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USER MANUAL PALLET LOADER V2

1. A Current Alarma 26 09 2007 17 01 59 22345 START STOP 22005 DESI cliens 2 012 01 AlarmText Inte oader fend oe 012 01 amp larmText Tap 12 01 AlarmText Tray feed 6 mem 012 01 AlarmText 3 2 012 01 amp larmText Top 2 S 6 012 01 AlarmText 000 00 Acknowledgeall nternal B amp R touchpanel system error 000 01 Bypassedal lnternal B amp R touchpanel system error 000 02 Systemlnt Internal B amp R touchpanel system error 000 03 Alarm Printout Restated Internal B amp R touchpanel system error 000 04 Printer Not Ready SC Internal B amp R touchpanel system error 000 05 CannotReadAlarmData Internal B amp R touchpanel system error 000 06 Printer Buffer Overflow Internal B amp R touchpanel system error 000 Battery Discharged Battery exhausted Contact Prinzen Do not turn off main power o UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 149 of 167 TROUBLE SHOOTING GUIDE rnnzen Q NO 1 First check and solve if needed the cause of the emergency stop 2 Make sure no persons are in danger before restarting the system 3 Restart the system by pulling out the emergency stop button s and then push the reset button on the panel to reset the em
2. d Qus Poesie Pes Yee Fab a dus 66 OPERATING TOP RAT D N S TEE 67 OPERATING SCREE S 68 KEYPAD M M m dau I 68 IR RTT nee eux np enna ea neat ee 69 TOBCHPANBLUOEORS lea mta te mV note oro M ap en hae cae ein leon nbi 70 BICI de s NOT OR 71 12 EENE CETERO 74 PRODUCTION MBNIL Sine dis whee Ron o VES 75 PRODUCTION SCREEN LOADER qe UTUEEUTEUUUUETTT 75 MANUAL MENU H 76 TOP TRAY DENBSTER MANUAI SCREEN 2 1 552 013 siden 9225 0091 a a e rero bab vai Es
3. 91 CHOOSE RECIPE e ddnm U UUUUUTPPUUUUTTUDEUUUUST 91 COPY RBOCIPE SCREEN DLL c 91 RR TT X M P HP H RN 92 STARTING PRODUCTION 100 PALLETANDYDIVIDERS SUPP Yu secant ne Sasa a ne hM ann ea E ER dc ed eo RR n pa ea dd 102 EUIS DEOR E2082 P RR 103 SES QC EN Ue DO SIMI NIRE T 104 TIES YS Us se m A 104 EMPTY THE SYSTEM UU 105 SELECT ANOTHER gei BC I D LM 106 9 CCE ANIN o 107 GENERAL merae a a E a 108 SAFETY REGULATIONS 2 LUE 108 CLEANING UTENSILS AND DETERGENTS 0 4 4 lt 108 RECOMMENDED CLEANING
4. 109 GENERAL CLEANING 109 CLEANING INTERVAL a REFER EIC RES AR PUE EV EFE 109 hislzizelsisdcm 109 CLEANING COMPONENTS 110 CLEANING PHOTO 5 25 digan ple vex RR MEE 110 CLEANING SAFETY SCREENS SE SE 110 CLEANING INSTRUCTIONS EEEENEERER NR IEEXERPRPEERERIAREIE 111 111 CRRRTRRRRRRRRRIRCR
5. ia 28 2 QUICK REFERENCE 222202022402 EEUU RUNE REDUCE aN 31 RI TUTUP E 32 GENERAU 32 3 MACHINE DESCRIPTION 37 SAFETY 65 38 MACHINE DESCRIPTION rrr 39 PALLET LOADER REPETIT 39 INTENDED Eg gcc TENOR 41 TECHNICAL ssh ree av tsa eas le Si EEE eA waco ace Oe E 42 SUM e Idem 43 PALLET STOCK 43 44 INFEED CONVE 45 47 STACKER CONVEYOR 48
6. 13 SYMBOLS qm T 14 ADDRESS MES 14 EC DECLARATION OF CONFORMITY FOR MACHINERY 1 15 1 SAFETY 17 EIN 572 MRRNRERRENNEUUT 18 SAFETY REGULATIONS 2 E PEEFenERESNVRR E PRaEET RauR Fax ERUSEVA VE DEREGEERFUtrA E M RACR E NES 19 SAFETY PROVISIONS SE 21 EMERGENCY STOP BUTTON 21 LOCKABLE DOOR TIT T Tm tine ay tT Teer eT tre irr Tete 22 PRC COVER naina u 22 SEMEL E Mae arse ET scars teases RR TERR MK 23 MUTING SAFETY SCREEN NRTTRCTRTRERRRRRETTER 24 SAFETY A 24 25 FTI PRR TNN ON 26 ATIR S PPLY SWITCH 26 SAFETY INSPECTION PROCEDURE 552 2 9 trrtru RES anu pena E pre rnsexCre e Y wreic pri reram sia 27 WARNING LABELS
7. ona ves vales 77 INBEEDIMANUATL SCREEN TTD RES 77 LOADER MANUAL SCREEN sc 78 OUTFEED MANUAL 2 S P cia po cic S E ONE vi acd Secu P OQ e QR edP T needs 80 SERVICE MENU PTT PM TU TE 81 EE 82 SERVICE INTERY AL ceo Dese cene deine Oct Ge idea oe Vaso dos Bio s Ge mesa Se diel bale ss dos eee ees 83 SOFTWARE 83 MACHINE SEMN OSM D E esr 84 PANE EAS SL a sense 88 55
8. 49 FORK AON a e ese eee ese seen 5 54 SINGER OUTEEEDCONVEYCGR aa 57 NILTTIPERXOUTEEED CONVEYORS 58 4 OPERA TION E 61 SAFETY REGULATIONS RREeRiRRBiGTRREADRRXEPERRRESSIEIRRRFPSsRRRGRRRXARIRREIGsRRRDNDARRGSRARRERZRIRDERXAX CEKRXRASAa 62 EXPLANATION OF THE 4 three rhe rne rrr 63 OPERATING PAN orea e E E E E a E E a a 63 INDICATOR IGHT h er D terete 65 HMTRNRRITHERI E O S 65 UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 5 of 167 TABLE OF CONTENTS A LENIN SIS 65 LOCAL OPERATION Re eee er er RR 66 OPERATING PANEL NEAR PAL EPT OUT EE D 0 Idea Sees sara
9. 117 ROD ENDS 117 PLAIN BEARINGS 118 CHAINS aee a a E E cco eters 118 GUIDES A rea e e E E E E E E E E e 118 REMOVING FILTER OPERATING PANEL csscccseccssccsccesccnscccssceucccusccusccusccasccasccsecasccusccaccessccusceusccusccasseesccescesseasscusceussceseeaecensceass 119 PLC BATTERY REPLACEMENT Pa led ok n iN SEERE IOE SERENE EEEE EEE EESTE 120 121 PREVENTIVE MAINTENANCE 5 6 122 DAILY PREVENTIVE MAINTENANCE ENeR Ne GERENS EEREY eSP o OVE ulla 122 WEEKLY PREVENTIVE MAINTENANCE am MON xa Dupin Sapa nena Ct lo aida RE ada ead wt a 123 MONTHLY PREVENTIVE MAINTENANCE ee EPE 126 2 YEARLY PREVENTIVE MAINTENANCE oe D MI UT ID E 129 2 YEARLY PREVENTIVE MAINTENANCE c
10. 111 6 PREVENTIVE MAINTENANCE nere nennen nnn hehehe nun he ne nu su RR Ra Rusa su s Resa suu sese sur u rsen 113 GENERAU TE T A A 114 SAFETY Pe GUE ION S PUES PIE MM PUE IDIMUI E ONEIMN ERIS SEEK FEE PUDE DONNE 114 MAINTENANCE UTENSILS rid Diss vnus FRPEDGUS PIS FREE FEE FEE Se FREE PESE 114 RECOMMENDED LUBRICANTS Pes FEY FOE S FEE FEET WE EN FUE IRI reas DU 115 GENERAL MAINTENANCE 116 AFTER 116 MAINTENANCE 5 4 66 6 117 BEARINGS 117 MOTORS AND REDUCTOR S s 22545 RR 117 GEARS RNC EE
11. 5 8 5 g Tii 5 Infeed m Loader omm Infeed Service Sensi Software debug Panelsatings Machine senings UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 69 of 167 OPERATION 5 TOUCHPANEL COLORS 012 01 amp larmText monat AN 22345 Menu START STOP 22 01 59 The background color 2 of a screen OU represents the possibility of changing the mode of units Dark gray Tray feed This color is only present on the main screen Infeed Touching a button in this screen immediately starts or stops a unit n Yellow This color is only present on the manual menu Off Touching a button in this screen immediately Afe alele sets a unit into the manual mode Light grey This color is present on all other screens Touching a button in this screen does not 012 01 AlarmText change the mode of a unit 22345 Manual menu 22 01 59 The color of the buttons 3 in the screens Ot Infeed f Loader feed except the main screen represent the feed iz operating level of the buttons White l ze When a button is white the current operating level is high enough for entering the submenu or activating the button s functionality I eck When a button is black the current operating level is too low for entering the submenu or activating the button s functionality To be able 012 01 Alarm
12. views MIB E M j zt 4 i CERA f gt i 3 Rana x 4 V e d Pe 1 8 gt 1 E 2 e lt A 2 gt gt Bo un 4 2 WI J lt m E Be L gt Ua db m 4 29 oM E N CS Sa 4 t Use The pallet loader is used to stack trays filled with eggs onto pallets Dividers are placed between the stacks Construction The Pallet loader consists of 1 Pallet stock 9 Pallet outfeed conveyor 2 Divider stock a Pallet stack position 3 Infeed conveyor b Pallet discharge position 4 Buffer conveyor 10 Electrical cabinet main 5 Stacker conveyor optional 11 Electrical cabinet fork carrier fork 6 Top tray denester optional support 7 Fork carrier 12 Operating panel 8 Fork support The layout of the Pallet loader is adaptable to the positions of the upstream and downstream equipments and the layout of the building The above picture is just an example The main electrical panel is positioned in the frame of the pallet loader The electrical parts controlling the fork carrier and fork support are positioned in the frame of the fork carrier See the electrical drawings for electrical details UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 39 of 167 MACHINE DESCRIPTION E
13. Ia Divider gripper open Divider gripper close T 7 r up Mr Venturi an venturi aff 2e venturi frame down ATTENTION Before starting manual control make sure it is safe to do so grippers cannot damage trays dividers or pallets or collide with other machine parts UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 OPERATION GRIPPERS In this screen it is possible to control the grippers of the fork support Before starting manual control make sure it is safe to do so grippers cannot damage trays dividers or pallets or collide with other machine parts Pallet gripper open close With these buttons it is possible to activate the movement of the bottom pallet grippers Divider gripper open close With these buttons it is possible to activate the movement of the top divider grippers Venturi frame up down With these buttons it is possible to control the position of the venturi frame Venturi on off With these buttons it is possible to switch the vacuum for the picking up carton dividers ON or OFF SERVO In this screen it is possible to control the fork carrier and the fork support manually Before starting manual control make sure it is safe to do so fork carrier fork support cannot push over stacks from the pallet or collide with other machine parts Horizontal With the left right arrow buttons it is possible to move the fork carrier left
14. e Step1 First check and solve if needed the cause of the emergency stop Step2 Make sure no persons are in danger before restarting the system Step3 Restart the system by pulling out the emergency stop button s and then push the blue reset button the panel to reset the emergency stop All emergency buttons of the whole line has to be pulled out and all the machines of the whole line has to be powered on Message Line emergency stop button extern pressed An external emergency stop button is pressed see external machines NOTE after a power on it will take about 30 seconds extra after the panel has been start up before the safety plc is in run and therefor the alarm can be resetted please take this time into account If after following the above instructions the alarm can still NOT be resetted contact Prinzen See also 1 Safety of this manual Page 150 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 p rinzen TROUBLE SHOOTING GUIDE 005 04 Message Line emergency stop button panel is pressed The panel emergency stop button is pressed Step1 First check and solve if needed the cause of the emergency stop Step2 Make sure no persons are in danger before restarting the system Step3 Restart the system by pulling out the emergency stop button s and then push the blue reset button the panel to reset the emergency stop All emergency buttons of the whole line has to be pulle
15. Total numberof egg gram erful eggs gram l 012 AlarmText 0l 01 amp larmText 22345 Es Loader Total Furerage History E Humb number of egg s a Data actual OPERATION PRODUCTION MENU Main screen 25 On some of the screens in the right bottom corner this home button is present After touching it the main screen appears Buttons 26 After touching one of the buttons the performance data of the particular unit appears At the moment there is only performance data of the loader present PRODUCTION SCREEN LOADER Previous 27 On some of the screens in the right bottom corner this up arrow button is present After touching it the previous screen appears Actual production data After touching this button the production data of the loader appears ACTUAL DATA Part of the information in this screen is only displayed when the optional infeed conveyor weighing unit is present in the pallet loader Pallet selection 28 Select the pallet or day from which you want to see the performance data Data history After touching this button the production data history screen appears Save 29 After touching this button the production data copied to the data history and the actual data is reset DATA HISTORY Here you can view the production data history With the arrow buttons it is possible to scroll through the
16. rinzen 012 01 AlarmText 012 01 AlarmText 22345 Home Menu START STOP 22 01 59 EMERGENCY STOP NOODS TOP NOT AUS ARRET DURGENCE OPERATION EMPTY THE SYSTEM Follow below steps to empty the system before stopping it 1 First stop the upstream systems and wait until no more stacks are supplied on the infeed conveyor of the pallet loader 2 Push the run empty button on the touchpanel 3 Wait until all stacks are placed onto the pallet and the fork carrier fork support stops at the park position 4 Wait until the pallet is discharged TIP Normally the pallet is discharged but a setting Feed pallet out in the change recipe rows screen determines this When don t feed pallet out is selected here the pallet remains on the pallet stack position 5 Wait until all movements of the system are stopped The start button turns OFF 6 Press an emergency button 7 Switch the power supply off by turning the main switch to OFF 8 Make sure the fork support is empty and switch OFF the air supply 9 Release the air through the outlet valve 10 At the end of a production day clean the pallet loader UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 105 of 167 OPERATION 5 B SELECT ANOTHER RECIPE 012 01 AlarmText 012 01 AlarmText 22345 Home Menu START STOP 01 Out Top Out Tray feed2 Infeed When you want to
17. AlarmText 22345 Inputs horizontal servo Loader 22 01 53 Homing O Controller ready PosHvyswyvitch O Running Controller status Trigger O Standatill Drive enable Triggerz Stopping 3 Metvvorklnit Hameswitch O Security ok Lag warning 3 Homing OK O Simulation 3 AxisError ror ten D Actual pos 0 D 5 Page 82 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen OPERATION 012 AlarmText 012 AlarmText 22345 Service 22 01 59 EDUC In this screen it is possible to enter a service 1234567800123 Reset action message and an interval counter for this message SERVICE INTERVAL Reset Reset Service description After touching this window a key pad appears d Enter a service action message for example Reset grease rod ends Set point Enter the service interval This is an amount of handled eggs After the entered amount of eggs has passed the service action message appears on the touchpanel Egg counter Here the amount of handled eggs since the last reset is displayed Reset When a service action message appears on the touchpanel first perform the service action and after this touch the corresponding reset button Its egg counter will be reset Reset 512 Of AlarmText A SOFTWARE MENU 012 AlarmText 22345 Software menu 22 01 59 it is possible to select a
18. After touching this button the change recipe infeed screen appears Pallet stock After touching this button the change recipe pallet stock screen appears Divider After touching this button the change recipe divider stock screen appears Outfeed After touching this button the change recipe outfeed screen appears UM PLV2 02 E 10 201 1 rinzen 012 AlarmText 012 AlarmText 22345 Change recipe infeed 22 01 59 Vertical semra Honzontal serva Position Infeedi ATTENTION Before starting manual control make sure it is safe to do so fork carrier fork support cannot push over stacks from the pallet or collide with other machine parts ATTENTION Make sure the saved value is a correct value Incorrect values result in collisions between the fork support and pallets dividers trays or machine parts resulting in damaged machine parts pallets dividers trays and eggs UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 OPERATION CHANGE RECIPE INFEED Tray type Here it is possible to select the appropriate tray type Select the same tray type in the change actual recipe outfeed menu Arrow buttons 70 With the arrow buttons it is possible to move the fork carrier and the fork support to the required position for picking up a row from the infeed conveyor Actual position 71 Here you can see the actual position of the fork carrier fork Support Pick up p
19. 6 ADJUSTMENTS Frequency Inverter 182 05 Alarm Outfeed timeout outfeed conveyor s runs too long 1 Pallet is stuck on outfeed conveyor 1 Release the stucked stack and start up again loose or broken or belt is not well adjusted 182 Alarm Outfeed timeout muting too long enabled 1 Pallet is stuck on outfeed conveyor 1 Release the stucked stack and start up again 2 Pallet has stopped in safetyscreen muting photocells 2 Move the pallet manually out Panel Manual gt Outfeed gt Feed pallet e e uU Message Outfeed pallet can be picked from last outfeed Pallet is placed on last position ready to pick up outfeeded pallet from last outfeed position conveyor Message Outfeed safetyscreen muting interrupted plc has not activated the muting safety screen Muting lamp 1 First solve if needed the cause of the safety interruption safety screen is but ae sure no persons are in danger 2 The alarm can be resetten by pressing the nearest blue reset button Muting lamp will turn green if successfully resetted If still after following the above instructions the alarm can NOT be resetted contact Prinzen See also 1 Safety of this manual Message Outfeed yellow muting lamp broken Muting lamp is broken Change muting lamp PLO MAIN 1 11H03 Message Outfeed yellow muting lamp Muting is active muting lamp is yellow PLO MAIN 1 11H03 185 04 Message Outfeed take
20. At least one other person should be present Before starting to clean maintain or inspect the machine or before remedying breakdowns follow the steps mentioned below Switch off the machine and secure it against accidental switching on Post Do not switch on warning sign on the main switch Operate the nearest emergency stop button Make sure that no components are moving Before switching on the machine you must check the following All safety devices are in place and are functioning No other persons are in underneath or above the system No tools or objects are in the system No other persons are at risk Do not use water to clean electricity cabinets and other electronic components For save and easy operation keep the area and floor around the machine clean free of oil grease or obstacles Remove superfluous fat and greasing oil after greasing duties When an extension cable is used for power supply make sure that the cable diameter in relation to the length of the cable is correct Make sure the cable is completely unrolled Manual activation of safety switches is forbidden When the safety devices are put out of operation the machine must first be switched off and secured against accidental switching on Work inside the electrical cabinet may only be undertaken by skilled personnel like Prinzen service engineers or its dealer s service engineers Always switch off the main switch before opening e
21. HOW TO USE THIS MANUAL The manual is constructed to provide a maximum amount of information with a minimum amount of searching The key to easy reference is the Table of contents Familiarize yourself with it and you won t have any trouble locating information from any area of machine WHO SHOULD USE THIS MANUAL Owner The owner contractor concern is the person that owns or hires the machine and puts this machine into production The owner must take care that the users of the system will read the manual Operator The operator is the person who operates the system as ordered by the owner The operator must read the chapters Introduction Safety Machine description Operation Cleaning Professional A professional is someone who can assess the duties appointed to him on account of his education knowledge and experience and who can assess the dangers attached thereby avoiding these dangers Maintenance engineer The maintenance engineer is the professional who is deemed qualified by the owner to perform certain duties The qualification only applies to those assigned duties The maintenance engineer must read the total manual MACHINE INFORMATION Machine type Pallet loader V2 Machine serial number Manual revision 02 October 2011 SERIAL NUMBER Each machine has a unique serial number printed on the machine tag which can be found in the electrical cabinet Note down this serial number to have it available when contact
22. Immediately call a qualified technician to repair this defective safety device TIP The safety screen does NOT switch off the infeed conveyor UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 27 of 167 SAFETY 5 rinzen WARNING LABELS The Prinzen system makes dangerous movements The system also contains dangerous parts when they contact the body The following labels are posted as a warning Understand and remember the meaning of the warning labels DANGER Keep the warning labels clean When labels become unclear replace them The flashlight label is used to warn for dangerous voltage inside a cabinet Contacting parts inside this cabinet may result in permanent personal injury or death This sign is used to warn for dangerous movements Keep a safe distance to those parts Disregarding this warning may result in permanent personal injury These signs are used to warn for the danger of limbs being pulled in Keep a safe distance to those parts Disregarding this warning may result in permanent personal injury Page 28 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 5 rinzen These signs are used to warn for crushing danger Keep a safe distance to those parts Disregarding this warning may result in permanent personal injury This sign is used to warn for dangerous movements of a lift Keep a safe distance to the lift Before entering
23. Turn the nuts clockwise for more tension and counter clockwise for less tension Tighten up the lock bolts after adjusting Make the same adjustment on both sides of the timing belt The distance between the lock bolt and the end of the conveyor 8 must be the same on both sides of the timing belt P ATTENTION A too high belt tension may result in wear on the belt pulleys and bearings Page 142 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 SPARE PARTS 8 SPARE PARTS UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 143 of 167 SPARE PARTS rinzen LIST WITH RECOMMENDED SPARE PARTS Part number Recommended Description 3107001016 Fork 5702300190 Filter mat EFMP200 6200600024 Proximity switch SME 8 K LED 24 6200700039 Valve VUVB L B42 D Q6 1C1 6201400003 Vacuum generator VN 05 H T3 PQ2 6400700001 Suction cup 8001100036 Frequency inverter V1000 8001300004 DC power supply 24V 5A 8001300017 DC power supply 5V 1A 8001500340 Battery PLC CR2477N 3V 8001600014 Sensor proximity E2A M12LS04WP B1 8001600070 Sensor through beam PD30CNT 15PMU sender 8001600071 Sensor through beam PD30CNT15PPRT receiver 8001600157 Sensor diffuse reflective PD30CNB15PP3335 8001600158 Sensor retro reflective PD30CNPO6PP3335
24. With a forklift or a hand pallet truck a stack of pallets is placed in between the bottom guides Here the pallets are picked up by the fork carrier fork support As soon as the last pallet is removed a message appears on the operating panel to supply a new stack of pallets Safety The pallet stock is positioned into the secured area of the pallet loader On all sides it is protected by fencing except the infeed side which is protected by a safety screen When the safety screen is interrupted the fork carrier fork support stops immediately DANGER Do not enter objects or body parts into the pallet stock when the system is running production ATTENTION Do not enter objects or body parts into the packer when it is running production UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 43 of 167 MACHINE DESCRIPTION oe DIVIDER STOCK Use The divider stock is used to place a pallet with dividers for automatic supply of dividers to the pallet stack positions Construction The divider stock consists of 1 Bottom guides 2 Side guides Process With a forklift or a hand pallet truck a pallet with dividers is placed in between the bottom guides Here the dividers are picked up by the fork carrier fork support As soon as the last divider is removed the fork carrier fork support places the empty pallet on the pallet stock after which a message appears on the operating panel to suppl
