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Partner Knowledge hub Pio Supplemental Commissioning Guide

Pio Supplemental Commissioning Guide

NOTE: The information in this article is intended for internal partner training purposes only.

For external use, please refer to the approved materials provided to you — including our live, always up-to-date website, official sales collateral, or reach out to our BDM team for additional resources and demo support.

The following information is intended for personnel who have completed the AutoStore Commissioning Engineer training and exam, and who have already familiarized themselves with all material in the AutoStore Commissioning manual on The Port. 

 

What is different about commissioning a Pio grid?

  • Pio provides the Application Server
    • Customer does not need to provide an SQL server
  • No Service Wall/mezzanine
    • The Service Tower module is used for Pio sites
  • Only south-facing, R5-series robots
  • Only Conveyor Port
  • Smaller Controller that should be mounted to the Service Tower by grid installers
  • Streamlined & efficient
    • Pio deployments are intended to be simple and standardized – commissioning should not take more than 24-48hrs on P100/200/400-sized systems, depending on when site networking and electrical is completed, the number of robots, and assuming there are no grid installation or module hardware faults identified.

If you feel you are not able to execute at this pace, please reach out to us at deployment@pio.com so that we can collaborate on identifying gaps and how to make the process even easier!

 

Schedule remote session with Pio before going to site!

Pio is committed to making commissioning as easy and streamlined as possible for our partners. However, for 2026 a remote session with Pio Operations will be required when completing final steps on the Application Server. Please open a case on the AutoStore Service Portal to confirm on-site dates and schedule the remote access session.

What to complete prior to remote session:

  • Confirm connectivity from Controller to Application Server using Remote Desktop and Pio Network Standards
  • Install the latest release of CubeDeploy from The Port on Controller, then install but do not activate nodes!
    • Node activation will take place during remote session with Pio Operations
  • Have initial .aslog file ready

On-site before remote session with time to spare after completing the above?

Here’s what you could be working on:

  • Wire, and configure Ports
  • Configure ASIO and wire Junction Box & Service Tower
  • Ensure electricians have connected power to the Service Tower and test Robot Door unlock button
    • Lift will not operate unless the grid is in Running or Service modes
  • Configure, mount, and wire up AutoStore Access Points
  • Confirm internet access on Application Server
  • Compliance stickers
  • Preparing robots for induction
  • Installing Customer Console on customer-provided Service PC
  • Setting up your organizations remote access software on customer-provided Service PC

General Configuration Information & Tips

Pio Network Standards

Follow AutoStore Standards in the Commissioning manual for Ports, Access Points, the ASIO, and the Controller.

Pio Standards
Pio Controller
B-Net
192.168.10.230
Pio Application Server
B-Net
192.168.10.232
Pio Application Server
C-Net
DHCP*
Service PC^ (customer provided)
A-Net
192.168.0.231

*We recommend using DHCP because Pio supplies the hardware, but may have no remote access to manage network changes. This minimizes client-side configuration errors and prevents loss of internet access required for operation.

^Successfully supporting a Pio site requires partners to have remote access to assist customer users with basic grid stops. Partners and customers should establish an agreed-upon method for the partner to have remote access to the Service PC for working with super users prior to the installation of the grid.

ASIO & Junction Box

Follow standard ASIO configuration steps, although consider setting the device name to “Service Tower” during commissioning of the ASIO

Note: The Service Tower module requires the use of an ASIO 3.0 or newer

For the Junction Box, please refer to the “Wiring diagram” page on the Service Tower Installation Manual. Take care to add the bridges for the Robot Door as shown in the diagram.

Console – Grid Design and Doors

The Robot Doors of the Service Tower are controlled by the unlock button on the Service Tower Control Panel, not in Console as with a Service Wall. You will not see the Robot Door(s) appear in Console when using a Service Tower, only the Grid Door.

If you are unsuccessful in getting the Grid Door to appear in Console, a likely cause is that your grid design is missing the Service Street cells that are required adjacent to the Exit cells. You may add them using “Add Cells” by right-clicking in the Grid tab of Service Console:

After making these changes, you may need to restart the ASIO and/or the CubeDeploy Controller node.

NOTE: The information in this article is intended for internal partner training purposes only.

For external use, please refer to the approved materials provided to you — including our live, always up-to-date website, official sales collateral, or reach out to our BDM team for additional resources and demo support.

 

 

FAQs

01 General Information
02 Technical Specifications
03 Installation
04 System Operations
05 Inventory and Order Management
06 Safety and Compliance
07 Integrations
08 Pricing
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General Information
Can we lease a Pio system?
Many of our customers secure leasing options through their financing providers.
Is it possible to add extra robots for a short time?
Yes, Pio offers a Booster Robot program, allowing you to add extra robots for a minimum three-month period to meet peak demand and reduce costs when activity decreases.
Is it easy to extend the Pio if we grow? What if we outgrow my Pio system?

Pio uses modularAutoStore technology, making it easy to expand the system as your business grows.

