Megamat - Swiss Instruments Ltd

Megamat 

Operating instructions 

for 

Megalift FSE storage & retrieval 

systems 

with 

microprocessor controller 

MM 550 

Megamat GmbH 

Büro- und Lagertechnik 

Megamat-Platz 1 

D-86476 Neuburg/Kammel 

Phone +49 8283 / 999 - 0 

Fax +49 8283 / 999 – 155

Operating Instructions MM550 


Dear customer, 

Please read these operating instructions through carefully before starting the 

machine. Initially commissioning of the machine may only be carried out by an 

instructed person who is familiar with the machine and its safety devices. 

Please operate the machine exactly according to these instructions, because 

otherwise any guarantee claims will be null and void. 

In addition, we also draw your attention to the supplied manual. 

General Operating Instructions for Megalifts 

These instructions describe the operation of the Megalift control MM 550 and consist 

of five sections: 

1. GENERAL........................................................................................................................................ 4 

2. KEYBOARD AND DISPLAY ........................................................................................................... 5 

3. USING THE CONTROLLER.......................................................................................................... 11 

4. SAFETY FEATURES OF THE MEGALIFT................................................................................... 53 

5. ERRORS........................................................................................................................................ 55 

6. ANNEX: FUNCTION DESCRIPTIONS.......................................................................................... 67 

If you have any queries, please contact our service department under the following 

address: 

Megamat GmbH 

Customer service department 

D-86476 Neuburg/Kammel 

Phone +49 8283/999-143 

Fax +49 8283/999-155 

Please ensure when making any queries that you have the Megalift Controller MM 

550 form at the ready which was completed by our technician during initial 

commissioning. This will make it easier to find the fault or provide the help you need. 

__________________________________________________________________ 

These technical documents are the intellectual property of Megamat GmbH. They 

may only be used for their proper purpose. They may not be forwarded or made 

accessible to third parties, particularly to competing companies. 

BA550FSEGBB.doc - 1 - Status: 01.09.2005



Table of contents 

1. GENERAL........................................................................................................................................ 4 

1.1 DESCRIPTION ................................................................................................................................... 4 

1.2 SCOPE OF THESE OPERATING INSTRUCTIONS..................................................................................... 4 

1.3 SPECIAL UNITS................................................................................................................................. 4 

1.4 BATTERY CHANGE............................................................................................................................ 4 

2. KEYBOARD AND DISPLAY ........................................................................................................... 5 

2.1 DISPLAY .......................................................................................................................................... 6 

2.2 KEYBOARD ...................................................................................................................................... 7 

2.2.1 CURSOR BLOCK AND FUNCTION KEYS ............................................................................................. 7 

2.2.2 FUNCTION KEYS ............................................................................................................................ 8 

2.2.2.1 Function keys in Main menu.................................................................................................... 8 

2.2.2.2 Function keys in menu storing ................................................................................................. 9 

2.2.2.3 Function keys in menu picking ............................................................................................. 10 

3. USING THE CONTROLLER.......................................................................................................... 11 

3.1 SWITCHING ON ............................................................................................................................... 11 

3.2 SWITCHING OFF.............................................................................................................................. 12 

3.3 MODE SELECTION........................................................................................................................... 14 

3.4 "TRAY" MODE ................................................................................................................................15 

3.4.1 ENTERING A TRAY USING THE NUMBER KEYS ................................................................................. 16 

3.4.2 LOCKING AND RELEASING THE TRAY IN THE ACCESS PORT.............................................................. 17 

3.4.3 BRINGING A NEW TRAY INTO THE MEGALIFT................................................................................... 18 

3.4.4 PICKING A TRAY FROM THE MEGALIFT........................................................................................... 19 

3.4.5 FILLING LEVEL OF THE MACHINE.................................................................................................... 20 

3.4.6 OPTIMISATION RUN ...................................................................................................................... 21 

3.5 STORING OR PICKING ARTICLE ........................................................................................................ 23 

3.5.1 STORING..................................................................................................................................... 23 

3.5.2 PICKING ...................................................................................................................................... 27 

3.5.3 CREATE NEW ARTICLE WITH STORAGE LOCATION........................................................................... 31 

3.5.4 DELETE ARTICLE.......................................................................................................................... 37 

3.5.5 SPECIAL FUNCTIONS .................................................................................................................... 40 

3.5.5.1 Create additional storage location.......................................................................................... 40 

3.5.5.2 Article search ......................................................................................................................... 41 

3.5.6 CHANGES.................................................................................................................................... 42 

3.5.6.1 Changing the article master data of an article........................................................................ 42 

3.5.6.2 Changing an article stock.......................................................................................................43 

3.6 EXPLANATION OF THE FUNCTION KEYS ............................................................................................ 44 

3.7 HELP FUNCTION AND LANGUAGE SELECTION.................................................................................... 45 

3.8 INFORMATION MENU ....................................................................................................................... 46 

3.8.1 INFORMATION MENU: SOFTWARE .................................................................................................. 47 

3.8.2 INFORMATION MENU: BRACKET DATA............................................................................................. 47 

3.8.3 INFORMATION MENU: TRAY DATA .................................................................................................. 48 

3.8.4 INFORMATION MENU: ERROR MEMORY .......................................................................................... 48 

3.9 LISTS............................................................................................................................................. 49 

3.9.1 ARTICLE LIST .............................................................................................................................. 49 

3.9.2 LOCATION LIST............................................................................................................................ 50 

3.9.3 MIN. STOCK LIST.......................................................................................................................... 50 

3.9.4 PRINT ......................................................................................................................................... 51 

3.9.4.1 Print article............................................................................................................................. 51 

3.9.4.2 Location print......................................................................................................................... 52 

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4. SAFETY FEATURES OF THE MEGALIFT................................................................................... 53 

4.1 SAFETY FEATURES TO PROTECT THE OPERATOR.............................................................................. 53 