25. contamination of the system and the influence of this contamination on the product quality and production process and if necessary change the cleaning methods and schedules AFTER CLEANING When the cleaning duties are finished follow steps below Consult your maintenance engineer in case of questions about the condition of parts Blow dry the system the system must be absolutely dry before putting it back into operation Lubricate moving parts that have been cleaned Remove excess grease after lubrication sure all cleaning utensils are removed from the machine UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 109 of 167 LEANIN E x rinzen CLEANING COMPONENTS CLEANING PHOTO SWITCHES Clean the lenses of the photo switches 1 and the reflectors 2 with a moistened soft fluff free cloth CLEANING SAFETY SCREENS Clean the lenses of the safety screens 3 and the surface of the accompanying mirrors 4 with a moistened soft fluff free cloth Page 110 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 LEANIN p rinzen hs CLEANING INSTRUCTIONS CLEANING BELTS Clean the guides 1 the stopper 2 and the belt 3 with a plastic scraper and a moistened cloth or brush CLEANING FLOOR Clean the floor 6 underneath the loader UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 111 of 167 PREVENTIVE MAINTENANCE 6 PREVE
26. this conveyor is assumed to be empty Time infeed conveyor has to be empty When the infeed conveyor runs for the set time and no stack of trays is detected this conveyor is assumed to be empty CALIBRATE LOADCELL The alongside screen is used for calibrating a replaced load cell Follow the below instructions during calibrating a load cell 1 Make sure the infeed conveyor is empty and touch the start empty measurement button step 2 2 Enter the weight of a reference mass into the calibration weight input window step 1 3 Place the reference mass on the infeed conveyor and touch the start weight measurement button step 3 4 Now you have calibrated the load cell At the bottom of the screen the calibration factor of the load cell is displayed Here you can check if the load cell is correctly calibrated The calibration factor should be around 0 4 When this is not the case you can temporarily enter 0 427 here to be able to run the system However you need to contact the Prinzen service department immediately because the load cell is not functioning correctly Page 85 of 167 OPERATION 5 rinzen 912 01 AlarmText AA LOADER SETTINGS MENU 012 AlarmText 22345 Settings Loader 22 01 59 In this screen it is possible to view change the parameter settings of the loader Servo speeds Sop dicate General Serva positions Servo speeds After touching this button the servo speed
27. transfers these stacks to the infeed conveyor Then the above sequence is repeated When starting up the pallet loader the amount of stacks on the infeed conveyor the buffer conveyor and the stacker conveyor is not known Because of this these conveyors are switched into a start up mode See the previous page for the start up sequence Safety The buffer conveyor is not completely secured with protective covers Therefore be cautious with loosely hanging clothes and long hair do not come too close to the conveyor and do not touch it when the system is running production Never touch the belt when the system is running production CAUTION Do not enter objects or body parts into the buffer conveyor when the system is running production CAUTION Interrupting the safety screen does not stop the conveyors ATTENTION Do not enter objects or body parts into the buffer conveyor when it is running production UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 47 of 167 MACHINE DESCRIPTION st E STACKER CONVEYOR Use The optional stacker conveyor transports the supplied stacks of trays from the upstream systems to the buffer conveyor During this transport the top tray denester places a top tray on top of the stack and turns the stacks for the even layers Construction The stacker conveyor consists of 1 Transport belt 2 Drive mechanism Above the stacker con
28. 3 of these rows A divider is placed on top of a layer On this divider the next layer is placed This way the pallet loader is able to load 5 layers optionally 6 onto a pallet with 4 optionally 5 dividers in between The pallet loader is designed to stack trays filled with eggs onto pallets as described above Only use the pallet loader for the purpose it was designed for Any attempt to change or modify the pallet loader may endanger persons and the machine When the pallet loader is used for a different purpose or faulty operated Prinzen B V cannot accept responsibilities for possible damage UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 41 of 167 MACHINE DESCRIPTION 5 oe TECHNICAL SPECIFICATIONS The construction of your system may differ slightly from the descriptions in this manual Because of this the data in the technical specifications may be incorrect and or incomplete for your system For complete and exact data see the lay out drawing the electrical drawings and the machine tag of your system Specifications Maximum capacity 80 000 eggs hour Electrical data Connection voltage 400V phase N PE 50Hz Pre fuse minimum 25 Amp slow blowing Pre fuse maximum 25 Amp slow blowing Power 6kW Maximum voltage deviation 6 to 10 Electrical protection IP55 For more information see the electrical diagrams of your pallet loader Pneumatic data Air pressure in be
29. 7 152 Alarm Infeed2 timeout buffer conveyor runs too long 1 Stack is stuck on buffer conveyor 1 Release the stucked stack and start up again 2 The lowest tray of a stack is empty or not complete full 2 If lowest tray is empty or not complete full remove all stacks on the 3 Sensor on buffer conveyor is loose broken or not adjusted buffer conveyor and startup again well 3 Check sensors on buffer conveyor PLO MAIN 91FCO03 91FC08 152 07 Alarm Infeed2 timeout stack conveyor runs too long 1 Stack is stuck on stack conveyor 1 Release the stucked stack and start up again 2 The lowest tray of a stack is empty or not complete full 2 Check sensors on stack conveyor PLO MAIN 91 FC1 1 3 Sensor on stack conveyor is loose broken or not adjusted 3 If lowest tray is empty or not complete full remove all stacks on the well stack conveyor and startup again Alarm Infeed2 stack too low on buffer conveyor 1 Stack at end buffer conveyor is less then 6 trays high 1 Stacker has been emptied so a stack lower then 6 trays high can be 2 Sensor loose broken or not well placed placed on infeed stacker conveyor else if not emptied check stacker or somebody has placed a low stack for the TopTray Z Check sensors PLO MAIN 4 90FCO03 91F C03 Alarm Infeed2 5 stacks detected on infeed conveyor 1 A stack was placed by hand on infeed or buffer conveyor 1 Remove the stack and startup again 2 The lowest
30. In this screen it is possible to control the forks Le of the fork support Fark side shitt in Fark side shitt out Before starting manual control make sure it is safe to do so forks cannot damage trays dividers or pallets or collide with other machine parts tt Forks horizontal flip With these buttons it is possible to activate the tilting movement of the forks Forks in out With these buttons it is possible to activate the retracting extending movement of the forks Forks side shift in out With these buttons it is possible to activate the side shift movement of the forks Trigger ATTENTION Before starting manual control make sure it is safe to do so forks cannot damage trays dividers or pallets or collide with other machine parts Test sensors 40 Here it is possible to test the sensors in the fork support that detect the rows 41 42 43 the pallet 44 and the carton divider 45 First switch a particular sensor ON by touching the ON OFF button and after this activate the sensor manually put something in between the transmitter and receiver Its circle should turn green The sensor is switched OFF automatically after leaving this screen Page 78 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen 012 01 amp larmText 22345 Manual Gripper enturi 22 01 53 Pallet gripper open Pallet gripper clase T ETE T
31. Loader gt press till screen 4165 2 Drive broken wiring error 3 Contact Prinzen 3 Drive settings changed unlikely Safety plc gt safetyscreen pallet and dividerstock not resetted 1 First solve if needed the cause of the safety interruption check if safety screen is not interrupted but make sure no persons are in danger 2 The alarm can be resetten by pressing the nearest blue reset button Message Loader safetyscreen pallet and dividerstock If still after following the above instructions the alarm can NOT be resetted contact Prinzen 03 Message Loader safetyscreen horizontal servo movement 1 Palletstock dividerstock and outfeedpositions are NOT well 1 Check and reposition if needed pallet on palletstock dividerstock or allowed interrupted positioned outfeedpositions 2 Little safetyscreen not well positioned 2 Check and reposition if needed the safetyscreen PLO BRI 84FC03 2 If not empty the recipe settings are NOT correct stop button ones the loader will stop cyclic 2 If dividerstock is not empty change the recipe settings Panel Recipe gt Change actual recipe gt divider stock 165 05 Message Loader dividerstock 2 is empty 1 Dividerstock 2 is empty 1 Wait till loader is stopped then you can fill the dividerstock Pressing the 2 If not empty the recipe settings are NOT correct stop button ones the loader will stop cyclic Change actual recipe
32. USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen EC DECLARATION OF CONFORMITY FOR MACHINERY Concerning the machinery directives Prinzen B V Weverij 18 7122 MS AALTEN The Netherlands 1 Herewith declares that we are the manufacturer of the egg packing machine on which this declaration applies Brand Prinzen Type Pallet Loader Serial number 2 The machine is developed in compliance with the demands of the machinery directive 2006 42 EC most recent 3 machine meets the provisions of the following directives The low voltage equipment directive 2006 95 EC most recent The EMC directive 2004 108 EC most recent 4 machine is developed and constructed according the following standard NEN EN IEC 60204 1 2006 Electrical equipment of industrial machines oigned in Aalten Date 22 09 2011 signed by G J van Eerden UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 15 of 167 SAFETY 1 SAFETY UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 17 of 167 SAFETY P rinzen GENERAL Only persons meeting the following requirements are authorized to work with the system These persons should be Skilled and specifically trained for their duties Familiar with the contents of this manual Familiar with the locations of the emergency stop buttons and other safety devices 18 years old or above Familiar
33. bearings have a life time lubrication No grease is needed TIP All bearings are sealed and lubricated for life and require no lubrication MOTORS AND REDUCTORS In the Prinzen systems normally motor reductors with a lifetime lubrication are used It is not needed to change the oil TIP All motors are provided with lifetime lubrication and require no lubrication GEARS In the Prinzen systems normally plastic gears are used These gears do not need lubrication TIP All gears are made from plastic and require no lubrication ROD ENDS Hod ends need lubrication weekly Apply Teflon spray after every 40 hours running production Rod ends that are cleaned with water need to be lubricated directly after cleaning UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 117 of 167 PREVENTIVE MAINTENANCE gt 5 PLAIN BEARINGS In the Prinzen systems bronze 1 and plastic 2 plain bearings are used Both types of plain bearings need lubrication weekly Lubricate bronze plain bearings with teflon spray and plastic plain bearings with silicone spray Do this after every 40 hours running production Plain bearings that are cleaned with water need to be lubricated directly after cleaning CHAINS In the Prinzen systems different executions of chains are used transport chains 3 and drive chains 4 Transport chains are chains that transport product
34. button turns ON When the stop button is pressed the light inside the start button starts FLASHING until the complete system is stopped Stop By touching the stop button you will stop the system The system stops after finishing certain internal controlling cycles Thus it may take some time before the system is completely stopped This is the normal procedure to stop the system Pressing the button twice stops the system immediately Reset After a breakdown first the breakdown needs to be solved During a breakdown the light inside the reset button FLASHES After solving the breakdown and pressing the reset button the controller verifies if all breakdowns are solved When this is the case the light inside the reset button turns OFF Now it is possible to start the system by pressing the start button again Page 64 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 d PERATION rinzen M INDICATOR LIGHT Above the pallet loader an indicator light indicates the status of the pallet loader Green System is running Red Breakdown Yellow System is in the manual mode When more colors are flashing in turns there is more than 1 status For example Green and yellow Part of the system is running and part of the system is in the manual mode BUZZER Underneath the operating panel a buzzer is positioned to attract the operator s attention After starting the system the buzzer emits a long beep When t
35. certain unit and Ot i i necs Loader 22 the appearing screen view information about the status of the software Top Qut Tray feed eed The software screens show information about 2 the status of the software and are intended to Tene be used by experienced users of the system Tray2 like software engineers or Prinzen service engineers During contact with a Prinzen service engineer to solve a breakdown you may be asked to pass on information from these screens 012 AlarmText 012 AlarmText 22345 Software Loader 22 01 53 Subi step Sub step Sub3 step Sub4 step UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 83 of 167 OPERATION 012 AlarmText 012 AlarmText 22345 Machine Settings 22 01 59 Infeed Loader Our feed Top Qut Tray feed Infeed 2 uis Tray ATTENTION Changing machine settings may result in malfunctioning and even damage of the system ATTENTION The machine settings screens should only be used by advanced users of the system like Prinzen engineers for testing the system 012 AlarmText 012 AlarmText 22345 Settings Infeed Settings Calibrate Loadcell Factory settings T Page 84 of 167 USER MANUAL PALLET LOADER V2 5 rinzen MACHINE SETTINGS MENU Here it is possible to select a certain unit and in the appearing menus view or change the parameters that control th
36. change over from for example plastic dividers to carton divider we recommend you to first empty the system See the run empty procedure on the previous page For sure the infeed should be empty Infeed Top Tray2 Follow below steps to select a different recipe C HOODSTOP 1 Make sure the infeed and fork support are empty otop the system the light inside the start button turns OFF Go to the recipe menu oelect choose recipe Select the required recipe Make sure the correct pallets and dividers EE are present in the stocks Start the system again Change Recipe pes m MARCHE ARRET REMISE NOT AUS ARRET DURGENGE Qo UI dc a 012 01 AlarmText 012 01 AlarmText A N Choose Recipe 012 01 AlarmText 012 01 AlarmText Page 106 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 CLEANING 5 CLEANING UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 107 of 167 CLEANING 5 oe GENERAL Cleaning personnel who are familiar with the installation may only perform cleaning duties When during cleaning duties questions arise regarding the condition of the system consult your maintenance engineer SAFETY REGULATIONS Read the chapters Introduction and Safety before starting operation cleaning maintaining the system or remedying breakdowns CLEANING UTENSILS AND DETERGENTS In general we advise to have t
37. correct position without the object it has to detect The LED 4 should be OFF Turn the potentiometer 5 clockwise until the lt LED goes ON A Place the object you need to detect in front of the photo switch LED should remain ON Pd o Turn the potentiometer counter clock wise eX until the LED goes OFF A Set the potentiometer in between A and B position C Now the sensor is adjusted The LED turns ON when an object is detected PROXIMITY SWITCHES In the Prinzen systems often Omron inductive sensors are used for controlling the positioning of moving parts The distance between the tip of the sensor and the detectable parts must be 1 mm UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 135 of 167 AD TMENT 4 vis gt rinzen AIR PREPARATION Normally the Prinzen systems need an air pressure of approximately 6 bars make sure your compressed air supply is between 8 and 10 bars Adjust this air pressure with the air pressure regulator Pull the knob 1 up and turn it to change the air pressure Press the knob down to lock it again On the air pressure regulator a manual ON OFF switch 2 is positioned See alongside pictures for the ON and the OFF positions Switch the air supply OFF during maintenance activities Next to the electrical start up valve 3 an optional soft starter 4 may be present It slowly builds up the air pressure towards the air cylinders after re
38. error Alarm Loader error vertical servo axle Vertical servo drive has an error UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 3 Servo not homed and servo manually moved a long distance the reset button and then it is ready to start up again 1 Only if alarm occurred in auto mode and a new recipe has been selected check recipe settings gt recipe gt Change actual recipe gt loader Then move the servo manually or by hand out again 2 Only if alarm occurred in auto mode and the general servo settings have been changed check general software limit switch settings Panel Service gt Machine Settings gt loader gt General servo settings gt Software limit switch Then move the servo manually or by hand out again servo not homed and manually moved gt first move the servo manually or by hand out again then a new start of the loader will automatically home the servo s 4 If moved manually in servo limit switch then move the servo manually or by hand out again 5 If wiring problem hardware limit switch PLO SUB 46B06 46B08 then check wiring and or contact Prinzen If the cause is detected and solved the loader can be resetted by pressing the reset button and then it is ready to start up again Check servo by Panel Service gt Machine Settings gt List gt Loader gt press gt till screen 4164 Contact Prinzen Check servo by Panel Service gt Machine Settings
39. lii cm LK cylinder has been reduced to much 132 Alarm TopTray2 timeout proximity switch centercylinders The centercylinder has not reached its end point sensor within Check if cylinder is not mechanical blocked or certain time end sensor PLO TT2485B10 85B14 is broken or loose or cylinder has been reduced to much 132 Alarm TopTray2 timeout proximity switch rotate cylinder The rotatecylinder has not reached its end point sensor within a Check if cylinder is not mechanical blocked or certain time end sensor PLO TT2 85B03 85B07 is broken or loose or cylinder has been reduced to much 132 10 Alarm TopTray2 stack too low 1 Stack in TopTray is less then 6 trays high 1 Stacker has been emptied so a stack lower then 6 trays high can be Se loose broken or not well placed placed on infeed stacker conveyor else if not emptied check stacker or somebody has placed a low stack for the TopTray 2 Check sensors PLO TT2 83FC03 and 83FCO7 1 Lu eee ee No empty trays or only a few trays present in denester Fill denester with empty trays PLO TT1 84FC03 aad 125 00 Message TopTray1 denester almost empty a If still after following the above instructions the alarm can still NOT be 135 00 Message TopTray2 denester almost empty 142 Alarm Infeed mode timeout end auto Stop button has been pressed ones but could not finish its stop Check for other alarms
40. manometer Valve broken Valve Use if the situation makes it possible without danger the manual control to test the cylinder Panel Manual gt Loader gt Forks or Gripper Venturi or Servo 162 35 Alarm Loader If something is picked manually pallet Manually something is picked and not replaced removed out of Replace Remove loader head manually Panel Manual gt Loader gt Forks divider row then it should be placed back or removed out head again Reason is that manually it is not clear if for example a or Gripper Venturi or Servo of head row is present on the forks or that only the forks are out no sensor present who detects a row on head 162 36 Alarm Loader trigger touch pallet active but not within The triggertouch sensor has been interrupted to early and not 1 Check the trigger sensors PLO BRI 85FCO06 85FC14 The trigger outfeedposition placezone within the first layer zone This can happen if sensors has to be put on to activate them this can be done in the manual 1 something has interrupted the trigger touch sensor or itis loader screen Panel Manual gt Loader gt Forks we positioned loose or broken 2 Check the layer zones Panel Service gt Machine Settings gt Loader 2 the first layer zone has been changed unlikely Alarm Loader wrong machine settings T or more machine settings are not correct not within zone Check machine settings Panel Service gt Machine Settings gt L
41. of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 PREVENTIVE MAINTENANCE rinzen 1 YEARLY PREVENTIVE MAINTENANCE Interval hours Yearly Maintenance Check the filter inside the air regulator for contamination and clean or replace it if necessary Check outfeed conveyors drive chains for wear Apply Teflon spray on the outfeed conveyors drive chains Check all bearings for wear Check complete system for loose parts bolts nuts etc 7 Page 129 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 PREVENTIVE MAINTENANCE 2 YEARLY PREVENTIVE MAINTENANCE 2 Yearly Maintenance Interval hours h 60 Replace the touchpanel internal battery 4800 TIP When the internal battery of the PLC is empty the system will malfunction and needs to be re tuned by a specialist from Prinzen TIP Although the battery has a lifetime of approximately 5 years Prinzen advises to replace the battery during a two yearly maintenance Page 130 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 ADJUSTMENTS 7 ADJUSTMENTS UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 131 of 167 ADJUSTMENTS GENERAL Only professionals who are familiar with the installation and its operation may perform adjustments In case of difficult or special adjustments consult the Service Department of Prinzen SAFETY REGULATIONS Bef
42. on end of cylinder cause For mechanical blockage and solve if needed the blockage Mechanical Blockage Reedcontact sensor on end of cylinder PLO BRI 83B10 14 if well Reedcontact end sensor s not well positioned loose or broken positioned loose or both broken No air pressure Air pressure see manometer Valve broken Valve Use if the situation makes it possible without danger the manual control to test the cylinder Panel Manual gt Loader gt Forks or Gripper Venturi or Servo 162 42 Alarm Loader servo direction not good put machine totally Hardware wiring not placed or loose Check wiring off and start up again EEE EEE UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 161 of 167 TROUBLE SHOOTING GUIDE p rnnzen 165 Message Loader lag horizontal servo Servo runs with a lag means it can not follow its calculated 1 Check machine for mechanical blockage position cause 2 Check servo by Panel Service gt Machine Settings gt List gt 1 Mechanical blockage Loader gt press till screen 4164 2 Drive broken wiring error 3 Contact Prinzen 3 Drive settings changed unlikely 165 01 Message Loader lag vertical servo Servo runs with a lag means it can not follow its calculated 1 Check machine for mechanical blockage position cause 2 Check servo by Panel Service gt Machine Settings gt List gt 1 Mechanical blockage
