AutoStore Level 1 Troubleshooting

Created by Markus Merkle, Modified on Fri, 29 Nov, 2024 at 2:33 PM by Franziska Möller

TABLE OF CONTENTS

First Steps

Check the Event Log in the Console (Service PC on the AutoStore mezzanine)
What errors or notifications are showing in the Event Log? You may need to scroll to find what's relevant.
Use the Status Lookup tool to find the error description and possible actions to take for resolution

Common Issues

System is Down

Is the Controller PC powered?
- Open the Controller cabinet and ensure the ASIO, Switch, and Controller PC, and UPS are on
  - How to power each module:
    - UPS: Press the long rectangular power button located at the bottom of the stack
    - Controller PC: Open the small door on the Controller PC and toggle the power button
    - Switch: Comes on automatically with the UPS
    - ASIO: (version 3.0) Press the circular power button on the right side of the front of the ASIO.
- Follow the steps in Restart After Power Outage

Is the Service PC powered?
- Power on the PC (look for the power button on the bottom, side, or back of the monitor)
- Open the AutoStore Console app on the Service PC

What is the system status in the Console on the Service PC?
- Disconnected
  - Ensure AS Driver is running on the Controller PC
  - Ensure all AutoStore services are running on the Controller PC
  - Ensure all AutoStore services are running on the Application Server
    - Contact local IT to confirm
- Stopped
  - Are there any errors in the Event Log on the Console?
  - Are AS Driver and all AutoStore services on the Controller PC running?
    - Use the remote desktop to access the Controller PC (IP: 192.168.0.230)
    - Ensure the AS Driver window is open, if it is not, double-click the icon on the desktop.
    - Read the latest messages in the AS Driver window. Have there been any disconnections?
    - In the Windows search bar, type "Services". Ensure all AutoStore services have a "Running" status. If they don't, start each service.
  - Are all AutoStore services on the Application Server running?
    - On the Application Server, in the Windows search bar, type "Services". Ensure all AutoStore services have a "Running" status. If they don't, start each service.
  - Is the ASIO in an error state?
    - Is there a red "i" showing on the Console near the system status?
    - (ASIO3.0) Is the error light on the ASIO illuminated?
    - Is the robot door open?
    - Is the grid door open?
    - (ASIO 3.0) Reset the key on the Service Wall
    - (ASIO 3.0) If the error is not resolved, try power cycling the ASIO by pressing the power button directly on the ASIO.
    - If the error persists after power cycling, check the Event Log in the Console for errors that might have triggered the ASIO error state.
- Alert
  - If the building fire alarm was triggered, it will need to be reset before the AutoStore can be started.
    - After the alarm is reset, press the Start button on the Console to start the system.

Port in error state and retry button does not resolve the error

Ensure the safety covers are properly in place

Look at the error code in the Event Log on the Console. Common Errors:
- SF Function [304]
  - Ensure the emergency stop is not engaged and the safety covers are properly in place
- Channel Fault [305]
  - Unplug the main power cable (black, round) from the interface box inside the port and plug it back in. Then, restart the port.
  - If this error keeps occurring, ensure that the front safety door of the port is securely in place. If it is loose, make adjustments to the brackets where the magnets attach to make a more secure connection.
  - See Channel Fault Error for more information
- Arm Battery Too Low [110]
  - The carousel arm capacitors have been drained and need 5-10 minutes to recharge.
  - This is typically caused by the port being turned off or left in an e-stop state for an extended period of time.
    - Ensure the operators know not to power the port down or to leave the emergency stop engaged, even when going on break or when leaving for the day.
- Encoder Sensor Mismatch [200], Arm Errors [303]
  - Check for dust/debris obstructing the arms or sensors inside the port
- Serial Com [111]
  - Power cycle the port
  - If power cycling doesn't resolve the issue, inspect the cabling and brushes

Robot attempts and fails to pick up a bin

Questions to ask:

Could the bin be overweight?
Is the bin warped or bowed?
Is there something obstructing the gripper holes on the bin?
Is the robot gripper shifting as it comes down into the port?
Is the bin sitting flat in the bin tray?
What errors are appearing in the Event Log on the Service Console?

Common errors:

Wire Failure [218]. Parity [200]
- Observe the robot picking and putting bins in the port. Is there any rubbing or misalignment?
  - If this occurs multiple times per week, contact Kardex.
- Bin is overstuffed, unbalanced, warped, or there is an obstruction to the gripper holes
  - Press the e-stop button on the port and manually swing the bin around to the operator position. Adjust and repack the bin if necessary. Release the e-stop and press the retry button. The arms should recalibrate and the robot should try to pick it up again.
  - If bin is warped: try to bend it back into place.

Bin Could Not Be Picked Up From Cell [116]
- Observe the robot picking and putting bins in the port. Is there any rubbing or misalignment?
  - If this issue occurs multiple times per week, contact Kardex.
- Bin is overstuffed, unbalanced, warped, or there is an obstruction to the gripper holes
  - Press the e-stop button on the port and manually swing the bin around to the operator position. Adjust and repack the bin if necessary. Release the e-stop and press the retry button. The arms should recalibrate and the robot should try to pick it up again.
  - If bin is warped: try to bend it back into place.

Bottom Too Early [216]
- Bin is overstuffed or there is an obstruction to the gripper holes
  - Press the e-stop button on the port and manually swing the bin around to the operator position. Adjust and repack the bin if necessary. Release the e-stop and press the retry button. The arms should recalibrate and the robot should try to pick it up again.
- The bin/gripper is hitting something on the way down
  - Inspect the grid cell for obstructions
- A bin is physically in a stack, but not logically in the system
  - Search for the bin number in the AutoStore Console. If the bin is not physically where it is logically, remove the bin from the grid and re=insert it at a port. Confirm in the Console that the physical and logical states of the bin match.

No Bottom Detected [215]
- Bin is overpacked
  - Inspect and repack if necessary
- Bin has been physically taken out of the system without logically removing the bin from the system
  - Contact Kardex

TABLE OF CONTENTS

Robot experiences a recurring issue which stops the system

Resolution depends on the error experienced
- See error lookup excel sheet

Errors such as NO_MIDPOS, ILLEGAL_TRACK, MISSING_GAP, TRACKSHIFT, and GAP_OVERFLOW
- Inspect track sensors and wheels for dirt/debris. Clean with a dry lint-free cloth.
- Ensure there are no loose connections
Remove the robot from the system and perform further inspection
Contact Kardex for further assistance