Denver UltraSort UserManual

Denver Public Library
9-Bin AST System
User Manual
Effective Date: 8 September 2010
Tech Logic Corporation 1818 Buerkle Road ● White Bear Lake, MN 55110 ● Tel: 800.747.0492 ● Fax: 651.747.0493 ● www.tech-logic.com
Legal Disclaimer
This manual, as well as the equipment and associated software described, is furnished under license and may be
used or copied only in accordance with the terms of such license. The content of this manual is furnished for
informational use only, is subject to change without notice, and should not be construed as a commitment by
Tech Logic Corporation. Tech Logic Corporation assumes no responsibility or liability for any errors or
inaccuracies that may appear in this manual.
Except as permitted by such license, no part of this manual may be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, whether electronic, mechanical, recording, or otherwise, without the
prior written permission of Tech Logic Corporation.
NOTICE ─ Systems and components described herein may be protected by one or more of the following U.S.
Patent Numbers:
6,000,770; 6,074,156; 6,203,262; 6,257,816; 6,422,457; 6,557,696; and 6,561,418.
© 2010 Tech Logic Corporation. All Rights Reserved.

Tech Logic Corporation, 1818 Buerkle Road, White Bear Lake, MN, 55110, USA
User Manual Revision Level

Rev Level Date Published
Initial 16 March 2010
UNCONTROLLED COPY WHEN PRINTED
Table of Contents
Legal Disclaimer ................................................................................................................................. 2
About This Manual .............................................................................................................................. 5
Documentation Set ............................................................................................................................................................ 5
Illustrations, Photographs, and Screen Shots ..................................................................................................................... 5
User Manual Icons ............................................................................................................................................................. 5
Training ............................................................................................................................................................................. 5
Contact Tech Logic ............................................................................................................................. 6
Tech Logic Customer Care ................................................................................................................................................ 6
Tech Logic Headquarters................................................................................................................................................... 6
Tech Logic – Australia and New Zealand ......................................................................................................................... 6
Introduction ......................................................................................................................................... 7
Tech Logic’s Mission ........................................................................................................................................................ 7
A History of Helping Libraries .......................................................................................................................................... 7
Safety Guidelines ................................................................................................................................ 8
Hazard Notices .................................................................................................................................................................. 8
Machine Hazard Warnings ................................................................................................................................................ 8
Hazard Warning Signs ....................................................................................................................................................... 9
Your UltraSort System ...................................................................................................................... 10
Sequence of Operation ..................................................................................................................... 11
Basic Sequence ................................................................................................................................................................ 11
System Description .......................................................................................................................... 12
How It Works .................................................................................................................................................................. 12
Book Drops (Optional) .................................................................................................................................................... 12
Fire Suppression System (Optional) ................................................................................................................................ 13
Conveyors ........................................................................................................................................................................ 14
Sizer/Squarer (Optional) .................................................................................................................................................. 16
Resensitizer Unit (Optional) ............................................................................................................................................ 17
Rotator Section (Optional)............................................................................................................................................... 17
Barcode Scanner (Optional) ............................................................................................................................................ 18
RFID Section (Optional) ................................................................................................................................................. 19
Sorting Section ................................................................................................................................................................ 20
Master Controls ............................................................................................................................................................... 20
Emergency Stop Buttons ................................................................................................................................................. 20
Disconnect Switch ........................................................................................................................................................... 21
Computer Hardware ........................................................................................................................................................ 21
Photo Eyes ....................................................................................................................................................................... 21
Slide Chutes ..................................................................................................................................................................... 22
Bin Present/Bin Full Kit (Optional)................................................................................................................................. 23
Smart Bin® Connection Kit (Optional) ........................................................................................................................... 23
Tech Logic Smart Bins® (Optional) ............................................................................................................................... 23
Loader/Unloader (Optional) ............................................................................................................................................ 25
Placer System (Optional ─ HiIQ System) ....................................................................................................................... 26
Cart Tilt Machines (Optional ─ HiIQ System) ................................................................................................................ 28
AST Software..................................................................................................................................... 29
Delivery Software ............................................................................................................................................................ 29
HiIQ Software (Optional) ................................................................................................................................................ 31
Menu Bars (Delivery and HiIQ Software)....................................................................................................................... 32
Interaction with ILS ......................................................................................................................................................... 36
Customization .................................................................................................................................................................. 36
Tech Logic Corporation AST.90911000.Denver Public Library Page 3 of 64

Operating Procedures ...................................................................................................................... 37

Starting the System .......................................................................................................................................................... 37
Shutting Down the System .............................................................................................................................................. 37
Pausing the System .......................................................................................................................................................... 38
Starting the System after Pause ....................................................................................................................................... 38
Addressing an E-Stop ...................................................................................................................................................... 38
Changing a Book Cart ..................................................................................................................................................... 38
Smart Bin® Procedures ................................................................................................................................................... 39
Loader/Unloader Procedures ........................................................................................................................................... 39
Controlling Windows® Automatic Updates.................................................................................................................... 40
Editing a Sort Table ......................................................................................................................................................... 41
Deleting a Sort Table ....................................................................................................................................................... 41
Sorting by Call Number ................................................................................................................................................... 41
General Maintenance ........................................................................................................................ 42
Maintenance Training ...................................................................................................................................................... 42
Preventative Maintenance................................................................................................................................................ 42
Corrective Maintenance ................................................................................................................................................... 42
Record Keeping ............................................................................................................................................................... 44
Smart Bin® Model 125 Maintenance .............................................................................................................................. 44
Smart Bin® Model 350 Maintenance .............................................................................................................................. 45
Photo Eyes Maintenance ................................................................................................................................................. 45
Maintenance Schedule ..................................................................................................................... 47
Maintenance Tools ............................................................................................................................ 50
Recommended Spare Parts List ...................................................................................................... 52
Troubleshooting ................................................................................................................................ 53
First Level Field Service Procedures ............................................................................................................................... 53
Power Disturbances ......................................................................................................................................................... 53
System Jam ...................................................................................................................................................................... 53
Bin Item Level Adjustment ............................................................................................................................................. 53
Photo Eye Adjustment ..................................................................................................................................................... 54
Software Issues ................................................................................................................................................................ 54
Glossary............................................................................................................................................. 56
Index .................................................................................................................................................. 61
Notes .................................................................................................................................................. 63
Page 4 of 64 AST.90911000.Denver Public Library Tech Logic Corporation

About This Manual

About This Manual
This manual is intended as a read-me-first guide for library staffs to provide an understanding about how the
system works, how to maintain the system, and how to correct system issues. Each component is described as it
is used in the system. The components included in this manual may or may not be part of your system. Your
system may include a combination of the components listed in the manual. Optional equipment that is available
for AST systems (that may or may not be part of your system) is listed as Optional. See page 10 to see your
specific system and its components included. Please read the entire manual before you begin to use your
system.
Documentation Set
The documentation set for your system includes a user manual, which includes a system description, operation
and maintenance instructions, and a spare parts list; a parts manual consisting of mechanical drawings; and a
CD that contains PDFs of the user manual and mechanical drawings. Please download the latest version of
Adobe® Reader® to view PDFs.
Illustrations, Photographs, and Screen Shots

Illustrations, photographs, and screen shots appear in this manual to clarify the text. It is important for you to
remember that these are examples only and do not necessarily represent your actual system configuration or
application.
User Manual Icons

In addition to the hazard signs, there are other icons present throughout the manual.
User Manual Icons

Icon Description
Indicates a note to consider while operating or
maintaining the system.
Indicates an important note to follow while
operating or maintaining the system. Failure to
follow an important note may affect system
performance.
Training
Your system has been custom built and designed specifically to meet your requirements and skillfully
manufactured to fit your facility. Your staff should have received training on the AST system. If not, please
arrange this with Tech Logic.

Contact Tech Logic

If you have any questions or concerns about your system, please contact Tech Logic. Customer care is available
24 hours a day, 7 days a week.
Tech Logic Customer Care

1-866-880-9981
Tech Logic Headquarters Tech Logic – Australia and New Zealand

1818 Buerkle Road PO Box 271
White Bear Lake, MN 55110 North Melbourne VIC 3051
USA Australia
Phone: 651.747.0492 Phone: +61 3 9376 9677

Toll free: 800.494.9330 Email: contactAUNZ@tech-logic.com
Fax: 651.747.0493
Email: contact@tech-logic.com
Contact Tech Logic

Introduction
Tech Logic’s Mission
Tech Logic is the leading provider of innovative automated sorting technologies, circulation staff support tools,
and patron self services for libraries.
Tech Logic accomplishes this through our unequalled expertise, dedication to quality, and world-class customer
support services.
A History of Helping Libraries

Since its founding in 1997, Tech Logic has focused exclusively on serving libraries, transforming the tasks
associated with material handling and patron self-service into streamlined, cost-effective processes. These
processes, using patented, intelligent machinery, and barcode or radio frequency identification (RFID)
capabilities, enable your staff to focus on patrons and library work, instead of library labor. Tech Logic products
and systems also empower your patrons (and your staff) by allowing patrons to reserve, check in, and check out
items easily, without requiring assistance.
The single greatest attribute of Tech Logic is that we work only with libraries. All of our products and services
are designed to meet the needs of libraries and their patrons. Tech Logic has been able to translate library
questions and problems in material management into automated technology that makes sense.
The Tech Logic Corporation Automated Sorting Technology (AST) systems are designed to protect valuable
library items, increase item availability, and reduce labor related injury. Each piece of the AST system performs
a specific task in processing library items. Tech Logic designs AST systems specifically for your library’s
needs.
Introduction

Safety Guidelines
Safety Guidelines
Remain aware of the hazards that apply to the system at all times. Use these safety guidelines to help identify
hazards. Improper installation, operation, or maintenance of equipment may result in hazardous conditions that
can cause personal injury or damage to equipment. Common sense and a thorough knowledge of the system
capabilities are required for an appropriate and safe approach to system operation.
Hazard Notices
Hazard notices are be found throughout this manual and on system equipment. They contain safety information
specific to different tasks to be performed. Read all hazard notices carefully, and follow the directions that are
given. A signal word (caution or warning) precedes the text of the hazard notices and communicates the degree
or level of hazard seriousness.
A caution notice indicates a potentially hazardous situation which, if not

avoided, may cause minor injury or system damage.
A warning notice indicates a potentially hazardous situation which, if not

avoided, can cause severe injury or substantial system damage.
Machine Hazard Warnings

The following list includes some common machine hazard warnings. This is not an all inclusive list.
Please follow all caution and warning notices when operating or maintaining your system.
Do not perform any maintenance requiring access to protected areas.
The AST system’s computer is intended only for the purpose of operating and controlling
the AST system. Other unintended uses may affect performance or operational ability.
Do not run virus scans with anti-virus software while the AST system is operating. Run
scans only when the AST software is off.
Control Microsoft Windows® Automatic Updates (see page 40).
Do not modify, change, or manipulate any components on the system. Tech Logic is not
responsible for the safety or performance of the system if unauthorized changes are made.
Unauthorized service voids the warranty. Contact Tech Logic before altering your system
in any way.
Do not operate the system without proper training.
Do not wear loose clothing; scarves, neckties, loose sleeves.
Do not wear hanging jewelry, watches, or rings.
Protect long hair.
Avoid pinch points.
Never remove safety guards while operating the system.
Never open cabinets or junction boxes.
Never stand, walk, or sit on a conveyor.
Always assume the system can start without warning.
Report and log all strange noises, loose parts, or excessive wear.
Report and log any damaged library items or unexpected operations.
Do not eat or drink near the AST system. Avoid liquid spills near the AST system.
Never climb on cart tilt machines (if equipped) or place your feet under them.
Safety Guidelines
Only use cart tilt machines (if equipped) to lift empty book carts.
Never operate the system while impaired. Some conditions include:
 Improper training
 Fatigued, sick, drowsy
 Inattentive, careless, confused
 Chemically influenced or altered
 Emotionally distressed
 Distracted by an outside influence (telephone, radio, TV, conversation, etc.)
Hazard Warning Signs

Hazard warning signs identify the hazard associated with the piece of equipment to which they are affixed.
Hazard warning signs are positioned so that they are plainly visible to anyone near the hazard. If a hazard is
associated with a procedure, the hazard is identified with the procedure.
Hazard Warning Signs

Sign Description
Electric Shock
Entanglement
General Warning
Pinch Point

Your UltraSort System

Your system is equipped with the following components.
1
3
2
4
2
11
7
Your UltraSort System
10
System Components
Item Description
1 Interior Book Drop
2 De-Shingling Conveyor
3 Belt Merge
4 Straight Conveyor
5 Line Shaft Conveyor
6 Loader/Unloader
7 RFID Section
8 8-Bin Sorting Section
9 Fixed Slides Chutes
10 Smart Bins, Model 125
11 Computer Area

Sequence of Operation
This section outlines the basic sequence of operation for the AST system. The system has been designed to run
with one or two operators. Operators are expected to constantly monitor the system. If jams occur, operators
need to remove them and reset the system. Operators need to monitor the flow of items in the system as well as
item levels in bins or carts. Important tasks including cleaning the machinery of debris and performing daily
maintenance are outlined in the maintenance section of this manual. Smart Bins® or book carts are also
routinely moved into and out of the machine.
Important! The AST system is not meant to operate unattended.
Throughput may be increased if operators manually add items to the system prior to the scanning section. Please
ask a trained Tech Logic technician where and when items may be added.
Basic Sequence
1. Patrons enter items through one of two interior book drops.
2. Items travel along and pass through a de-singling conveyor.
3. Depending on which interior book drop was used, items may merge onto a straight conveyor.
4. Items merge onto the line shaft conveyor.
5. Items may be unloaded into a loader/unloader if the system is busy or loaded onto the conveyor when the
system is available.
Note: Additional items may be added by the library staff in the loader/unloader.
6. Items enter the RFID section.