43. position by using the servo manual screen When it is safe press the start button The pallet loader starts initializing the light inside the start button turns ON Now the fork support moves upwards until the vertical home sensor turns ON Then the fork carrier moves backwards towards the pallet stock until the horizontal home sensor turns ON MARCHE ARRET REMISE Page 100 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 2011 OPERATION 9 After the pallet loader is initialized it is running and starts scanning to determine the profile of the pallet on the pallet stack position s UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 101 of 167 OPERATION 5 PALLET AND DIVIDERS SUPPLY DANGER Make sure no persons are inside the fencing of the pallet loader before you start the pallet loader DANGER Push the safety key emergency button before you go inside the pallet loader Keep the safety key in your pocket while you are inside the pallet loader CAUTION Make sure no persons are working near the supply belt or inside the pallet loader before you start up the pallet loader ATTENTION Pallets and dividers should be correctly stacked Check for properly stacked columns Follow below steps to supply pallets in the pallet stock or dividers in the divider stock 1 Amessage appears on the touchpanel when the last pallet or divider is picked from the
44. position it is possible to lock the switch with a padlock During maintenance activities switch the air supply OFF and lock it with a padlock Page 26 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 gt SAFETY SAFETY INSPECTION PROCEDURE Before starting the machine all protective covers must be in place and doors should be locked The emergency stop buttons and safety screens should be operating Trained personnel must check safety devices on a daily basis to assure proper operation Check emergency stop buttons 2 Start and stop the system Wait until the system has completely stopped and push an emergency stop button Push the start button the machine should not start Release the emergency stop button and reset the emergency circuit Repeat the above steps 2 3 and 4 for all emergency stop buttons Make sure that the machine does not start when any emergency stop button is pressed Check safety screens 6 Start and stop the system Wait until the system has completely stopped and Interrupt a safety screen Push the start button the machine should not start Reset the emergency circuit Repeat the above steps 2 3 and 4 for all safety screens Make sure that the machine does not start when a safety screen is interrupted OP Urs eke ON If the machine operates when an emergency stop button is pressed or a safety screen is interrupted this machine is not safe to operate
45. recipe 3 Touch the copy recipe button Now the settings of the source recipe are copied to the destination recipe Change the name of the new recipe in the choose recipe screen UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 91 of 167 OPERATION 012 AlarmText 012 AlarmText 22345 Change Actual Recipe 22 01 59 Infeed Loader Our feed Top Qut Tray feed Infeed 2 Tray2 ATTENTION Changing parameter settings may result in malfunctioning and even damage of the system TIP Normally the parameters in these screens are factory set and do not need to be changed 012 AlarmText 012 01 AlarmText 22345 Change actual loader recipe position 22 01 59 Infeed Divider Outteeg feed Stack 3 Pallets Qutfeed Outfeed Infeedz Stack Divider 3 4 Page 92 of 167 USER MANUAL PALLET LOADER V2 5 rinzen CHANGE RECIPE MENU Here it is possible to select a certain unit and in the appearing menus view or change the recipe settings of that unit Changed settings are immediately used by the system Top tray At the moment there is no recipe for the top tray denester Infeed After touching this button the change recipe infeed screen appears Loader After touching this button the change recipe loader menu appears Outfeed After touching this button the change recipe outfeed screen appears CHANGE LOADER RECIPE MENU Infeed
46. right as long as a button is touched One arrow is a slow movement two arrows is a faster movement Vertical With the up down arrow buttons it is possible to move the fork support up down as long as a button is touched Home servos With this button it is possible to move the loader to its initial position Keep this button touched until both the fork support vertical and the fork carrier horizontal are homed both home indication circles should be green ATTENTION Before starting manual control make sure it is safe to do so fork carrier fork support cannot push over stacks from the pallet or collide with other machine parts Page 79 of 167 OPERATION 012 AlarmText 012 AlarmText 22345 Manual Qutteed If pressed pallet will be inf eded Mote If loader moves it will stop immediatly if Es safetyscreen iz interrupted UM If pressed pallet will be outfeeded Mote If MN Feed loader moves it vill stop immediatly if Pallet out safetyscreen iz interrupted 012 AlarmText 012 AlarmText 22345 Manual Outteed 22 01 59 Exten Exten sion sionz Outfeed bh Page 80 of 167 USER MANUAL PALLET LOADER V2 5 rinzen OUTFEED MANUAL MENU Feed pallet in As long as this button is touched the outfeed conveyor supplies a pallet to the pallet stack position Keep holding the button until the pallet is stopped automatically Fee
47. settings that are used by the system to load pallets are stored in a recipe It is possible to make several different recipes for pallet divider tray types After touching this button the recipe menu appears Via this menu it is possible to choose copy or change an actual recipe Run empty 17 After touching this button first the conveyors stacker buffer and infeed start to run until all stacks are removed by the fork carrier fork support which places these stacks on the pallet Then the fork carrier fork support moves to its park position fork support up fork carrier normally above infeed conveyor Depending on the chosen recipe setting the pallet with stacks remains on the pallet stack position or it is transferred to the pallet discharge position Operator assistance Besides the alarms on the top of the screen also an operator assistance screen may pop up This may happen after scanning a pallet stack position when the operator needs to inform the controller about the presence of a divider on the stacked pallet When such a screen appears touch the arrow button 18 to view the possible information the system needs Look in the system for the status of the system and touch the applicable text and subsequently the Confirm button Confirm UM PLV2 02 E 10 2011 USER MANUAL PALLET LOADER V2 Page 73 of 167 OPERATION p rinzen ALARMS SCREEN SNNT ese es The Alarms current screen shows all prese
48. start button starts FLASHING until all these units are stopped EMERGENCY STOP Stop By touching the stop button you will stop the fork carrier fork support and the pallet outfeed conveyors They stop after finishing certain internal controlling cycles Thus it may take some time before these units are completely stopped Pressing the button twice stops the units immediately Reset After an interrupted safety screen the light inside this reset button FLASHES After pressing this reset button the controller verifies if the safety screen is no longer interrupted When this is the case the light inside the reset button turns OFF Now it is possible to start the fork carrier fork support and pallet outfeed conveyor s again by pressing the local start button PALLET OUTFEED _ DANGER Pallet outfeed Make sure nobody Is present inside the pallet When a full pallet has arrived at the end of the loader before resetting an interrupted safety RUE pallet outfeed conveyor s it should be removed by the operating personnel As soon as the pallet is lifted up with a fork lift the light inside the pallet outfeed button starts flashing First remove the pallet completely from the pallet outfeed conveyor and after this press DANGER the pallet outfeed button to confirm that the Make sure the pallet is completely removed pallet is really removed The light inside the from the pallet outfeed conveyor A next pallet
49. stops the downward movement of the fork support when it hits an obstruction Safety The fork carrier is completely secured by fencing and a safety screen which immediately stops the pallet loader when it is interrupted Make sure it is not possible to start the system when you are inside the pallet loader DANGER Make sure it is not possible to start the system when you are inside the pallet loader DANGER Make sure the safety catch is OUT before entering the pallet loader UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 53 of 167 MACHINE DESCRIPTION oe Use FORK SUPPORT The fork support is used to lift the stacks of trays the dividers and the pallets Construction fork support 1 Forks Forks flipping cylinder Forks flip sensor 4 Forks horizontal sensor 5 Forks in out cylinder 6 Forks out sensor 7 Forks in sensor 8 Forks side shift cylinder 9 Forks side shift sensors 10 Plastic divider grippers 2x 11 Plastic divider gripper cylinders 2x 12 Plastic divider gripper closed sensor 13 Pallet gripper 2x 14 Pallet gripper cylinder 2x 15 Pallet gripper closed sensor 16 Suction cups 8x 17 Venturi frame cylinder 18 Venturi frame up down sensors 19 Venturi frame touch sensor 20 Scan row 1 touch sensor place row 21 Scan row 2 divider pallet 22 Scanrow 3 23 Pallet placed sensor Scanning The scan sensors 20 21 and
50. system Serial number Here the serial number of the CPU is displayed During contact with a Prinzen service engineer to solve a breakdown you may be asked to pass on this serial number Temperature CPU ENV Here the temperature of the CPU Central Processing Unit and its surrounding temperature is displayed Whenever the temperature rises too high a message appears on the screen and the cabinet of the CPU needs to be cooled immediately Backup battery status The back up battery status shows the status of the battery When the battery becomes exhausted not OK appears In that case do not power off the system and contact Prinzen for the exchange procedure of the battery or see PLC battery replacement procedure Power up cycles The amount of power up cycles switching ON the system is displayed here Operation hours The time that the system was running production is displayed here USER MANUAL PALLET LOADER V2 Page 89 of 167 OPERATION 012 AlarmText 012 AlarmText 22345 Touch screen settings Screensaver 012 AlarmText 012 AlarmText 22345 Metweaork netmask node number 0 90 167 USER MANUAL PALLET LOADER V2 5 rinzen TOUCH SCREEN SETTINGS SCREEN With the contrast buttons 60 it is possible to adjust the contrast of the display With the brightness buttons 61 it is possible to adjust the brightness of the display After tou
51. transfers the full pallet to the 3 conveyor This is repeated until the pallet is detected at the end of the last conveyor A message appears on the operating panel to remove the full pallet from this conveyor With a forklift or a hand pallet truck it is possible to remove the full pallet When the pallet is not removed the next full pallet is transferred to the penultimate outfeed conveyor This is repeated until all the outfeed conveyors are full When a pallet is removed on the last conveyor and the pallet outfeed acknowledge button is pressed all other conveyors start to run to move all the pallets to the next conveyor Page 58 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 MACHINE DESCRIPTION E pides Safety Some of the conveyors are not positioned in the secured area of the pallet loader Be cautious with loosely hanging clothes and long hair do not come too close to these conveyors and do not touch them when the system is running production Do not stand or walk on the outfeed conveyors When they suddenly starts to discharge a pallet you may fall or your limbs feet may get pinched between the moving pallet and machine parts resulting in permanent injury DANGER Make sure it is not possible to start the system when you are inside the pallet loader CAUTION Interrupting the safety screen does not stop the transport conveyor CAUTION Do not enter objects or bod
52. with the national and regional regulations regarding safety These persons should have reached the minimum legal age required to perform this work These persons are NOT under influence of any drug medicine or alcoholic drink DANGER Keep children and incompetent persons away from the system The system is only to be used for the purpose it was designed for See the chapter Machine description for details Page 18 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen SAFETY REGULATIONS Do not use the system when safety devices have been removed This system may contain sharp edged parts moving parts and rotating parts When protective covers are removed sharp edges and pinch points may be exposed Use extreme caution and avoid touching or striking these areas with your hands or body because they may cause injuries Do not enter parts of your body or objects into openings in the system This may lead to serious physical injury or damage to the system It is dangerous to be in on or under the system while it is operational Loosely hanging clothing wide sleeved clothing ties chains or rings are prohibited Long hair should be worn tied back Make sure that there is sufficient light around the machine Do not touch or come near moving or rotating parts Physical contact with these parts is dangerous Do not stand or walk on any of the system parts Do not work alone on the system
53. 0 Silicone spray See below table for alternative lubricants and their manufacturers On the websites of the manufacturers you can find a local dealer for your desired lubricant Component Chains Rod ends Guides Bronze plain bearings Plastic guides Plastic plain bearings Lubricant Fin Food Lube Supplied in Aerosol Fin Lube TF Aerosol TFO89 PTFE spray Aerosol www interflon com Interflon Food grade www griffon nl Griffon Kl beroil 4NH1 4 220N Aerosol Kl beroil CM 1 220 Aerosol www klueber com Kl ber Cassida PL Cassida FL5 Aerosol Gleitmo 985 HR260 Silicone spray Aerosol Aerosol www fuchs com www griffon nl Fuchs Griffon UNISILKON M 2000 Aerosol www klueber com Kl ber Cassida Silicone fluid spray Aerosol Stabylan SI 210 ATTENTION When you want to use different types of lubricants than the lubricants used by Prinzen make sure that these lubricants do not form a harmful product when contacting the lubricants used by Prinzen Aerosol www fuchs com Fuchs NOTE Use H1 classified lubricants These lubricants are approved to use in the food processing industry NOTE Residues of lubricant must be discharged as chemical waste TIP UM PLV2 02 E 10 201 1 Prinzen uses Interflon Fin Food Lube Teflon spray and Griffon HR260 Silicone spray USER MANUA
54. 01 1 rinzen 012 01 AlarmText pomme AN 22345 Change recipe outteed 22 01 53 i Pn Calculate position outteed 1 Row pozitionz outteed 7 Rou positions outteed Don t teed pallet out at emptying line ATTENTION Before starting manual control make sure it is safe to do so fork carrier fork support cannot push over stacks from the pallet or collide with other machine parts ATTENTION Make sure the saved value is a correct value Incorrect values result in collisions between the fork support and pallets dividers trays or machine parts resulting in damaged machine parts pallets dividers trays and eggs UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 OPERATION CHANGE RECIPE ROWS Arrow buttons 110 With the arrow buttons it is possible to move the fork carrier and the fork support to the required position for placing the rows on the pallet or the divider Actual position 111 Here you can see the actual position of the fork carrier fork Support Row position 1 2 and 3 outfeed Here you can see the positions of 3 rows on the pallet or the divider With the up down arrow buitons it is possible to change the value Teach row 1 row 2 row 3 When the fork carrier fork support is on the correct position for placing a particular row row 1 row 2 or row 3 on the pallet or divider it is possible to save this hori
55. 1 1 rinzen 012 01 AlarmText 012 01 AlarmText 22345 Change recipe divider stock 22 01 59 vertical semra Horizantal serra 1 Pallet Off Pick last divider pe stock 1 2 Pick pallet divider Teach stock 1 E 2 Height after picking 1234 Time standing still after carton 0 1mm picking carton divider 0 015 t veal ATTENTION Before starting manual control make sure it is safe to do so fork carrier fork support cannot push over stacks from the pallet or collide with other machine parts ATTENTION Make sure the saved value is a correct value Incorrect values result in collisions between the fork support and pallets dividers trays or machine parts resulting in damaged machine parts pallets dividers trays and eggs UM PLV2 02 E 10 2011 USER MANUAL PALLET LOADER V2 OPERATION CHANGE RECIPE DIVIDER STOCK Divider type Here it is possible to select the appropriate divider type Pallet type Here it is possible to select the appropriate pallet type Arrow buttons 90 With the arrow buttons it is possible to move the fork carrier and the fork support to the required position for picking up dividers from the divider stock Actual position 91 Here you can see the actual position of the fork carrier fork support Pick last divider stock 1 Here you can see the pick up parameters for pickin
56. 2 a 122 Alarm TopTray mode timeout end auto Stop button has been pressed ones but could not finish its stop k for other alarms or messages sequence k machine for mechanical blockage resetted contact Prinzen 122 01 Alarm TopTray safety Machine safety is activated for example safety screen is or has Step1 First solve if needed the cause of the safety interruption for example been interrupted or door is or has been opened etc See also 1 Safety of this manual check if safety screen is not interrupted or the door is closed but make sure no persons are in danger Step2 The alarm can be resetten by pressing the nearest blue reset button 122 02 Alarm TopTray frequency controller There is a problem with the denester gripper frequency inverter Check the message on the frequency inverter PLO TTI 44U03 and read the manual of the frequency inverter for more details See also 6 ADJUSTMENTS Frequency Inverter 122 05 Alarm TopTray maximum retries denester reached Bad trays or no trays present or denester mechanically not correct Check the trays or fill the denester with trays if its empty or adjust the adjusted denester mechanically note press emergency stop and put power off by adjusting the denester M bl ie ee M long too heavy or has been stuck gripper runs heavy or stuck try to find out why 122 07 Alarm TopTray timeout denester tray proximity sw
57. 22 are scanning the pallet stack positions to determine where to start stacking Process placing pallet The fork carrier moves the fork support above the pallet stock Above the pallet stock it moves down first fast until the scan pallet sensor 21 detects a pallet From this position it moves a fixed distance down The pallet grippers 13 close to pick up the pallet after which the fork carrier moves the fork support above the pallet stack position Here the fork support moves a fixed distance down to place the pallet on the pallet stack position When the pallet hits the ground before the fork support has reached its bottom position the pallet is lifted up and the pallet placed sensor 23 immediately stops the fork support movement Process pallet stacking The fork carrier moves the fork support with retracted forks to the infeed conveyor First the forks are inserting underneath a row of stacks and then the forks are tilting backwards After this the fork carrier moves the fork support to the pallet stack position where the touch sensor 20 detects the exact height of the pallet or divider Page 54 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 MACHINE DESCRIPTION After this it moves a fixed distance down to place the row of stacks on the pallet or divider This sequence is repeated for the 2 and 3 row After placing the 3 row on the pallet or divider the fork support will p
58. 5 Depending on the execution of the total system the pallet loader has its own operating panel or it is controlled by the operating panel of the speedpack Process The operator has to supply a stack of pallets and a stack of dividers and has to remove the stacked pallets While doing so the pallet loader is able to continue operating The pallet loader automatically places pallets on the pallet stack positions Stacks with trays enter the pallet loader on the infeed conveyors The fork carrier fork support picks up 4 stacks from the supply belt and places them on the pallet on one of the pallet stack positions As soon as a complete layer is placed on a pallet it also places a divider on top of this complete layer As soon as a pallet is completely loaded it is automatically discharged from the pallet loader after which the next pallet is positioned on the pallet stack position by the fork carrier fork support Security The security of the system is created through a balance between safety and workability An optimal workable situation is created for the operating personnel but safety was kept in mind Dangerous movements of the system are mostly protected with protective covers fencing or safety screens but there are exceptions On a lot of places in the system it is possible to sustain injuries The conveyors to supply stack of trays and to remove the stacked pallets are not completely secured When the safety screen is int
59. A VA ue e E A v 142 TRANSPORT CONVEYOR TIMING BELT TENSION trette ttost toset 142 8 SPARE 5 143 LIST WITH RECOMMENDED 5 4 145 9 TROUBLE SHOOTING GUIDE 147 Ciim 148 SAEBTY HEGULEATIONS 148 HARDWARE TROUBLE 149 UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2
60. ANUAL PALLET LOADER V2 Page 155 of 167 TROUBLE SHOOTING GUIDE p rnnzen 155 Message infeed2 weigh calibration factor not within zone The loadcells on the infeedconveyor are not yet correctly Goto Panel Machine Settings gt press infeed or infeed2 gt press calibrated gt check calibration factor 0 427 162 Alarm Loader mode timeout end auto Stop button has been pressed ones but could not finish its stop Check for other alarms or messages sequence Check machine for mechanical blockage Alarm Loader safety Machine safety is activated for example safety screen is orhas 1 First solve if needed the cause of the safety interruption for example been interrupted or door is or has been opened etc A if Aa screen is not interrupted or the door is closed but make sure Alarm Loader horizontal servo not on right position 2 mechanical blockage Loader gt press till screen 4165 no persons are in danger 2 The alarm can be resetten by pressing the nearest blue reset button IM Alarm Loader vertical servo not on right position 3 servo has an error 162 07 Alarm Loader horizontal servo runs too long Loader speed is set to low Check if speed has not been changed on the Panel Service gt Machine Mechanical blockage Settings gt Loader gt Speeds Check machine for mechanical blockage Mechanical blockage Machine Settings gt Loader gt Speeds Check machine for mechani
