while observing national regulations.

2.5 Dangers
This section provides information about various dangers and damages which may occur when
operating the sort machine system.
• Only carry out maintenance and repair work once the machine has been de-energized and
measures have been taken to ensure that it cannot be started accidentally;
• Organize additional safety measures for passageways and to stop people, except for
operators, reaching into the operating sort machine;
• Never remove protective covers;
• Regularly inspect safety equipment / emergency stops;
• Never reach into a live machine;
• Never wear loose clothing;
• Never wear jewelry, such as necklaces or bracelets;
• If you have long hair, always wear a hair net;
• Always remove materials and objects which are not required for sorting purposes from the
work area;
• Regulate and monitor the position of goods;
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• Regularly inspect the conveyor for visible damage;
• Stop the device immediately and ensure that it cannot be started accidentally in the event of:
Smoke, unusual noises, trapped or broken goods, defective support stands, side guides or
accessory appliances;
• A specialist must locate the source of the fault immediately;
• Do not put your hand(s) between trays during operation;
• Do not put your hands inside the sort machine behind the red plastic glass during operation;
• Do not put your head inside the sort machine during operation;
• Do not climb inside the sort machine during operation;
• Do not climb on the sort machine during operation;
• Carry out maintenance and inspections regularly;
• Only use original spare parts.

2.6 Interfaces to other devices
Danger zones can arise when integrating the sort machine into a logistic system. These zones will not
be described in these operating instructions and must be analyzed during installation and initial start-
up of the respective system.

After connecting the sort machine to other modules, machines, destinations or equipment, always
check the entire system for new danger zones prior to initial start-up.

2.7 Sort machine safety light system
To prevent operators using the machine, when it is in a state that it can be dangerous for man en
machine, signal towers have been placed in the areas that are covered by the views of all the
operators.

These signal towers show the state of the machine according to the following color scheme

Green light:
- Normal situation;
- Machine is in operation;
- No action required.

Orange light:
- Cautious situation;
- Machine has been stopped by the automatic crash detection
system of the sort machine;
- Take action before starting the machine!

Red light:
- Emergency situation;
- Machine has been stopped by an emergency stop;
- Take immediate action according to the proper procedures!

At the bottom of each signal tower a signal horn is placed to notify the operator(s) that the machine is
started up and will start moving in 2 seconds.

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Operator instructions Page : 10

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3 Product specifications
3.1 Sort of products
Products that are sorted by the Equinox MHE BV sorting system are non-critical products such as
garments and hand bags. Non critical products are products that will not damage or break easily when
inducting them into the sorting system.

These products:
- do not have a sticky surface;
- package is not damaged;
- do not have loose ends that can be picked up by the machine.

3.2 Product dimensions
To sort the products via the sort machine system the product dimensions have to be between the
given minimum and maximum dimensions (height, width, length and weight).

• Volume:
L [mm] W [mm] H [mm]
Max. 650 450 200
Min. 70 70 2

• Weight:
W [kg]
Max. 5
Min. 0,02

All the products have to be inducted in the middle of the barcode in the tray with the long side of the
product in the direction of the sort machine.

The aero-dynamical aspects of products are also a factor. In particular light-weight products with large
surface, such as A4 paper sheets, fly away when they are sorted. The supervisor has to check
whether light products can be sorted or not.

Products that have one or more of its dimensions fall outside of the given measurements may
not be inducted into the sorting system. This could cause serious damage to the machine!

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4 Inducting products
At the induction stations on the platforms the items will be inducted into the sort machine machine.
This must be done according to the right procedures. The following paragraphs will explain these
procedures and their tools.

4.1 Induction station
The induction station is the basis for the operator. At this location the operator will scan the items and
place them in the sort machine system.

4.1.1 Induction screen / monitor
On this screen the operator can see what item and the amount of the item that must be inducted.

For the usage of the Equinox MHE BV Exact software that runs on the touch screens see manual:
“ESS_Carry_Poznan_short”.