7. Items are scanned, checked in, and sent on to be sorted.
8. A popup transfer stops items at a sort location and guides them to a bin.
Note: Sort locations are pre-programmed based on library sort requirements. Bins are filled
and monitored by a computer. When a location is full, a signal is sent to the computer
to alert the operator.
Sequence of Operation

System Description
System Description
Your AST System is custom designed for your facility.
Tech Logic incorporates modules that your system may or may not include.
How It Works
The AST system accepts items that the patrons place in the book drop, moves the items through a conveyor
system, reads their RFID tags, and sorts them into bins based on the item properties and the sorting rules that
have been established. As it operates, it also maintains logs of the items it processes and performance statistics.
Machine operation is controlled by software running on a computer. This software communicates with the
machine through a dedicated network. Using this network, the AST system keeps the AST software program
up-to-date on the state of the machine and all of its components. As items are checked in, the AST software
updates item information on the user interface. For more information on AST software, see page 29.
Book Drops (Optional)

Book drops are a place for patrons to return items borrowed from the library. An exterior book drop is located
outside of the library and usually features a speaker and an automatic sliding door that opens only when a
patron lifts an item to the door and triggers the sensor. An interior book drop does not have a door or a speaker
and is located inside of the library. Depending on the library’s needs, systems can be equipped with a
combination of book drop types.
Exterior Book Drops
Exterior book drops, also known as hands-free book drops, detect the presence of an item through photo
sensors (photo eyes). If the photo eyes are triggered (covered), the system determines whether the
conveyor attached to that book drop is available to accept items. If belt conveyor is unavailable at an
exterior book drop, the door does not open. Once the belt is clear, the door opens and the patron can
insert items. The book drop door remains open as long as one of the photo eyes is covered. After all of
the photo eyes are uncovered, the door remains open for a fixed time and then closes.
Speaker
Photo Eye Sensor
Opening
Exterior Book Drop
Exterior book drops include a speaker that plays three messages to inform patrons about the state of the
AST system.
A greeting message instructing the patron to insert an item.
A message instructing the patron that the AST is paused and unavailable.
A message instructing the patron to wait momentarily for room to become available on the AST.

Manual Book Drops
System Description
In addition to the hands-free book drop, there is also an exterior manual book drop available that
requires patrons to lift open the book drop door in order to return items. Manual book drops do not have
a speaker system. A patron lifts open the door, inserts the items, and the door gently closes on its own.
Once the item triggers a photo eye on the conveyor connected, the conveyor starts moving the item
toward the sorting section. The manual book drop has an option to manually lock the book drop door
from inside of the book drop face.
Manual Book Return Manual Lock
Interior Book Drops
Interior book drops, also known as interior book returns, have a photo eye inside the book drop opening
where the patron places items on the belt. The photo eyes inside the book drop opening trigger the
conveyor to move. The conveyor belt does not start moving unless the system is available to take items.
When the system is available, the belt moves items toward the sorting system.
Opening
Interior Book Drop
Fire Suppression System (Optional)

Installed just inside the exterior book drop, the fire suppression system automatically detects a broad range of
both flaming and smoldering fire conditions using photoelectric smoke detection. If these conditions are
detected, the system closes the exterior book drop door and the containment door on the conveyor belt, and
stops the conveyor. Any fire threats are controlled between these two doors.
Fire suppression systems consist of a control panel that monitors and controls the system, fire alarm with horns
and strobe lights, smoke detector that automatically detects a broad range of both flaming and smoldering fire
conditions using photoelectric smoke detection, CXV controller that trips and releases pressurized nitrogen to
initiate the dispersion of FM-200 agent, and a suppression system that uses automatic detection and containment
and a chemical suppression agent dispersing system (FM-200 Agent).

System Description
Control Panel Book Smoke Detector CXV Strob Suppression Containment

Drop (Interior) Controller e Agent Cylinder Door
Fire Suppression System
The fire suppression system can also be manually activated by pulling the safety pin on the CXV controller and
turning the release handle or by pulling the safety pin on the suppression agent cylinder and pulling the release
handle.
Release Handle
Safety Pin
Release Handle
Safety Pin
CXV Controller Suppression Agent Cylinder
Certification
Clients may want to notify the local fire marshal to witness and certify the system. Certification is the
responsibility of the client and its coordination with local fire officials.
Integration
Integrating Tech Logic fire suppression systems with onsite fire monitoring systems is the responsibility
of the client.
Battery Back-Up
The control panel includes a built-in battery charger and space for one set of 1.2 AH, sealed lead acid
batteries to be housed within the enclosure to provide 24 hours of standby operation. If the system is
without power for more than 24 hours, contact Tech Logic Customer Care.
Conveyors
There are two different types of conveyors: belt conveyors and line shaft conveyors. Depending on the library
layout, a variety of conveyors are used to navigate an item from initial drop off to the sorting section. Your AST
system may contain a combination of the following conveyors.

Belt Conveyors
System Description
Belt conveyors are computer controlled using photo eyes to sense the item’s location. Belt conveyors
deliver items to the system from multiple points of entry, including exterior and interior book drops. The
exterior book drop doors open when the patron places an item in front of the photo eye. The belt begins
to move and materials placed on the belt are carried into the system when the system is available. When
the belt conveyors fail to detect a new item for a predetermined period of time, they turn off. There are a
variety of different types of belt conveyors, including straight conveyors, sandwich conveyors, de-
shingling conveyors, and staff induction points.
Straight Conveyors
Straight belt conveyors can include a tail, intermediate, and drive

section. Straight conveyors are used with other conveyors,
depending on the library layout, to move the items to the sorting
section.
Sandwich Conveyors Straight Conveyor
Sandwich belt conveyors have an upper and lower belt to hold and move items on steep grades.
These conveyors move items vertically between floors in a library. The compact design saves
space and unnecessary equipment.
Reversing Conveyor Incline/Decline Conveyor
De-Shingling Conveyors
De-shingling belt conveyors pull items away from each other when they are
stacked on top of each other. Using an incline and varying belt speeds and
treads, these conveyors deliver items to the system one at a time. Many
AST systems de-shingle items directly before the sorting section.
De-Shingling Conveyor

System Description
Staff Induction Station
These belt conveyor sections offer a convenience to library staff

for placing additional items in the AST system. Designed for ease
of use and ADA compliant, it features a lower guide rail section
for easily placing items on the conveyor belt. Some straight
conveyors may be low enough for staff to place items on, using
them as a staff induction station.
Staff Induction Station
Line Shaft Conveyors
Line shaft conveyors are a series of rollers that move items through the system. Line shaft conveyors are
specifically used with popup transfers in the sorting section (see page 20).
Line Shaft Conveyor Rollers
Curved Conveyors
Curved conveyors move items around corners. Tapered rollers allow the
items to maintain their orientation and travel the curve without hitting the
sides. Curved line shaft conveyors are used with belt conveyors, depending
on the library layout, to move items to the sorting section.
Curved Conveyor
Sizer/Squarer (Optional)
The sizer/squarer, hereafter called the sizer, is present on systems equipped with a placer system (see page 26).
The sizer primary functions are to square the item and determine the size of the item. When an item moves into
the sizer area, it is pushed all the way to the fixed left stop and forward until it reaches the front popup stop. If
the item covers two of the perpendicular photo eyes, it is determined to be squared, and its height and width is
recorded in the HiIQ software.
The sizer drops the front popup stop once the item is squared and moves the item back to the middle of the
sizer. If the item is oversized, it is pushed onto the slide chute into a reject bin. If the item is within the size
limits, the sizer sends the item to the next section.

System Description
Front Popup Stop Left Fixed Stop
(Not Displayed)
Sizer/Squarer
Resensitizer Unit (Optional)

Library items with security tape anti-theft systems pass through the resensitizer unit within a line shaft conveyor
section. When the resensitizer unit senses the presence of a library item, it generates a magnetic field and
reactivates the security tape. Resensitizer units may be included with systems that do not use RFID security.
Magnetic Field
Resensitizer Unit
Rotator Section (Optional)

Rotators are included on systems with a placer system present. A dual rotator is used on placer systems with a
barcode scanner. If the barcode is not read by the first scanner set, the item is rotated 90 degrees by a rotator
that pops out of the line shaft conveyor. The items moves to the second set of scanners that attempt to read the
barcode. If needed, a second rotator pops out to position the item in the proper alignment in order for the placer
system to sort the item. A single rotator can be used on placer systems with RFID items.
Rotator

Barcode Scanner (Optional)

System Description
Systems are equipped with an RFID section, barcode section, or both. On barcode systems equipped with a
placer system, a line barcode scanner projects a visible laser light at an angle from above and below the line
shaft conveyor to read the item’s barcode. If the barcode is not read by the first scanner set, the item is rotated
and moved to the second set of scanners to attempt to read the barcode. If the barcode can still not be read, it is
sent to the reject bin. On a barcode system that is not equipped with a placer system, an omni-directional
barcode scanner reads the barcode from above the line shaft conveyor. Patrons must place items in the book
drop with the barcode face up in order to be read.
When a barcode is read, the ILS server uses the item number to check in the item and then sends that
information to the software. The software uses item information to sort the items. The sort location depends on
where it was assigned in the sort tables. Items that cannot be checked in because they do not have a barcode,
have a defective barcode label, belong outside the library system, or otherwise fail to be checked in are moved
to a reject bin (unless it is an RDIF item).
Scanner Scanner
Rotator
Line Barcode Scanner Omni-Directional Barcode Scanner

(Placer System) (Without Placer System)
Important: Keep the barcode labels clean for accurate scanning.
Line Barcode Scanner Specifications

Type Description
Readable Bar Width From 0.15 mm (.005 in.)
Largest Readable Label Width 404 mm (15.91 in.)
Supported Codes Code 39, ITF, Industrial 2 of 5, Standard 2 of 5, COOP 2
of 5, Coda bar, Code 128, GS1-128 (EAN-128), Code 93,
UPC/EAN, GS1 DataBar (RSS)
Number of Readable Digits 74 digits (148 digits with Code 128 start character C)

Omni-Directional Scanner Specifications
System Description
Type Description
Readable Barcode Width From 0.25 mm (0.009 in.)
Conveyor Speed (Max.) 1.8 m/sec. (350 ft/min.)
Supported Codes All standard 1D barcodes
Total Scan Lines 120
RFID Section (Optional)

Systems are equipped with an RFID section, barcode section, or both. On RFID systems, after an item is placed
in one of the book drop locations, the conveyor system delivers the item to the sorting section. Normally, the
RFID antenna is located directly before the sorting area. When an item moves to the RFID section, the antenna
(located beneath the line shaft conveyor) detects the item’s RFID tag, checks in the item, and enables the item’s
security as soon as it reaches the exit photo sensor on the conveyor belt. After an item number is read, the
information is sent through the AST software with a check-in request to the Integrated Library System (ILS)
server.
Any item with a readable RFID tag automatically has the anti-theft bit activated when it has been read. When an
RFID tag is read, the ILS server uses the item number to check in the material and then sends that information
back to the AST software. The software uses the item information, such as the collection code, reserve status,
and owning agency to sort the items in bins.
Once the item is checked in and the anti-theft bit is activated, it moves to a sort location. The sort location
depends on where it was assigned in the sort tables. Items that cannot be checked in because they do not have an
RFID tag, have a defective RFID tag, belong outside the library system, or otherwise fail to be checked in are
moved to a reject bin (unless it is a barcode item).
RFID Antenna
(Under)
RFID Section
Important! Keep all metal objects (desk, light fixtures, metal chairs) away from this area as
metal affects the performance of the system.