61. CREENS Touchpanel After switching the power supply ON first the start up screen appears this take around 90 seconds Then it takes another 30 seconds to start up the safety PLC Because of this wait at least 2 minutes after switching ON the system before trying to run it See page 25 for more information about the safety PLC Touch the arrow button on the start up screen to go to the main screen On the main screen colored buttons represent the status of the units When the system is running production all these buttons should be light green See page 72 for more information about the main screen 23 02 2008 17 00 012 01 AlarmText p m 012 01 AlarmText Inzen 22345 Menu START STOP 22 01 58 Out Palletloader Out Tray feed Yoo 2 Top 2 Ott M 2 fo Ales Sa rar ENEMIES A OUR T NT See page 68 for more information about using the menu s and screens to operate the system Alarms and messages Alarms and messages are displayed on the touchpanel including a code Use this code to find the alarm or message and its corresponding cause and action to solve the error in the trouble shooting guide OPERATION Running production 1 Supply pallets and dividers to the pallet stock and the divider stock Switch the main power switch ON Wait until the start up screen appears approximately 90 seconds Touch the arrow button on the sta
62. IS DIFFUSE 135 PROXIMITY SWITCHES NT e ee 135 AIR PREPARATION 136 E er AN NID EI 136 CYLINDER AIR CUSHIONING 136 VALVES eea caters ign tn re cs ot tpn cca eno acd ei gn ccs acne ect se paca E 137 137 138 POWER SUPPLIES ena TNT RR RE 139 OPERATION ADJUSTMENTS NS CMS ES ERA TS 140 POBRE POSITIONS Pe Re Re Ce UM C ME MEE M M MR E 140 PAENISXNUSSEESMRRRNREREPCEKP K 141 TRANSPORT BELT TENSION 141 TIMING BELT TENSION FORK SUPPORT 141 TIMING BELT TENSION FORK AVR EFE RE VET PS LPSE Ve tud i Va YE Ee Vete d VA E
63. L PALLET LOADER V2 Page 115 of 167 PREVENTIVE MAINTENANCE 5 rnzen GENERAL MAINTENANCE PROCEDURE Before actually starting to maintain the system first follow below steps See to it that all eggs are removed by letting the machine run empty Switch off the system and secure it against accidental switching on Perform the maintenance Check the condition of the system during maintenance Perform the maintenance according the advices and intervals as described in the Preventive maintenance instructions further on in this chapter TIP The maintenance advices and intervals described in this manual are general For your specific products and production process the maintenance schedule may need alteration During the first production months observe the performance of the system and the influence of the maintenance and if necessary change the maintenance methods and schedules AFTER MAINTENANCE When the maintenance duties are finished ensure the following A All fasteners are secure All safety covers are in place and safety doors are closed All tools are removed from the system Excess lubricant is removed The system is tested before starting production Page 116 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 PREVENTIVE MAINTENANCE MAINTENANCE COMPONENTS BEARINGS In the Prinzen systems normally bearings without a grease nipple are used These
64. LO BRI 82B10 14 if well Reedcontact end sensor s not well positioned loose or broken positioned loose or both broken No air pressure Air pressure see manometer Valve broken Valve Use if the situation makes it possible without danger the manual control to test the cylinder Panel Manual gt Loader gt Forks or Gripper Venturi or Servo 162 33 Alarm Loader timeout reedcontact forksideshift cylinder Timeout gt movement of cylinder takes to long detected by Check sensor s on end of cylinder cause For mechanical blockage and solve if needed the blockage Mechanical Blockage Reedcontact sensor on end of cylinder PLO BRI 83B03 07 if well Reedcontact end sensor s not well positioned loose or broken positioned loose or both broken No air pressure Air pressure see manometer Valve broken Valve Use if the situation makes it possible without danger the manual control to test the cylinder Panel Manual gt Loader gt Forks or Gripper Venturi or Servo 162 34 Alarm Loader timeout reedcontact forkflip cylinder Timeout gt movement of cylinder takes to long detected by Check sensor s on end of cylinder cause For mechanical blockage and solve if needed the blockage Mechanical Blockage Reedcontact sensor on end of cylinder PLO BRI 82B03 07 if well Reedcontact end sensor s not well positioned loose or broken positioned loose or both broken No air pressure Air pressure see
65. NTIVE MAINTENANCE UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 113 of 167 PREVENTIVE MAINTENANCE 5 rnzen GENERAL Only professionals who are familiar with the installation and its operation may perform maintenance repairs and replacement of defective or worn out parts In case of difficult or special repairs consult the Service Department of Prinzen Inspections must be carried out before during and after operation of the machine Mechanical flaws such as loose bolts and ball bearings must be repaired upon discovery The operator is responsible for noticing and locating abnormal noises and other unusual signs indicating flaws If the operator cannot locate the flaw he must stop the installation and inform his superior Take preventive actions against vermin as they may cause failures to the electrical cables and such SAFETY REGULATIONS Before starting operation cleaning maintaining the system or before remedying breakdowns first read the chapters Introduction and Safety MAINTENANCE UTENSILS In general we advise to have the following tools available for preventive maintenance of the Prinzen systems Padlock Lubricants Set of Allen keys Set of wrenches Set of screwdrivers Page 114 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen RECOMMENDED LUBRICANTS PREVENTIVE MAINTENANCE Prinzen uses Interflon Fin Food Lube Teflon spray and Griffon HR26
66. OADER V2 UM PLV2 02 E 10 201 1 PREVENTIVE MAINTENANCE Monthly Maintenance Interval hours Check the belt tension of all conveyors Check the electrical wiring for damages Check the air hoses for damages Clean forks front rear guides with a solvent and a soft cloth Apply Teflon spray on the guides Do not spray direct on the guides but use a cloth to apply a film of lubricant on these guides 2x Clean fork carrier guide with a solvent and a soft cloth Apply Teflon spray on the guide Do not spray direct on the guide but use a cloth to apply a film of lubricant on this guide Clean fork support guides with a solvent and a soft cloth Apply Teflon spray on the guides Do not spray direct on the guides but use a cloth to apply a film of lubricant on these guides 2x UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 127 of 167 PREVENTIVE MAINTENANCE e p Monthly Maintenance Interval hours Check the fork carrier timing belt tension Check the fork carrier timing belt for wear and damages Check the fork support timing belt tension Check the fork support timing belt for wear and damages Check the wheels of the fork carrier for wear and damages 3x Check the timing belt tension of all the outfeed conveyors Check the timing belts of all outfeed conveyors for wear and damages eo a _ Page 128
67. Page of 167 INTRODUCTION INTRODUCTION UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 9 of 167 INTRODUCTION 5 rinzen CAUTION This manual must be read by or to each person before that person operates cleans repairs supervises the operation of or uses this machine in any way CAUCION Este manual debe ser leido por a cada persona antes de comenzar a operar limpiar reparar supervisar la operaci n de o utilizar esta maquina de cualquier manera ATTENTION Ce manuel doit tre lu par ou a toute personne avant qu elle ne mette en route nettoie r pare supervise le fonctionnement ou utilise cette machine de quelque mani re que ce soit Jeder der diese Maschine bedienen reinigen reparieren berwachen oder auf irgendeine Weise benutzen soll mu vorher diese Hinweise lesen oder vorgelesen bekommen ATTENTIE Een ieder die deze machine bedient reinigt repareert controleert of op enige andere wijze gebruiken zal dient vooraf deze bedieningsvoorschriften te lezen Ill presente manuale deve essere letto da o ad ogni membro del personale prima che tale persona operi pulisca ripari diriga il funzionamento o utilizzi la macchina in qualsiasi modo Page 10 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 INTRODUCTION LIABILITY Prinzen BV cannot be held responsible for any costs damage or personal injury if its system is not u
68. Text meam to use black button you have to change the 22345 Manual Loader Menu 22 01 59 operating level Gripper Fork Venturi Page 70 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 o PERATION rinzen 2 4 PASSWORD SCREEN 012 01 amp larmText CL S O 22345 Password 22 01 58 operator 2 234567892 Here you can enter your password Depending on the operating level you get the possibility to change settings of the system and or move parts of the system manually Passwords will be handed over to certain dedicated persons within your company Operator level ATTENTION It is not allowed to use the Prinzen password With the Prinzen operating level it is possible to change settings that may damage the system The level window 5 shows the current operating level For the lower operating levels the passwords are also visible After touching a visible password 6 a keypad pops up in which it is possible to change the password ATTENTION Never create the same password for 2 different operating levels After touching the password window 7 a keypad appears 8 After entering the correct password and confirming it with the V button 9 the operating level changes DANGER By working on a higher operating level you have more possibilities to control the system manually Before starting to move parts of the system you have to assure yourself
69. This is only possible with the local flashing reset button Make sure the safety screen remains interrupted when you are supplying pallets or dividers to the pallet stock or divider stock When you are completely into the system the safety screen does not detect this and other persons are able to start the system When more than one safety screen is present the controller knows which safety screen is interrupted When entering a part of the system through a safety screen only adapt the part of the system that is protected by this particular safety screen because only this area is scanned after resetting this safety screen DANGER Make sure it is not possible to start the system when you are inside the system _ DANGER Make sure nobody is present inside the pallet loader before resetting an interrupted safety screen CAUTION Interrupting the safety screen does not stop the conveyors TIP Never use the safety screen for a normal production stop This may cause start up problems UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 23 of 167 SAFETY rinzen MUTING SAFETY SCREEN Crosswise placed sensors reflectors 9 are able to overrule mute the safety screens when both sensors are interrupted at the same time This allows pallets to exit the pallet loader without activating the emergency circuit DANGER Make sure it is not p
70. UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 145 of 167 TROUBLE SHOOTING GUIDE 9 TROUBLE SHOOTING GUIDE UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 147 of 167 TROUBLE SHOOTING GENERAL Only professionals who are familiar with the installation and its operation may remedying breakdowns Immediately consult the Service Department of Prinzen if any problems occur or questions arise during remedying breakdowns SAFETY REGULATIONS Before starting operation cleaning maintaining the system or before remedying breakdowns first read the chapters Introduction and Safety Page 148 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 gt i TROUBLE SHOOTIN IDE ONES OU SHOOTING GU HARDWARE TROUBLE SHOOTING TIP For all electrical failures first check the circuit breakers motor protection switches and fuses When the system was not able to finish a certain movement within the allowed time given for this movement an alarm message appears on the upper line in the touchpanel 1 By touching the alarm button 2 the alarm screen appears 3 displaying the current alarm messages The below table shows the possible specific alarms that may pop up In the table beside the alarm the alarm code the possible cause and an action to solve the error are described When an alarm pops up use its alarm code 6 to find the corresponding cause and action in the below table
71. V LED 6 is ON and F is visible on the display Manually controlling the inverter In some situations it is easy to be able to run one of the motors by directly controlling it with its frequency inverter Follow below procedure to manually control the inverter sure the system is stopped and trays or eggs are on the part of the system that you want to control manually Set the inverter in the local controlled mode by pressing the LO RE button 7 until the LED inside this button turns ON Press the RUN button 8 to start the inverter The connected motor starts running now Press the STOP button 9 to stop the motor Set the inverter back in the remote controlled mode by pressing the LO RE button 7 until the LED inside this button turns OFF USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 ADJUSTMENTS POWER SUPPLIES The power supply switch 10 must always be set to 230 Vac even when your local power supply has a different voltage The power supplies are factory set Do not change this setting 11 73 The power supplies are factory set Do not change the power supply switch and do not change setting of the potentiometer UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 139 of 167 AD TMENT 4 vis gt rinzen OPERATION ADJUSTMENTS FORK POSITIONS The positions of the forks are individually adjustable Ad
72. a new recipe has been selected check recipe settings Panel Recipe gt Change actual recipe gt Loader Then move the servo manually or by hand out again 2 Only if alarm occurred in auto mode and the general servo settings have been changed check general software limit switch settings Panel Service gt Machine Settings gt loader gt General servo settings gt Software limit switch Then move the servo manually or by hand out of the limit switch again 3 If servo not homed and manually moved gt first move the servo manually or by hand out again then a new start of the loader will automatically home the servo s 4 lf pushed by hand in servo limit switch then move the servo manually or by hand out again b If moved manually in servo limit switch then move the servo manually or by hand out again 6 If wiring problem hardware limit switch PLO SUB 43B06 43B08 then check wiring and or contact Prinzen If the cause is detected and solved the loader can be resetted by pressing 1 Recipe servo settings not correct only if alarm occurred in auto mode and a new recipe selected or actual recept has been changed 2 General servo settings changed and or software 3 4 Moved manually in servo limit switch 5 Wiring problem hardware limit switch 10 Alarm Loader vertical servo limit switch active hardware B Alarm Loader error horizontal servo axle Horizontal servo drive has an
73. afety manager to discuss if a work permit is required for this job All safety devices in the machine and the safety indications mentioned in this manual are conditions to control the machine safely The owner and his qualified personnel are in the end the ones responsible for the safe use of the machine owner is responsible for the ability of the qualified personnel to perform its duties according to the safety measures Technical changes which influence the safety working of the machine may only be executed by the service department of Prinzen Do not change controls and or PLC programs without written permission from Prinzen because this may affect the safety of the machine Only use genuine Prinzen parts or CE certified parts for replacement Prinzen cannot be held responsible for any consequential damages to the system or other installations that were caused by technical changes unprofessional maintenance and repairs on our system which were executed by the customer Warranty becomes invalid when consequential damages to the system caused by technical changes unprofessional maintenance and repairs were executed by the customer DANGER Failure to obey legal regulations may result in permanent personal injury or death ATTENTION Failure to obey legal regulations may result in damage to the system Page 12 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen INTRODUCTION
74. ansfers it above the stack Following the centering unit closes to center the stack Now the pusher moves back and the tray drops onto the stack After this the rotating unit turns the stack 90 after which the centering unit opens up and the stack is transferred towards the pallet loader UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 49 of 167 MACHINE DESCRIPTION ts E The denester 1 consists of a Bunker b Upper grippers C Lower grippers d Tray lift e Drive mechanism f Bunker almost empty detection The pusher 2 consists of a Pusher cylinder b Pusher plate c Tray carriers d Pusher IN sensor e Pusher OUT sensor f Tray on pusher detection 2x The centering unit 3 consists of a Centering cylinders 4x b Centering unit open sensors 2x c Stack detection d Stack height 6 trays detection The rotating unit 4 consists of 1 Rotating cylinder Safety The optional top tray denester is not completely secured with protective covers Therefore be cautious with loosely hanging clothes and long hair do not come too close to the denester and do not touch it when the system is running production CAUTION Do not enter objects or body parts into the top tray denester when the system is running production CAUTION Interrupting the safety screen does not stop the top tray denester ATTENTION Do not enter obje
75. at unit Top tray At the moment there is no settings screen for the top tray denester Infeed After touching this button the infeed settings menu appears Loader After touching this button the loader settings menu appears Outfeed At the moment there is no settings screen for the outfeed INFEED SETTINGS MENU In this screen it is possible to view or change the parameter settings of the infeed Settings After touching this button the infeed settings screen appears in which it is possible to view or change the parameter settings of the infeed Calibrate load cell After touching this button the calibrate load cell screen appears in which it is possible to calibrate the load cell underneath the infeed conveyor Factory settings After touching this button the factory settings of the infeed are restored These settings are not immediately used but are used after switching the system OFF and ON again Then all changed parameter settings are lost UM PLV2 02 E 10 201 1 rinzen 012 AlarmText HO 22345 Settings Infeed 22 01 53 Delaytime start buffer conveyor after stack conveyor runs for transfer stack Delaytime start infeed conveyor after buffer conwewyar runs for tranzfer stack Delaytime row at end infeed conveyor Time stack conveyor has to be empty Time buffer conveyor has to be empty 12345 Time infeed conveyor has to be empty 012 AlarmTex
76. ation and information protected by rinze copyright of Prinzen BV Reproduction or transmission of any part of this document to third parties or the use thereof is only permitted after express written permission of Prinzen BV V n lt gt All rights rest with Prinzen BV Aalten The Netherlands S 721523 Written by Visser Machine Services UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 11 of 167 INTRODUCTION 5 rinzen GENERAL This manual contains important information concerning safety operation cleaning maintenance and breakdown remedies At all time this manual must be accessible for all personnel working with the system Keep it in a permanent place close to the system When the manual is lost or damaged order a new copy as soon as possible The user of the system should read and understand the total user manual before operating cleaning maintaining and repairing the system Never change the sequence of procedures as described in this manual SAFETY REGULATIONS Before starting operation cleaning maintaining the system or before remedying breakdowns first read this chapter and chapter Safety LEGAL REGULATIONS All safety directions stated in this manual must be observed Along with the safety regulations in this chapter the instructions of the qualified trade organization of your country must be observed to avoid accidents Before starting to repair or maintain the machine always consult your s
77. ays present in denester Fill denester with empty trays PLO TT1 84FC03 132 Alarm TopTray2 mode timeout end auto Stop button has been pressed ones but could not finish its stop Check for other alarms or messages sequence Check machine for mechanical blockage resetted contact Prinzen 132 01 TopTray2 safety Machine safety is activated for example safety screen is or has Step1 First solve if needed the cause of the safety interruption for example been interrupted or door is or has been opened etc See also 1 Safety of this manual check if safety screen is not interrupted or the door is closed but make sure no persons are in danger Step2 The alarm can be resetten by pressing the nearest blue reset button the manual of the frequency inverter for more details See also 6 ADJUSTMENTS Frequency Inverter 05 Alarm TopTray2 maximum retries denester reached Bad trays or no trays present or denester mechanically not correct Check the trays or fill the denester with trays if its empty or adjust the adjusted denester mechanically note press emergency stop and put power off by adjusting the denester ee long too heavy or has been stuck gripper runs heavy or stuck try to find out why 132 07 Alarm TopTray2 timeout denester tray proximity switch The pushercylinder of the denester of the toptray has not reached Check if cylinder is not mechanical blocked or
78. bjects or body parts into the infeed conveyor when it is running production ATTENTION Do not enter objects or body parts into the entry of the pallet loader when the system is running production Page 46 of 167 USER MANUAL PALLET LOADER V2 5 rinzen When starting up the infeed the amount of stacks on the infeed conveyor the buffer conveyor and the stacker conveyor is not known Because of this these conveyors are switched into a start up mode 1 The buffer conveyor starts to run fora certain time to determine if there are stacks on this conveyor 2 When stack is detected at the end of this conveyor it is transferred to the infeed conveyor 3 When no more stacks are detected on the buffer conveyor the stacker conveyor is started to supply 1 stack to the buffer conveyor 4 The buffer conveyor transfers this stack to the infeed conveyor 5 he above steps 3 and 4 are repeated until 4 stacks are present on the infeed conveyor 6 Now the conveyors start to run in the normal production mode see previous page It is possible to use the start up mode for manually supplying stacks to the pallet loader To do this stop the system when there are less than 4 stacks on the infeed conveyor Now manually place a stack on the buffer conveyor and start the system again The manually placed stack will be transferred to the infeed conveyor and stacked on the pallet In total not more than 4 stacks sho