4.2 MONITORING THE PRODUCT ............................................................................................................ 54 

5. ERRORS........................................................................................................................................ 55 

5.1 ERROR HANDLING .......................................................................................................................... 55 

5.2 ERROR MESSAGES AND THEIR MEANINGS ........................................................................................ 56 

6. ANNEX: FUNCTION DESCRIPTIONS.......................................................................................... 67 

Article and quantities management ....................................................................................................... 67 

Picking................................................................................................................................................... 69 

Storage locations ................................................................................................................................... 70 

Lists ....................................................................................................................................................... 70 

Printout (option) .................................................................................................................................... 71 

Networking (option).............................................................................................................................. 71 

Data back-up and data exchange ........................................................................................................... 71 

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1. General 

Read the supplied manual 

General operating instructions for Megalifts 

thoroughly before starting to work with Megalift. It contains the operating instructions, 

safety regulations and safety devices in the Megalift. Please comply with these 

instructions exactly, because otherwise any guarantee claims will be null and void. 

1.1 Description 

The electrical equipment of the Megalift has been tested and approved by an 

authorised agency. The manufacturer is in possession of a survey for the electrical 

safety of the machine. The controller thus complies with the following standards: 

• EN 60204 – Electrical equipment of machines 

• EN 60950 – Safety of information technology equipment, including electrical 

office machines 

1.2 Scope of these operating instructions 

These operating instructions describe working with the controller in the standard 

version. 

1.3 Special units 

You will receive separate descriptions for special units. Please always comply with 

the procedures explained there !! 

1.4 Battery change 

The control has a battery to buffer certain data. 

This battery has a service life of 4 years and must be replaced after 

this period. 

 

The due date for the battery change is stated on a sticker on the control plate. If you 

have concluded a maintenance contract with our customer service department, 

then the battery will be replaced in good time as part of the annual maintenance 

procedure. 

- 4 -



2. Keyboard and display 

MEGALIFT FSE 

Display 

Storing 

Picking 

numerical 

keys 

F1 F2 F3 F4 F5 F6 

Funktion keys F1-F6 

Start 

Stop 

Delete 

Cursor block 

alphanumerical 

keyboard area 

Controller MM 550 shown above is available with an alphanumerical keyboard for the 

entry of alphanumerical article numbers. 

- 5 -



These operating instructions present information relating to keyboard entries 

as follows: 

• Entries with function keys (F1-F6) or other keys are shown highlighted and 

bold. 

Examples 

• means press the cursor button "down". 

• means press the key START. 

• '1-2-3-4-5-6' means enter number 123456 

followed by key START. 

2.1 Display 

The display: 

• graphic-compatible, backlit LCD-Display - monochrome 

• for output of system and fault messages 

• all entries are shown in the display 

- 6 -



2.2 Keyboard 

The control keyboard is divided into three parts with 

• six function keys underneath the display. 

• The middle section has the cursor block with the start-, stop-, delete-, 

storing-, picking-, and the numerical keys 

• the alphanumerical keyboard is in the lower section 

2.2.1 Cursor block and function keys 

• this key is always used to 

conclude entries; 

start Megalift 

go down one menu stage 

• n confirm error messages 

stop the Megalift. 

(Interruption of an optimisation run, e.g.) 

• go up one menu stage 

interrupt entries 

and leave functions (menus) 

• The arrow keys are used 

to move the cursor to the right or left 

(moving to the left deletes a character, for example) 

to select default settings 

to go to the field above or below 

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2.2.2 Function keys 

• The six function keys F1-F6 directly underneath the display are allocated 

by the software to the functions shown in the icons. 

2.2.2.1 Function keys in Main menu 

F1 F2 F3 F4 F5 F6 

Info Menu 

Optimisation run 

release tray 

Lock tray 

Parking position 

Help 

- 8 -



2.2.2.2 Function keys in menu storing 

F1 F2 F3 F4 F5 F6 

Put away 

Storage location master data 

Article master data 

Additional Storage location 

Help function 

- 9 -



2.2.2.3 Function keys in menu picking 

F1 F2 F3 F4 F5 F6 

release tray 

Storage location master data 

Article master data 

Help function 

- 10 -



3. Using the controller 

3.1 Switching on 

• Where applicable, open sliding door and switch main switch on. 

• Once the self test has finished, the controller responds with: 

• Press: 

The platform now moves to the reference point: 

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After the reference run, the controller responds with the main menu. 

The Megalift is now ready 

If there are any error messages in the control display, please refer to the chapter 

"Error messages". 

3.2 Switching off 

 

Before switching the Megalift off, the tray in the 

access port should be stored in the Megalift or removed 

from the Megalift ! 

The empty platform should be moved to the parking 

position ! 

Otherwise you can expect a prolonged reference run next 

time the machine is switched on! 

• if necessary, go to "tray mode". by pressing 

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• Store the tray at the access port by pressing 

• then move the empty platform to the parking position, 

by pressing the function key F2: 

F2 

The Megalift can now be switched off. 

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3.3 Mode selection 

After pressing once or repeatedly the I-key 

display. 

, the main menu appears on the 

In the main menu, the individual modes can be selected 

• with the cursor keys and START , , 

or 

• by entering the corresponding numbers and pressing START 

Tip: 

If you are not sure which menu you are in, simply press the key 

the main menu appears on the display again. 

until 

- 14 -



3.4 "Tray" mode 

With the tray mode, you can bring preselected trays to the access port or transport 

them back to the lift. 

Go to "tray" menu: 

- 15 -



3.4.1 Entering a tray using the number keys 

In the "tray" mode, you can request the tray by entering the tray number: 

• Enter the tray number ( e.g.): 

1 - 3 

and 

• Your entry can be checked on the display. 

• Typing error? Cancel with: 

deletes the whole input 

Enter the tray number again and start the Megalift. 