Sorting Section
System Description
The sorting section is comprised of line shaft conveyors and pop up transfers that transfer items into bins via
slide chutes. Line shaft conveyors are the series of rollers that move items to the popup transfers that pop out of
the line shaft, directing items onto the slide chutes into specific bins based on the sorting software. Emergency
stop buttons and photo eyes are also located throughout the sorting.
Line Shaft Conveyor
Popup Transfers
E-Stop Button
Slide Chute
Photo Eyes
Bin
Sorting Section
Popup Transfers
Popup transfers receive items from the left, right, and rear. At times, items are available from multiple
directions. When this happens, the transfer prioritizes direction based on user specification in the AST
software. See page 30 for more information on transfer options and settings.
Master Controls
There are two main control buttons mounted on the system. The main power button is the
green button, labeled as Run, used to start the system. There is also a master E-Stop button
next to the Run button. The Master E-Stop button has to be reset if an E-Stop is triggered.
Once the emergency is resolved and the button is released, reset the Master E-Stop button,
and press the green Power On button next to the Master E-Stop to power the system up
again.
Emergency Stop Buttons Master Controls
Emergency Stop (E-Stop) buttons are red, mushroom shaped buttons located throughout the
system on the conveyors and the sorting section of the system. Use these buttons in
emergencies to instantly remove drive power from the system and stop all movement and
activity. Sensors and control power remains on. Once an E-Stop button is pressed, it stays
pressed. The system is not able to start until the button is rotated and pulled out (released).
E-Stop

Disconnect Switch
System Description
Disconnect Switches
Computer Hardware
The system is equipped with a computer, monitor(s), keyboard, and mouse. The
monitor displays the software interface. See page 29 for more information on the
AST Software. A computer desk is not included with installation.
Anti-Virus Software
Computer Setup
Do not run virus scans with anti-virus software while the AST system is
operating. Run scans only with the AST software off. Anti-virus software used
while the AST software is running affects performance or operational ability.
The AST system’s computer is intended only for the express purpose of
operating and controlling the AST system. Other unintended uses may affect
performance or operational ability.
Computer Backup
It is very important that users back up the computers that control the AST system. Timely backups help
prevent problems in the future if files are lost or if a computer needs to be replaced. Many options exist
for computer backups. Writeable CDs, USB drives, tape, and network servers are all suitable for backing
up AST computers. IT departments should be able to provide the necessary tools. There are two key
directories that need to be backed up; it is not necessary to back up the entire computer.
The directories are C:\Program Files\TLCSoftwareLibrary and C:\TLCFinalDlls
If an AST computer has never been backed up, it should be backed up immediately. In the future,
computers should be backed up whenever the software has been updated or when substantial changes
have been made to configurable data such as sorting tables or hold slip layouts.
Photo Eyes
The AST system tracks the progress of items by way of photo eyes which are covered and uncovered as the
system operates. Photo eyes are optical sensors that use visible or infrared light to detect objects. When the
photo eyes are covered, it indicates that an item is present. Photos eyes are located at the book drop opening, at
the start and end of conveyors, and on each side of the slide chutes openings. For more information on photo
eyes, see page 12.

System Description
The software operates the AST system based on information regarding the photo eyes status. On occasion, items
that are irregularly shaped or transparent may cause the photo eyes to be covered or uncovered in a way that
may mislead the software about the true state of the AST system. If this happens, it is possible that the AST
system may not function properly.
Slide Chute Photo Eyes Conveyor Photo Eyes Book Drop Photo Eye
Slide Chutes
Slide chutes used to transition items from the popup transfer on the line shaft conveyor into the Smart Bins. A
variety of types are available based on the sorting application and hardware, including stationary, diverting
fixed, and retractable.
Stationary
Stationary, plastic slide chutes (also known as fixed slide chutes)

smoothly transition books and library items into the bins.
Stationary
Diverting Fixed
These slide chutes have rollers in the surface and a center that is higher
than the outer edges. These provide an even distribution of items in the
larger bins.
Diverting Fixed
Retractable
Items trip a photo eye at the opening of the slide chute. Retractable slide
Extended
chutes slide out from the side and extend over the bin to allow the item to
transition gently into the bin. Retracted
Retractable

System Description
Bin Present/Bin Full Kit (Optional)
The bin present/bin full kit includes photoelectric sensors located under the slide chutes. The bin present sensor
determines if an object is present at a bin location. If a bin is not present, the sensor sends a message to the
software to alert the operator and sends items to different bins (as set by sort table) until the bin is present. The
bin full sensor is aimed at a point above a bin that when an item reaches it, the bin is considered to be full.
Note: Depending on the size of the bins used with the system, the bin full sensor may have
to be adjusted.
Slide Chute
Bin Full Senor
Bin Present Senor
Bin Present/Bin Full Kit
Smart Bin® Connection Kit (Optional)

The Smart Bin connection kit connects Smart Bins (I/A bins) to the system. It includes a power cord plug-in and
a communication cable to plug into the Smart Bin. When the Smart Bin is plugged into the system, the bins are
in Auto mode and communicate with the software, alerting the operator when the bins are full or not present.
See page 24 for more information on Smart Bin operation modes. For information on how to connect a Smart
Bin to the system, see page 3938.
Connection Kit
Tech Logic Smart Bins® (Optional)

Smart Bins are wheeled bins that contain an automatic floor controlled by a photoelectric eye that detects the
presence or absence of items. A transfer conveyor stops items at a sort location and transfers them to a Smart
Bin. Bin locations have been pre-programmed based on library sort requirements. The bins communicate their
load status with the machine and inform operators when they are full. There are two models: Model 125 and
System Description
Model 350. Both models are easy to load and unload, because the floor rises and lowers depending on the level
of items inside of the bin.
Tech Logic Smart Bin® Models 125 and 350
Smart Bin Model 125 is a smaller bin option that holds 125 items. Smart Bin Model 350 is a larger bin
that holds 350 items. When the bins are under the control of the AST computer, they are always in Load
mode. Keep the Smart Bin’s power cord plugged in so that the bin charges.
Smart Bin® Model 125 Smart Bin® Model 350
Smart Bin® Control Panel (Models 125 and 350)
A control panel is mounted on the Smart Bin that controls the bin functions. When a bin’s
communication cable is disconnected from the AST, the buttons on the control panel become active.
Through the control panel, turn the bin on and off, raise and lower the bin manually, and switch the bin’s
mode. The bins can be in Automatic or Manual mode.
Automatic Mode
With the cart on (and in Auto mode for Model 350), switch the bin to Auto Unload mode to
raise the floor of the bin automatically in response to the level of items in the bin to easily
access the items while unloading the bin.
Switch the bin to Automatic Load mode to lower the floor of the bin automatically in response
to the level of items in the bin to make room for additional items.
Note: To reach into the bin without the floor lowering while connected to the system, press
the Manual mode button to disable the photo eyes on the bin.
Manual Mode
With the cart on and in Manual mode, the operator controls the lowering and rising of the bin
floor with the Manual Up or Manual Down buttons.

System Description
Model 125 Control Panel Model 350 Control Panel
Loader/Unloader (Optional)
A loader/unloader is a device added to the system that runs perpendicular to the line shaft and acts as an
overflow buffer. It is comprised of a conveyor belt assembly and a Smart Bin®. When the system is stalled,
paused, or busy processing items on the line shaft, item are unloaded into the loader/unloader. When the system
is online and idle, the items are loaded back onto the system.
If the bin attached to the loader/unloader is not a Smart Bin®, items can only be unloaded into the
loader/unloader. The loader/unloader includes a de-shingling conveyor belt, retracting slide chute, bin tilter, E-
Stop, and safety strap.
De-Shingling
Conveyor
Smart Bin
Unloading Loading
Loader/Unloader Controls
Loader mode on the Delivery software Main Screen controls the loader/unloader (see page 30). When
the loader/unloader is in Unload mode, the Smart Bin’s floor moves items up onto the de-shingling
conveyor, moving items onto the line shaft. There are three de-shingling belts running at different
speeds during Unload mode. The de-shingling belts pull items away from each other, so they move onto
the line shaft conveyor one at a time.
Occasionally more than one item moves onto the belt at a time.
Operator intervention may be required to separate the items when this happens. The loader/unloader can
act as a buffer loading location to hold additional items entering the system during busy times. An E-
Stop button and a Smart Bin plug-in are also mounted on the loader/unloader.
When the loader/unloader is in Load mode, the loader/unloader de-shingling conveyor and slide chute
transfers items from the line shaft conveyor into a Smart Bin. When the loader/unloader is in Unload
mode and the Smart Bin is empty, the software defaults to Load mode. When the Smart Bin is moved
away from the loader/unloader, the unit automatically reverts to Unload mode until it is replaced with a
System Description
new Smart Bin.
Book Drop Override
If a patron attempts to add items in the book drop when the conveyor is busy or blocked and the
loader/unloader is in Load mode, the system diverts items into the loader/unloader so that the patron can
continue to add items even when the system is busy.
Placer System (Optional ─ HiIQ System)

Placers systems work with HiIQ software to automatically sort and load items onto book carts (also known as
book trucks). Each shelf on a book cart is composed of three designated sort locations (zones). With three
shelves, each book cart can have up to nine zones. The placer system places items from the line shaft conveyor
one at a time into the correct zone on the book cart. When a zone on the book cart is full, the operator is directed
by the HiIQ software to change the book cart. Two carts are positioned on each side of a placer to accept items.
Items are sorted based on the sort information in the HiIQ software. High demand items may require more shelf
room on a cart. The operator may assign sort codes to more than one cart shelf or zone on a cart.
Line Shaft Conveyor

Placer Head
Book Cart Z-Axis (Positioning System)
X-Axis (Positioning System)
Cart Tilt
Placer System
(Operator Control Console Not Displayed)
The placer system primary component is a placer head, which is a tilting platform that holds items as they are
transferred from the line shaft conveyor to the book cart. Four components structure the placer head.
Placer Paddle
Stack Packer Blade
Placer Head
1. Tilting Actuator ─ Mechanical device that tilts the placer head between the Accepting position (placer head
System Description
tilted back in order to accept items from the line shaft conveyor) and the Placing position (head is straight
and aligned with a book cart zone in order to load items from the placer head onto the book cart).
2. Placer Paddle ─ Handle that pushes an item onto the book cart zone from the placer head.
3. Stack Packer Blade ─ Blade that extends from placer head. The placer head moves back, and the blade
pushes items on the book cart back, creating more space in the zone.
4. Positioning System ─ System composed of an x-axis and z-axis that moves the placer head from the
Accepting position to the Placing position and back.
Placer System Operation
HiIQ software determines the item classification and what zone to sort the item on the book cart. The
popup transfer guides the item onto the placer head. Simultaneously, the tilt actuator tilts the placer head
to the Accepting position. When the item is moved onto the placer head, the positing system drives the
placer head to the proper elevation, aligning the head with the appropriate zone to sort the item (Placing
position). The stack packer blade pushes the items back, filling any gaps between the items, creating
more space in the zone. The photo eye on the placer head scans for the edge of the last item placed. The
paddle pushes the item from the placer head into the cart zone. The placer returns to the Accepting
position once finished. When a book cart zone can no longer accept items, the operator is directed by the
software to change the full book cart.
Operator Control Console
There are controls mounted on a stand in front of each individual placer on the system. These controls
include an E-Stop button, cart tilt controls, and operation mode (Run/Pause) controls. Press the E-Stop
button to shut down the entire system during an emergency (see page 20 for more information on E-
Stops). The left cart tilt controls tilt the book cart to the left of the placer up or down. The right cart tilt
controls tilt the book cart to the right of the placer up or down. To use the cart tilt buttons, you must
press and hold the button until the book cart stops moving (either tilting up or down). Press Pause to stop
the individual placer to change a full book cart or if there is a jam or other problem. Always pause the
system when entering the placer workspace to avoid a pinch point. Never enter the workspace when the
placer equipment is running. Press Run to start an individual placer.
Left Cart Tilt Up Run

