Warren Systems, Inc.
A b o u t    U s

TWP Expansion System Extensions (Exhibit B)

The following details the software modifications to be made to the IDAB and/or the PLC software to extend the functionality of the existing system.

  1. truck docks accessible from both loops increase from 12 to 14
  2. The database will be expanded and renumbered for the devices associated with docks. They are the trippers for each loop, the chute jam segments for each loop, a single dock conveyor, and a Check-in station. Two additional trippers will be the net result.

    The system has been sized, according to Section 4.4.1 or the FSpec to accommodate the increased number of devices, and their signals. However, there are not enough spare board entries without discharger devices to avoid "doubling up" for these additional docks. Only two boards, numbers 36 and 38, are without trippers. Therefore, one of the purge stations on each loop will be removed from the network. This will leave a single purge station on each loop. PURGE3 on the green loop in the Upper Mailroom near the keyline will be renamed PURGE1, and PURGE2 will remain the yellow loop purge line. The other two will be removed. This allows the trippers to be staggered, one per board.

    Installation and connection of the signal cable from distribution panels to Tray, Chute and conveyor control points as required. These control points are to be provided by TWP. The Assembly and installation of monitors and intercoms into TLM enclosure will be performed. Equipment listed in Exhibit B, items A13-16 are required.

  3. Straight-through Conveyor docks increase from 8 to 16
  4. Eight new docks will be added to the database, the names given above. Within each dock will be a counter ABR1 through ABR8. In the data base table, eight slots will be reserved to include the fake counter signals required by the VAX/PLC interface. Another eight slots will be for the conveyor running status. This will require modification to the interface, and the VAX real-time task that processes the data supplied by the PLC. Only the Annex conveyors will have defined conveyor status signals. Therefore, the Opto boards will still provide the conveyor running status from the lower mailroom.

    The PLC Contractor to WSI will install the code to the straight-through conveyor docks to allow them to be functionally equivalent to the existing straight-through conveyor docks located in the Lower Mailroom.

    The Electrical Contractor to WSI will provide and install all cabling and conduit required to connect this equipment to the Wonderware PC, and the Annex terminal server as appropriate. Equipment for this effort is listed in Exhibit B, items A9 and A10.

  5. docks with Check-in stations increase from 12 to 23
  6. The mailroom docks will be named from CIN1 through CIN14. The TLMs will be renamed from TLM1 through TLM14 as well. (Note that the first Pre-Checkin Station has been renamed from TLM13 to JACK2.) The straight through conveyors/tyelines will be associated with docks 7 through 14.

    The Robinson Terminal Annex straight through docks will be CINR1 through CINR8, with the TLMs named TLMR1 through TLMR8. The Pallet Load Dock, and its TLM, will be CINRP and TLMRP.

    The appropriate data base tables and scripts will be modified to reflect this new mapping. The TLMs will be assembled and installed according to the equipment description given in Exhibit B, items A3-4. Wall cutouts will be made by TWP according to specifications furnished by WSI.

  7. Upper Mailroom tyelines rearranged so all have dual-loop access
  8. The data base network will have to be modified such that all tyelines are configured in a similar fashion as the SLS tyelines are currently configured. Bypass outputs will be defined for all green loop tray loaders that do not currently contain them. This allows the bundle to pass to the yellow loop tray loader. The Key Line will be relocated from TY16 to TY13, placing it on the last of the Upper Mailroom tray loaders.

    The wiring trough in the upper mailroom will be removed and replaced as part of this item. All existing control cabling to the loaders will be removed and replaced with new cabling.

    The data base tables associated with the Opto boards and modules will also be modified for the device index fields associated with the renumbered, and/or removed devices.

    Disconnecting, and removal of cabling associated with the moved loaders, and the subsequent installation and connection of the replaced/modified loaders is provided in this agreement. Equipment listed in Exhibit B, items A13-A16, A23 and A29 are required.

  9. overhead yellow loop tray loaders added to lower mailroom straight-through docks
  10. The existing software will process all bundle drop messages sent by the overhead loaders, once the data base is set up properly for the network. No additional code is required for this process. Additional tyelines will be created for the product assignment. These too, require only extensions to the database, and not code modifications. The system has been sized, according to Section 4.4.1 or the FSpec to accommodate the increased number of devices, and their signals. Operator commands to control the destination of bundles, whether to the tray, or to the dock, are part of the existing Tray Control software.