• The Megalift stores the tray at the access port, e.g.: 10 

• The requested tray is then brought to the access port. 

• After the tray has been pushed out, the required article can be retrieved. 

As soon as the cursor flashes again at the last digit for entering trays, you can: 

• enter a new tray number, or 

• press to select another mode. 

- 16 -



3.4.2 Locking and releasing the tray in the access port 

Your Megalift has an automatic tray locking feature. 

When the tray is pushed out from the platform into the access port, the tray remains 

locked. 

F3 

F4 

Releasing: 

Lock 

Release 

Tray 

• Press the key : F4 “release tray” see above 

• The drawer mechanism releases the tray. 

• Press the function key F4 "release" again to transport the tray currently in the 

access port to the front part (if there is one). 

Locking: 

• Before locking a tray again, first ensure that the tray is in the right position at the 

access port. 

• Now you can lock the tray with the key: F3 “Lock tray” 

• Press the special function key F3 “Lock tray” again and the tray currently in the 

access port is taken into storage in the lift. 

The tray locking feature can be switched on/off under Settings / Parameters / Control. 

When the tray is pushed from the platform into the access port, the tray is then 

immediately released (also applies to pushing the tray onto the front part). 

The released trays can still be locked as described above. 

- 17 -



3.4.3 Bringing a new tray into the Megalift 

Note: Applies to all modes 

 

Before a new tray is pushed in, the empty platform 

must be on the level of the access port. 

If necessary, press 

to store the current tray and 

press again to bring the platform to the 

access port again. 

• If a tray is pushed into the Megalift access port from the outside, then the 

controller will automatically ask you to enter the tray number: 

• Enter the tray number, e.g..16 

The controller checks whether this tray number is valid or whether there is 

already another tray with this number in the system 

Now you should lock the tray as described above with: 

- 18 -



F3 

lock 

tray 

release 

• The tray remains standing at the access port and can now be filled by you 

• To store the tray in the Lift, press 

Tip: 

For several Megalifts, it is advisable to number all trays consecutively so that 

each tray number only exists once in the whole warehouse. 

Valid tray numbers are 1 to max. 32,767. 

3.4.4 Picking a tray from the Megalift 

• If a tray is picked from the access port (after unlocking), the controller 

continues to show the menu "tray". 

• The tray is booked out of the system and is no longer available in this 

Megalift. 

- 19 -



3.4.5 Filling level of the machine 

The filling level of the machine can be checked at any time. 

Therefore you have to press the function key F5 (optimisation run) in the main 

menu or in the tray menu. 

F5 

Now you see the actual filling level of the machine: 

Graphic Display 

Occupancy in % 

Total free storage space 

Free, max. connected location height 

Start of the optimisation run 

- 20 -



3.4.6 Optimisation run 

This function closes the gaps which are created over time when trays of different 

height are stored and picked. It is only possible for Flexiloc systems. 

An optimisation run is necessary, when you get at an storing procedure the error 

message “Height correction”. This means, that an storage location, which needs a 

certain height, cannot be found within the Lift. 

The execution of the optimisation run is reasonable in regular time distances 

and in the case that the maximum location height gets very low in comparism 

with the available storage space within the Lift. 

Procedure: 

• There may not be any trays at the access port or on the platform. 

• If necessary, store trays by pressing the “Start” – key. 

• The optimisation run is then started from the filling level menu. 

• Therefor call the filling level menu, like described above. 

• The cursor is already in the line “Start optimisation?” 

• Start the optimisation run by pressing the “Start” – key. 

- 21 -



During the optimisation you will see the following message in the display 

• If optimisation is not necessary, the display goes back to the main menu. 

• Press the “Stop” - key to interrupt at any time. 

• The started movement is finished. 

• You can then carry on working normally. 

- 22 -



3.5 Storing or picking article 

3.5.1 Storing 

• Go to main menu 

• Cursor in line 1 "storing". Press 

to confirm. 

• Then select an article using one of the following possibilities: 

- 23 -



1. Enter ident. number or a designation line and confirm with 

F2 

OR 

2. Press function key F2 to select article from total article list with cursor. 

Press 

to confirm. 

If the cursor is in one of the description lines, 

the descriptions of the articles are displayed. 

• The cursor now flashes in the "qty" field. Enter the quantity to be stored and 

press 

to confirm. 

- 24 -




- deletes the whole input or 

• Enter the quantity to be stored again and press to confirm. 

3. If there are several storage locations for one article, select required storage 

location from storage location list with cursor and press 

to confirm. 

- 25 -



Now the tray is made ready. 

• After confirming the storing quantity with ,the stocks are updated to the 

new value. The storing procedure is completed and you will see the following 

display message: 

• Press or to go to the article selection menu and store an new 

article. 

• Press to return to the main menu. 

- 26 -



3.5.2 Picking 

• Select main menu 

• Cursor in line 2 "picking". Press 

to confirm. 

• Then select an article using one of the following possibilities: 

1. Enter ident. number or a description line. Press to confirm. 

F2 

- 27 -



OR: 

2. Press function key F2 to select an article from the entire article list with the 

cursor. Press 

to confirm. 

• The cursor now flashes in the "qty" field. Enter the quantity to be picked and 

press 

to confirm. 


- deletes the whole input or 

• Enter the quantity to be stored again and press to confirm. 

- 28 -



If there are several storage locations of an article, select the required storage location 

from the storage location list with the cursor. Press 

to confirm. 

• Now the tray is made ready 

- 29 -



• After confirming the storing procedure with , the stocks are updated to the 

new value. 

The picking procedure is completed, you will see the following display message: 

• Press or to go to the article selection menu. 

• Press again to return to the main menu. 

- 30 -



3.5.3 Create new article with storage location 


• Cursor in line 1 "storing". Press 

to confirm. 

• Enter new ident. number and press to confirm. 

- 31 -



• Set "create new article" to yes with the cursor and press to confirm. 