Right Cart Tilt Up
E-Stop
Right Cart Tilt Down

Left Cart Tilt Down Pause
Operator Control Console (Placer System)
The placer operator control console flashes different indicator light colors based on the state of the
placer system. When the placer is in Run mode, the Run button illuminates solid green. When the placer
is operating or an item is being sent to the placer, the Run button continuously flashes green. When the

placer is paused, the Pause button illuminates solid green. When an E-Stop is triggered, the entire
System Description
system shuts down, and all of the lights on the operator console where the E-Stop was pushed
continuously flash red. The cart tilt buttons continuously flash green when they are pressed and held
(while the book cart is being tilted). The cart tilt buttons turn a solid green when the book cart has
reached the Up or Down position if a book cart is placed on the cart tilt machine; if a book cart is not on
the cart tilt at this time, no color is displayed. The cart tilt buttons illuminate yellow when the book cart
is full on that side. The book cart should be changed (see page 38).
Cart Tilt Machines (Optional ─ HiIQ System)

Cart tilt machines hold a book cart in position to accept items from the placer without the items tipping over,
utilizing the most space possible on each shelf. The cart tilt rests on a platform adjacent to the placer. This
platform is tilted to a 15-degree angle, which holds the items loaded into the cart in a reasonably upright
position. The cart tilt machine has a single, high-force actuator that lifts the cart platform to the proper angle.
This actuator has internal sensors to determine the end of travel in each direction. An electric brake is applied
when the actuator is parked in either the Up or Down position. The cart tilt machine has external sensors to
detect if the cart tilt is up or down and determine the presence of a book cart on the platform.
All operation of the cart tilt is performed from the operator console. To control the cart tilt movement, click
Raise or Lower from the HiIQ Main Menu. Control the cart tilt actuator, tilting the cart to the operating angle.
When the book cart must be exchanged, lower the cart tilt via menu selection, and exchange book carts. With
the cart tilt in the down position, remove a full book cart and place an empty cart on the cart tilt platform. Push
the cart forward until the leading end of the cart is against the plastic stop.

AST Software
Information contained here includes systems with Delivery and/or HiIQ software programs.
HiIQ software is only included on systems that have a placer system present.
The software’s user interface allows you to start and stop the AST system, establish sorting rules, view the state
of the system, and review logs and statistics.
Delivery Software
The Delivery Main Screen serves as a home screen for the AST software interface. The Main Screen includes a
menu bar, Check-In Messages, System Status Message Center, Pager Status Message Center, Device Color
Key, Transfer Options, Delivery Options, Loader Mode (if equipped), and the component layout diagram.
Menu Bar
Component Layout
Diagram
AST Software
Delivery Main Screen
Menu Bar Options
The menu bar contains a variety of options for the system. The menu bar consists of a File, Operation
Mode, Look Up Forms, Setup, and Help menu. For more information on specific menus, see page 32.
Tech Logic and ACS Check in Messages
Tech Logic and ACS Check in Messages displays information about the last item the AST system
checked in, including the sort number, the barcode, the agency destination, the reserve status, the check-
in message, the collection code, the call number, and the item type code. It also displays the current time
and date and the date being used for backdating.
Note: If the AST system is not backdating, the back date entry is the current date.

System Status Message Center
System Status Message Center provides information about the state of the system, such as its operation
mode (Run or Pause) and any error conditions that need to be addressed.
Pager Status Message Center
The message center indicates whether the AST system has detected any jams, and, if applicable, sends
the error message to a specified pager.
Transfer Options
The transfer options include Night Time mode or Priority settings. Transfer options are only displayed if
the function is possible on a specific transfer. Choose a specific transfer by selecting it from the drop-
down menu. Night Time mode sets the popup transfer to sort items into the first available bin and the
item is not checked in. Priority settings determine which direction a transfer takes item from when
multiple items are available at the same time. Settings include Left, Right, Alternate, or Upstream
Priority.
Left Priority ─ The transfer always takes an item from the left conveyor.
Right Priority ─ The transfer always takes an item from the right conveyor.
Alternate Priority ─ The transfer alternates between the left, right, and rear conveyors.
Upstream Priority ─ The transfer always takes an item from the rear conveyor.
AST Software
Delivery Options
The delivery conveyor system options include Pause, Accumulate, and Purge. Choose a specific
conveyor node by selecting it from the drop-down menu. All changes made are applied to that specific
conveyor node. Select Pause to stop the delivery system during maintenance, cleaning, or any issues or
jams. Select Accumulate to run the conveyors at a shortened time (specified in the software),
lengthening the life of the conveyors. Items are only moved the length of time needed to push to item
onto the next conveyor. Items accumulate on the conveyor system. Select Purge to continuously run the
conveyor system, moving all of the accumulated items to the sorting section.
Color Key
The color key defines the meanings of the color codes used to represent the status of the components
shown on the component layout diagram in the middle of the screen.
Loader Mode (Optional)
The Loader Mode only is available for systems that are equipped with a loader/unloader. These radio
buttons control the loader/unloader unit. When the loader/unloader is in Unload mode, the Smart Bin
pushes items onto the de-shingling belts. When the loader/unloader is in Load mode, the de-shingling
belts transfer items into the Smart Bin.
Component Layout Diagram
The component layout diagram represents the components of the AST system and their current state.
The color of the components changes as the corresponding part of the system changes. The labels of the

transfers show the sort location number. The bin icons change to reflect the state of the AST system’s
bins. If a bin is not connected, its icon disappears, and if a bin is full, its icon turns red.
HiIQ Software (Optional)

HiIQ is only included on systems that are equipped with a placer system (see page 26). HiIQ software’s user
interface allows users to start and stop the HiIQ system, establish sorting rules, view the state of the system, and
review logs. The Main Screen has several components which include a menu bar, ACS Check-In Messages,
System Status Message Center, Connection Status, Shelf Sort Tracking, System Status, and the component
layout diagram.
Menu Bar Options
The menu bar contains a variety of options for the system including a File, Operation Mode, Look Up
Forms, Setup, and Help menu. For more information on specific menus, see page 32.
ACS Check-In Messages
This message box displays information about the last item HiIQ checked in, including the sort number,
the bar code, the agency destination, the reserve status, the check-in message, the collection code, the
call number, and the item type code. It also displays the current time and date and the date being used
for backdating (if HiIQ is not backdating, the back date entry is the same as the current date).
AST Software
System Status Message Center
System Status Message Center provides information about the state of the system, such as its running
state and any error conditions that need to be addressed.
Connection Status
Connection Status indicates whether the HiIQ is communicating with Delivery and the ACS (ILS). If it
is connected and communicating, the corresponding icon illuminates green. If not is not connected and
communicating, it is black.
Shelf Sort Tracking
Shelf Short Tracking indicates the sort number of the item currently held by the various devices on the
system.
System Status
System Status defines the meanings of the color codes used to represent the status of the components of
the system, as represented by the component layout diagram in the middle of the screen.
Component Layout Diagram
Located in the middle of the screen, the component layout diagram represents the components of HiIQ
and their current state. The color of the components changes as the corresponding part of HiIQ changes.
Also the bin icons change to reflect the state of the bins. If a bin is not connected, the icon disappears; if
a bin is full, the icon turns red.

HiIQ Interaction with Delivery
As HiIQ runs, it stays in constant communication with the Delivery system. When Delivery sends a
message to HiIQ, it updates it on the following parameters.
The state of the E-stop button ─ If an E-stop is initiated on the Delivery system, HiIQ pauses and
informs the user that the system has been stopped.
The state of the previous line shaft (running or not running) ─ If Delivery indicates that the line shaft
is running, it starts the sizer in anticipation of receiving an item.
HiIQ also sends messages to Delivery periodically. It updates Delivery about the following parameters.
Whether or not the sizer is empty ─ As long as HiIQ indicates that the sizer is not empty, Delivery
does not send it any items.
The state of the E-stop button ─ If a user presses an E-stop on the HiIQ, it informs Delivery so that
Delivery can stop all operations on all devices.
HiIQ operation state (running or paused) ─ Normally, Delivery does not send any items to HiIQ if
HiIQ is paused. However, if the user chooses Accumulate mode on HiIQ, Delivery sends items
whenever all of the bins are unavailable or if the sizer is empty.
Whether or not HiIQ is in Accumulate mode.
Menu Bars (Delivery and HiIQ Software)

The menu bars contain a variety of options for the system. The Delivery and HiIQ menu bar options are almost
AST Software
identical. Any differences are listed below.
File Menu
Exit (shut down) the software program by selecting Exit.
Operation Mode Menu
Run (start) the AST system by selecting Run.
Look Up Forms Menu
The Look Up Forms menu includes options for backdating, sorting, and viewing statistics and logs.
Delivery software also allows an Auto Export to be performed. The sort tables include an option on the
bottom of the screen to search for (Find) an item. If the Match Whole Field check box is selected, the
system searches only for words that match the exact phrase typed. If Case Sensitive is selected, the
system searched for only the exact case of the word or phrase that was typed. You can automatically
replace a word or phrase with another through the Replace option. The phrase typed in the Replace box
replaces the phrase typed in the Find box. Select the field in which to perform the search: Sort Number,
Collection Codes, or All Fields.
Backdating
The system can backdate items to avoid fining patrons. Specify the back date using the
backdating form. To access the backdating form, on the Look Up Forms, select Check In
Sortation > Backdating.

Backdating Screen
Choose one of three options:

1. Use Today’s Date, which causes the software to use the current date as the check-in date.
2. Use Backdate To, which always backdates to the date specified.
3. Use Auto Backdate, which automatically backdates starting at midnight and continuing to
the time specified. Until the stop time is encountered, the software backdates to the day
specified. When the stop time is encountered, the software stops backdating.
The software uses the item details provided by the ILS to determine the proper sort bin. Items
can be sorted based on any of three criteria. The software reviews each of the criteria and stops
when it discovers that the current item satisfies a criterion. If an item satisfies none of the three
AST Software
criteria, it is sent to the reject bin by default.
Sorting, Reserve
If an item is on reserve or hold for another user, it is sorted based on the Reserve table. Edit the
hold status of items and rules on this table.
Reserve Table
Sorting, Agency
If an item needs to be transferred to another library, then it is sorted based on the Agency table.
Edit the destination agency code of an item and, and specify where to sort items. If an item’s
transit (agency) code is not found, the item is sent to the reject bin.

Agency Table
Sorting, Collection Code
If an item is neither on reserve nor in transit to another library, it is sorted based on the
Collection Code table. Edit the collection code of the item, such as if books are fiction or non-
fiction, and specify where to sort the items. If the item’s collection code is not found, the item
is sent to the reject bin. It is also possible to sort items with the same collection code to
different sort locations based on their call numbers.
AST Software
Collection Code Table
Logs
As the system operates, it records the details of the items it processes in three logs. Access the
logs from the Look Up Forms Menu, select Maintain System, and select a log type.
The ACS Log records the details of the communications between the system and the ILS.
The Transactions Log records details of all items that are checked in.
The Reject Log records details of any items that could not be sorted.
All three logs can be cleared from the File menu by clicking Purge History. Users should
clear the logs periodically to prevent them from growing too large.
Statistics
As the system runs, it maintains statistics about its operation. These statistics can be displayed
by accessing the File menu and clicking Statistics.