If you require additional customizations as your business scales up, we can also assist with the transition to a full AutoStore solution.

My warehouse doesn't fit the heights you have suggested in your pricing. Can I get a shorter/lower one?
Yes, Pio can be customized to meet specific height requirements. Contact us for more information.
How reliable is the system?
Pio and AutoStore sites maintain a 99.7% uptime, with no single point of failure. In case of a robot malfunction, the affected robot can be parked, and the system remains operational while you address the issue or await a replacement.
How do we fix something if it breaks?
A Pio super user should always be onsite when operating Pio. A trained superuser should be able to address the most common issues.
What do we do if the system stops working?
The Pio Help Center provides troubleshooting articles and is always accessible. If you need further assistance, submit a ticket through the Help Center, and Pio Support will contact you as soon as possible to help resolve the issue.
What servicing or maintenance is necessary for the system?
To perform robot swaps or service, you operate the lift up and down.
How does one clean the system?
The ports and grid tracks should be vacuumed annually or when visibly dusty. This process takes less time than cleaning a manual warehouse.
What are the bin dividers made of?
The bin dividers are made of cardboard.
How many ports do I need?
Pio always includes a minimum of two ports, assuming space allows. The required number of ports depends on the daily volume of order lines. One worker can handle over 1,000 order lines at a single port in an 8-hour shift, but specific requirements depend on each case.
Can you move the system to another location?
Yes, Pio systems can be deconstructed and relocated.
What is the ROI for a Pio system?
Considering all cost savings, Pio typically achieves an ROI within 10-18 months, depending on the initial investment.
How much space can we save?
Pio can reduce your storage footprint by 75-90%, requiring significantly less space. Additionally, with a faster inbound/putaway process, less buffer storage is needed, reducing warehousing costs and enabling growth.
How many people do I need to run Pio?
Pio supports pick-and-pack operations, delivering over 130 order lines per hour per port. One worker can typically handle picking and packing from two ports, providing a scalable solution without increasing labor costs.
Technical Specifications
What is the size of a bin?
Bins have inside dimensions of 16 × 24 × 12 inches (403 × 603 × 312 mm), a storage volume of 2.67 cubic feet (75.5 liters), and a load limit of 30 kg (66 lbs). They can store 1, 2, 4, 8, or 16 SKUs per bin.
What is the bin capacity?
A bin can hold up to 100 t-shirts, 200 iPhones, or 5 shoe boxes.​
How many SKUs can I fit in a bin?
Pio bins can store 1, 2, 4, 8, or 16 SKUs per bin.
Can you fit more than one SKU in a bin?
Yes, you can store 1, 2, 4, 8, or 16 SKUs per bin.
How many robots do we need?
Typically, we suggest 3 robots per port, which generally provides 130 bin presentations per hour for pick-and-pack operations. This means one worker can pick and pack approximately 1,000 order lines in an 8-hour shift. During busy periods, the workday can be extended to pick more from the same port.
How many bins do we need?
Calculating the right number of bins for your business involves both science and art. One approach is to estimate your current storage space and assume a 75-90% reduction in required footprint. This reduced footprint can help you determine the number of bins needed. You can start with a smaller Pio setup and expand as needed.
How long does it take to dig a bin from the bottom?
When manually requesting a bin without preparation time, retrieval time averages 25 seconds across Pio systems. In the worst case, for a bin at the bottom of a full-height stack, wait time is 3 minutes and 36 seconds.
Installation
How long does installation take?
For a standard P100 system, installation and commissioning take approximately five days. For custom systems, duration is available upon request.
How long from signed contract until installation?
Delivery of a Pio system typically takes around 10 weeks in Europe, up to 16 weeks on the East Coast of the U.S., and up to 20 weeks on the West Coast and in Japan.
What permits are required?
Required permits depend on location and may include fire protection, structural, and electrical permits.
System Operations
What happens if the power goes down?
A backup power supply enables a controlled shutdown in case of a power outage, preventing data loss. Once power returns, the system can be restarted and resume operations.
What happens if the internet goes down?
Pio software requires a stable internet connection for communication with cloud-based software. If the internet connection is lost, Pio and other fulfillment-related software, such as ecommerce, ERP, and shipping platforms, will be unavailable.
How much power does the system use?
Each robot uses approximately 100 watts per operating hour. Ten robots consume about as much energy as a single vacuum cleaner (1,000 watts).
Does Pio have the ability to track expiration dates?
Pio does not currently track expiration dates, but the FIFO (first in, first out) picking algorithm can be set to prioritize older stock. An inventory report with "days on shelf" and "date added" can help monitor stock age.
Can Pio track batches or lots?
Pio does not support tracking batch or expiration dates by default, but this can be managed by your WMS with License Plate Numbers (LPNs) added to the batch date.
Do we need a WMS if we use Pio?
Pio can operate without a WMS, and many customers use Pio with inventory and order management features in their ERP or ecommerce platform. However, Pio also integrates well with a WMS if required.
Inventory and Order Management
What is the difference between order lines and bin presentations?
At Pio, an order line is defined as each SKU in an order. For example, if a customer orders 4 SKUs, that equates to 4 order lines. Occasionally, more bin presentations are required than the number of order lines due to large order volumes of certain SKUs. For instance, if 10 units of a SKU are required, the first bin might have only 7 units, necessitating another bin for the remaining 3 units.
How do we restock the Pio system?
Use the Storing flow in the Pio app to restock the grid. Choose the appropriate compartment size, add items, and confirm when the compartment is full. A new compartment will be presented immediately.
Should we keep everything in the grid?
To simplify inventory management, aim to store as much as possible within the grid. For items that don’t fit, Pio supports shelf locations and batch picking, enabling seamless order consolidation from shelves and bins.
How does Pio handle large B2B orders?
B2B orders are processed as regular orders in Pio. By adding a tag and setting a prioritization rule, B2B orders can be scheduled for specific time slots, allowing priority to be given to customer orders.
How do we handle items that do not fit in the grid?
For items that don’t fit in bins, Pio supports shelf locations and batch picking, with a consolidation flow to merge orders from shelves and bins.
How does inbound/putaway work?
Use the Storing flow in the Pio app for putaway. Select a bin layout, add items to compartments, and confirm. The Purchase Order feature can also be used for put-away, updating the order as items are received.
How does Pio handle returns?
Return orders are processed in your ERP, WMS, or ecommerce platform and stored in Pio using the standard storing flow. Returned items can be placed in small compartments to prioritize them for picking, or stored with existing SKUs for better fill rates.
How can we make sure that the fill rate of the system is optimized and that one SKU is not spread out across many locations?
The Pio picking algorithm optimizes fill rates by consolidating compartments with a few items. For optimal distribution and access, spreading SKUs across multiple compartments is beneficial, though poor fill rates can be addressed using the inventory report.
Safety and Compliance
Can I store lithium ion batteries or other hazardous materials in Pio?
Lithium ion batteries or other hazardous materials should be stored according to safety guidelines and assessed for risk. A risk assessment with supplier documentation can determine if additional safety measures are necessary.
Is there a risk of injury at the ports?
All AutoStore modules (which are also used by Pio) meet global safety standards, making port operation safe and ergonomically beneficial compared to manual warehousing tasks.
Integrations
Can I have more than one CMS connected to Pio?
Yes, multiple external integrations can be active simultaneously.
Do you have an open API?
Yes, a public integration API is available at https://pio.dev.
How are the shipping labels printed?
Pio integrates with shipping management software to automate label printing when Pick & Pack completes. A selection of pre-integrated shipping software is available, and additional integrations are supported via the API.
Can we use other forms of automation in sync with Pio, e.g., a packaging system?
Yes, it is possible to set up larger systems of physical automation to sync with Pio.
Will Pio integrate with my WMS? ERP? CMS? Ecommerce platform?
Pio offers a selection of pre-integrated WMS/ERPs, and additional integrations can be made through the open API.
Pricing
How much does a Pio cost?
Pio pricing depends on how your product is configured. There is an upfront cost for the hardware and installation, along with a monthly subscription that covers the Pio app, robots, and ports.