79. ble to manually move the fork carrier fork support to certain positions The green windows show the actual positions of the fork carrier and fork support Calculate layers After entering the software limits for the vertical movement you can touch this button and all layer heights are automatically calculated and shown in the table ATTENTION After using the calculate button check all the calculated layers before starting to use this table The calculated values may be incorrect when your vertical servo limits are faulty USER MANUAL PALLET LOADER V2 Page 87 of 167 OPERATION 5 rinzen PANEL SETTINGS 012 01 AlarmText TES 22 01 58 In this menu the user of the system is able to change touchpanel settings using submenus Some of these submenus are not available for Language CPL Network the operator and some are also not available for the supervisor After touching this button the language screen appears In this screen it is possible to select the language of the touchpanel After touching this button the Date amp Time screen appears In this screen it is possible to set the correct date and time This screen is not available for the operator CPU After touching this button the CPU screen appears This screen shows information about the status of the control system Touch screen After touching this button the touch screen settings screen appears In this screen it is possible to adjust the c
80. button turns OFF and the pallet loader can may knock down the previous pallet causing discharge the next full pallet permanent injury to the operating personnel Page 66 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 PERATION rinzen 9 OPERATING TOP TRAY DENESTER START STOP RESET EMERGENCY STOP Emergency stop After pushing the red button the system stops immediately Only use this button in case of emergencies Start the system with the start button on the main operating panel TIP Only use the emergency stop button for real emergencies Follow the normal stop procedure to stop the system Start When the top tray denester is stopped breakdown it is possible to start this unit by pressing this start button The light inside the button turns ON When the stop button is pressed the light inside the start button starts FLASHING until this unit is stopped Stop By touching the stop button you will stop the top tray denester It stops after finishing certain internal controlling cycles Thus it may take some time before the top tray denester is completely stopped Pressing the button twice stops this unit immediately Reset After a breakdown of the top tray denester only the top tray denester stops First the breakdown needs to be solved During a breakdown the light inside this reset button FLASHES After solving the breakdown and pressing the reset button the control
81. cal blockage If still after following the above instructions the alarm can NOT be resetted contact Prinzen See also 1 Safety of this manual Horizontal servo movement has stopped to early it has not 1 Check for other alarms and or messages reached its absoluut movement position because 2 Check machine for mechanical blockage 1 another alarm occurred 3 Check servo by Panel Service gt Machine Settings gt List gt 2 mechanical blockage Loader gt press till screen 4164 3 servo has an error Vertical servo movement has stopped to early it has not reached 1 Check for other alarms and or messages its absoluut movement position because 2 Check machine for mechanical blockage 1 another alarm occurred 3 Check servo by Panel Service gt Machine Settings gt I O List gt Page 156 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 TROUBLE SHOOTING GUIDE 1 Recipe servo settings not correct only if alarm occurred in auto mode and a new recipe selected or actual recept has been changed 2 General servo settings changed 3 4 Pushed by hand in servo limit switch 5 Moved manually in servo limit switch 6 Wiring problem hardware limit switch 162 Alarm Loader horizontal servo limit switch active hardware and or software 3 Servo not homed and servo manually moved a long distance 1 Only if alarm occurred in auto mode and
82. carriers for example egg grippers Check those chains monthly for wear and tension and lubricate them every 200 hours running production with teflon spray Drive chains are chains that transfer the rotating movement of one shaft to another Normally these chains have a chain tensioner Check those chains half yearly for wear and tension and lubricate them every 1200 hours running production with teflon spray Chains that are cleaned with water need to be greased directly after cleaning GUIDES In the Prinzen systems several types of linear guides are used Lubricate plastic guides 5 weekly with silicone spray Do this after every 40 hours running production Lubricate other guides 6 monthly with teflon spray Do this after every 200 hours running production Before lubricating clean the guides with a solvent and a soft cloth Do not spray lubricant directly on the guides Use a cloth to apply a film of lubricant on the guides Guides that are cleaned with water need to be lubricated directly after cleaning Page 118 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 5 rinzen UM PLV2 02 E 10 201 1 PREVENTIVE MAINTENANCE REMOVING FILTER OPERATING PANEL In the electrical cabinets an air inlet and air outlet is present A filter is placed in front of these inlet and outlet Check these filters once a month for contamination and replace them with a clean filter if necessary F
83. ching the orientation button 62 you can calibrate the touchpanel part of the display Dots appear on the screen Touch these dots with a pointed but not sharp object 63 After touching the last dot the touchpanel part of the display is calibrated ATTENTION It is forbidden to press on the Touch Panel with sharp objects because this may also damage the Touch Panel TIP The touchpanel is calibrated in the factory Because of this normally it is not necessary to calibrate the touchpanel Screensaver Here you can enter the time that the touchpanel should be active after its latest touch After this time has elapsed the screen saver is activated NETWORK SCREEN In this screen it is possible to enter the IP addresses to be able to communicate with an external computer via an Internet connection Normally these addresses are entered by Prinzen engineers and are for information only In case it is necessary to change these addresses ask your network administrator to do this UM PLV2 02 E 10 201 1 rinzen 012 AlarmText 012 AlarmText 22345 Recept menu 22 01 59 012 AlarmText 012 AlarmText 22345 Choose Recipe 22 01 59 012 AlarmText 012 AlarmText 22345 Copy recipe source recipenumber Destination n recipenumber en OPERATION RECIPE MENU In a certain recipe all the settings for loading a part
84. correct use of this cleaning agent contact Cid lines Visit their website to find a local dealer www cidlines com Prinzen recommends this cleaning agent instead of others but we cannot verify the correct use of it and thus we cannot guarantee a good cleaning result and avoiding negative influences of it on our systems GENERAL CLEANING PROCEDURE Read the below general cleaning procedure to clean the system For specific cleaning instructions see the cleaning instructions further on in this chapter See to it that all products eggs trays are removed by letting the machine run empty Switch off the system and secure it against accidental switching on Clean the complete system with a vacuum cleaner compressed air a dry cloth and a plastic scraper Remove persisting scrap with a moistened cloth Clean the floor underneath and around the system Check the condition of the cleaned parts during cleaning CLEANING INTERVAL Remove all dirt inside and around the system after every 8 hours running production Clean the system thoroughly after every 40 hours running production and afterwards lubricate the moving parts according to the preventive maintenance instructions further on in this manual TIP The cleaning advices and cleaning intervals described in this manual are general For your specific products and production process the cleaning schedule may need alteration During the first production months observe the
85. creen In that case do not power off the system until you are going to replace the battery Battery replacement procedure 1 When the system is turned OFF turn the power ON and leave it ON for at least 10 minutes 2 After atleast 10 minutes power ON turn the power OFF Now within 10 minutes replace the old battery with the new one 3 Touch the housing or other ground connection to discharge any electrostatic charge from your body Remove the cover of the battery at the rear side of the touchpanel 4 Carefully pull the strip out to remove the old battery Do not touch the battery on 012 01 amp larmText its edges 5 Carefully place the new battery into the 22345 Cpu data Ze battery slot Make sure the strip remains underneath the new battery and sticks Temperature CPU 7 out of the slot for the next replacement 6 Close the cover and switch ON the power Temperature 250 28 Backup battery status nao 2 7 7 Check the battery status in the CPU Power Up cycles screen Make sure OK displayed Operation hours 1234 121 efe e im Used batteries must be discharged as chemical waste 3 u Page 120 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 PREVENTIVE MAINTENANCE AIR SUPPLY The air supply coming into the Prinzen systems must be clean and dry This air goes through a water separator 10 with filter that sepa
86. cts or body parts into the top tray denester when it is running production Page 50 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 MACHINE DESCRIPTION FORK CARRIER Use The fork carrier fork support transports the stacks of trays from the infeed conveyors towards the pallet stack positions Besides this it also transports the pallets and the dividers from their respective stocks towards the pallet stack position Construction horizontal movement The fork support vertical movement is attached to the fork carrier horizontal movement which runs forwards and backwards on a frame above the pallet stock divider stock infeed conveyors and both pallet stack positions The construction taking care of the horizontal movement consists of 1 Fork carrier frame Guide rail Notched belt Motor Wheels Limit switches Home sensor Crash detection screen On one side the fork carrier runs on a guide rail On the other side the fork carrier uses wheels to run on the frame The motor with an encoder and a fan drives the fork carrier via the notched belt The limit switches on the fork carrier protect it against moving too far forwards or backwards The home sensor determines the initial position of the fork carrier The crash detection screen detects obstructions on the open sides of the pallet loader and prevents collisions with the pallets in the pallet stock pallet with dividers or pallet w
87. d out and all the machines of the whole line has to be powered on NOTE after a power on it will take about 30 seconds extra after the panel has been start up before the safety plc is in run and therefor the alarm can be resetted please take this time into account If after following the above instructions the alarm can still NOT be resetted contact Prinzen See also 1 Safety of this manual 005 05 Message Line emergency stop button toptray is pressed A toptray emergency stop button is pressed Step1 First check and solve if needed the cause of the emergency stop Step2 Make sure no persons are in danger before restarting the system Step3 Restart the system by pulling out the emergency stop button s and then push the blue reset button on the panel to reset the emergency stop All emergency buttons of the whole line has to be pulled out and all the machines of the whole line has to be powered on NOTE after a power on it will take about 30 seconds extra after the panel has been start up before the safety plc is in run and therefor the alarm can be resetted please take this time into account If after following the above instructions the alarm can still NOT be resetted contact Prinzen See also 1 Safety of this manual 005 Message Line emergency stop button loader is pressed The loader emergency stop button is pressed Step1 First check and solve if needed the cause of the emergency stop Step2 Make sure no pers
88. d pallet out As long as this button is touched the outfeed conveyor removes the pallet from the pallet stack position to the end of this conveyor where it can be removed with a forklift or a hand pallet truck Keep holding the button until the pallet is stopped automatically OUTFEED MANUAL SCREEN The extension buttons and last buttons in this screen are only displayed when the multiple outfeed conveyors are present in the pallet loader Outfeed With these buttons it is possible to control the outfeed conveyor manually After touching one of the arrow buttons the conveyor moves forwards or backwards as long as a button is touched Extension With these buttons it is possible to control the extension conveyor manually After touching one of the arrow buttons the conveyor moves forwards or backwards as long as a button is touched Last With these buttons it is possible to control the last conveyor manually After touching one of the arrow buttons the conveyor moves forwards or backwards as long as a button is touched UM PLV2 02 E 10 201 1 rinzen 012 AlarmText 012 AlarmText 22345 Service Menu 22 01 59 IA list Sotware Machine Service Panel settings ATTENTION Changing parameter settings may result in malfunctioning and even damage of the system ATTENTION The service screens should only be used by advanced users of the system like Prinzen engineers for testing the sy
89. e trigger sensors PLO BRI 85FC06 85FC14 The trigger sensors has to be put on to activate them this can be done in the manual loader screen Panel Manual gt Loader gt Forks 162 24 Alarm Loader divider placed but not all rows detected By placing the divider not all rows beneath it has been detected 1 Check rows if no empty trays are present on the row 1 Empty trays detected on row Trigger sensor looking through 2 Check the trigger sensors PLO BRI 85FC06 85FC14 The trigger 2 Trigger sensors broken sensors has to be put on to activate them this can be done in the manual loader screen Panel Manual gt Loader gt Forks 162 25 Alarm Loader servo movement not allowed because little 1 Palletstock dividerstock and outfeedpositions are NOT well 1 Check and reposition if needed pallet on palletstock dividerstock or safety screen is interrupted check palletstock dividerstock positioned outfeedpositions and outfeedpositions 2 Little safetyscreen not well positioned 2 Check and reposition if needed the safetyscreen PLO BRI 84FC03 Page 158 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 p rinzen TROUBLE SHOOTING GUIDE A pallet has fallen out of head by picking or transporting it or could not be lost by placing cause 1 a bad pallet was picked 2 The middle trigger sensor is not well positioned loose or broken 1 Check the state of the pallet and also the pall
90. ead remove A carton divider has fallen out of the head by picking or 1 Check the state of the divider and also the dividersin the dividerstock manually transporting it or could not be lost by placing cause 2 Adjust venture frame or suction cups or change actual recipe Height 1 a bad divider was picked after picking carton and Time standing still Panel Recipe gt Change 2 Venturi not well positioned or to little vacuum or actual recipe gt Loader gt divider stock recipe settings not correct Height after picking carton and 3 Check the trigger sensors PLO BRI 85FC06 85FC14 The trigger Time standing still because second divider picked also sensors has to be put on to activate them this can be done in the manual 3 middle trigger sensor is not well positioned loose or loader screen Panel Manual gt Loader gt Forks broken NOTE This alarm can NOT be resetten directly because to be sure the lost pallet has been taken out of the machine and to release the machine that no pallet is placed in the head The procedure is Panel Manual gt loader gt Gripper Venturi 2 Press Open gripper but only if you are sure no pallet is in the head If a pallet is in the head move the pallet in the head manually on the palletstock Panel Manual gt Loader Servo 162 41 Alarm Loader timeout reedcontact venturi frame cylinder Timeout 2 movement of cylinder takes too long detected by Check sensor s
91. econds to start up the safety PLC Because of this wait at least 2 minutes after switching ON the system before trying to run it When the start up screen appears wait at least 30 seconds before trying to reset any alarms UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 25 of 167 SAFETY 5 rinzen AIR PREPARATION The system may be equipped with one or more air preparation units The following parts may be present in these units 10 Manual ON OFF switch 11 Air pressure regulator 12 Electrical start up valve 13 Pressure sensor 14 Slow starter With the manual ON OFF switch it is possible to switch the air supply ON or OFF Push the switch towards the regulator to switch the air supply ON Push the switch away from the regulator to switch the air supply OFF A DANGER Switch the air supply OFF before starting to perform activities on the system With the air pressure regulator it is possible to adjust the required air pressure for the system The electrical start up valve switches the air supply OFF during an emergency stop The pressure sensor is used by the controller to verify the air pressure The soft starter slowly builds up the air pressure towards the air cylinders after resetting the system to prevent unexpected fast movements of air cylinders AIR SUPPLY SWITCH With the alongside depicted air supply switch it is possible to switch the air supply ON or OFF In the OFF
92. ed position conveyor Page 166 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 p rinzen TROUBLE SHOOTING GUIDE 2 The alarm can be resetten by pressing the nearest blue reset button Muting lamp will turn green if successfully resetted If still after following the above instructions the alarm can NOT be resetted contact Prinzen See also 1 Safety of this manual Message Outfeed yellow muting lamp broken Muting lamp is broken Change muting lamp Message Outfeed yellow muting lamp on Muting is active muting lamp is yellow o 205 04 Message Outfeed taken pallet is not confirmed Orange lamp flashes if pallet is picked up sensor has come free Only press this button if pallet is completely moved away from outfeed last position on outfeed is completely free o 205 01 Message Outfeed safetyscreen muting interrupted Safety plc has not activated the muting safety screen Muting lamp 1 First solve if needed the cause of the safety interruption safety screen is not interrupted but make sure no persons are in danger UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 167 of 167
93. en LED should be ON 2 Press and hold the teach button for 3 seconds until both LEDs are flashing 3 Place the object you need to detect in front of the photo switch 4 Press the teach button once Now the sensor is adjusted The yellow LED turns ON when an object is detected PD30 RETRO REFLECTIVE Adjust the sensor according the below procedure 1 Align the sensor and the reflector to their correct positions without the object it has to detect Both LEDs should be ON 2 Press and hold the teach button for 3 seconds until both LEDs are flashing 3 Place the object you need to detect in between the sensor and the reflector 4 Press the teach button once Now the sensor is adjusted The yellow LED turns OFF when an object is detected USER MANUAL PALLET LOADER V2 Page 133 of 167 ADJUSTMENTS 5 rinzen PD30 THROUGH BEAM 4 Adjust the sensor according the below procedure 1 Align the transmitter and the receiver to their correct positions without the object it has to detect Both LEDs on the receiver N should be ON Press and hold the teach button on the receiver for 3 seconds until both LEDs are flashing 3 Place the object you need to detect in between the transmitter and the receiver C OFF while detecting 4 Press the teach button once Now the sensor is adjusted The yellow LED turns OFF when an object is detected Push once QS18 DIFFUSE REFLECTIVE Follow below procedure to adjust t
94. en the fork carrier moves the fork support above the pallet stack position Here the fork support moves down until the scan divider sensor 21 detects the upper layer From this position it slowly moves down until the touch sensor 19 turns OFF Now the vacuum switches OFF and the divider is placed on the layer UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 55 of 167 _ MACHINE DESCRIPTION 5 oe Process side shift When carton dividers are used for some recipes the stack orientation changes The stacks of the 1 the 3 and the 5 layer are all placed unturned but the stacks of the 2 4 and 6 layer are all turned 90 Because of this for stacking the 2 4 and 6 layer the insert position of the forks have to shift with respect to the insert position of the 1 3 and 5 layer After placing the 1 3 and 5 carton divider the side shift cylinder moves the forks to a different insert position Safety The fork support is completely secured by fencing and a safety screen which immediately stops the pallet loader when it is interrupted Make sure it is not possible to start the system when you are inside the pallet loader DANGER Make sure it is not possible to start the system when you are inside the pallet loader DANGER Make sure the safety catch is IN before entering the pallet loader DANGER Make sure the fork support is in its bottom position before entering the system Never s
95. en view the status of its Top aL inputs Sensors and outputs motors valves Tray feed Infeed After touching a particular unit first the inputs of this unit are displayed With the left right Line arrow buttons it is possible to view the outputs uir of the particular unit As an example below the inputs and outputs of the line are shown 012 AlarmText 012 01 AlarmText 22345 Inputs line 22 01 59 In this screen it is possible to view the status Button reset pressed the inputs sensors and outputs motors Button start pressed valves Button stop pressed When the circle in front of the input is green O 12 Frequency converter s OK then the input is ON for example the Stop O Button emergency button panel MOT pressed tsil button IS pressed When the circle in front of the input is not green the input is OFF for example the stop button is NOT pressed Button emergency button extern pressed sil Button emergency button extern NOT pressed 221 012 AlarmText 012 AlarmText 22345 Output line 22 01 59 O O Q Alarm beeper on Alarm lamp amber light on Alert lamp green lamp on Alert lamp red light an Lamp reset button on Lamp start button on Safe Plc emergency stop circuit released 301 Safe Plc emergency stop circuit released 027 ES 012 AlarmText 012
96. equired position for picking up pallets from the pallet stock Actual position 81 Here you can see the actual position of the fork carrier fork Support Pick last pallet stock 1 Here you can see the pallet pick up parameters for picking up the last pallet from the pallet stock With the up down arrow buttons it is possible to change the value Pallet stock 1 full This parameter determines the maximum allowed height of the pallets on the pallet stock When the pallet stock is full and the empty pallet from the divider stock has to be placed on the pallet stock the height of the pallets on the pallet stock should not exceed this position With the up down arrow buitons it is possible to change the value Teach When the fork carrier fork support is on the correct position for picking up the last pallet from the pallet stock or the fork support is the maximum allowed height it is possible to save this position directly using this teach button The position value in the green numerical window is transferred to the yellow numerical window Off Here it is possible to disable the pallet stock Trigger When the fork support is moving down from a particular height is starts to use the row 2 sensor 82 to detect the pallet height The trigger value determines the distance the fork support moves down after the row 2 sensor has detected the pallet for the exact height to pick up the pallet UM PLV2 02 E 10 20