Statistics Screen
The left hand section of the Statistics Screen displays cumulative statistics, which are
maintained until the user clears them through Purge History on the File menu.
Running Time Statistics shows the time the machine was in Run mode, which is not
necessarily the same as the difference between the start and end time. The right hand portion of
the screen displays daily totals. For each of the last ninety days, the system records five
individual statistics:
1. The run time in minutes
2. Number of items processed
AST Software
3. The average number of items processed in an hour
4. Number of local hold and local non-hold items
5. Number of transit hold and transit non-hold items
Item Totals By Sort Location provides the total number of items that have gone into each sort
location. To view an individual sort location, use the drop-down menu.
Auto Export (Delivery Software Only)
Auto Export allows you to specify pre-set times when the software automatically exports, and
optionally purges, the statistics data. Three options are available for Auto Export. To export,
or to export and purge, specify the following frequencies.
Daily: up to four times per day
Weekly: one day of the week

Monthly: one day of each month
Setup/Timers Menu
Access the setup options. Normally the setup options are determined and set during machine installation.
Setup options include configuring the voice messages, patron card reader, SIP, security window,
receipts, and reader.
After editing any options, click Apply, and then OK to implement the changes. Click Cancel to opt out
of any changes made.
Help Menu
Access onscreen help information about the Main Screen by selecting Help.
Interaction with ILS

AST Software
When the barcode reader reads an item’s barcode or RFID tag it sends a message to the ILS with the item’s ID
number and the desired backdate. The ILS changes the item’s status to check-in and then replies with the details
of the item, such as its title and collection code. The software displays these details on the Main Screen and then
uses them to determine the proper sort bin for the item, based on the rules that are established.
Customization
To further customize your software, please call Customer Care at Tech Logic.

Operating Procedures
Important! Ensure that you read and are aware of all warning and hazard notices on the
equipment before operating the system.
Starting the System

1. Walk around the entire system to complete a visual check.
Check that all of the available bins are attached to or in position next to the sorter depending on bin type.
Check the floor for items that may have fallen off of a bin.
Check that all of the bins connected to the sorter are in Load mode if applicable.
2. Check that the Power On light is on.
a. If the main Power On light (button) is off:
i. Verify that the software is not running.
ii. Press the Power On button.
iii. If the main Power On light turns on, reload the software.
iv. If the main Power On light does not turn on or is blinking, check all of the E-Stops to make sure that
they are not pressed. If no E-stops are pressed, check with building maintenance to ensure that there
is power to the system.
b. If the main power light is on, continue with system startup.
3. If the computer is powered off:
a. Press the computer power button to turn it on.
b. Double-click the Delivery icon on the computer.
c. Verify that the Delivery software is connected and the connection status light is green on the Main
Screen.
d. If the system has a placer system, double-click the HiIQ icon.
e. Verify that the HiIQ software is connected and communicating to the Delivery software, if applicable.
Note: Systems that have a placer system have two monitors; one for Delivery and one for
HiIQ. Some systems may have two computers that have to be turned on.
f. From the Operation Mode menu, click Run System (or F5).
Shutting Down the System

1. From the Operation Mode menu, click Pause.
2. Push an E-Stop button to stop the AST system.
3. Shut down the software by clicking the X in the upper right hand corner or by selecting Exit from the File
menu.
4. Turn off the computer by selecting Shut Down from the Start menu on the taskbar.
5. Remove any items remaining on the line shaft conveyor.
6. Turn the disconnect switch to the Off position.
Power interruptions or outages may cause damage to the software or sorting

equipment. Please shut down the software properly before shutting down the
system.

Pausing the System

Pause the AST system to correct a situation or when preparing to shut down the system. In Delivery and HiIQ,
from the Operation Mode menu, click Pause. The system status message center displays that the system is
paused.
Note: While the system is paused, exterior book drops do not function and conveyor belts
remain stationary.
Starting the System after Pause

When the system is paused, from the Operation Mode menu, click Run to restart the system.
Addressing an E-Stop
When an E-Stop is pressed, power is shut off to the entire system. The main green system power light turns off.
The book drops do not operate until system restart.
1. Determine the cause of the E-Stop. Call a supervisor or lead worker if necessary.
2. Contact the service desk and inform them that the system is down.
3. Correct the situation.
Important! Use caution when resolving jams or E-Stop situations.
4. Exit the software.

Click X in the upper right hand corner of all open windows.
Check the task bar on the bottom of the monitor to verify that all applications are closed. If there are still
applications open, right-click the task bar icon, and click Close.
5. Restore the power.
a. Pull out the activated E-Stop button.
b. Press the system power button. The system power light illuminates as a constant green. If the system
power button is on but you do not see a constant light and the system does not start, there may be
another E-Stop button pushed in somewhere. Repeat steps 1─4 until all of the E-Stops are deactivated.
Note: If an E-Stop has been pressed, wait at least 30 seconds before restoring power. After
power has been restored, wait at least 30 seconds before starting the software.
6. Launch the software.

7. Check the System Status Message Center at each workstation. A message stating System is Running
appears.
8. Contact the Service Desk and inform them that the system is properly running again.
Changing a Book Cart

When a book cart needs to be changed because it is full, the AST software will indicate that the book cart is full,
and the operator control console mounted in front of the placer system will turn yellow.
1. Pause both placer systems that feed items to the book cart that is full by pressing the Pause buttons on the
operator control consoles.

2. Lower the book cart by pressing and holding the Cart Tilt Down button on one of the paused operator
control consoles until the book cart is completely lowered.
3. Remove the full book cart.
4. Roll a new book cart onto the cart tilt. Ensure it is pushed entirely onto the cart tilt.
5. Raise the book cart by pressing and holding the Cart Tilt Up button on the operator control console.
6. Press the Run buttons on both of the paused placer systems.
Smart Bin® Procedures

Moving a Smart Bin®, Model 125 Away from the AST System
1. Unplug the communication cable and the power cord.

2. Grasp the metal brake release bar and pull the bar towards you. The release lever allows the user to
maneuver the bin.
Connecting a Smart Bin® to the AST System
A communication cable connection is required when the bin is attached to the sorter. This allows the bin
to communicate its full status with the AST system.
1. Before connecting the bin to the AST system, ensure that the power is switched to Off.
2. Connect the data cable to the AST system.
3. Plug in the power cord to the AST system.
4. Turn the power switch to On.
In order to allow the bins to run automatically, turn the power switch to On. On the 350 Model, switch
the mode to Auto mode. Switch the Load/Unload button to Auto Load. As items are placed into the bin,
the bin’s floor lowers to make room for additional items. Keep the Smart Bin’s power cord plugged into
the AST system. Raise and lower the bin manually by switching the bin’s mode to Manual.
Loader/Unloader Procedures
Adding a Bin to the Loader/Unloader
1. Push the Smart Bin over the bin tilter until it stops.
2. Secure the safety strap around the outside of the bin, and hook it onto the ring on the frame.
3. Connect the data cable.
4. Connect the power cord.
Note: The system may take 15 seconds to initialize and begin moving the bin. The system
may take 30 seconds to change modes (Load to Unload).
Ensure that the area around the bin tilter is free from obstacles and people
before the bin starts moving. The bin is tilted at a 15-degree angle, leaving it
approximately 16 inches off the floor.
5. Use the software to modify the loader/unloader mode if necessary.
Removing a Bin from the Loader/Unloader
1. After the bin tilter returns the Smart Bin to the Down position, remove the safety strap.
2. Disconnect the data cable.
3. Disconnect the power cord.

4. Move the Smart Bin away from the bin tilter.
Controlling Windows® Automatic Updates

Microsoft Windows® Automatic Updates must be controlled. Automatic Updates downloads, updates, and then
installs them. The restart required after the installation of updates shuts down the AST software. The update
process must be divided into separate steps.
Set the computer to download updates, and leave the installation of the updates for manual installation. Auto-
install reboots the computer and stops the AST application.
1. From the Start menu, click Control Panel > System. The System Properties window appears.
Check Button
System Properties
2. Click the Automatic Updates tab. Check Download updates for me, but let me choose when to install
them.
Note: If these options are grayed out and unavailable, such as when individual computers
are controlled by a network administrator, contact the administrator for help.
3. Before installing the updates, turn off (close) the AST software.
4. When the AST software is closed, a dialogue box may appear with an Error 91 message. This is part of a
file clean-up operation and is normal. Ignore the message, and close the dialogue box.
5. Install the updates as needed.

Editing a Sort Table

1. Pause the AST system.
2. Open the sort table you wish to edit in the AST software.
3. Find the item you wish to edit.
4. Click in the text field you wish to edit (code, description, sort location, etc.)
5. Type the new entry.
6. Click OK to save the changes or Cancel to disregard the changes.
Deleting a Sort Table

1. Pause the AST system.
2. Open the sort table you wish to edit in the AST software.
3. Find the item you wish to delete.
4. Click the row number on the left-side of the screen to highlight the item’s entire row.
5. Click Delete to delete the row.
6. Click OK to save the changes or Cancel to disregard the changes.
Sorting by Call Number

It is also possible to sort items with the same collection code to different sort locations based on their call
numbers.
1. Access the sorting form from the Look Up Forms menu on the AST software Main Screen (Delivery or
HiIQ, depending on what system you wish to edit), select Check In Sortation > Sorting.
2. Select Edit Collection Code Table.
3. Type a Y in the Call # Sort text box. The Sort Position field is then filled in with the location where the
software starts searching for the call number. The Num Chars field is filled in with the number of
characters to use. For example, if you specify 3 for Sort Position and 3 for Num Chars, and the software
encounters the following call number: XY123.45, then the software would use 123 as a call number.
4. After the call number of an item is determined, the software compares that number to the minimum and
maximum call number specified. If the item’s call number falls between the minimum and maximum values
specified, the software sorts the item to the first sort location bin that is not full.

General Maintenance
General Maintenance
Maintenance Training
Tech Logic provides the initial training the general maintenance personnel to perform periodic service tasks,
including cleaning, adjusting, general observation, and occasional lubrication. The next level of service,
including replacement of mechanical instruments such as motors, chains, belts, sensors, or fuses would need to
be replaced by an experienced mechanical technician or conveyor mechanic. Tech Logic can provide this
service to the library through a service contract. Call customer service for more information.
Preventative Maintenance
Preventative maintenance is the care and servicing by personnel for the purpose of maintaining equipment by
providing for systematic inspection, detection, and correction of early failures either before they occur or before
they develop into major defects. Keep up with preventive maintenance is an important part of owning a Tech
Logic AST system. Ensure that you read all warning and hazard notices on the equipment before maintaining
the system. There are five major preventative maintenance objectives:
1. Keep the machine clean.
Periodically clean dirt from sensitive areas. Certain items such as photo eyes require periodic cleaning
because they are sensitive to deposits of dirt and dust. Keep the area around the system clear of clutter and
maintain easy access for operators. General housekeeping is the responsibility of the library and can further
the longevity of the system. Do not attempt to clean the system when it is operating. Follow the maintenance
checklist for cleaning frequency.
2. Inspect for symptoms of a failing component.
If a part fails, there are usually symptoms such as unusual wear on products, poor performance, or unusual
noise or vibration. Periodic inspection and a diligent operator usually identify these conditions in advance of
a failure.
3. Provide lubrication.
Periodic lubrication is required to prevent premature wear or failure on moving parts.
4. Provide necessary adjustments.
Parts of this system may need re-adjustment over time with exposure to vibration, shock, or aging. This
adjustment is normally required when the operator notices changes in the performance of the system.
5. Inspect components for normal wear and tear.
Some mechanical parts wear out through use, and their replacement is expected. These replacements are
typically not scheduled, but they are done as required, based on observation of performance.
Corrective Maintenance
Corrective maintenance is required when an item has failed or worn out, to bring it back to working order.
Programming the PowerFlex Drive
The following provides basic navigation instructions on how to program the first Program Group
parameter on the PowerFlex 4 Adjustable Frequency AC Drive.
1. When power is applied, the last user-selected Display Group parameter number is briefly displayed
with flashing characters. The display then defaults to that parameter’s current value.
2. Press ESC once to display the Display Group parameter number. The parameter number flashes.
3. Press ESC again to enter the group menu. The group menu letter flashes.
4. Press the Up Arrow or Down Arrow to scroll through the group menu (d, P, and A).
5. Press Enter or SEL to enter a group. The right digit of the last viewed parameter in the group flashes.
General Maintenance
6. Press the Up Arrow or Down Arrow to scroll through the parameters that are in the group.
7. Press Enter or SEL to view the value of a parameter. If you do not want to edit the value, press ESC
to return to the parameter number.
8. Press Enter or SEL to enter Program mode to edit the parameter value. The right digit flashes and the
Program LED illuminates if the parameter can be edited.
9. Press the Up Arrow or Down Arrow to change the parameter value. If desired, press SEL to move
from digit to digit or bit to bit. The digit or bit that you can change flashes.
10. Press ESC to cancel a change or press Enter to save a change. The digit stops flashing and the
Program LED turns off. If cancelled, the previous value is restored.
11. Press ESC to return to the parameter list. Continue to press ESC to back out of the programming
menu. If pressing ESC does not change the display, then d001 [Output Frequency] is displayed.
Press Enter or SEL to enter the group menu.
Allen Bradley PowerFlex 4 VFD Parameters (Settings)
Loader/ Transfer Line Shaft 1/2 HP Belt 1 HP Belt