4.1.2 Cash desk scanner
With the scanner the operator scans the barcode of the item which sends the data to the sorer system.
At this moment the sorting system knows which item will be inducted and finds the location where to
drop the item.
After scanning the item the operator can place the item into one of the trays.

4.1.3 Start and stop button
At induction stations 1 and 5 a start and stop button are mounted to start and stop the machine.

4.1.4 Emergency stop
All induction screens are equipped with an emergency stop that will directly stop the total sorting
system. Sort machine, conveyors and lift.

4.2 Scanning the product by hand
To sort the product to the right customer the sorting system first needs to know what kind of product
will be inducted. To get the information into the system the product barcode has to be scanned via a
scanner that is located in the induction screen.

The following steps explain how to scan the product:
- Keep the, to be inducted, product with its, good visible barcode, in front of the scanner;
- The scanner will make a sound, bleep, to let you know that it did identify the barcode;
- The monitor on the induction screen now shows a green area with the amount of this item to
be inducted (only one item per tray is allowed);
- This amount of items can be inducted into the sort machine without scanning the barcode
again;
- After the right amount of items is inducted the screen will turn red and the next product item
can be scanned.

4.3 Inducting products
To drop the product at the right client station the item has to be inducted into the machine, on to a tray.
This inducting has to happen the proper way so there will be no damage to the product, machine and /
or inductor.
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The following steps explain how to induct the product the right and most secure way for both operator
and machine:

- Place the product with its long side aligned to the trays long side;
- Place the product in the middle of the tray;
- Place only one (1) product per tray per induction station.

If the product is inducted the wrong way do not try to get it out or try to put it right .
When this occurs follow the next steps:
- Directly push on the e-stop button on the bottom of the induction screen to stop the sort
machine;
- Tell the supervisor which item was induction wrongly;
- The super visor will place the item the right way into the tray;
- Supervisor will start up the machine.

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4.4 How to Safely induct items into the sorting system.

1. Scan the barcode of the product.

2. After barcode has been scanned
(manually or automatically) the screen
shows a green area with the amount of
the still to be inducted items.

3. Only induct one large or small item per
Wrong way!
tray per induction station

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4. Put the product in centre of the tray half Wrong way!
with the long sides aligned.

5. Place big items in the centre of the tray.
Beware that nothing of the items fall over Wrong way!
the tray.

6. Stop with inducting the product when the
amount area on the screen turns red.

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4.5 Prohibited!!!!

1. Arm / hand between trays. 2. Touch the inside of the machine.

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5 Assigning client box
5.1 Assign a box to the sort machine system.
For manually operate the box assigning at the beginning of a wave or batch follow the next steps:
- Light, of the PTL module, at each drop station that will be used is turned red;
- Place an empty box on the table, with the barcode facing outside of the sort machine;
- Scan the barcode on the sort machine, next to the red button, with the mobile scanner;
- Scan the barcode on the empty box in the station;
- Light of the PTL module is turned off;
- Box is now linked to the drop station / client and can be used.

5.2 Full box.
For manually operate a full box in the sort machine system complete the following steps:
- When the sort machine system notifies a full box in a station it will turn the light of this station
red;
- Check the middle conveyor for an empty space to push the full box onto the conveyor;
- Push the box onto the middle conveyor;
- Place a new box and assign this box to the system(see chapter 6.1).

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6 Available functions on the drop stations
Each drop station is equipped with light and button. Following is the description of available
functionality.

6.1.1 Light on drop station:
- Light off – carton is assigned, drop station operational. If no carton assigned and light is off –
drop station is not used.
- Light solid – drop station cut-off performed and there is no carton assigned to a drop station.
Light will also be solid when new wave is loaded to indicate that carton has to be assigned to
this particular drop station.
- Blinking – drop station is suspended – no product will drop to such drop station.