• In the menu "new article", press 

designation. 

to go to "Descr. 1" and enter a new 

• Press again to go to "Descr. 2" and enter another designation. 

- 32 -



The following additions can be programmed for the article: 

MinStock 

Minimum quantity; when 0 is entered no minimum quantity 

management is active. 

PU 

Packaging unit as information field 

Storage 

here you can set the following Storage methods 

- with quantity management 

- without quantity management 

- free storage (i.e. when quantity is 0, storage location is deleted). 

• Then press until the line "save" appears. 

Set the cursor to yes and press 

to confirm. 

• If the article is managed with quantity management, the cursor now flashes in 

the "qty" field. Enter the already stored quantity of the newly created article 

and press 

to confirm. 

- 33 -



In the next menu, key in the storage location data 

Explanation: storage location and size of the storage location 

Every storage system is divided during the commissioning process into the following: 

Tray 

Tr 

Location Lo from left to right 

Location depth De from front to back 

These divisions are stored in the controller and are valid throughout the whole 

storage system. 

Due to its size and qty., each article requires a certain space on a tray. 

Therefore to each article has to be dedicated the corresponding space when creating 

the basic grid of the tray. 

Location increments dX from left to right hand side 

Depth increments dY from front to back 

Example: Tray: 4 Product Id: 2502 - 0095 

Location: 1 Depth = 1 dX: 2 dY: 2 

Example occupies altogether 4 storage locations 

Storage location and size for example : Tray: 4 Product: Id = 2502 - 0095 

Depths in units "De" 

1 2 3 4 5 

1 2 3 4 5 6 7 8 9 10 11 12 13 

Locations in width units "Lo" 

- 34 -



F1 F2 F3 F4 F5 F6 

search for the next free 

storage location 

search for the next free 

storage location on the next tray 

For entering and search of storage locations, there are various possibilities: 

1. Enter location: enter the required values for Tr, Lo, De, dX, dY. 

2. Search location: enter "0" for Tr, Lo, De, enter required values for dX, dY, 

complete storage location is suggested 

3. Search location: enter "0" for Lo, De, enter required values for Tr, dX, dY. 

storage location on desired tray is suggested 

If there is found a valid storage location, confirmation can be done by use of the 

function key (F6) or the “Start“ – key. 


- 35 -



• After confirmation, the stocks are upated to the new value. The storing 

procedure is completed. The updated display appears and the new article has 

been created. 

• Press or to go to the article selection menu. 

• Press again to return to the main menu. 

- 36 -



3.5.4 Delete article 

For deleting an article you have to do the following steps: 

1. pick the complete stock of the article 

2. delete storage location 

3. delete article 

Detailed: 

• Press the “I” – key until you are in the main menu 

• Change to the picking menu 

• Search for the desired article either by use of the ident. number or 

description line, or find the article using the matchcode search 

• Enter the complete stock as picking quantity 

• If there are several storage locations, you are asked in the next menu to select 

the corresponding storage location 


- 37 -



• Press the function key 

(F4) in the corresponding window 

• Press the function key (F2) in the next window to delete the storage 

location. 

• Set "delete" to yes with the cursor. Press to confirm 

• Pick the article from the tray 

• Repeat this procedure until all storage locations of this article are deleted 

• Press the special function key (F3) “article master data” in the 

corresponding window 

- 38 -



• In the next window, press function key (F2) 

• Set "delete?" to yes with the cursor. Press to confirm and the article is 

completely deleted 

- 39 -



3.5.5 Special functions 

3.5.5.1 Create additional storage location 


• Cursor in line 1 "storing". Press to confirm. 

• Search for the desired article either by use of the ident. number or description 

line, or find the article using the matchcode search 

• Enter the quantity and confirm with 

• Press function key (F4) (create additional storage location). 

• In the next menu, enter the storage location data for the additional storage 

location consisting of Tr (tray), Lo (location) De (depth), dX (location units) 

and dY (depth units). Press 

to confirm each time. 

• Entering the storage location or searching is identical to an normal storing 

procedure 

• Confirm the storage location by pressing 

• Further steps are identical to an normal storing procedure. 

- 40 -



3.5.5.2 Article search 

Article search is comfortable possible with the so called matchcode search 

• Therefore enter a few characters in one of the lines Id, Descr. 1 or Descr. 2. 

• Press the function key (F2) to adopt. 

• The display then shows the article list with all articles which have these 

characters in the corresponding line. 

- 41 -



3.5.6 Changes 

3.5.6.1 Changing the article master data of an article 

• Go to the main menu. 

• Cursor in line 1 "storing" or line 2 "picking". Press to confirm. 

• Search for the desired article either by use of the ident. number or description 

line, or find the article using the matchcode search 

• Press function key (F3) (article master data) in the corresponding window. 

• Here you can make any changes you need (except “total stock”). 

Every change has to be confirmed with the 

button. 

- 42 -



• Then press until the line "save?" appears. 

• Press again to confirm. 

• This adopts all the changes immediately. 

3.5.6.2 Changing an article stock 

To change the stock of an article, you have 2 possibilities: 

1. Make an picking or storing procedure 

2. Change the article stock in the "storage location master" menu. 

Therefor press function key 

corresponding window. 

(F4) (storage location master data) in the 

Here you can change the stock directly. 

- 43 -



3.6 Explanation of the function keys 

This key brings the platform to the parking position 

This key locks the tray, and clears the tray when pressed again 

This key releases the tray 

This key triggers the optimisation function (optimises the storage space) 

This key opens the corresponding help menu 

This key opens the article list 

This key creates an additional storage location 

This key can be used to change an article stock 

This key deletes a storage location 

This key changes the article master data such as Id, Des. 1 or Des. 2 

This key deletes an article 

This key overtakes all changes from the whole screen 

This key carries a tray from the extraction into the machine 

Scroll screen page down 

Scroll screen page up 

This key opens the information menu 

This key opens the language selection menu 

This key opens the access level menu 

- 44 -



3.7 Help function and language selection 

No matter which mask or function is currently in the display, a help function can be 

called with the function key (F1) for every screen. 