Unloader Conveyor Conveyor
VFD # Parameter Description Display
P031 Motor Name Plate Volts 230 230 230 230 230
P033 Motor OL Current 0.4 0.4 1.8 2.2 4.4
P034 Minimum Freq 20 20 20 20 20
P035 Maximum Freq 90 60 60 60 60
P036 Start Source 2 2 2 2 2
P038 Speed Ref 4 4 4 4 4
P039 Accel Time 1 0.1 0.1 0.1 0.1 0.1
P040 Decel Time 1 0.1 0.1 0.1 0.1 0.1
A51 Digital In1 Sel 4
A52 Digital In2 Sel 4
A67 Accel Time 2 0.1
A68 Decel Time 2 0.1
VFD-1 A70 Manual Pre-Set Freq 50 50 50 50 50
A71 Fwd Pre-Set Freq 45 45 45 45 45
A72 Rev Pre-Set Freq 45 45 45 45 45
VFD-2 A70 Manual Pre-Set Freq 50
A71 Fwd Pre-Set Freq 45
A72 Rev Pre-Set Freq 90
VFD-3 A70 Manual Pre-Set Freq 50
A71 Fwd Pre-Set Freq 45
A72 Rev Pre-Set Freq 25

Record Keeping
General Maintenance
Tech Logic recommends that an activity log is kept to provide tracking of service and operating issues. The
activity log should include records of the following items.
1. Operating activities
2. Unplanned system stoppages with date, time, cause, operator name, and action
3. Damaged library items
4. Maintenance records
5. Calls to Tech Logic
Smart Bin® Model 125 Maintenance

To avoid equipment damage, only allow authorized, fully trained personnel to
perform the following task.
Replacing a Fuse
If anything unusual begins to happen with the operation of the bin, the fuses inside of the control box
should be checked to see if replacement is necessary.
An F1 10 amp fuse is attached to the motherboard in the control box and a 5 amp fuse is located in the
main AC receptacle on the bottom of the box. A spare 5 amp fuse is included as a replacement and is
located in the main AC receptacle.
1. Remove the four #6-32 button head screws on the back panel of the control box.
2. F1 10 amp fuse is attached to the motherboard. Remove the old fuse.
3. Replace the fuse with a new 10 amp fuse.
Note: Five amp fuses are located in the main AC receptacle on the bottom
of the box.
4. Push the button inside the control box to lift the fuse panel.
5. Remove the old 5 amp fuse.
6. Replace the fuse with a new 5 amp fuse. There is one spare 5 amp fuse included.
Replacing the Control Box
1. Push the power button off.

3. Unplug the power cord.
4. Disconnect the control box cable from the bin connector.
Important! The smart bin could be damaged if the bin is not properly disconnected.
5. Pull the control box straight out from the bin.

6. Slide in the new control box.
7. Connect the control box cable to the connector at the bottom portion of the bin.

Replacing the Battery
General Maintenance
Tech Logic recommends returning Model 125 bins for battery replacement.
Smart Bin® Model 350 Maintenance

To avoid equipment damage, only allow authorized, fully trained personnel to
perform the following task.
Replacing a Fuse
Before you begin:
1. Push the power button Off.

3. Unplug the power cord.
Important! The Smart Bin could be damaged if the bin is not properly disconnected.
If anything unusual begins to happen with the operation of the bin, the fuses inside of the control box
should be checked to see if replacement is necessary.
Three 4-amp fuses are located in the electrical compartment on the back of the bin.
1. Using a 9/64-inch Allen wrench, remove the five screws on electrical
compartment door.
2. Find the fuse bank near the top of the electrical compartment.
3. Pull down the fuse compartment cover(s) to access the fuse(s).
4. Each fuse has a tipped end and a flat end. To replace a fuse, insert the tipped end
first.
Fuse Compartment Cover Insert Fuse
Photo Eyes Maintenance

Tools:
Windex®
Q Tips®

Photo eyes can occasionally become dirty which may cause errors when detecting library items on the sorting
General Maintenance
system. To clean the photo eyes use Windex® and a Q Tips® to gently clean the glass. The photo eyes should
be cleaned according to a regular maintenance schedule. Photo eyes are located on book drops, conveyors, and
throughout the sorting section.
Sorting Section Photo Eyes Conveyor Photo Eyes Book Drop Photo Eye

Maintenance Schedule
Periodic maintenance consists of inspection, lubrication, and cleaning.
See Safety Guidelines on page 8 before performing any maintenance on the machine.
As Needed Maintenance Initial and date when procedure is completed

Clean book drop areas
Adjust photo eyes
Vacuum electrical cabinets and under

conveyor
Oil printer slide bearings (if equipped)
Oil popup transfers when noisy
Grease or gear oil bearing surfaces, ball

screws, and rails
Daily Maintenance
Visual Check belts, rollers, in and under system, wear products, debris, lost library items, and
loose parts.
Inspect all components of the fire suppression system (if equipped). Check the tank
gauge and the control panel’s green power LED is lit.
Audible Listen to machine operation for unusual sounds of squeaking, grinding, or clunking.
Cleaning Lightly dust or wipe all photo eyes, and clean camera lenses.
Do not clean the moving parts of the system do not need cleaning unless something is
spilled.
DO NOT GO UNDER THE SYSTEM WHEN IT IS OPERATING.
Rags or towels may catch in the system rollers or belts and cause injury to the operator or
damage to the system.
Weekly Maintenance Initial and date when procedure is completed
Check under system
for debris/lost items
Listen for any unusual

noises that may indicate
needed repair or maintenance
Look for misaligned photo eyes. Dust

or clean photo eyes
Check incline/decline conveyor belts to

see if items are slipping and clean as
necessary

Weekly Maintenance Initial and date when procedure is completed

Check fire extinguishers
Monthly Maintenance Initial and date when procedure is completed

Use mild soap and water solution to
clean the book drop face
Short-term lubrication: bearings, belt
conveyors, book depositories, rotator
cylinders. These require a periodic
application of light oil when operation is
erratic. Clean old grease before
applying.
Clean photo eyes on book drop doors,
inside and outside
Use a stainless steel cleaner to clean the
book drop face
Watch book drop door operation to see
that it is moving smoothly
Check urethane drive bands on
conveyor for worn and/or broken bands

Clean urethane bands on transfers if
necessary
Check conveyor return rollers for
unrestricted rotation
Clean any dust, dirt, excess oil, or
grease from system.
Check conveyor belt splices and/or
lacings, look for signs of unusual wear
Clean Smart Bins, check photo eyes,
listen for unusual noises
Check conveyor belts for tension
Inspect system in operation

for proper function
Listen to all chain drives,
drive pulley popups
Check return rollers (bottom side of
the conveyor) for free rotation
Check for loose parts
Check for worn parts
Check transfers for smooth

up and down movement
Vacuum under system

Monthly Maintenance Initial and date when procedure is completed

Clean barcode scanner face (if applicable)
Clean printer mechanism; check for

obstruction in path of receipt paper
Check studs that have a hex nut on them
one on each end of the line shaft
conveyor rollers, replace as needed
Semi-Annual Maintenance Initial and date when procedure is completed
Check gauge and verify the fire
suppression system is charged
Have fire suppression system inspected
by a professional technician
Annual Maintenance Initial and date when procedure is completed

Check setscrews on three bolt bearings
sprockets, and pulleys
Grease actuator lead screw on popup
transfer
Listen for unusual vibration,
bearing noise, etc.
Grease all chains under oval guards
Grease all chains under large guards
Check conveyor belts for wear and

tension; replace as needed
Check bins for normal operation
in manual/automatic modes
and up/down modes
Check all belt conveyor photo eyes.
Make sure they are clean and work
properly
Check the belts on all line shaft Note: If you hear a squeaking, the belt drive pulleys are probably not aligned properly
conveyors to make sure they are
aligned properly
Check all indicator lights on book drop
for proper operation; clean as needed
Check that E-stops are operational

Maintenance Tools
Recommended Tools for AST Maintenance, Troubleshooting, and Cleaning
Additional tools may be necessary for system repair.
 3-in-one oil
 3/8 inch drive set of sockets

Socket sizes 3/16 through 3/4 inch
 Allen wrenches, standard and metric
 Cleaning supplies
Soft cloth for the scanners
Cotton swabs for cleaning photo eyes
Rags, towels, etc.
Optical lens cleaning solvent for scanners.
Mild dishwashing liquid or Simple
Green®
Glass cleaner for photo eyes
Shop vacuum cleaner or vacuum cleaner
with hose attachments
Scrub brush bucket
Medium bristled toothbrush or equivalent
 Crescent wrench (adjustable)
Maintenance Tools

 Flashlight
 Multimeter
 Screw drivers
Phillips micro size
Regular micro size
 Thread-locking compound
 White lithium grease
Maintenance Tools

Recommended Spare Parts List
Recommended Spare Parts List

Critical spare parts are available for 24-hour delivery from Tech Logic. If you need assistance, please call Tech
Logic Customer Care.
Stocked by
Part No. Qty Description Location
Tech Logic
25008204 4 Belt, Drive, Conveyor, Line Shaft, Urethane, 0.18” × 14.87” Line Shaft Y
25008205 4 Belt, Drive, Conveyor, Line Shaft, Urethane, 0.18” × 4.75” Line Shaft Y
25008634 4 Belt, Urethane, Transfer, 83A Durometer, 0.18” × 53.87” Line Shaft Y
25012617 2 Belt, Timing, Drive, 0.37” Pitch, 0.5” Wide, 17.3” Long Line Shaft Y
25013534 1 Resensitizer/Desensitizer Belt Resensitizer N
25013015 4 Sensor, Photoelectric, 3-Pin Pico Conn. Transmitted Beam Conveyors Y
35003477 2 V-Groove Pulley, 17.5” Face, 2” Diameter, 0.75” Bore Belt Conveyor Y
25007963 2 Sprocket, Roller-Chain, #25-24t, 0.75” Bore Belt Conveyor Y
25001139 2 Bearing, Ball, 0.75” ID, 3-Bolt Flange Belt Conveyor Y
25007965 † Belt, Conveyor, Rough-Top, 17.5” Wide Belt Conveyor Y
25008470 2 Control, Electric, Photo Eye, Retro-Reflective 11-28 V DC Placer Y
25013481 2 THK 20 mm Bearing Block Placer Y
25013510 1 Bumper, McMaster-Carr 9223K49 Placer Y
25001256 2 Bearing, Ball, 0.5” ID, 0.31” Wide, 1.12” OD Placer Y
25013167 1 Electrak 01 S24-17A8-02 Placer N
25013521 1 Timing Belt, 135L, 36 Tooth, 0.75” Wide Placer Y
25013502 1 Timing Belt, 173L, 45 Tooth, 0.5” Wide Placer Y
Control, Electric, Photo Eye, Visible Red Plastic Fiber Optic,
25011066 2 Series 45FS, 24 V DC, 5 M-Wire Leads Placer Y
25011059 1 PowerFlex4 VFD, 0.25 Hp Any Cabinet Y
25011451 1 PowerFlex4 VFD, 0.5 Hp Any Cabinet Y
25013168 1 Si3540 Stepper Drive Any Cabinet Y
25013169 1 Si5580 Stepper Drive Any Cabinet Y
25013514 1 Stac6-Q Stepper Drive Placer N
25013515 1 ST-5-Q Stepper Drive Placer N
25018100 2 Relay, Double Pole Double Throw, 8 Blade Any Cabinet Y
25009709 1 24 V DC Power Supply Any Cabinet Y
25009529 1 Beckhoff Ethernet Module Any Cabinet Y
25010941 1 Beckhoff Input Card Any Cabinet Y
25009309 1 Beckhoff Output Card Any Cabinet Y
25008603 1 Beckhoff Output Card Any Cabinet Y
† Order by length specified on conveyor