    The bypass counts provided by the straight through PLC will still be available to the VAX, and will cause bundles to be credited to any checked-in truck via the normal operation of the system network when the loader is in bypass mode. This will not require software modifications.

    Modifications to the VAX will be necessary to cause bundle countdowns for non-warehouse trucks receiving bundles directly from the Straight-through Conveyor system. In this fashion, when the demand at the dock has been satisfied, the pacer will shut and allow no more bundles to be delivered.

    Connectors and cabling will be provided and installed between these overhead loaders and the distribution panels according to Exhibit B, items A13-A16 and A23.

  11. two additional Pre-Check-in Stations provides a total of three
  12. The name of the existing screen device will be renamed to avoid conflict with the Truck Load Monitors. The existing one will change from TLM13 to JACK2, and the new ones added as JACK1 and JACK3. The port assignments are detailed in the Configuration chapter in this document. Database flags to allow draw augmentation will be implemented on JACK2 and JACK3. We will provide trenching and repair for conduit to the following locations: approximately 30ft South of the existing pre-check-in Station; and approximately l00ft North.

    Installation of a 110 VAC feed in conduit to new pre-check-in stations, installation of monitors and intercoms into TLM enclosures, and installation into conduit for three cables from each station to: the distribution panels underneath Upper Mailroom Office; the intercom station in Upper Mailroom Office; and the intercom station in Circulation Office

    These Pre-Check-in Stations will be post mounted, weather resistant enclosures according to the equipment list in Exhibit B, items A2 and A6. As there are not enough spare ports on the existing terminal servers in the mailroom, eight ports will be added to terminal server TRAY03. LTA Port definitions will be made to the VAX/VMS system.

  13. two additional marquees give a total of four
  14. Additional entries in the data base tables for the screen devices will be required. These will be copied from the existing marquee entries, MQ1 and MQ2. The new devices, MQR1 and MQR2, will be connected to the tenth and eleventh port of the new terminal server. The equipment is listed in Exhibit B, item A8.

  15. two overhead monitors extend the total to seven
  16. The same command will be displayed on these additional monitors, allowing the current truck loading status to be viewed. Two additional tasks will now be active in the Tray Control software: USER_MON6 and USER_MON7. The new devices will be connected to the twelfth and thirteenth port of the new terminal server. Assembly and installation information is given in Exhibit B, item A7.

  17. new terminal server added for the display devices in the Robinson Terminal Annex
  18. A new terminal server will be installed in the Robinson Terminal Annex. To this device, the entire operator interface displays and monitors to be installed in the Annex are connected. The terminal server itself is connected to the LAN by a hub. This hub will be provided by TWP in close proximity to the terminal server. The extension of the LAN from the existing mailroom facilities to the Robinson Terminal Annex hub shall be the responsibility of TWP.

    The Emulex P8000 32-port terminal server is to be utilized. This server can be extended to 128 ports, if necessary in the future. It provides dual internal redundant DC power supplies, as well as primary and secondary network connections. While 10Base2 (Thinnet), and 10Base5 (Thicknet) connections are part of the network communications module, a transceiver will be used to allow 10BaseT (Twisted Pair) cabling to the Hub, to be used. Complete specifications are given in Exhibit B, item A1.

  19. Pyramid Integrator/Panel View replacement
  20. The Pyramid Integrator used to communicate to the palletizers and the lower mailroom straight-through conveyor equipment; and also the upper mailroom tray control room Panel View will be replaced. Six Allen-Bradley 540/E PLCs will be utilized. These will connect to the TWP provided hub in the wiring cabinet underneath the control room via 10BaseT cabling. The Wonderware PC will replace the Panel View. The existing equipment will be removed, and the new equipment will be assembled and installed as part of this agreement.

    The equipment required is given in Exhibit B, items A26-A28.

  21. Master Intercom replacements
  22. The existing Intercom master stations in the upper mailroom control room, and the circulation office do not have the number of ports required to access all the check-in, and pre-check-in stations in the expanded system. Therefore, these will be replaced with forty-channel Aiphone master stations.

    The equipment required is given in Exhibit B, item A12.

Comments to: Webmaster@WarrenSystems.com
May 1, 2001
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