The Service Level Agreement (SLA) is excluded from the monthly subscription.

You can explore different product configurations and get an estimated price here:  https://pio.com/pick-your-pio
Are there different pricing plans for the app and services?
We’re committed to simplicity and transparency. With one straightforward pricing plan, we make it easy for you to get the most out of our services and apps.
What’s included as part of the one-time fee?
The hardware purchase price includes the aluminum grid, bins, service tower, and walls. An additional fee will be quoted based on your warehouse location and covers delivery and implementation services, local building and fire permits, shipping, additional scope items, installation and build, and mandatory training.
Will there be any additional costs not covered by the one-time fee?

Shipping and customs costs are not shown online. Additionally, you’ll need to source and purchase any peripheral equipment, such as iPads, scanners, and printers, as these items are typically already owned by customers. A workstation or desk for storing and fulfillment operations is also not included.

Depending on your warehouse, there may be additional costs for any building modifications required by your insurance company or local regulations. We can offer initial guidance, but you are responsible for building modifications and any necessary permits. Many customers work with an experienced service provider for this process, and Pio is building a network of partners to assist where needed.

Lastly, if you’re connecting to Pio through the API, you’ll be responsible for setting up the integration. We’re building a network of integration partners who can assist—just reach out for more information.

What’s included in the monthly fee?
The monthly fee covers hardware rental (robots, ports, chargers, service trolley, and controller), the Pio software, and our Pio Essentials service and support package.
Can I add more robots to the system to cover peak periods?
Yes, you can order booster bots for a minimum of 3 months. If you need a more permanent increase in throughput, you can keep them as long as needed. We’ll charge the same monthly rate per additional robot, plus a one-time fee for shipping and administration.

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