F2 

Press the key F2 to open the language selection menu 

Choose the language with the cursor and confirm with 

- 45 -



3.8 Information menu 

The information menu can be used to access information about the machine. 


• Press function key 

(F6) 

From the information menu you can branch into various sub-menus. 

Read software statuses 

Bracket data recognised during setup 

Tray data recognised during setup 

Saved error messages with internal 

status registers 

- 46 -



3.8.1 Information menu: software 

• Select information menu 

• Cursor in line 1 "Software". Press to confirm. 

The display shows the software statuses of the operator terminal and control. 

3.8.2 Information menu: bracket data 


• Cursor in line 2 "Bracket data". Press 

to confirm. 

The display shows the bracket data read during setup. 

- 47 -



3.8.3 Information menu: tray data 


• Cursor in line 3 "Tray data". Press to confirm. 

The display shows the tray data read during setup. 

3.8.4 Information menu: error memory 


• Cursor in line 5 "Error memory". Press 

to confirm. 

As soon as an error occurs during operation, internal statuses such as 

position counter etc. are recorded and loaded in a buffer. The recorded errors 

are shown in the information menu. 

- 48 -



3.9 Lists 


• Cursor in line 5 "Lists". Press to confirm. 

3.9.1 Article List 

With this function it is possible to request article master data as well as the to 

the article belonging location information. 

The article search does operate identically as the function „storing“. 

- 49 -



3.9.2 Location List 

Using this function you can access the article number of an occupied location. 

For selecting a location, the location can be indicated completely with it’s 

coordinates (Machine, Tr, Lo, De), then the master data of this location is 

displayed including the article number. 

If there are indicated only a part of the coordinates (i.e. Machine, Tray) or no 

coordinates, there can be selected a location from the list of the occupied 

locations. 

3.9.3 Min. stock list 

With this function all articles are listed, whose stock fell below the min. Stock. 

- 50 -



3.9.4 Print 

Attention! 

To use the printing function, a printer with an serial interface has to be 

connected with the optional printer interface. 

3.9.4.1 Print article 

With that function you can print all articles including the master data. 

The following definitions can be selected: 

• From “article number” To “article number” 

• Num.: max. number of articles to be printed 

• Type: only order proposals (articles which fell short off the minimum stock), or 

all articles are printed 

- 51 -



3.9.4.2 Location print 

With this function all occupied locations can be printed as a list. 

Therefore the following restrictions may be choosen by entering another figure than 

the predefined „0“: 

• Restriction to a machine 

• Restriction to a Tray 

• Maximum number of locations to be printed 

- 52 -



4. Safety features of the Megalift 

4.1 Safety features to protect the operator 

There are the following safety features for the operator in the Megalift FSE 

• Safety photocells 

• EMERGENCY STOP button 

• Main switch with EMERGENCY STOP function 

If one of these safety systems is triggered, for example the safety photocells, the 

controller reacts with: 

• Eliminate the cause of the fault, release the EMERGENCY STOP key. 

• Now press 

to confirm the error message. 

• Now you have to enter the required tray number in the tray menu again. 

- 53 -



4.2 Monitoring the product 

• Before a tray is stored, the controller uses the height measuring system to 

check whether the product will protrude beyond the contours of the tray ! 

• If this is the case, the following message appears: 

• After the movement "tray from access port to platform", the system checks 

whether parts protrude to the front. 

If so, the tray is moved back to the access port again and the following 

message appears: 

In both cases, check that none of the products protrude over the back or front edge 

of the tray. Eliminate the problem. 

Then start the controller again by pressing . 

- 54 -



5. Errors 

5.1 Error handling 

Handling errors and although errors, which were caused by the machine (mechanical 

or electrical errors) were normally recognized by the controller and displayed with an 

error message in the display: 

Error messages are generally confirmed with: 

z. e.g. entering an incorrect tray number 

• When a tray number is entered which does not exist in Megalift, the following 

error message appears: 

• confirm the message with 

• Once the original display appears again, you can enter another tray number. 

Note: 

If this or other error messages cannot be eliminated as described, please contact our 

service department. 

Address and phone numbers are on page one. 

- 55 -



5.2 Error messages and their meanings 

The detailed functions within the controller to observe the sensors and all expirations 

ensures that errors were recognized and diagnosed fast 

Following the possible error messages and their meanings: 

Error 

No. 

Access Content 

Meaning 

F 501 1 Emergency Stop left The Emergency Stop button left was triggered 

F 502 1 

Emergency Stop 

right 

The Emergency Stop button right was triggered 

F 503 1 Emergency Stop 3 The Emergency Stop button No. 3 was triggered 

F 504 1 Safety Photocells 

F 505 1 Error Muting 

F 506 1 Safety Stop Vertical 

F 507 1 Relay Control 

F 508 1 Fault Safety Relay 

Interruption of the light barrier e.g. during vertical or horizontal 

movement. 

Both muting sensors are in a different status for longer than 2.5 

seconds. 

Illegal movement attempt with muted light barrier (switched off), or 

open sliding door. 

On acknowledging an error, not all contacts are released or not all 

contacts have opened. 

The Cedes unit reports a lock-out, e.g. if it is damaged or the 

safety light barrier is not connected. 

F 509 1 FC Vertical The frequency converter for vertical drive is damaged or dead. 

F 510 1 FC Horizontal The frequency converter for horizontal drive is damaged or dead. 

F 511 1 Encoder Vertical Vertical encoder is not counting. 

F 512 1 Direction Vertical Vertical encoder is counting in the wrong direction. 

F 513 1 

Standard Tolerance 

Vertical 

Nominal and actual values in the frequency converter are too far 

apart, e.g. overloading or jamming of the platform. 

