werma StockSAVER User manual

StockSAVER
Software version 2.1
WERMA Signaltechnik GmbH + Co. KG
D-78604 Rietheim-Weilheim
Telephone: [phone]
Fax: [phone] / 9557-44
[e-mail]
www.werma.com
310.865.005 0317_AA

Table of contents
StockSAVER manual - Software version 2.1
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Table of contents
1Introduction........................................................................................................................................5
1.1 Target groups.....................................................................................................................................5
2Safety information.............................................................................................................................6
2.1 Proper use...........................................................................................................................................6
2.2 General safety instructions..............................................................................................................6
3Product description..........................................................................................................................7
3.1 Overview of hardware components ............................................................................................8
3.2 SensorBox............................................................................................................................................9
3.3 Overview: SmartBox .......................................................................................................................10
3.3.1 SmartBox controls......................................................................................................................10
3.3.2SmartBox display messages.....................................................................................................10
3.3.3 SmartBox connections..............................................................................................................11
3.4 Overview: Transceiver....................................................................................................................12
3.5 Barcode scanner (optional).........................................................................................................13
3.6 Software module overview...........................................................................................................14
4Getting started: Overview of installation and commissioning...............................................15
5Attaching the hardware to racks................................................................................................16
5.1 Preparation ......................................................................................................................................16
5.1.1 Unpack devices and components........................................................................................16
5.2 Installing the hardware..................................................................................................................17
5.2.1 Installing the sensors..................................................................................................................17
5.3 Installing a SensorBox .....................................................................................................................18
5.3.1 Wiring a SensorBox.....................................................................................................................18
5.3.2 Wiring the bus.............................................................................................................................19
5.4 Installing the SmartBox...................................................................................................................20
5.5 Installing a Transceiver...................................................................................................................21
5.6 Functional test.................................................................................................................................22
5.7 Installing the software ....................................................................................................................23
5.7.1 System requirements.................................................................................................................23
5.7.2 Network stability and security.................................................................................................25
5.7.3 Overview: System architecture...............................................................................................25
5.7.4 Installing WERMA StockSAVER.................................................................................................27
5.7.5 Advanced Server Installation..................................................................................................29
5.7.6 Installing a client on other PCs................................................................................................30
5.8 Commissioning the hardware......................................................................................................31
5.8.1 Wiring the racks..........................................................................................................................31
5.8.2 Connecting and configuring the Transceiver......................................................................31
5.8.3 Connecting and configuring the SmartBox.........................................................................33
5.8.4 Connect the SmartBox and Transceiver to the rack..........................................................36

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5.8.5 Configuring racks.......................................................................................................................37
5.8.6 Configuring the bus cabling....................................................................................................38
6System operation............................................................................................................................39
6.1 Overview: Control Station.............................................................................................................39
6.2 Overview: Material Requirement List ..........................................................................................40
6.2.1 Material Requirement List columns: Displaying a Single Location...................................40
6.2.2 Material Requirement List columns: Displaying Total Material..........................................41
6.3 Overview: Material Master............................................................................................................42
6.4 Analysis..............................................................................................................................................43
6.4.1 Analysis and export function...................................................................................................47
6.4.2 Export to Excel............................................................................................................................48
6.5 Configuring racks............................................................................................................................49
6.6 Changing Settings ..........................................................................................................................50
6.6.1 General........................................................................................................................................50
6.6.2 Views............................................................................................................................................51
6.6.3 Devices........................................................................................................................................52
6.6.4 Location ......................................................................................................................................52
6.6.5 Reports.........................................................................................................................................53
6.6.6 Functions .....................................................................................................................................53
6.7 System expansion ...........................................................................................................................54
6.7.1 Changing the bus wiring..........................................................................................................54
6.8 Routing..............................................................................................................................................54
6.9 Connections.....................................................................................................................................56
6.10 CSV Interface...................................................................................................................................56
6.10.1 Exporting material movements to CSV.................................................................................56
6.10.2 Importing Material Master data from CSV...........................................................................59
6.10.3 Importing Location assignments from CSV...........................................................................61
6.11 XML interface...................................................................................................................................62
6.11.1 Configuring the Interface Service..........................................................................................62
6.11.2 XML import of Material Master data sets..............................................................................67
6.11.3 XML export of Material movements ...........................................................................................70
6.11.4 Journal..............................................................................................................................................74
7Software administration.................................................................................................................75
7.1 Uninstalling the software................................................................................................................75
7.2 Installing updates............................................................................................................................75
7.3 Unsupervised client installation ....................................................................................................75
7.4 Administration console: Managing data...................................................................................75
7.4.1 Option: Manage data via the command line....................................................................76
7.5 Adjusting and synchronising the time.........................................................................................76
7.6 Alter the Server Service/database connection........................................................................77
7.7 Firmware update ............................................................................................................................77
8Troubleshooting...............................................................................................................................78

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8.1 Transceiver problems .....................................................................................................................78
8.2 SmartBox problems.........................................................................................................................79
8.3 SensorBox problems........................................................................................................................79
8.4 Sensor problems..............................................................................................................................80
8.5 Software setup problems...............................................................................................................80
8.6 Software problems..........................................................................................................................80
8.7 Information on log files...................................................................................................................83
8.7.1 Request log files from the software........................................................................................83
8.7.2 Activating detailed logging....................................................................................................83
8.7.3 Log file parameters ...................................................................................................................83
9Technical data................................................................................................................................84
9.1 General.............................................................................................................................................84
9.2 Ratings...............................................................................................................................................84
9.3 Wireless..............................................................................................................................................85

Introduction
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1Introduction
These instructions provide all the information required to operate the WERMA StockSAVER. The
instructions must be read by all persons assigned to work on this system.
1.1 Target groups
This manual is intended for:
−Production logisticians who will be working with the system.
−IT professionals who will be performing software configuration.
−Professional electricians who will be assembling the hardware components.