6.1.2 Drop station suspend/release:
- If drop station has to be temporally suspended – button should be shortly pressed on the drop
station that has to be suspended.
- Pressing the button when drop station is in suspend state will release drop station and make it
available for sorting.
- Light will be blinking when drop station is suspended.

6.1.3 Carton Cut-off :
- If carton is assigned to a drop station (light is off) scanning drop station barcode will
automatically perform carton cut-off operation.
- Light on the drop station will be solid after successful cut-off. New carton has to be assigned
to a drop station.

6.1.4 Carton Assign :
- When drop station light is solid, scan drop station barcode first and than carton barcode with
RF or wireless scanner. If light goes off – carton was successfully assigned to drop station.

Important!
Light on the drop station is indicating that items will not be dropped to this place until carton is not
assigned or button is not pressed again (in case of suspend).

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7 Error messages on sort machine control pc screen
This paragraph contains information only needed by the system supervisor!

Stop Reason Text Device numbers Corrective actions
Stopped from StarGaze N/A None - not a fault
Not started N/A None – not a fault. Sorter was
never started since last computer
reboot
Internal system error N/A Contact Equinox. If possible, do
not start any software before
computer is checked by Equinox
Eventer or RTX timeout N/A Contact Equinox. If possible, do
not start any software before
computer is checked by Equinox
Locked out for maintenance N/A Make sure that maintenance
activities are finished, open
“System lockout” window from
Stargaze Actions menu and enter
unlock password
No input from Encoder N 1 If motor not starting at all –
problem is caused by faulty
motor or inverter. If motors runs
briefly before the fault – check
encoder.
Motor input N activated 1-2 Make sure that it’s safe to restart
the sorter and switch on
maintenance switch near sorter
motor
Motor overload N activated 1 Investigate reasons why one of
the motors is overloading. It
could be chain jam or some other
mechanical problem. Do not
attempt to restart sorter until
mechanical problems are fixed.
Emergency stop N activated 120 – at induction 1
121 – at induction 2`
122 – at induction 3
220 - at induction 5
221– at induction 6
224 – on panel 2 door
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Stop button N activated 1 – at induction 1
99 – on panel door
Inverter fault N activated 11 – inverter 1 not Reset inverter by cycling panel
ready signal power.
12 – inverter 1 fault
signal

Emergency stop circuit N 1 Emergency stop button or pull
activated cord is released but Preventa
safety relay still has to be reset by
turning key switch on the panel 1
door
External emergency stop N 100 Emergency stop signal is coming
activated from the external system.
Low air pressure sensor N 1 Check and restore compressed air
activated supply
Emergency pull cord N activated 124 – induction 5-8
side
125 – inductions 1-4
side
Closing station crash PE N 10 and 20 inside. Check closing station for products
activated 11 and 21 outside stuck between tray and carrier.
Location indicated by Check for broken trays. Reset
flashing orange light. fault by pressing orange button
near closing station
Hanging garment crash PE N 10 or 20. Location Check trays around closing
activated indicated by flashing station for products hanging
orange light. under the tray. Reset fault by
pressing orange button near
closing station
Inside confirmation PE failure (too 73 – before induction Check solenoids to be sure that
many not seens) 5 no solenoid is stuck and opening
80 – before induction every tray. Check the photo eye
1 and reflector alignment. Clear
dust from the photo eye and
reflector. Check for damaged
cables. If photo eyes has been
moved from it’s initial position –
contact Equinox to recalibrated
sorter.
Outside confirmation PE failure 74 – before induction Check solenoids to be sure that
(too many not seens) 5 no solenoid is stuck and opening
81 – before induction every tray. Check the photo eye
1 and reflector alignment. Clear
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dust from the photo eye and
reflector. Check for damaged
cables. If photo eyes has been
moved from it’s initial position –
contact Equinox to recalibrated
sorter.
Carrier cycle PE N covered too 2 – BCC photo eye at Check the photo eye and reflector
long induction 1 alignment. Clear dust from the
photo eye and reflector. Check
3 - BCC photo eye at for damaged cables. Check for
induction 5 tray with broken swivels about 1
82 – rear plate before meter after the photo eye
closing station before
induction 5
83 - rear plate before
closing station before
induction 1
First carrier PE N covered too long 1 Check the photo eye and reflector
alignment. Clear dust from the
photo eye and reflector. Check
for damaged cables

Inside confirmation PE N covered 73 – before induction Check the photo eye and reflector
too long 5 alignment. Clear dust from the
80 – before induction photo eye and reflector. Check
1 for damaged cables.