F 514 1 Encoder horizontal Horizontal encoder is not counting. 

F 515 1 Direction horizontal Horizontal encoder is counting in the wrong direction. 

F 516 1 


Horizontal 

F 517 1 End position down 

F 518 1 End position up 

F 519 1 

Sensor TR in 

Access 

F 520 1 Sensor Locking E1 

Nominal and actual values in the frequency converter are too far 

apart, e.g. overloading or jamming of the platform. 

The platform is in the lower end position, the reference switch of 

the vertical axis is attenuated. 

The platform is in the upper end position, the reference switch of 

the vertical axis is attenuated. 

The sensor of the centering roll is not in the right status. The 

sensor on the centering roll has not switched between platform and 

access during the horizontal movement of a tray 

The sensors for the end positions for tray locking both switched at 

the same time. A sensor for tray locking has not switched during 

the set period, or the end position was not reached. 

- 56 -



Error 

No. 

F 522 1 


Sensor TR on 

Extractor 

F 523 1 Sensor Finger 

F 524 1 Sensor Finger front 

F 525 1 Sensor Finger back 

F 526 1 Sensor rocker 

F 527 1 Sensor rocker up 

F 528 1 Sensor rocker down 

Meaning 

The platform is supposed to move vertically without tray, but the 

tray sensor on the platform is on. The sensor is already on before 

the tray moves to the platform. The sensor has not gone off after a 

movement of a tray from the platform. 

Both sensors are attenuated at the same time, 

which must not happen. 

Drive finger is in the front position, but the corresponding sensor is 

not attenuated. 

Driver finger is in the back position, but the corresponding sensor 

is not attenuated. 

Both sensors are attenuated at the same time, 

which must not happen. 

The sensor rocker up did not switch in the set time, or the end 

position was not reached 

The sensor rocker down did not switch in the set time, or the end 

position was not reached. 

F 529 1 TR not available The requested tray is not in the machine. 

F 530 1 TR exists already 

F 531 1 Height Correction 

Error on awarding a new tray number. 

A tray with this number is already in the machine. 

Storage space in lift no longer sufficient for tray being taken into 

storage. Stored goods have interrrupted the last beam of the height 

sensor and are therefore too high. The improved overlap control 

was switched on, but the bottom beam of the height sensor was 

not interrupted on pulling the tray in (height sensor fitted too high). 

F 532 1 Stor. Goods front Height sensor: stored goods at the front. 

F 533 1 Stor. Goods back Height sensor: stored goods at the back. 

F 534 1 

No Basic Position 

hor. 

F 536 1 Tray position 

F 537 1 Tray restricted A restricted tray was requested. 

F 538 1 

Setup Fault useful 

depth 

One of the following statuses must apply before a vertical 

movement: 

• The driver finger must be in position 2 or position 3, the 

rocker must be up and there must be a tray on the 

platform. 

• The driver finger must be between position 2 and position 

3 and the rocker must be down. The reference run was 

bypassed after switching on and an attempt is being made 

to work with the machine. 

During the vertical movement, the drive fingers move 

outwards past positions 2 and 3. 

The tray is not in the right position at the access or the sensor tray 

in access is on when the tray is supposed to be cleared out of the 

access or locked. 

An incorrect effective depth was entered during setup. 

F 539 1 Low Battery The control buffer battery has fallen below a certain voltage value. 

- 57 -



Error 

No. 


Meaning 

F 540 1 Error Height Sensor Light barrier is defect. 

F 541 1 

Call tray on 

plattform 

Tray height was not measured on pushing in, please request new 

tray! 

F 542 1 Sensor back door Back door reported open and closed at same time. 

F 543 1 

Time out – back 

door 

Back door should open or close and corresponding basic setting 

was not reached within the set time, respectively the corresponding 

sensor has not switched. 

F 544 1 Sensor front door Front door reported open and closed at same time. 

F 545 1 

Time out – front 

door 

F 546 1 Back door not open 

F 547 1 

F 548 1 

Back door not 

closed 

Tray other access 

port 

Front door should open or close and corresponding basic setting 



Back door is not open although a movement is pending between 

platform and access. 


platform and a bracket 

Request for a tray in another access port, which is not permitted. 

F 549 1 Operator Safety! Collective error, e.g. light barrier, emergency off 

F 550 1 Encoder Fronttable No counting pulses 

F 551 1 Direction Fronttable Encoder showing wrong direction. 

F 552 1 


Fronttable 

Act/Nom deviation of push-in/push-out speed 

F 553 1 Sensor Fronttable Both sensors pin up and down are on at same time. 

F 554 1 

F 555 1 

F 556 1 

F 557 1 

Sensor Fronttable 

up 


down 


behind 


front 

The sensor pin up did not switch in the set time or the end position 

was not reached. 

The sensor pin down did not switch in the set time or the end 


No signal on reaching back end position. 

No signal on reaching front end position. 

F 558 1 FC Fronttable Collective error message front table frequency converter 

F 559 1 

Sensor Tray on 

Fronttable 

Sensor tray on front table has not switched although there is a tray 

on the front table. 

- 58 -



Error 

No. 


Meaning 


F 561 2 


right 








F 568 2 

Sensor TR in 

Access 



F 572 2 Error Height Sensor Light barrier defect 


movement. 


seconds. 

















F 574 2 


door 





F 576 2 


door 


F 578 2 

F 579 2 

Back door not 

closed 


port 











F 582 2 


Fronttable 



- 59 -



Error 

No. 

F 584 2 

F 585 2 

F 586 2 

F 587 2 



up 


down 


behind 


front 

Meaning 








F 589 2 


Fronttable 




F 591 3 


right 








F 598 3 

Sensor TR in 

Access 



F 602 3 Error Height Sensor Light barrier is defect 


movement. 


seconds. 

















F 604 3 


door 





F 606 3 


door 



sensor has not switched 

- 60 -



Error 

No. 