Safety information
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2Safety information
2.1 Proper use
The device must be assembled and wired in accordance with the assembly instructions by a
professional electrician. Only use the components supplied.
The software must be configured by an IT professional.
The system must be commissioned and operated in accordance with this manual to ensure
the safety of operating personnel and protect the StockSAVER system from incorrect
operation.
Read the operating instructions carefully before assembly and commissioning. Keep these
operating instructions in a convenient place for future reference.
Special arrangements must be made if your production logistics processes involve returning
opened bins to storage from the withdrawal side to avoid irregularities in material requisition
and analysis functions.
Data is processed exclusively by the StockSAVER software. The system does not support direct
read or write access to the database content or alterations to the database structures by
other software. WERMA reserves the right to optimise the software and connected database.
Updates can lead to alterations, replacements and deletions in the database. Unauthorised
alterations can affect the operation of the software or individual functions.
2.2 General safety instructions
−The system must only be connected by a professional electrician taking into account the
operating instructions and the guidelines as well as standards applicable in the area of
use.
−Maintenance tasks must be performed by a professional electrician with the system
disconnected from the power supply.
−The operator is solely responsible for adherence to local safety regulations, for monitoring
and control of the StockSAVER system and for the results achieved using the system. The
purchaser must test the software thoroughly for applicability in their specific situation
before beginning productive use. The purchaser is obliged to make suitable provisions for
the eventuality that the system does not work properly either entirely or in part (e.g. by
backing up data, documenting the use of the software, fault diagnostics, regular testing
of results, emergency planning). It is the purchaser's responsibility to ensure the viability of
the system's working environment.
−When not in use, keep the WERMA StockSAVER system in the original packaging to ensure
optimum protection against damage.
−Modification of the system or improper use renders the guarantee void and invalidates
the manufacturer's responsibility.
−Usage that is not described in the manual is considered to be improper. The operator of
the product is liable for damage caused by improper use.

Product description
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3Product description
The StockSAVER system serves as a signal point in the logistics chain and monitors fill levels of
commercially-available FIFO flow racks. Fill levels are communicated wirelessly and visualised
in the StockSAVER software based on the intelligent interaction of the system components.
Sensors mounted in the racks record the fill levels. This status information is collected by the
SensorBox and transmitted to the SmartBox using a bus system. The data is transmitted
wirelessly to the Transceiver and written to the database by the software.
Misplaced replenishments can also be promptly detected if an optional barcode scanner is
employed.
StockSAVER software provides a wide range of functions for optimising work processes using
FIFO flow racks and the production logistics process.
The system sensor, SmartBox and SensorBox components and the mounting materials have
been developed for installation in FIFO flow racks. The following rack types have been tested
for compatibility:
−SSI Schäfer KDR live carton storage racks
−Creform pipe racks, Ø 28 mm series
−Bito live storage racks, type 36-33250
−Bosch Rexroth XLEAN material supply racks
Compatibility with other rack types and mounting options must be established before
installation.

Product description
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3.1 Overview of hardware components
Item
Components
Function
1 Sensor Detects bins and forwards the status information to
the SensorBox.
2 SensorBox Receives the sensor status of up to 4 bins per
location. Forwards the data to the bus system.
3 SmartBox Receives data from up to 50 SensorBoxes via the
bus system and transmits it to the Transceiver.
If the optional barcode scanner is used, the
SmartBox also warns about misplaced products.
4
Transceiver
Receives statuses from up to 20 SmartBoxes.
Transfers data to the Server Service (Software). The
data is then stored the database and displayed on
client PCs.
Up to 4 Transceivers may be connected to a
database.
Power is supplied via the included mains plug-top
adapter. The Transceiver is connected to the
network via Ethernet cable. Maximum wireless
range: 300 m (line-of-sight)

Product description
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3.2 SensorBox
Up to 4 sensors may be connected (see right)
LED
Function
Bus LED flashes blue
Power supply present; bus connection interrupted
Bus LED off
No power supply and no bus connection
Bus LED steady blue
Power supply and bus connection present

Product description
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3.3 Overview: SmartBox
3.3.1 SmartBox controls
Icon
LED
Function
Hold down for approx. 5 s to access the volume menu.
Close the volume menu.
Increase the volume when in the volume menu
Reduce the volume when in the volume menu
If misplaced products are detected: Acknowledge
correction of misplaced products
On (Green)
Wireless connection present
Flashes (Red)
Wireless connection not present
On
Bus connected to following SensorBox
Flashes
Bus not connected to following SensorBox or no
SensorBox connected
On (Green)
Known material
Flashes (Green) Database query running
On (Yellow) Unknown material
Flashes (Red)+ Misplaced Replenishment
3.3.2 SmartBox display messages
Message
Cause
Ready... The system has a wireless connection, has
been initialised and is ready for operation.
Initialisation…
SmartBox is being initialised.
No connection… No wireless connection to the Transceiver is
present.