97. er that tighten up the 4 bolts again ATTENTION Be careful with adjusting the belt tension A too high tension will result in wear on the belt the gearwheels and the bearings TIMING BELT TENSION FORK SUPPORT The upwards and downward movement of the fork support is controlled by a timing belt Adjust the tension of this timing belt in such a way that when both sides of the timing belt are pressed together a small gap remains between the belt sides To adjust the tension first loosen up the lock nuts 2 of the bottom tensioner Adjust with the tensioning bolt 3 Tighten up the lock nuts after adjustment ATTENTION A too high belt tension may result in wear on the belt pulleys and bearings ADJUSTMENTS rinzen TIMING BELT TENSION FORK CARRIER The forwards and backwards movement of the fork carrier is controlled by a timing belt For more tension first loosen up nuts 4 and then tighten up nuts 5 Tighten up nuts 4 after adjustment For less tension first loosen up nuts 5 and then tighten up nuts 4 JN ATTENTION A too high belt tension may result in wear the belt pulleys and bearings TRANSPORT CONVEYOR TIMING BELT TENSION On the outfeed side of the transport conveyor it is possible to adjust the tension of the 3 timing belts To adjust a timing belt first loosen up the lock bolts 6 on both sides of the pulley and adjust the tension with the adjustment nuts 7
98. ergency stop All emergency buttons of the whole line has to be pulled out and all the machines of the whole line has to be powered on Emergency stop button is or has been pressed or main power has been turned off Alarm Line emergency stop activated NOTE after a power on it will take about 30 seconds extra after the panel has been start up before the safety plc is in run and therefor the alarm can be resetted please take this time into account If after following the above instructions the alarm can NOT be resetted contact Prinzen See also 1 Safety of this manual 002 01 Alarm Line SafePlc module not ready SafePlc is starting up normally within 2 minutes after power on or Contact Prinzen if after 2 minutes after power on the alarm is still present wiring problem in the safety circuit See also 1 Safety of this manual 002 02 Alarm Line frequency inverter There is a problem with one of the frequency inverter Check the message on the frequency inverter PLO MAIN 42U03 47U03 and read the manual of the frequency inverter for more details See also 6 ADJUSTMENTS Frequency Inverter Message Line CPU temperature too high Temperature PLC processor too high Contact Prinzen 1 Message Line PLC temperature too high Surrounding temperature PLC too high Contact Prinzen Message Line battery empty Memory backup battery empty Contact Prinzen Do NOT switch off the system
99. errupted the fork carrier fork support stops immediately but the conveyors remain running Therefore be cautious with loosely hanging clothes and long hair do not come too close to the conveyors and do not touch them when the system is running production Read the safety instruction of the units in the chapter unit descriptions DANGER Make sure the system is not able to start when you are inside the pallet loader CAUTION Interrupting the safety screen does not stop the conveyors CAUTION Do not enter objects or body parts into the conveyors or their opening to the pallet loader when the system is running production Do not come too close to the conveyors and do not touch them when the system is running production ATTENTION Do not enter objects or body parts into the conveyors or their opening to the pallet loader when the system is running production L Never use the safety screen or emergency stop buttons for a normal production stop This may cause start up problems Page 40 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 MACHINE DESCRIPTION INTENDED USE The pallet loader is used to stack trays filled with eggs onto pallets Dividers are placed between the stacks A tray is filled with 30 eggs in a pattern of 5x6 Six of these trays on top of each other form a stack Four of these stacks form a row One layer on a pallet exists out of
100. es top trays on the stacks and turns some of the stacks Construction The top tray denester consists of Denester Pusher Centering unit Rotating unit Electrical cabinet Local operating panel Underneath the top tray denester the stacker conveyor is positioned for transporting the stacks Process plastic trays When plastic trays are used the top tray denester is not used Process paper trays for layer 1 3 and 5 Trays are manually supplied into the bunker when the machine is stopped and rest on the top grippers Stacks are supplied by the upstream systems and are stopped underneath the top tray denester The denester places one tray from the bottom of the stack of trays onto the pusher which transfers it above the stack Following the centering unit closes to center the stack Now the pusher moves back and the tray drops onto the stack After this the centering unit opens up and the stack is transferred towards the pallet loader Process paper trays for layer 2 4 and 6 When carton dividers are used for some recipes the stack orientation changes per layer The stacks of the 2 4th and 6 layer are all turned 90 Trays are manually supplied into the bunker when the machine is stopped and rest on the top grippers Stacks are supplied by the upstream systems and are stopped underneath the top tray denester The denester places one tray from the bottom of the stack of trays onto the pusher which tr
101. ets in the palletstock 2 Check the trigger sensors PLO BRI 85FC06 85FC14 The trigger sensors has to be put on to activate them this can be done in the manual loader screen Panel Manual gt Loader gt Forks NOTE This alarm can NOT be resetten directly because to be sure the lost pallet has been taken out of the machine and to release the machine that no pallet is placed in the head The procedure is Manual gt loader gt Gripper Venturi 2 Press Open gripper but only if you are sure no pallet is in the head or may fall down If a pallet is in the head move the pallet in the head manually on the palletstock Panel Manual 162 26 Alarm Loader pallet lost or stuck at head remove pallet from head manually Loader gt Servo 162 28 Alarm Loader palletstock is full remove pallet manually 1 The palletstock is filled with to many pallets 1 Take one or more pallets from palletstock 2 Recipe value palletstock full is wrong 2 Change recipe Panel Recipe gt Change actual recipe gt Loader gt Palletstock gt Pallet stock full manually Manual gt Loader gt Gripper Venturi Alarm Loader timeout reedcontact pallet gripper cylinder Timeout gt movement of cylinder takes to long detected by Check sensor s on end of cylinder or both sensors are on cause For mechanical blockage and solve if needed the blockage 162 31 Alarm Loader timeout reedcontact divider g
102. g up the last divider from the pallet in the divider stock With the up down arrow buttons it is possible to change the value Pick pallet divider stock 1 Here you can see the pick up parameters for picking up the empty pallet from the divider stock With the up down arrow buttons it is possible to change the value Teach When the fork carrier fork support are on the correct position for picking up the last divider or the pallet from the divider stock it is possible to save this position directly using this teach button The position value in the green numerical window is transferred to the yellow numerical window Trigger divider When the fork support is moving down to pick up a divider from a particular height it starts to use the row 2 sensor 92 to detect the height for divider stock The trigger divider value determines the distance in 0 1 mm the fork support moves down after the row 2 sensor has detected the top of the divider stock Plastic divider At this position the plastic divider is picked up Carton divider From this position the fork support moves down until the touch sensor 93 turns OFF after which the carton divider is picked up Page 95 of 167 OPERATION 5 rinzen Off Here it is possible to disable the divider stock Pallet manual auto With this button it is possible to select pallet remove from divider stock manual or auto When manual is selected the empty pallet rema
103. gt List gt Loader gt press gt till screen 4165 Contact Prinzen Page 157 of 167 TROUBLE SHOOTING GUIDE p rnnzen not up on homing sensor 162 14 Alarm Loader vertical and horizontal servo axles runs Software fault simultanuously 162 15 Alarm Loader spare horizontal sevo 0010 Prinze O 162 16 Alarm Loader spare vertical servo Contact Prinze S O 162 17 Alarm Loader vertical servo is up and a trigger sensor is A trigger sensor is not well positioned loose or broken or Check the trigger sensors PLO BRI 85FC06 10 14 86FC10 87B03 The active something covers it trigger sensors has to be put on to activate them this can be done in the manual loader screen Panel Manual gt Loader gt Forks The triggertouch sensor has been interrupted to early and not within the active layer zone This can happen if 1 Check the trigger sensors PLO BRI 85FC06 10 14 86FC10 87B03 The trigger sensors has to be put on to activate them this can be done in the manual loader screen Panel Manual gt Loader gt Forks 2 Check the layer zones Panel Service gt Machine Settings gt Loader 1 something has interrupted the trigger touch sensor or it is not well positioned loose or broken 162 18 Alarm Loader trigger touch row divider active but not within active layer zone 2 the layer zones has been changed 2 Reedcontact not well positi
104. gt divider stock Message Loader palletstock 1 is empty 1 Palletstock 1 is empty 1 Wait till loader is stopped then you can fill the palletstock Pressing the 2 If not empty the recipe settings are NOT correct stop button ones the loader will stop cyclic 2 If palletstock is not empty change the recipe settings Panel Recipe gt Change actual recipe gt palletstock 2 If not empty the recipe settings are NOT correct stop button ones the loader will stop cyclic 2 If palletstock is not empty change the recipe settings Panel Recipe gt Change actual recipe gt palletstock Message Loader palletstock 1 is full 1 Palletstock 1 is full 1 Wait till loader is stopped then you can unfill the palletstock Pressing 2 If not full the recipe settings are NOT correct the stop button ones the loader will stop cyclic Change actual recipe gt palletstock Message Loader palletstock 2 is full 1 Palletstock 2 is full 1 Wait till loader is stopped then you can unfill the palletstock Pressing 2 If not full the recipe settings are NOT correct the stop button ones the loader will stop cyclic 2 If palletstock is not full change the recipe settings Panel Recipe gt Change actual recipe gt palletstock Message Loader dividerstock 1 is empty 1 Dividerstock 1 is empty 1 Wait till loader is stopped then you can fill the dividerstock Pressing the 2 If dividerstock is not empty change the reci
105. h it when the system is running production Do not stand or walk on the outfeed conveyor When it suddenly starts to discharge a pallet you may fall or your limbs feet may get pinched between the moving pallet and machine parts resulting in permanent injury DANGER Make sure it is not possible to start the system when you are inside the pallet loader CAUTION Interrupting the safety screen does not stop the transport conveyor CAUTION Do not enter objects or body parts into the transport conveyor when the system is running production ATTENTION Do not enter objects or body parts into the transport conveyor when the system is running production UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 57 of 167 MACHINE DESCRIPTION rinzen MULTIPLE OUTFEED CONVEYORS Use The multiple outfeed conveyors are placed on the pallet stack position for discharging more pallets without removing them immediately Construction All outfeed conveyors consist of 1 Notched belts 3x 2 Pallet guides 3 Drive mechanism 4 Pallet at end of conveyor sensor 5 Stop pallet infeed sensor Process As soon as a pallet is completely loaded the 1 outfeed conveyor starts to run to transfer this pallet to the 274 outfeed conveyor As soon as the pallet is removed the fork carrier fork support starts to place a new pallet from the pallet stock onto this conveyor At the same time the 2 conveyor
106. he following tools cleaning utensils and detergents available during cleaning duties Padlock Vacuum cleaner Compressed air Plastic scraper Moistened cloth Water and neutral soap Lubricants CAUTION When using warm water to moisten a cloth make sure the temperature of the water is below 45 C Above this temperature it is possible to incinerate body parts ATTENTION Do not use abrasive cleaning detergents or utensils on non longwearing parts Do not use aggressive cleaning products Use cleaning product with a PH value higher than 6 Do not use chlorinated cleaning agents After cleaning with a cleaning product rinse off with plenty of water ATTENTION The system is NOT designed for wet cleaning Do NOT clean the system with water and certainly NOT with a high spraying pistol Only use moistened cloths for cleaning Do NOT clean bearings printers robots electrical parts and pneumatic parts with water NOTE Use H1 classified lubricants These lubricants are approved to use in the food processing industry TIP Prinzen uses Interflon Fin Food Lube Teflon spray and Griffon HR260 Silicone spray Page 108 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 LEANIN rinzen 5 RECOMMENDED CLEANING AGENT Prinzen customers often use Hatchonet cleaning agent for hatcheries for cleaning their systems The supplier of this cleaning agent is Cid lines For safe and
107. he sensor Align the sensor to its correct position without the object it has to detect The green LED 4 should be ON Should be ON Turn the potentiometer 5 clockwise until the yellow LED goes ON B ON while detecting Place the object you need to detect in front of the photo switch yellow LED should remain ON Turn the potentiometer counter clock wise until the yellow LED goes OFF A oet the potentiometer in between A and B position C Now the sensor is adjusted The c ES yellow LED turns ON when an object is A CD detected NS Min 0518 RETRO REFLECTIVE Follow below procedure to adjust the sensor Align the sensor and the reflector to their a Should be ON correct positions without the object it has to OFF while detecting T and the yellow LED 4 Turn the potentiometer 5 counter clockwise until the yellow LED goes OFF A Place the object you need to detect in between the sensor and the reflector yellow LED should remain OFF Turn the potentiometer clock wise until the yellow LED goes ON B Set the potentiometer in between A and B position C Now the sensor is adjusted The yellow LED turns OFF when an object is detected Page 134 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 o AD TMENT rinzen des 2 ON while detecting DIFFUSE REFLECTIVE Follow below procedure to adjust the sensor Align the sensor to its
108. he system needs assistance the buzzer emits a short beep and an alarm ora message appears on the touchpanel MUTING LIGHT A safety screen is positioned around the pallet outfeed conveyors Above this safety screen a muting light indicates the status of this safety screen Green Muting mode disabled Safety screen is operational Yellow Muting mode activated A pallet interrupts the safety screen It is allowed to pass through OFF Safety screen is interrupted UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 65 of 167 OPERATION 5 rinzen LOCAL OPERATION OPERATING PANEL NEAR PALLET OUTFEED Emergency stop After pushing the red button the system stops immediately Only use this button in case of 7 2 m emergencies Start the system with the start the safety 80 button and jen the button on the main operating panel safety key in your possession while you are This emergency button is equipped with a inside the system safety key Releasing this emergency button is only possible with this key TIP Only use the emergency button for real emergencies Follow the normal stop procedure Start to stop the system When the fork support fork carriage or pallet outfeed conveyors are stopped breakdown or interrupted safety screen it is possible to start these units by pressing this start button The light inside the button turns ON When the stop button is pressed the light inside the
109. icular pallet divider tray tyoe combination stored Via this menu the user of the system is able to select copy or change a recipe using submenus Choose recipe After touching this button the choose recipe screen appears where it is possible to select a recipe Copy recipe After touching this button the copy recipe screen appears where it is possible to copy the parameter settings of a particular recipe to another recipe This screen is not available for the operator Change actual recipe After touching this button the change recipe menu appears Via this menu it is possible to change the parameter settings of the current recipe This screen is not available for the operator CHOOSE RECIPE SCREEN Here it is possible to select a different recipe After touching a particular recipe the parameter settings of this recipe are used to control the pallet loader After touching a recipe name a keypad pops up after which it is possible to change the recipe name Ten recipes are available Use the arrow button to scroll to the next 5 recipes COPY RECIPE SCREEN Here it is possible to copy the settings of a particular recipe to another recipe This way it is possible to make a new recipe First copy an existing recipe to a new recipe and after that start to change the new recipe settings via the change actual recipe menu To copy a recipe follow the below procedure 1 Select the source recipe 2 Select the destination
110. ing on the machine Safety devices are 2 Emergency stop buttons 3 Lockable doors 4 Protective covers 5 Safety screens EMERGENCY STOP BUTTON To stop the machine in case of an emergency the system has one or more emergency stop buttons 2 Only use the emergency stop button in case of an emergency When the emergency stop button is pressed the system stops immediately The button stays mechanically locked so the machine cannot start until it is considered safe to do so Release the emergency stop button by turning it clockwise Do not release the emergency stop button when it is not certain why and by whom it was pressed Personnel working with the system must know the positions of the emergency stop buttons One of the emergency buttons is equipped with a safety key Releasing this emergency button is only possible with this key Before entering the system always push this emergency button and keep the safety key in your possession while you are inside the system It prevents restart of the system by other persons UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 21 167 EP p rinzen LOCKABLE DOOR Lockable doors are doors that can only be opened with a key 3 The key should only be in possession of a Supervisor DANGER Lockable doors safeguard dangerous machine areas These doors are of utmost importance to operate the machine safely Never operate the machine when doors a
111. ing panel 6 Top tray denester optional 13 Local operating panel pallet outfeed 7 Fork carrier 14 Local operating panel top tray 8 Fork support denester For more information about the construction of the pallet loader see page 39 For more information about the operation of the pallet loader see page 63 START STOP RESET EMERGENCY STOP TIP CONNECTIONS Power connection 400V 3 phase N 50Hz Air connection in between 8 and 10 bars For more specifications of the pallet loader see page 42 UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 33 of 167 QUICK REFERENCE GUIDE 5 oe SAFETY Before starting to use the system read the safety chapter first Perform the safety inspection procedure daily See page 27 for the safety inspection procedure OPERATING PANELS With the main operating panel it is possible to start and stop the complete system With the local operating panels it is only possible to start or stop part of the system near this operating panel For more information about the operating panels see page 63 di N START STOP RESET EMERGENCY STOP 228 N i e TIP EMERGENCY STOP START ee M E EMERGENCY STOP START STOP RESET pa O o o PALLET OUTFEED MARCHE ARRET REMISE WOT AUS GC ARRET D URGENCE Emergency stop button After pushing one of the red butt
112. ing the Prinzen service department Weverij 18 7122 MS Aalten Netherlands 1 31 0 543 490060 P rinzen Fax 31 0 543 476205 Machine type Pallet Loader Rated voltage 3 N 50Hz 400 230V Max prim fuse 25 Serial number 401000999 Date 08 2010 www prinzen com UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 13 of 167 MEC 5 rinzen SYMBOLS Symbols are used in the manual when special attention caution is required while working on the system The special symbols and their meaning are depicted in the below table Meaning DANGER This symbol is used when instructions should be followed to the letter If not they may result in permanent personal injury or death CAUTION This symbol is used when instructions should be followed to the letter If not they may result in permanent personal injury ATTENTION This symbol is used when instructions should be followed to the letter If not they may cause damage to the system NOTE This symbol advises to use edible products and to work in a hygienically way Disregarding this advice may cause illness TIP This symbol is used as a helpful hint to simplify the execution of certain tasks ADDRESS PRINZEN Prinzen BV Weverij 18 7122 MS AALTEN P O Box 85 7120 AB AALTEN The Netherlands Telephone 31 0 543 490060 Fax 31 0 543 476205 E mail info prinzen com Website www prinzen com Page 14 of 167
113. ing the machine Make sure no persons are in danger CAUTION Make sure no persons are working near the infeed or inside the pallet loader before you start up the pallet loader Make sure all protective covers are in place ATTENTION Make sure no tools or other objects are present inside the system ATTENTION Before starting the system make sure maintenance is performed according to the maintenance instructions further on in this manual Follow below steps to power on and start up the system 1 Place pallets in the pallet stock and a pallet with dividers in the divider stock P rinzes when this is necessary 2 Make sure the stacks are not skew Push pallets or dividers against the guides Make sure the height of the stack remains below the top of the guide 3 Make sure all emergency stop buttons are released 4 Switch air supply ON Set the main air EMERGENCY pressure to 6 bars 5 Switch on the main power by turning the main switch ON 6 Wait until the start up screen appears ARRET DURGENCE This takes around 2 minutes 7 When the start up screen appears wait 30 seconds and then press all the FLASHING reset buttons 8 Before you start the pallet loader you have to make sure it is safe to initialize it fork carrier cannot push over stacks or collide with other machine parts If it is not safe move the fork carrier to a safe
114. ings venturi frame 4x Check vacuum cups for damages 8x UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 123 of 167 PREVENTIVE MAINTENANCE e p Weekly Maintenance Interval hours Check the functionality of the limit switches 4x Apply silicon spray to the top tray denester block up down guide 4x Apply silicon spray to the top tray denester lower grippers in out guides 4x Apply silicon spray on the top tray denester upper gripper s plain bearings 8x Apply Teflon spray on rod ends 30 cell top tray denester 4x Page 124 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 PREVENTIVE MAINTENANCE Weekly Maintenance Interval hours Apply silicon spray to the top tray denester pusher guides 2x Apply Teflon spray to the top tray denester rotator cylinder rod end Apply silicon spray to the top tray denester centering unit guides 8x UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 125 of 167 PREVENTIVE MAINTENANCE gt p MONTHLY PREVENTIVE MAINTENANCE Monthly Maintenance Interval hours Clean motor fans with compressed air Check the filters of the electrical cabinet for contamination and replace if necessary CAUTION Wear eye protection during cleaning of the motor fans with compressed air Page 126 of 167 USER MANUAL PALLET L