F 608 3 

F 609 3 

Back door not 

closed 


port 

Meaning 








F 612 3 


Fronttable 



F 614 3 

F 615 3 

F 616 3 

F 617 3 


up 


down 


behind 


front 








F 619 3 


Fronttable 




F 621 4 


right 


F 622 4 Emergency Stop 3 The Emergency Stop button Nr. 3 was triggered 






F 628 4 

Sensor TR in 

Access 




movement. 


seconds. 
















- 61 -



Error 

No. 


Meaning 



F 634 4 


door 





F 636 4 


door 


F 638 4 

F 639 4 

Back door not 

closed 


port 











F 642 4 


Fronttable 



F 644 4 

F 645 4 

F 646 4 

F 647 4 


up 


down 


behind 


front 








F 649 4 


Fronttable 




F 651 5 


right 


F 652 5 Emergency Stop 3 The Emergency Stop button Nr. 3 was triggered 






movement. 


seconds. 





- 62 -



Error 

No. 



F 658 5 

Sensor TR in 

Access 



Meaning 














F 664 5 


door 





F 666 5 


door 


F 668 5 

F 669 5 

Back door not 

closed 


port 











F 672 5 


Fronttable 



F 674 5 

F 675 5 

F 676 5 

F 677 5 


up 


down 


behind 


front 








F 679 5 


Fronttable 



- 63 -



Error 

No. 


F 680 - Tray overweight! 

F 681 - 

F 682 - 

F 683 1 

F 684 2 

F 685 3 

F 686 4 

F 687 5 

F 688 1 

F 689 2 

F 690 3 

F 691 4 

F 692 5 

F 693 1 

F 694 2 

F 695 3 

F 696 4 

F 697 5 

F 698 1 

F 699 2 

F 700 3 

F 701 4 

F 702 5 

F 703 1 

F 704 2 

F 705 3 

F 706 4 

F 707 5 

F 708 1 

CAN-error FC 

vertical 

CAN-error FC 

Horizontal 

CAN-error FC door 

back 

CAN-error Safety 

Relay 

CAN-error FC 

Fronttable 

Emergency Stop 4 

Timeout Muting door 

Meaning 

The optional overload safeguard has registered that a tray is 

overweight. 

Error has occurred on triggering the vertical frequency converter 

via the CAN bus. 

An error has occurred on triggering the horizontal frequency 

converter via the CAN bus. 

An error has occurred on triggering the door frequency converter 

via the CAN bus. 

Initialising the Cedes safety relay via the CAN bus has failed (no 

response). 

An error has occurred on triggering the front table frequency 

converter via the CAN bus. 

The Emergency Stop button No. 4 was triggered. 

The two safety-relevant inputs door closed (Cedes safety relay) 

were switched unevenly for longer than 2.5 s. 

F 709 2 

F 710 3 

F 711 4 

F 712 5 

Timeout Muting 

horiz. 

The two safety-relevant inputs Muting horizontal (Cedes safety 

relay) were switched unevenly for longer than 2.5 s. 

- 64 -



Error 

No. 

F 713 1 

F 714 2 

F 715 3 

F 716 4 

F 717 5 

F 718 1 

F 719 2 

F 720 3 

F 721 4 

F 722 5 

F 723 1 

F 724 2 

F 725 3 

F 726 4 

F 727 5 

F 728 1 

F 729 2 

F 730 3 

F 731 4 

F 732 5 

F 733 - 

F 734 - 


Timeout Muting vert. 

Mutingresistor 

Safety Photocells 

Muting vert. 

Safety Photocells 

Muting hor. 

Disable Emergency 

operation! 

Operator Safety 

(Emerg. operat.) 

Meaning 

The two safety-relevant inputs Muting vertical (Cedes safety relay) 

were switched unevenly for longer than 2.5 s. 

The muting resistor at the Cedes safety relay (muting lamp) is 

defect. 

The light barrier was interrupted while the vertical muting inputs 

were not switched. 

The light barrier was interrupted while the horizontal muting inputs 

were not switched. 

The Emergency key switch is on but Cedes safety relay does not 

show any defect. 

Safety component was activated during emergency operation 

(safety door not closed, Emergency Stop button …). 

F 735 - Speed too high vert. Maximum vertical speed clearly exceeded (platform in free-fall). 

F 736 - Speed too low vert. Minimum vertical speed clearly undercut (jammed). 

F 737 - Speed too high hor. Maximum horizontal speed clearly exceeded. 

F 738 - Speed too low hor. Minimum horizontal speed undercut (jammed). 

- 65 -



Error 

No. 


Meaning 

F 739 2 

F 740 3 

F 741 4 

F 742 5 

CAN-error XIO A100 

door back 

Error on triggering the XIO module A100 of the slave access port 

via the CAN bus 

F 743 - 

Error 

synchronisation 

vertical 

F 744 - Vertical endposition 

F 745 - Error Servo left Error in left servo drive. 

F 746 - Error Servo right Error in right servo drive. 

F 747 - 

F 748 - 

F 749 1 

F 750 2 

No reference 

vertical 

Difference vertikal 

N-channel 

Too much difference in the position of the drives left and right 

vertical. Platform at a slant. 

At start of reference run, machine vertical on end position switch. 

Move manually away from end position switch. 

No reference run and positioning started. 

N-channel of encoder too far apart on the left and right. 

F 751 3 

FC door back 

Frequency converter for door lift drive is defect or dead. 

F 752 4 

F 753 5 

- 66 -



6. Annex: Function descriptions 

Article and quantities management 

• Article numbers can be entered alphanumerically in 1 to 20 digits 

• Article designation fields can be entered alphanumerically 2x20 digits. 

A separate match code search is possible after every designation field. 

• Up to 10,000 individual articles are possible in each system, and one system 

can consist of 1 or several machines. The number of additional modules can be 

extended to 20,000. An even larger number of articles is available on request. 