Troubleshooting
First Level Field Service Procedures
When there is an issue with the AST system, complete a quick analysis to discover and understand the issue.
Operators should contact the system manager for assistance. If the system stops, check for one of the following
occurrences:
1. An E-Stop is activated.
2. There is a power interruption.
3. There is a communication interruption or failure.
4. There is a mechanical failure.
If there is no obvious cause for the system to be stopped, check the computer display for the system status.
When the machine is stopped by an E-Stop, all power is off to the equipment, but the computer remains on.
Resolve the situation and restart the system.
Power Disturbances
The AST system can be interrupted by power disturbances, extreme line noise or spikes, temporary power
failures, or a lowering of the line voltage below normal levels (brown-outs). When this happens, a section of the
system or the entire system stops. This requires a complete system shut down and restart. The most accessible
way to shut down the system is to activate an E-Stop and then follow the startup procedure (see page 37). If
Troubleshooting
there is an unexplained interruption in the system operation that seems to occur regularly, contact Tech Logic.
System Jam
If an item continues to cover the exit photo eye of a belt conveyor for an extended period even though the belt
remains on, the system reports a jam. The following things occur when a jam is detected.
The belt stops moving.
The belt conveyor’s icon on the user interface main screen flashes red and white.
A Resolve Jam button displays on the main screen.
Important! Use caution resolving jams or E-Stop situations.
Clear the jam, and then click Jam Resolved to indicate to the software that the system can restart.
Bin Item Level Adjustment

If a bin is not responding to the correct item level:
Make sure the power is on to the control box.
If the bin is plugged in to the AST system, verify the AST computer shows that a bin is present.
Check the photo eyes at the top of the bin, and verify they are clean and unobstructed.
If the bin is not connected to the AST system, plug in the power cord to any wall outlet to charge the bin
battery.

Photo Eye Adjustment

Tools:
5/32-inch Allen wrench
2 mm flathead screwdriver
Important: Photo eyes should not need adjustment under ordinary operating conditions.
Keep the photo eyes clean to ensure proper operation.
1. Use a 5/32-in. Allen wrench to remove the screw on the housing cover.
2. Identify the photo eye that has a black cable attached to it. This is the photo eye to adjust.
3. Using the 2 mm flathead screwdriver, turn the adjustment screw on the photo eye all the way to the left.
4. Use a book to block the beam between the photo eyes. The red light flickers on and off as the book blocks
the photo eye beam.
5. Slowly move the book farther away from the photo eye until the red light stops flickering. Turn the
adjustment screw slowly to the right to turn up the intensity of the photo eye beam.
6. Continue to adjust the beam until the book is detected all the way across the belt.
1 2
Troubleshooting
3 4
Software Issues
Photo Eye Problem Icon
A problem icon may display on the main screen to indicate a photo eye problem. Click the icon to
display a form that lists the time, date, and details of the photo eye problem to help diagnose operational
difficulties caused by photo eye problems.

Troubleshooting Screens
Display the troubleshooting screen for any component by clicking the component’s icon. To access a
troubleshooting screen for any given component, select Pause mode from the Operation Mode menu.
Troubleshooting screens are not used in ordinary operation, but they are useful in diagnosing problems.
The troubleshooting screens have five parts:

1. The Output Commands section allows you to activate the mechanisms on the system such as
motors and valves.
2. The Test Commands section allows you to test mechanisms on the system. The system can turn
alternately on and off.
3. Inputs indicate the state of photo eyes on the system through icons. If the icon next to a photo eye is
green, that photo eye is covered; if the icon is black, the photo eye is uncovered.
4. Outputs indicate which outputs are turned on. If an indicator is green, the corresponding output is
on; if it is black, the output is off.
5. Current Transfer State provides information about the current state of the transfer components.
Delivery Software HiIQ Software
Troubleshooting
Troubleshooting Screen Examples

Glossary
── A ──
ACS Terminal Client ─ Software used by the AST system to check in items, by the library to manually check in items
and write tags and patron IDs; and by patrons as a self-service check-out station.
Actuator ─ A device that performs a mechanical action in response to an input signal.
Alarm ─ An electronic or mechanical device that warns of a dangerous or undesirable event by means of a sound or
signal.
Allowable Item Size ─ The minimum and maximum required size an item must be to be correctly centered with the
sizer/squarer. Any book with at least one dimension less than 4 inches or greater than 16 inches is rejected.
Automated Circulation System (ACS) ─ A computer system (hardware/software) that is used to support basic library
functions, such as acquisitions, cataloging and circulation. Also referred to as Integrated Library System (ILS).
Automated Sorting Technology (AST) System ─ System/Machinery that eliminates the hard physical labor of sorting
and moving items in a library. Tech Logic AST systems include UltraSort and QuickSort systems. These systems are
designed to use barcodes, RFID tags, or both.
Automatic ─ Operated by a self-regulating system that is independent of external influence.

── B ──
Barcode ─ A code consisting of a group of printed and variously patterned bars and spaces and sometimes numerals
that is designed to be scanned and read that contains information (as identification) about library items.
Barcode Scanner ─ An optical scanning device designed to read information printed in the form of bars of different
size by detection and processing of the varying reflectivity of light in the barcode.
Belt ─ See Conveyor.
Book Cart ─ The wheeled, shelved (sometimes segmented) cart used to bring items to the library shelves. Also referred
to as a book truck.
Book Drop ─ A slot, door, or open belt that patrons and library staff use to return borrowed from the library.
Book Return ─ See Interior Book Drop.
Book Placer System ─ See Placer System.
Book Truck ─ See Book Cart.
Breaker ─ A device with over-current protection used to connect a power source to a load or another power source. A
circuit breaker automatically interrupts an electric circuit under an abnormal condition. Breakers can be manually or
automatically operated.
── C ──
Call Number ─ A number used in a serially based system of numbering cataloging records in the LCCN (Library of
Congress Control Number) system.
Cart ─ See Book Cart.

Glossary
Cart Tilt ─ A mechanism that lifts book carts at an angle to keep placed books from falling over.
CircIT® ─ Tech Logic library self-checkout software used to automatically check-in items. Used by the library to
manually check-in books, write tags and patron IDs and by patrons as a self-service check-out station.

Circulation ─ The total number of items borrowed from a library.
Collection Code ─ Shorthand/abbreviations for defining and parsing a library's book, reference, or other collections.
Controls ─ A set of instruments used to operate, regulate, or guide a machine.
Conveyor ─ A mechanical apparatus for moving items from place to place.
Curved Conveyor ─ A section of the delivery system that has a sectioned belt or a set of rollers to negotiate a turn.
── D ──
Data Cable ─ Multiple-pin (from 4 to 9) cables communicate data to and from components in the AST system.
Delivery Software ─ Application program that runs the AST systems without a placer system, including conveyors and
the sorting section. If a placer system is equipped with the system, Delivery software works with HiIQ software.
De-Shingle ─ The process by which items that are overlapping are spaced out on the belt conveyor. See de-shingling
conveyor.
De-Shingling Conveyor ─ Belt conveyors that pull items away from each other when they are stacked on top of each
other by using an incline and varying belt speeds and treads.
Disconnect Switch ─ A two-position switch located on the power distribution box. Turn this switch to the Off position
to remove all electrical power from the system, including sensors and electrical controls.
── E ──
Emergency Stop (E-Stop) Buttons ─ The prominent, red buttons on the AST system and in the software that staff can
activate to stop the system in the event of an emergency.
Enable ─ To make operational.
Exception Bin ─ See Reject Bin.
Exterior Book Drop ─ A place for patron to return borrowed items from the library that features a speaker and an
automatic sliding door that opens only when a patron lifts an item to the door and triggers the sensor. Also known as a
hands-free book drop, it is usually located outside of the library. See also Book Drop.
EZ Tag/RFID Tagging Station ─ A portable tagging station that includes a laptop computer, RFID tag printer,
barcode reader, and rolling stand.
── G ──
Grab and Hold ─ A library card-reading module that contains two imagers that read barcodes, a solenoid to eject the
card, and a receipt printer. Also used to describe the twin imager/solenoid setup, a part of the Grab and Hold or personal
payment system.
── H ──
Hands-Free Book Drop ─ See Exterior Book Drop.
Hazard ─ A possible source of danger; a condition that could cause injury to personnel or damage to equipment.
HiIQ Software ─ Application program on AST systems that are equipped with a placer system that checks in items and
moves them to the correct Smart Bin or book cart.
Glossary
Hub Tag ─ An RFID tag that is round with a removable center for placement on CDs and DVDs.
── I ──
I/A Bin ─ See Smart Bin.

Imager ─ Small camera devices used to take pictures and interpret barcodes.
Integrated Library System (ILS) ─ The database software that libraries use to keep track of their inventory.
Interior Book Drop ─ A place for patrons to return borrowed items from the library that does not have a door or a
speaker and is usually located inside of the library. See also Book Drop.
Inventory ─ The quantity of items or materials on hand.

── L ──
Light-Emitting Diode (LED) ─ A semiconductor diode that emits light when a voltage is applied to it and that is used
especially in electronic devices (as for an indicator light).
Line Scanners ─ An imaging device which uses photo-electronic detectors combined with a rotating mirror which
sweeps across the ground surface taking in image data a line at a time. These laser barcode scanners are usually on
systems that do not use RFID.
Line Shaft Conveyor ─ The system of rollers that move the items through the sorting section of the system.
Line Shaft Motor ─ Motors that control the rollers on the line shaft conveyor. There may be more than one motor
along the line shaft conveyor.
Loader/Unloader ─ Conveyor belt assembly with a Smart Bin, that attaches to the line shaft conveyor and acts as an
overflow buffer. When the system is stalled, paused or busy processing items on the line shaft, books are routed to the
loader/unloader.
── M ──
Machine ─ See Automated Sorting Technology (AST) System.
Maintenance ─ The upkeep of property or equipment.
Master ─ A switch or function that has control over other switches or functions.
Micro Rollers ─ Rollers that run perpendicular to the line shaft and are used with a popup transfer. These rollers
contain their own motor. When a popup transfer is in the Up position, the micro rollers transfer the item left or right.
── O ──
Omni-Directional Scanner ─ A barcode scanner that can scan in several directions negating the need to orientate the
scanner with the bar code.
Operator ─ Any employee authorized to work on and maintain control of the system
── P ──
Patron ─ One who buys the goods or uses the services offered by the library.
Patron Card Imager (PCI) ─ A library card reading module that contains an imager that reads barcodes.
Personal Computer (PC) ─ Control center containing software for the AST system.
Personal Payment System (PPS) ─ A patron self-payment module that includes a Grab and Hold library card reader.
Allows the patron to pay fees and fines along with self check out.
Personal Payment System Imager (PPSI) ─ A patron self-payment module that includes a patron card imager.
Glossary
Allows the patron to pay fees and fines along with self check out.
Photo Eyes ─ Optical sensors that use visible or infrared light to detect objects.