115. ins on the divider stock and has to be removed manually When auto is selected the empty pallet is transferred automatically from the divider stock to the pallet stock Height after picking up carton When carton dividers are used the fork support lifts up the carton moves a certain distance up and waits there for some time to allow cartons sticking to the picked up carton to drop back down to the divider stock This parameter determines the certain distance that the fork support moves up Time standing still after picking carton divider When carton dividers are used the fork support lifts up the carton moves a certain distance up and waits there for some time to allow cartons sticking to the picked up carton to drop back down to the divider stock This parameter determines the time that the fork support waits Page 96 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen 012 01 amp larmText 012 01 amp larmText 22345 Change recipe outteed vertical semra 22 01 59 Horizantal serva divider on pallet Pallet position outteed 1 Top tray Rotate off ATTENTION Before starting manual control make sure it is safe to do so fork carrier fork support cannot push over stacks from the pallet or collide with other machine parts ATTENTION Make sure the saved value is a correct value Incorrect values result in collisions between the fork supp
116. it crawl or walk underneath the fork support Page 56 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 MACHINE DESCRIPTION Use SINGLE OUTFEED CONVEYOR On the pallet stack position an outfeed conveyor is placed for automatic removal of the stacked pallets For discharging more pallets without removing them multiple outfeed conveyors are available Construction The transport conveyor consists of Notched belts 3x Pallet guides Drive mechanism Stop pallet infeed sensor Pallet at discharge sensor Process As soon as a pallet is completely loaded the transport conveyor starts to run to transfer the full pallet from the pallet stack position towards the end of the conveyor At the same time the fork carrier fork support starts to pick a new pallet from the pallet stock and places this pallet on the pallet stack position when the full pallet is detected at the end of the conveyor A message appears on the operating panel to remove the full pallet from the end of the conveyor With a forklift or a hand pallet truck itis possible to remove the full pallet Safety The transport conveyor is partially positioned into the secured area of the pallet loader On all sides it is protected by fencing except the outfeed side Here a safety screen is placed Be cautious with loosely hanging clothes and long hair do not come too close to the conveyor and do not touc
117. itch The pushercylinder of the denester of the toptray has not reached Check if cylinder is not mechanical blocked or pushercylinder its end point sensor within a certain time end sensor PLO TT1 84B10 84B14 is broken or loose or cylinder has been reduced to much 122 Alarm TopTray timeout proximity switch centercylinders The centercylinder has not reached its end point sensor within a Check if cylinder is not mechanical blocked or certain time end sensor PLO TT1 85B10 85B14 is broken or loose or cylinder has been reduced to much 122 Alarm TopTray timeout proximity switch rotate cylinder The rotatecylinder has not reached its end point sensor within a Check if cylinder is not mechanical blocked or certain time end sensor PLO TT1 85B03 85B07 is broken or loose or cylinder has been reduced to much Alarm TopTray stack too low 1 Stack in TopTray is less then 6 trays high 1 Stacker has been emptied so a stack lower then 6 trays high can be 2 Sensor loose broken or not well placed placed on infeed stacker conveyor else if not emptied check stacker or 140404 somebody has placed a low stack for the TopTray eoo If still after following the above instructions the alarm can still NOT be 2 Check sensors PLO TT1 83FC03 and 7 Page 152 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 p rinzen TROUBLE SHOOTING GUIDE No empty trays or only a few tr
118. ith stacks 01 W PO Process The fork carrier moves forwards and backwards from pallet stock divider stock and infeed conveyor to the pallet stack positions The fork support moves upwards and downwards to pick up pallets dividers and stacks and to place these pallets dividers or stacks on the pallet stack position UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 51 of 167 MACHINE DESCRIPTION 2 s redi Prinzen Page 52 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 J o MACHINE DESCRIPTION rinzen Construction vertical movement The fork support runs upwards and downwards in the frame of the fork carrier The construction taking care of the vertical movement consists of 1 Guide rails 2x Notched belt Motor Limit switches Home sensor Strip with protrusions Safety catch cylinder Safety stop sensor Fork support base plate The fork support runs over 2 guiding rails The motor with an encoder a brake and a fan on top of the fork carrier drives the fork support via a notched belt The limit switches on the fork carrier protect the fork support against moving too far up or down The home sensor determines the initial position of the fork support vertical movement 2 The piston of the safety catch cylinder moves into the strip with protrusions to prevent the downward movement of the fork support when the machine is stopped The safety stop sensor immediately
119. just the positions of the forks in such a way that they are able to insert underneath the 4 stacks at the pick up position and are able to lift the stacks up without tilting them sideways When carton dividers are used normally per layer the stack orientation changes On the 1 the 3 and the 5 layer the stacks are placed unturned On the 27 and the 4 layer the stacks are turned 90 For the 2 and the 4 layer the forks are shifted sideways Is this the case in your system make sure your forks are on the correct position for picking op stacks which are not turned and stacks which are turned 90 Follow below procedure to change a fork position 1 Pull the lever down 2 Loosen up the lever by turning it 3 Move the fork left or right to the correct position 4 Tighten up the lever by turning it 5 Push the lever up to lock the fork again 6 Repeat the above for all the forks 7 After adjustment make sure the forks are able to pick up the stacks from the infeed conveyor and place them on the pallet without damaging stacks or eggs Page 140 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 ADJUSTMENTS TRANSPORT BELT TENSION The complete drive is attached to the transport belt with 4 bolts 2 on each side of the belt Loosen up these 4 bolts 1 For more belt tension lower the complete drive When the belt tension is correct first make sure the complete drive is leveled and aft
120. lace a divider on top of the layer For paper trays and carton dividers the touch sensor 20 is not used After placing a carton divider this height position is used The fork support moves to this position Then it moves a fixed distance down to place the row on the pallet or divider Process placing plastic divider The fork carrier moves the fork support above the divider stock Above the divider stock it moves down first fast until the scan divider sensor 21 detects a divider From this position it slowly moves a fixed distance down The divider grippers 10 close to pick up the divider after which the fork carrier moves the fork support above the pallet stack position Here the fork support moves down until the scan divider sensor 21 detects the upper layer From this position it moves a fixed distance down and places the divider on top of this layer Process placing carton divider The fork carrier moves the fork support above the divider stock The forks are extended Above the divider stock first the venturi frame expands after which the fork support moves down first fast until the scan divider sensor 21 detects dividers From this position it slowly moves down until the suction cups are pushing on the divider and the touch sensor 19 turns OFF The vacuum switches ON and the fork support move a certain distance up and stops for a certain time to allow more stuck cartons dropping down on the divider stock again Th
121. larm Outfeed mode timeout end auto Stop button has been pressed ones but could not finish its stop Check for other alarms or messages sequence Check machine for mechanical blockage 202 01 Alarm Outfeed safety Machine safety is activated for example safety screen is or has 1 First solve if needed the cause of the safety interruption for example been interrupted or door is or has been opened etc a if a screen is not interrupted or the door is closed but make sure no persons are in danger 2 The alarm can be resetten by pressing the nearest blue reset button If still after following the above instructions the alarm can NOT be resetted contact Prinzen 202 02 Alarm Outfeed frequency inverter There is a problem with one of the frequency inverter Check the message on the frequency inverter and read the manual of the frequency inverter for more details See also 6 ADJUSTMENT S gt Frequency Inverter 202 05 Alarm Outfeed timeout outfeed conveyor s runs too long 1 Pallet is stuck on outfeed conveyor 1 Release the stucked stack and start up again loose or broken or belt is not well adjusted 202 Alarm Outfeed timeout muting too long enabled 1 Pallet is stuck on outfeed conveyor 1 Release the stucked stack and start up again cc uA out BO eee Message Outfeed pallet can be picked from last outfeed Pallet is placed on last position ready to pick up Pick outfeeded pallet from last outfe
122. lectrical cabinets After switching off the main switch parts inside the electrical cabinet remain live for approximately 1 minute The frequency inverters may hold a high voltage charge during this time Do not touch parts inside the electrical cabinet as long as displays of frequency inverters are on UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 19 of 167 SAFETY Several parts inside the electrical cabinet maintain voltage even when the main switch is turned off main switch main power supply terminals for egg collecting belts etcetera DANGER Failure to obey safety regulations may result in permanent personal injury or death ATTENTION Failure to obey safety regulations may result in damage to the system nian Page 20 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen DANGER 1 Push the safety key emergency button before you go inside the pallet loader Keep the safety key in your pocket while you are inside the pallet loader DANGER Make sure it is not possible to start the system when you are inside the pallet loader SAFETY SAFETY PROVISIONS Before operating the machine the safety devices must be checked for correct functioning Repair or replace safety devices before using the system if they do not work properly Never rely solely on safety devices Always switch off the system and lock up the power source 1 before work
123. ler verifies if the breakdown is solved When this is the case the light inside the reset button turns OFF Now it is possible to start the top tray denester by pressing the start button on the operating panel of the top tray denester Tip For adjustment and test purposes it is possible to manually control the top tray denester by pressing the TIP button When the system is started pressing the TIP button sets the top tray denester into the manual mode In the manual mode shortly pressing the TIP button starts and stops the denester movement In the manual mode when holding the TIP button the denester makes one cycle and stops To set the top tray denester back into the automatic mode just press the start button on the operating panel of the top tray denester UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 67 of 167 OPERATION 20226100 O OPERATING SCREENS After switching on the system with the main switch the start up screen appears Palletloader After touching this 1 button the main screen appears KEYPAD After touching yellow windows the alongside keypad appears Enter a correct value and confirm it with the V button STEN Page 68 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 OPERATION OPERATING TREE The below picture gives an overview of the present menus and screens and the how to find a particular screen 3 amp 8
124. list UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 75 of 167 OPERATION 5 MANUAL MENU 012 AlarmText 012 AlarmText 22345 Manual menu 27 01 58 Here it is possible to select a certain unit and cr with the appearing screen control parts of that Infeed Loader unit manually Out Notice the background color of this screen Tray feed It is yellow After touching a button in this screen immediately sets the selected part of the system into the manual mode 2 5 P Top tray a En After touching this button the top tray denester manual screen appears Infeed After touching this button the infeed manual screen appears Loader After touching this button the loader manual screen appears Outfeed After touching this button the outfeed manual screen appears With the manual screens it is also possible to verify correct functioning of sensors motors and valves These are depicted in these screens Whenever a sensor detects something or a motor or a valve is activated it colors yellow or green Password screen 30 After touching this button the password screen appears in which it is possible to change the operating level of the system DANGER Before starting to move parts of the system you have to assure yourself no other persons are in danger Make sure nobody is around the part you intend to move ATTENTION When you move parts man
125. n Only if the process is interrupted by feeding a pallet out the outfeed position and a new one back in again it is possible that the loader has something picked and can not execute a new task In normal process this may not happen Only if the process is interrupted by feeding a pallet out the outfeed position and a new one back in again it is possible that the loader has something picked and can not execute a new task In normal process this may not happen Only if the process is interrupted by feeding a pallet out the outfeed position and a new one back in again it is possible that the loader has something picked and can not execute a new task appear if a scan detects that the outfeedposition is empty 5 appear if a scan detects that the outfeedposition i is empty appear if a scan detects that the outfeedposition i is empty appear if the outfeedposition IS full appear if the outfeedposition i IS full appear if the outfeedposition i IS full appear if the outfeedposition is full Message Loader remove divider from loaderhead manually If outfeedposition has no automatic outfeed this message will appear if a scan detects that the outfeedposition is empty In normal process this may not happen Only if the process is interrupted by feeding a pallet out the outfeed position and a new one back in again it is possible that the loader has something picked and can not execute a new task Message Loader f
126. n pallet is not confirmed Orange lamp flashes if pallet is picked up sensor has come free press this button if pallet is completely moved away from outfeed last posten curses compete free eee on outfeed is completely free PLO MAIN 1125H03 Alarm Outfeed mode timeout end auto EE button has been pressed ones but could not finish its stop Check for other alarms or messages sequence Check machine for mechanical blockage 01 Alarm Outfeed safety Machine safety is activated for example safety screen is or has 1 First solve if needed the cause of the safety interruption for example been interrupted or door is or has been opened etc if 2 screen is not interrupted or the door is closed but make sure no persons are in danger 2 The alarm can be resetten by pressing the nearest blue reset button If still after following the above instructions the alarm can NOT be resetted contact Prinzen 192 02 Alarm Outfeed frequency inverter There is a problem with one of the frequency inverter Check the message on the frequency inverter and read the manual of the See also 6 ADJUSTMENTS Frequency Inverter 192 05 Alarm Outfeed timeout outfeed conveyor s runs too long 1 Pallet is stuck on outfeed conveyor 1 Release the stucked stack and start up again loose or broken or belt is not well adjusted 192 Alarm Outfeed timeout muting too long enabled 1 Pallet is stuck on outfeed co
127. n you will enter the alarm screen Buttons 12 With the buttons it is possible to switch parts of the system ON or OFF Beside this the buttons indicate the status of these units White Unit is not running Light green Unit is running Dark green Unit is initializing Hed Unit has a breakdown Yellow Unit is in the manual mode Notice the background color of this screen It is dark gray After touching a button in this screen immediately starts or stops the selected part of the system Top tray After touching the top tray button the top tray denester is switched ON Infeed After touching the infeed button the infeed conveyor is switched ON Loader After touching the loader button the fork carrier fork support are switched ON Outfeed After touching the outfeed button the pallet outfeed conveyor s are switched ON Manual submenu 13 After touching this button the manual menu appears in which it is possible to manually control parts of the system Service submenu 14 After touching this button the service menu appears In this menu the operator is able to change a number of settings using submenus Production menu 15 After touching this button the production menu appears In this screen the performance of the system amount of loaded pallets is visible Page 72 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 o PERATION rinzen 2 Recipe 16 All the
128. nd start up again 2 Check sensors on stack conveyor PLO MAIN 91 FC1 1 3 If lowest tray is empty or not complete full remove all stacks on the stack conveyor and startup again 1 Stacker has been emptied so a stack lower then 6 trays high can be placed on infeed stacker conveyor else if not emptied check stacker or somebody has placed a low stack for the TopTray 2 Check sensors PLO MAIN 90FC03 91FCO3 1 Remove the stack and startup again 2 If lowest tray is empty or not complete full remove all stacks on the infeed conveyor and startup again 3 Check sensors on infeed and buffer conveyors PLO MAIN 90FC03 91FCO08 1 Remove the stack and startup again 2 Check sensors on infeed and buffer conveyors PLO MAIN 90FCO03 91FC098 1 Remove the stack and startup again 2 If lowest tray is empty or not complete full remove all stacks on the infeed conveyor and startup again 3 Check sensors on infeed conveyors PLO MAIN 90FCO03 90FC1 7 1 Remove the stack and startup again 2 Check sensors on infeed and buffer conveyors A no 12 Alarm Infeed stack at end and begin infeed conveyor 1 A stack was placed by hand on infeed or buffer conveyor 2 Sensor on infeed buffer conveyor is loose broken or not well 125 Message infeed weigh calibration factor not within zone The loadcells on the infeedconveyor are not yet correctly m Panel Machine Settings gt pres
129. neath the top tray denester starts to run as long as this button is touched Buffer conveyor After touching this arrow button the buffer ae ee ere conveyor starts to run as long as this button is touched 2 tt Infeed conveyor After touching this arrow button the infeed conveyor starts to run as long as this button is touched Release stacker ON OFF When for whatever reason the pallet loader is not able to run it is still possible to run the upstream speedpack with PS4 tray stacker However the stacks should be manually removed from the infeed conveyors To run the speedpack without the pallet loader switch the release stacker ON Starting the infeed automatically switches the release stacker OFF again UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 77 of 167 OPERATION 5 012 AlarmText 012 AlarmText 22345 Manual Loader enu 22 01 59 LOADER MANUAL SCREEN Here it is possible to select a certain part of the loader and with the appearing screen control Fark Servo that part of the loader manually Fork After touching this button the fork manual screen appears Gripper Venturi After touching this button the gripper venturi tt manual screen appears Servo After touching this button the servo manual screen appears 012 AlarmText 012 AlarmText 22345 Manual Loader Fork 22 01 59 Fork horizontal Fork flip FORKS b o REST Eats GIs
130. no other persons are in danger Make sure nobody is around the part you intend to move ATTENTION By working on a higher operating level you have more possibilities to control the system manually When you move parts manually it may be possible that parts will collide resulting in damage of the system ATTENTION By working on a higher operating level you have more possibilities to control the system manually Using the manual buttons may result in damaging pallets dividers trays eggs and machine parts We advise you to remove all pallets dividers and trays from the system before starting to use these buttons ATTENTION By working on a higher operating level you have the possibilities to change parameter settings This may result in malfunctioning and even damage of the system ATTENTION The manual screens should only be used by advanced users of the system like Prinzen engineers for testing the system UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 71 of 167 OPERATION 5 MAIN SCREEN In the main screen the operator is able to control the system On the main screen the following information is visible Alarm message line 10 On the top of the screen the alarm messages may appear when the system needs assistance See alarm messages for possible alarms that may popup Alarm screen 11 On all screens the alarm screen button is available After touching this butto
131. no persons are in danger 2 The alarm can be resetten by pressing the nearest blue reset button If still after following the above instructions the alarm can NOT be resetted contact Prinzen 172 02 Alarm Outfeed frequency inverter There is a problem with one of the frequency inverter Check the message on the frequency inverter PLO MAIN 46U03 optional See also 6 ADJUSTMENTS Frequency Inverter 172 05 Alarm Outfeed timeout outfeed conveyor s runs too long 1 Pallet is stuck on outfeed conveyor 1 Release the stucked stack and start up again loose or broken or belt is not well adjusted 172 Alarm Outfeed timeout muting too long enabled 1 Pallet is stuck on outfeed conveyor 1 Release the stucked stack and start up again 2 Pallet has stopped in safetyscreen muting photocells 2 Move the pallet manually out Panel Manual gt Outfeed gt Feed pallet E Ru ILE UI Message Outfeed pallet can be picked from last outfeed Pallet is placed on last position ready to pick up outfeeded pallet from last outfeed position conveyor Message Outfeed safetyscreen muting interrupted 2 plc has not activated the muting safety screen Muting lamp 1 First solve if needed the cause of the safety interruption safety screen is e 4 but ud sure no persons are in danger 2 The alarm can be resetten by pressing the nearest blue reset button Muting lamp will turn green if successfully resetted If still afte