• Quantities management (quantities 6 digits, up to 999999, no decimal places). 

Quantities management can be activated/deactivated for each article. 

• Minimum quantity management 

After the booking a message is output when the quantity falls below the 

stipulated minimum. If 0 is entered as minimum quantity, quantity monitoring for 

this article is deactivated. 

A list showing every time the quantity falls below the stipulated minimum can be 

called into the display or printed. 

• Turnover frequency as counting number (sum of all storing/picking 

movements). 

Can be shown in the article master or displayed and printed via a list function. 

Use the function button to reset. 

• Filling level display 

A bar display and % value shows 

- total free storage position heights in mm 

- maximum free storage position heights in mm 

A limit can be adjusted which produces a warning when exceeded. The shuffle 

mode can be started directly from the filling level display by a function button. 

- 67 -



• Multi-position management 

One article can be stored in several different storage locations. The locations 

where the article is located are available for selection when picking. 

• FIFO with return function (option) 

Abbreviation for "first in first out". Stipulates that the first stored articles must 

also be the first to be picked. The storing procedure always looks for a new 

storage location. The picking procedure selects the tray with the oldest storage 

location. If a storage location is empty, it is automatically deleted. Return is a 

special form of storing. For FIFO articles it takes account of the storing date. For 

returned articles, the storing date is set to a point in time before the storing date 

of the same article which has been in storage the longest. In subsequent 

picking procedures, this means that the returned goods are picked before all 

other stocks of the same article. The different date means that the goods cannot 

be stored at the same location as other stocks of the same article already in 

storage. 

• Container/packing unit 

Can be entered in the information field "quantity per packaging unit". 

• Loading aid/container (option) 

Containers with corresponding sizes can be pre-defined and then stated during 

the storing process as part of the storage location search instead of the storage 

position size. 

• Stock movement journal (option) 

With This option you can log the various stock movements in chronological 

order. 

• User and access rights management (option) 

With this option you can manage and limit the access to the machine and to 

various funktions. Every user has to log on to the machine with name and 

password and gets so the authorisiations , which were assigned to him. 

- 68 -



Picking 

• Order processing (option) 

An order i.e. a combination of different articles belonging to an order, is sent by 

an overriding host computer. This order is processed and then deleted from the 

control memory. 

• Parts list management (option) 

Frequently used article combinations (e.g. components or recurring assembly 

kits) can be stored as parts lists in the system. 

Max. 20 lists with up to 100 items can be saved. 

The parts lists can either be entered from the operator panel or imported as 

ASCII file (see data exchange). 

The parts lists are selected for processing by entering the parts list designation 

from the operator panel or from the overriding host computer. 

The parts list consists of the following fields: 

Parts list: 

Article: 

Designation: 

Quantity: 

Item no. 

parts list designation 

article number 

designation of the article 

quantity of the article for the partss list 

item number within the parts list 

The parts list can be edited as follows: 

Create new parts list item 

Change parts list item 

Delete parts list item 

Search for parts list articles 

A list of all existing parts lists can be produced in the display or on a printer using the 

list functions or with “MegaData”. 

- 69 -



Storage locations 

• UP to 512 trays or carriers per Megalift or Megamat 

• Maximum 10000 storage locations per machine 

• Maximum 1024 storage locations on every tray/carrier. 

Positions up to max. 245; depths to 99 

There is free choice of configuration: for example, there can be up to 245 

storage positions and 4 depths, or 100 storage positions and 10 depths, etc. 

• Empty position management: when a new article number is created, the 

automatic suggestion can be used or a selection made by scrolling through the 

storage position list. It is also possible to enter the storage location coordinates 

directly. 

• Every tray/carrier is divided with tray grids, the same for all trays in the 

machine. 

• Composite compartments: the size of the storage position can be selected as 

a multiple of the tray grid. 

• Access locking of tray and machine 

The access to a tray or to the whole machine can be controlled by password. 

There is one password for each tray and another one for the machine as a 

whole. 

• Function "manual lock" 

A key switch can be fitted to every control panel which restricts access to a tray 

only to the article management. Intervention in the manual mode is only 

possible with the key. 

Lists 

• All article and storage position information can be displayed. 

All articles are ordered by alphabet/number and scrolling is possible either 

individually or in larger steps. The display shows the article designation and 

current stock. Selection of the article then shows the data belonging to the 

article, such as storage position, minimum stock, turnover frequency. 

• Match code search is possible by article no./article designation. 

- 70 -



Printout (option) 

• Serial printer connection (RS 232) (option) 

• Printing of all articles and storage lists with all the information belonging to the 

article, such as article designation, current stock, minimum stock, storage 

location, turnover frequency 

• Printing of the existing parts lists and storing/picking lists with all information 

using the program “MegaData” 

Networking (option) 

• Networking with up to 31 machines 

Implemented via an Ethernet extension module (option). 

The entered article can be positioned automatically at the right machine, no 

matter which machine had originally stored it. The machine operator is given a 

corresponding message. 

• Auto-start function (option) 

The right machine is addressed and storing/picking starts automatically. 

• Connection of a barcode reader 

Implemented via RS232 for reading the article numbers for storing/picking 

procedures; quit by reading in twice 

• Smooth transfer of data storage when connected to our PC-based 

warehouse management software Megalogistik. 

Data back-up and data exchange 

• Data backup is possible with the PC software using the serial interface. 

Here a serial connection lead is available together with the data backup 

software on CD-ROM. The programs run under Win 95/98/NT/2000/XP. The 

software can be used to load the whole data base onto the PC and then load it 

back again. It is also possible to edit the individual data fields on the PC before 

loading them back to the control panel. 

• Output of the data backup file as ASCII file for importing in Microsoft programs 

such as Excel or Access. 

- 71 -



Notes: 

- 72 -

Megamat - Swiss Instruments Ltd

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