Outside confirmation PE N 74 – before induction Check the photo eye and reflector
covered too long 5 alignment. Clear dust from the
81 – before induction photo eye and reflector. Check
1 for damaged cables.

Encoder N speed too low 1 Typically caused by motor or
inverter problems. If sorter runs
at normal speed – check encoder
Encoder N speed too high 1 Faulty encoder – replace.

Divert fail limit reached on 1 to 144 Repair faulty solenoid, or reroute
Divertor N products to another lane.
Half open tray crash sensor N 10 or 20 location Only inside or outside part of the
activated indicated by flashing tray opened for large product
orange light occupying the whole tray.
Remove product (if any) from half
open tray at closing station.
Broken tray sensor N activated 10, 11, 20, 21 – Signal phase difference between
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location indicated by two BCC photo eyes is different
flashing orange light from expected. Possibly damaged
tray or some other mechanical
problem with the tray
Too many full lanes Clear full lanes and restart the
sorter
First carrier not found or First 1 Make sure that tray #1 has
carrier PE N failure reflector attached and it’s seen
by carrier #1 photo eye. This
error can also be caused by
incorrectly mounted or faulty
encoder. The error can also occur
if system is restarted after power
loss on Panel 3
Round trip count error on First 1 This error is typically caused by
carrier PE N problems with mechanical
mounting of encoder. Less
common cause is internal faults
of the encoder itself. The error
can also occur if system is
restarted after power loss on
Panel 3
Scanner N failure (too many 1 – for induction 1-4 Scanner (camera) is transmitting
noreads) 2 – for induction 5-8 data but not able to decode any
barcoces. Repair the scanner.
Scanner N failure (too many not 1 – for induction 1-4 Scanner (camera) is not
seens) 2 – for induction 5-8 transmitting any data. Make sure
that scanner is powered up and
laser is ON. Check network cable
from scanner to network switch

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8 Company information
8.1 About us
Equinox is a logistics systems integrator providing turn-key solutions for your global supply chain.
Equinox's solutions provide for a high return on investment and help our clients' achieve bottom line
profitability and competitiveness. Our industry-proven software provides automated solutions for
clients' challenges both locally and world-wide. Equinox experts can create an optimal design based
on your needs and then implement that design, train your staff and provide round-the-clock customer
service and technical support.
Our clients are our partners. Not only do they benefit from Equinox solutions, they play an active role
in the development of new products to meet their changing needs in this active and competitive
economy.
Equinox's worldwide organization has 4 offices and more than 100 specialists in logistics, warehouse
management, software development, mechanical engineering, electrical engineering, implementation
and technical support. As this booklet provides an overview of our capabilities please do not hesitate
to contact us to explore how we can help your profitability

8.2 Contact information
You can contact Equinox at the following addresses:
West Europe
Equinox MHE
Pastoorslaan 57
2182 BW Hillegom
Netherlands
tel. +31 252-526 000
www.EquinoxMHE.com

East Europe
UAB Equinox Europe
Zeimenos g. 9
Kaunas LT-3009
Lithuania
tel. + 370 37 386 812

North America
Equinox SCS INC.
3350 Shelby Street
Suite 200
Ontario, California 91764
USA
tel. +1 909 944 2511
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Asia Pacific
Equinox Australia LTD
Suite 1404, 401 Docklands Dr.
Docklands VIC 3008
Australia
tel. +61 3 9642 4466

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