Placer Paddle ─ The vertical bar on the placer head that pushes the items off of the placer head onto the book cart.
Placer Stack Packer Blade ─ Blade that extends from placer head. The placer head moves back, and the blade pushes
items on the book cart back, creating more space in the zone.
Placer System ─ The assembly that check items in, accepts them from the line shaft conveyor, and sorts them on book
carts.
Popup Transfer ─ A set of urethane bands that run perpendicular across the line shaft conveyor and raises up off the
line shaft to sort items into bins or onto placer system. Also acts as a popup stop.
Portable Document Format (PDF) ─ A computer file format for the transmission of a multimedia document that
cannot be edited further.
Programmable Logic Controller (PLC) ─ An electronic device that uses instructions from a host computer to
automate monitoring and control of machine functions.
── Q ──
QuickSort ─ An expandable, stand alone sorting system that consists of three or five bins. This system checks in items
and sorts them into software-specified bins.
── R ──
Radio Frequency Identification (RFID) ─ Technology that enables multiple items to be read simultaneously. RFID
streamlines self check-in and check-out for patrons and library staff though an automatic identification method, relying
on storing and remotely retrieving data using RFID tags and RFID antennas.
Reject Bin ─ A default sort location for items that cannot be checked in or do not meet the sort criteria. Also known as
overflow and exception bins.
RFID Tag ─ Solid state device with an antenna and micro-chip, which is programmed to identify library items.
Contains an anti-theft bit detectable by properly tuned security gates.
Rotator ─ A component that ops out of the line shaft conveyor and rotates an item if its barcode is not read by the first
scanner set. If needed, a second rotator pops out to position the item in the proper alignment in order for the placer
system to sort the item.
── S ──
Sandwich Conveyor ─ A conveyor system employing two belts, one on top of the other, which allows materials to be
lifted vertically as well as horizontally.
Screen Designer ─ An application within CircIT that allows the user to change the appearance of screens seen by
patrons.
Screen Shot ─ An image that shows the contents of a computer display.
SIP 2 ─ Standard Interchange Protocol 2.0 This protocol provides a standard interface between a library's ACS terminal
and library automation devices. The SIP server provides the IP address and port number that allows communication
between the ACS terminal and AST system.
Sizer/Squarer ─ A series of photo eyes and retractable and fixed stops (walls) that determine the dimensions of an item
so that it is centered it reaches the rotator section. Items that are beyond the allowable item size or fail to be centered are
sent to a reject bin.
Slide Chute, Diverting Fixed ─ An inclined plane that has rollers on the surface and a center that is higher than the
Glossary
outer edges, transferring items at an even distribution.
Slide Chute, Retractable ─ An inclined plane that transfers items from the line shaft conveyor to a sort bin. When not
in use, retractable chutes move out of the way.

Slide Chute, Stationary ─ An inclined, fixed plane that transfer items from the line shaft to a sort bin.
Smart Bin® ─ Large, wheeled bin that automatically lowers the floor as books are added, and raises the floor as items
are removed, creating greater ease for the handler and less damage to items. Floor can also be manually raised and
lowered. These bins are used to move items between agencies (libraries). Also known as interagency (I/A) bin.
Smart Card ─ Any pocket-sized card with embedded, integrated circuits that processes information.
Smart Card Reader ─ A piece of equipment that reads and writes Smart cards.
Solenoid ─ A magnetic device that converts energy into linear motion. As part of a Grab and Hold, it is used to eject a
library card.
Sort Location ─ The bin or zone on a book cart for which a specific shelf location is assigned in the sorting software.
This helps to group items by bin or on the book carts that belong in the same section of the library.
Sorting Tables/Sorting Profile ─ User-specified sorting rules to determine proper sorting locations.
Staff Induction Station ─ A lower guide rail section for easily placement of additional items on the conveyor belt by
the library staff.
Straight Conveyor ─ Belt conveyors that move items toward the sorting section that are free from curves, bends,
angles, or irregularities and may include a tail, intermediate, and drive section.
Switch ─ A device used to open an electric circuit or divert current from one conductor to another.
System ─ See Automated Sorting Technology (AST) System.

── T ──
Throughput — The quantity or amount of items processed within a given amount of time.
Timing Belt ─ Black rubber belt that moves the line shaft conveyor.
── U ──
UltraSort ─ Optimized bin sorting system for high volume libraries and central sorting operations with up to 108 sort
locations. These systems include customized conveyance, multiple book drop induction points, item check-in, and a
variety of sorting options.
Uninterruptible Power Supply (UPS) ─ A power supply that includes a battery to maintain power in the event of a
power outage. The UPS keeps a computer running for several minutes after a power outage, allowing data to be saved
and perform a controlled shut down of the computer.
Urethane Bands ─ Translucent rubber bands that power line shaft rollers and move items on popup transfers.
── Z ──
Zone ─ The designated sort location on each shelf on a book cart. Each shelf on a book cart can have up to three zones.
Glossary

Index
Index
A F
Anti-Virus Software ............................................................... 21 Field Service Procedures ....................................................... 53

AST Software ........................................................................ 29 File Menu............................................................................... 32
Auto Export............................................................................ 35 Fire Suppression System ....................................................... 13
Automatic Updates ................................................................ 40
H
B
Hazard Notices ........................................................................ 8
Backdating ............................................................................. 32 Hazard Signs ............................................................................ 9
Barcode Scanner .................................................................... 18 Help Menu ............................................................................. 36
Specifications .............................................................................. 18 HiIQ Software ....................................................................... 31
Belt Conveyors ...................................................................... 14
Bin Present/Bin Full Kit......................................................... 23
Book Drop Override .............................................................. 26 I
Book Drops ............................................................................ 12
Brake Release Bar .................................................................. 39 I/A Bin Connection Kit .......................................................... 23
ILS Interaction with Software ............................................... 36
Inputs ..................................................................................... 55
C Interior Book Drops ............................................................... 13
Cart Tilt Machines ................................................................. 28

Cautions ...................................................................................8 J
Collection Table ..................................................................... 34
Component Layout Diagram .................................................. 30 Jam in System ........................................................................ 53
Contact Information .................................................................6
Control Box Replacement ...................................................... 44
L
Control Panel
Smart Bins ................................................................................... 24
Current Transfer State ............................................................ 55 Loader/Unloader
Add Bin ....................................................................................... 39
Curved Conveyors ................................................................. 16
Operating Modes ......................................................................... 25
Customer Care .........................................................................6
Look Up Forms Menu ........................................................... 32
Customize Software ............................................................... 36
M
D
Maintenance .......................................................................... 42
Delivery Software .................................................................. 29 Annual......................................................................................... 49
De-Shingling Conveyors ........................................................ 15 Daily ........................................................................................... 47
Directories.............................................................................. 21 Monthly................................................................................. 48, 49
Disconnect Switch ................................................................. 21 Schedule...................................................................................... 47
Diverting Fixed Slide Chutes ................................................. 22 Tools ........................................................................................... 50
Dual Rotator ........................................................................... 17 Training....................................................................................... 42
Weekly ........................................................................................ 47
Menu Bar Options ................................................................. 32
E Menu Bar, Delivery Software ................................................ 29
Menu Bar, HiIQ Software...................................................... 31
Emergency Stop Buttons .................................................. 20, 38
E-Stop Buttons ....................................................................... 20
Exterior Book Drops .............................................................. 12 O
Operation Mode Menu........................................................... 32

Output Commands ................................................................. 55
Outputs .................................................................................. 55
Tech Logic Corporation AST.90909000.Prescott Valley Library Page 61 of 64

P Connect to System ...................................................................... 39

Index
Control Panel .............................................................................. 24

Maintenance .......................................................................... 44, 45
Pause Procedure ..................................................................... 38
Manual Mode .............................................................................. 24
Photo Eyes ............................................................................. 21 Move Away From Sorter ............................................................ 39
Adjustment .................................................................................. 54 Troubleshooting .......................................................................... 53
Maintenance ................................................................................ 45
Software ................................................................................. 29
Troubleshooting .......................................................................... 54
Troubleshooting Screens ............................................................. 55
Placer Head ............................................................................ 26 Sorting Section ...................................................................... 20
Placer Paddle.......................................................................... 27 Spare Parts List ...................................................................... 52
Placers .................................................................................... 26 Squarer ................................................................................... 16
Positioning System ...................................................................... 27
Stack Packer Blade ................................................................ 27
Popup Transfers ..................................................................... 20
Staff Induction Station ........................................................... 16
Power Disturbances ............................................................... 53
Startup Procedure .................................................................. 37
Stationary Slide Chutes ......................................................... 22
R System Jam ............................................................................ 53
Record Keeping ..................................................................... 44

T
Reject Bin ........................................................................ 18, 19
Resensitizer ............................................................................ 17
Test Commands ..................................................................... 55
Retractable Slide Chutes ........................................................ 22
Tools, Maintenance ............................................................... 50
RFID Antenna ........................................................................ 19
Training ................................................................................... 5
Rotator ................................................................................... 17
Maintenance ................................................................................ 42
Transfers ................................................................................ 20
S Transit Table .......................................................................... 33
Troubleshooting ..................................................................... 53
Safety Guidelines .....................................................................8 Screens ........................................................................................ 55
Smart Bins................................................................................... 53
Sandwich Conveyors ............................................................. 15
Sequence of Operations ......................................................... 11
Shut Down Procedure ............................................................ 37 U
Sizer ....................................................................................... 16
Slide Chutes ........................................................................... 22 User Interface ........................................................................ 29
Diverting Fixed ........................................................................... 22
Retracable.................................................................................... 22
Stationary .................................................................................... 22 W
Smart Bin Connection Kit ...................................................... 23
Smart Bins ............................................................................. 23 Warnings.................................................................................. 8
Automatic Mode.......................................................................... 24 Signs ............................................................................................. 9
Book Level .................................................................................. 53

Notes
Notes

1818 Buerkle Road
White Bear Lake, MN 55110
USA
Phone: 651.747.0492
Toll free: 800.494.9330
Fax: 651.747.0493
Email: contact@tech-logic.com

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Denver Public Library

9-Bin AST System

6,000,770; 6,074,156; 6,203,262; 6,257,816; 6,422,457; 6,557,696; and 6,561,418.

© 2010 Tech Logic Corporation. All Rights Reserved.

User Manual Revision Level

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Operating Procedures ...................................................................................................................... 37

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About This Manual

Illustrations, Photographs, and Screen Shots

User Manual Icons

User Manual Icons

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Contact Tech Logic

Tech Logic Customer Care

Tech Logic Headquarters Tech Logic – Australia and New Zealand

Phone: 651.747.0492 Phone: +61 3 9376 9677

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A History of Helping Libraries

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A caution notice indicates a potentially hazardous situation which, if not

A warning notice indicates a potentially hazardous situation which, if not

Machine Hazard Warnings

Hazard Warning Signs

Hazard Warning Signs

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Your UltraSort System

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Important! The AST system is not meant to operate unattended.

6. Items enter the RFID section.

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Book Drops (Optional)

Exterior Book Drops

Photo Eye Sensor

Exterior Book Drop

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Manual Book Drops

Manual Book Return Manual Lock

Interior Book Drops

Interior Book Drop

Fire Suppression System (Optional)

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Control Panel Book Smoke Detector CXV Strob Suppression Containment

Fire Suppression System

CXV Controller Suppression Agent Cylinder

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Straight belt conveyors can include a tail, intermediate, and drive

Sandwich Conveyors Straight Conveyor

Reversing Conveyor Incline/Decline Conveyor

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Staff Induction Station

These belt conveyor sections offer a convenience to library staff

Line Shaft Conveyor Rollers

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Resensitizer Unit (Optional)

Rotator Section (Optional)

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Barcode Scanner (Optional)

Line Barcode Scanner Omni-Directional Barcode Scanner

Important: Keep the barcode labels clean for accurate scanning.

Line Barcode Scanner Specifications

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