132. nt 012 01 AlarmText alarms from the system including its alarm 012 01 AlarmText code Use this alarm code to find this alarm and its corresponding cause and action to solve the error in the trouble shooting guide By touching the up or down arrows 20 it is possible to scroll through the alarm list An active alarm is colored red After touching the alarm history button 21 the alarm history screen appears 012 01 amp larmText 012 01 AlarmText 012 01 amp larmText 012 01 amp larmText 012 01 AlarmText History alarms 28 D8 2007 17 01 59 Submenu Alarm history The Alarm history screen shows the history of 3bm Sbd 36 Y 012 01 AlarmText all alarms from the system u By touching the up or down arrows 23 it is possible to scroll through the alarm list iem od S5 96H Alarm Test i amp m od S5 D1 2 Alarm Test Siem 5ed e SSH seh 012 01 amp larmText iem 5ed e eh 01 2 01 Alarm Text i6m od S8 D1 2 01 Alarm Test Page 74 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen 012 AlarmText 012 AlarmText 22345 Production menu 22 01 59 Infeed ned 1 Top Tray e Infeed x 2 im EI fs 012 AlarmText 012 AlarmText 22 01 59 012 AlarmText 012 AlarmText 22345 Production Loader actual data Forerage Pale Total Last
133. nveyor 1 Release the stucked stack and start up again 2 Pallet has stopped in safetyscreen muting photocells 2 Move the pallet manually out Panel Manual gt Outfeed gt Feed pallet out E UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 165 of 167 TROUBLE SHOOTING GUIDE p Message Outfeed pallet be picked from last outfeed Pallet is placed on last position ready to pick up outfeeded pallet from last outfeed position conveyor Message Outfeed safetyscreen muting interrupted O plc has not activated the muting safety screen Muting lamp 1 First solve if needed the cause of the safety interruption safety screen is i but nae sure no persons are in danger 2 The alarm can be resetten by pressing the nearest blue reset button Muting lamp will turn green if successfully resetted If still after following the above instructions the alarm can NOT be resetted contact Prinzen See also 1 Safety of this manual Message Outfeed yellow muting lamp broken Muting lamp is broken Change muting lamp Message Outfeed yellow muting lamp on Muting is active muting lamp is yellow e 195 04 Message Outfeed taken pallet is not confirmed Orange lamp flashes if pallet is picked up sensor has come free Only press this button if pallet is completely moved away from outfeed last I on outfeed is completely free 202 A
134. o 1096 the speed of all the movements of the loader are reduced to 1096 of its normal speed Page 86 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen 012 AlarmText 012 AlarmText 22 01 59 AccrDec in 012 AlarmText 012 AlarmText 22345 Settings loader servo postions 0 1 mm 22 01 59 vert Hor Hor vert Sema Software limit min Park position honzontal Safety Layer ves e a limit max Calculate Layers First software T ims UM PLV2 02 E 10 201 1 OPERATION LOADER ACCELERATION DECELERATION In the alongside screen the acceleration and deceleration settings of the fork carrier horizontal and fork support vertical during their particular movements are displayed Acc Dec in Normally this setting is 100 For testing purposes it is possible to set this value in between 1096 and 10096 When this value is set to 1096 the acceleration and deceleration of all the movements of the loader are reduced to 1096 of its normal acceleration and deceleration speeds LOADER SERVO POSITIONS In the alongside screen the stop positions of the fork carrier horizontal and fork support vertical for loading a pallet are displayed Besides this also the park position for entering the pallet loader and the maximum allowed positions are displayed here With the arrow buttons it is possi
135. oader Contact Prinzen Alarm Loader wrong recipe settings One or more Recipe settings are not correct not within zone Check recipe settings Panel Recipe gt Change recipe settings gt Loader Contact Prinzen Page 160 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 p rinzen TROUBLE SHOOTING GUIDE 162 39 Alarm Loader divider lost or not placed by head remove A plastic divider has fallen out of the head by picking or 1 Check the state of the divider and also the dividersin the dividerstock manually transporting it or could not be lost by placing cause 2 Adjust gripper 1 a bad divider was picked 3 Check the trigger sensors PLO BRI 85FC06 85FC14 The trigger 2 Gripper not well positioned sensors has to be put on to activate them this can be done in the manual 3 The trigger sensor is not well positioned loose or broken loader screen Panel Manual gt Loader gt Forks NOTE This alarm can NOT be resetten directly because to be sure the lost divider has been taken out of the machine and to release the machine that no divider is placed in the head The procedure is Panel Manual gt loader gt Gripper Venturi gt Press Open gripper but only if you are sure no divider is in the head or may fall down If a pallet is in the head move the pallet in the head manually on the palletstock Panel Manual gt Loader gt Servo 162 40 Alarm Loader divider lost or not placed by h
136. ollow below procedure to replace the filters of the electrical cabinet 1 Stop the system 2 Switch OFF the main switch on the electrical cabinet 3 Open up the filter holder by pulling the clip on the topside 4 Replace the contaminated filter in the filter holder by a clean filter 5 Take note of the filter orientation The arrows should point towards the electrical cabinet and the TOP text should be up 6 Close the filter holder again CAUTION Always switch OFF the main switch before opening the filter holder USER MANUAL PALLET LOADER V2 Page 119 of 167 PREVENTIVE MAINTENANCE gt rnzen PLC BATTERY REPLACEMENT Battery replacement Parameter settings of the system are stored in the memory of the PLC When the system is not powered ON the power for the memory is supplied by a battery ATTENTION Y During normal circumstances never remove the battery Without battery data may be lost resulting in malfunctioning of the system To prevent loss of the parameter settings replace this battery of the PLC every 2 years Try to have a spare battery on stock before the 2 years have passed The battery is a long lead item but keep in mind that a battery on stock is leaking juice so do not keep a battery on stock for more than 1 5 years Battery type CR2477N 3V Prinzen part number 8001500340 In case the battery is exhausted the message Battery discharged appears on the s
137. on the system stops immediately One of the emergency buttons is equipped with a safety key Releasing this emergency button is only possible with this key When somewhere on the system an emergency button is pressed you have to reset and start the system again by pressing the reset and the start button on this main operating panel Emergency stop When an emergency button is pressed the alarm 00200 appears on the touchpanel together with a message informing the operator which emergency button is pressed After releasing this emergency button the message disappears but the alarm remains present until it is reset on the main operating panel Start With the start button it is possible to start the system or unit The start button is ON when the system or unit is running The start button FLASHES when the system or unit is stopping the stop button is pressed Stop With the stop button it is possible to stop the system or unit The start button FLASHES while the system or unit is stopping Pressing the stop button twice stops the system or unit immediately Reset With the reset button it is possible to reset a breakdown in the system or unit The reset button FLASHES during a breakdown of the system or unit It is not possible to start the system when the reset button FLASHES Page 34 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 REFERENCE GUIDE p rinzen QUIC CE GU OPERATING S
138. oned loose or broken 2 Check reedcontact PLO BRI 84B14 Loader head has been vertical lift up while it is collided Check the situation what happened and call Prinzen Sensor not well positioned loose or broken Check if sensor PLO BRI 84B10 is positioned and functioned correctly Alarm Loader more then one state Software fault Contact Prinzen 162 22 Alarm Loader wrong row sequence detected during 1 The pallet has been feeded in on the outfeed position 1 Feed pallet out turn pallet 180 degrees and feeded in again scanning incorrectly wrong direction 2 Check the trigger sensors PLO BRI 85FC06 85FC14 The trigger 2 A trigger sensor is not well positioned loose or broken or sensors has to be put on to activate them this can be done in the manual something covers it loader screen Panel Manual gt Loader gt Forks 162 23 Alarm Loader scanned layer is higher then maximum layer 1 Pallet infeeded with tomany layers stacked 1 Feed pallet out defined in the recipe 2 Layer settings not correct 2 Change layer settings gt Service gt Machine Settings gt Loader gt 3 Recipe number of layer not correct General Servo Settings 4 Wrong recipe chosen 3 Change recipe settings Panel Recipe gt Change actual recipe gt 5 something has interrupted the trigger touch sensor or itis not Outfeed gt Layer well positioned loose or broken 4 Change recipe 5 Check th
139. ons are in danger before restarting the system Step3 Restart the system by pulling out the emergency stop button s and then push the blue reset button the panel to reset the emergency stop All emergency buttons of the whole line has to be pulled out and all the machines of the whole line has to be powered on NOTE after a power on it will take about 30 seconds extra after the panel has been start up before the safety plc is in run and therefor the alarm can be resetted please take this time into account If after following the above instructions the alarm can still NOT be resetted contact Prinzen See also 1 Safety of this manual UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 151 of 167 TROUBLE SHOOTING GUIDE p Message Line Service Description5 A Prinzen or own defined service message has appeared Read the message Message Line Service Description6 A Prinzen or own defined service message has appeared Read the message 06 Message line network set gateway incorrect 1 Anerror occurred during saving the network gateway address ContactPrinzen 08 Message line network get netmask incorrect 7 Anerror occurred during reading the network subnet mask ContactPrinzen 09 Message line network get gateway incorrect Anerror occurred during reading the network gateway address ContactPrinzen 000020 gt Chec Chec
140. ontrast the brightness and the orientation of the display This screen is not available for the operator Network After touching this button the Network screen appears In this screen it is possible to adjust the communication between the machine and via the internet an external computer This screen is not available for the operator and the supervisor 512 Of AlarmText LANGUAGE 012 AlarmText 22345 Language 22 01 58 In this screen it is possible to select the language of the touchpanel Touch the flag that represents your native language Page 88 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen 012 AlarmText 012 AlarmText 22345 Date Time settings 22 01 59 year 2000 5 o Sy v gu Z jJ hour 3 a qu T accept date amp time AD 5 S ds 012 AlarmText 012 AlarmText 2345 Cpu data 22 01 59 Serial number Temperature 25 0 Backup battery status notos Power up cycles 1234 Operation hourz 1234 UM PLV2 02 E 10 201 1 OPERATION DATE amp TIME SCREEN After touching year month day hour or minute a keypad appears Enter the correct date and time and confirm this with the V button Now touch the button accept date amp Time to activate the correct date and time CPU SCREEN This screen shows information about the status of the control
141. oose broken or not well placed 1 A stack was placed by hand on infeed or buffer conveyor 2 The lowest tray of a stack is empty or not complete full 3 Sensor on infeed buffer conveyor is loose broken or not adju sted well 1 A stack was placed by hand on infeed or buffer conveyor 2 Sensor on infeed buffer conveyor is loose broken or not adjusted well 1 A stack was placed by hand on infeed conveyor 2 The lowest tray of a stack is empty or not complete full m Sensor on infeed conveyor is loose broken or not adjusted el p rinzen 1 First solve if needed the cause of the safety interruption for example check if safety screen is not interrupted or the door is closed but make sure no persons are in danger 2 The alarm can be resetten by pressing the nearest blue reset button If still after following the above instructions the alarm can NOT be resetted contact Prinzen See also 1 Safety of this manual 1 Release the stucked stack and start up again 2 If lowest tray is empty or not complete full remove all stacks on the infeed conveyor and startup again 3 Check sensors on infeed conveyor PLO MAIN 90FC03 90FC17 1 Release the stucked stack and start up again 2 If lowest tray is empty or not complete full remove all stacks on the buffer conveyor and startup again 3 Check sensors on buffer conveyor PLO MAIN 91FCO03 91FC08 1 Release the stucked stack a
142. or messages sequence Check machine for mechanical blockage UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 153 of 167 142 e 142 e A N O N 142 142 142 142 O 142 1 TROUBLE SHOOTING GUIDE Alarm Infeed Alarm Infeed Alarm Infeed Alarm Infeed Alarm Infeed Alarm Infeed Alarm Infeed detected Alarm Infeed not present safety timeout infeed conveyor runs too long timeout buffer conveyor runs too long timeout stack conveyor runs too long stack too low on buffer conveyor 5 stacks detected on infeed conveyor too quickly a stack at end of buffer conveyor row on end infeed conveyor but fourth stack Machine safety is activated for example safety screen is or has been interrupted or door is or has been opened etc 1 Stack is stuck on infeed conveyor 2 The lowest tray of a stack is empty or not complete full 3 Sensor on infeed conveyor is loose broken or not adjusted well 1 Stack is stuck on buffer conveyor 2 The lowest tray of a stack is empty or not complete full 3 Sensor on buffer conveyor is loose broken or not adjusted ell w 1 Stack is stuck on stack conveyor 2 The lowest tray of a stack is empty or not complete full 3 Sensor on stack conveyor is loose broken or not adjusted w ell 1 Stack at end buffer conveyor is less then 6 trays high 2 Sensor l
143. ore starting operation cleaning maintaining the system or before remedying breakdowns first read the chapters Introduction and Safety AFTER ADJUSTMENTS When the adjustments are finished ensure the following All fasteners are secure All tools are removed from the system A All safety covers are in place and safety doors are closed The system is tested before starting production Page 132 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen COMPONENT ADJUSTMENTS Should be ON ON while detecting OFF while detecting UM PLV2 02 E 10 201 1 ush once ADJUSTMENTS PHOTO SWITCHES There are 3 types of photo switches Diffuse reflective photo switch 1 This is a photo switch which transmits a light beam An object is detected when the photo switch receives the light beam back because it reflects on the object Retro reflective photo switch 2 This is s a photo switch which uses a reflector to receive its transmitted light beam back An object is detected when it interrupts the light beam Through beam photo switch 3 This photo switch consist of a transmitter and a receiver part The transmitter sends a light beam to the receiver An object is detected when it interrupts the light beam PD30 DIFFUSE REFLECTIVE Adjust the sensor according the below procedure 1 Align the sensor to its correct position without the object it has to detect The gre
144. ork is not out Trying to move manually the venturiframe down but the fork is not Move manually the forks out out Message Loader venturi frame is not up Trying to move manually the forks in but the venturiframe is not Move manually the venturiframe up up 165 27 Message Loader check sensor Venturiframe trigger sensor is not well positioned loose or broken Check venturiframe trigger sensor PLO BRI 87B03 diPxTriggerServoVenturiFrame On USER MANUAL PALLET LOADER V2 ba the loader by pressing the stop button When stopped loader not in auto the recipe can be changed but be sure the infeed s is empty 1 Empty palletstock with one or more pallets or empty head manually Panel Manual gt Loader gt Gripper Venturi and or Servo 2 Change recipe settings Panel Recipe gt Change actual recipe gt Palletstock Make the loaderhead free manually Panel Manual gt Loader gt Forks and or Grippers Venturi and or Servo Make the loaderhead free manually Panel Manual gt Loader gt Forks and or Grippers Venturi and or Servo Make the loaderhead free manually Panel Manual gt Loader gt Grippers Venturi and or Servo Stop the loader by pressing the stop button When stopped loader not in auto a pallet can be filled by hand on the outfeedposition Stop the loader by pressing the stop button When stopped loader not in auto a pallet can be filled by hand on the outfeedposition Stop the loader by pre
145. ort and pallets dividers trays or machine parts resulting in damaged machine parts pallets dividers trays and eggs UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 OPERATION CHANGE RECIPE OUTFEED Tray type Here it is possible to select the appropriate tray type Select the same tray type in the change actual recipe infeed menu Divider type Here it is possible to select the appropriate divider type Pallet type Here it is possible to select the appropriate pallet type Weight Here the weight of the tray divider and pallet should be entered This information is used for calculating the weight of the stacked pallet Arrow buttons 100 With the arrow buttons it is possible to move the fork carrier and the fork support to the required position for placing rows on the pallet Actual position 101 Here you can see the actual position of the fork carrier fork Support Pallet position outfeed 1 Here you can see the position of the pallet on the outfeed With the up down arrow buitons it is possible to change the value Teach When the fork carrier fork support are on the correct position for placing a pallet it is possible to save this position directly using this teach button The position value in the green numerical window is transferred to the yellow numerical window Trigger divider When the fork support is moving down with a plastic divider in the grippers from a partic
146. ositions infeed 1 Here you can see the row pick up parameters With the up down arrow buitons it is possible to change the value Teach When the fork carrier fork support are on the correct position for picking up a row from the infeed conveyor it is possible to save this position directly using this teach button The position value in the green numerical window is transferred to the yellow numerical window Off Here it is possible to disable the infeed conveyor This may be used when a pallet loader has 2 infeed conveyors Page 93 of 167 OPERATION 012 AlarmText 012 AlarmText 22345 Change recipe pallet stack1 22 01 53 Pick last pallet stock 1 C Pallet Stock full Teach Before starting manual control make sure it is safe to do so fork carrier fork support cannot push over stacks from the pallet or collide with other machine parts ATTENTION Make sure the saved value is a correct value Incorrect values result in collisions between the fork support and pallets dividers trays or machine parts resulting in damaged machine parts pallets dividers trays and eggs Page 94 of 167 USER MANUAL PALLET LOADER V2 5 rinzen CHANGE RECIPE PALLET STOCK Pallet type Here it is possible to select the appropriate pallet type Arrow buttons 80 With the arrow buttons it is possible to move the fork carrier and the fork support to the r
147. ossible to start the system when you are inside the pallet loader _ DANGER Make sure the safety catch is IN before entering the pallet loader SAFETY CATCH In systems with a heavy vertical moving unit like for example the fork support a safety catch cylinder is provided A strip with protrusions 10 prevents the downward movement of the lift when the machine is stopped Whenever a safety device is not released or when the system is powered OFF the piston 11 of the spring returned safety catch cylinder moves outwards in between the protrusions in the strip A sensor on the cylinder detects the safety catch cylinder IN position When this sensor is not ON the lift will not move and the message Safety latch vertical lift not appears on the touchpanel DANGER Whenever it is necessary to work in the area where the lift moves up and down make sure the safety catch is OUT DANGER Make sure the fork support is in its bottom position before entering the system Never sit crawl or walk underneath the fork support Page 24 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 SAFETY SAFETY PLC All safety devices emergency buttons safety switches trolley switches and safety screens are connected to the safety PLC After switching ON the system first the touchpanel has to start up It takes around 90 seconds before the start up screen appears Then it takes another 30 s
148. pe settings Panel Recipe gt Message Loader palletstock 2 is empty 1 Palletstock 2 is empty 1 Wait till loader is stopped then you can fill the palletstock Pressing the 2 If palletstock is not full change the recipe settings Panel Recipe gt 165 10 Message Loader timeout too long in choise main program The loader head can NOT execute a task Check for other alarms messages check sitiuation Check the situation for example row on head and pallet not present at outfeed impossible and change the situation if needed Page 162 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 p rinzen TROUBLE SHOOTING GUIDE in loaderhead and palletstock full replace remove pallet manually out of loaderhead 165 Message Loader Trying to pick a pallet out of palletstock but head not free free loaderhead manually 165 Message Loader Trying to place a divider pallet on pallet stock but head not free free loaderhead manually 165 Message Loader Trying to pick a divider but pallet gripped in head free loaderhead manually UM PLV2 02 E 10 201 1 Loader recipenumber can be changed Factor runs and present on panel change recipe page because loader runs Message Loader try to scan an outfeed position but pallet 1 Pallet in head but can Not be placed back in palletstock it is full 2 If not full the recipe settings are incorrect In normal process this may not happe
149. r following the above instructions the alarm can NOT be resetted contact Prinzen See also 1 Safety of this manual Message Outfeed yellow muting lamp broken Muting lamp is broken Change muting lamp PLO MAIN 101H03 Message Outfeed yellow muting lamp on Muting is active muting lamp is yellow PLO MAIN 101H03 175 04 Message Outfeed taken pallet is not confirmed Orange lamp flashes if pallet is picked up sensor has come free Only press this button if pallet is completely moved away from outfeed last outfeed is completely free PLO MAIN 102SH03 SEC OUI RN NN NN sequence Check machine for mechanical Besse 182 01 Alarm Outfeed safety Machine safety is activated for example safety screen is or has 1 First solve if needed the cause of the safety interruption for example been interrupted or door is or has been opened etc RS if 2 screen is not interrupted or the door is closed but make sure no persons are in danger 2 The alarm can be resetten by pressing the nearest blue reset button If still after following the above instructions the alarm can NOT be resetted contact Prinzen Page 164 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 p rinzen TROUBLE SHOOTING GUIDE 182 02 Alarm Outfeed frequency inverter There is a problem with one of the frequency inverter Check the message on the frequency inverter PLO MAIN 47U03 optional See also
150. rates the liquids and the pollution which has mixed with the air flowing through the air distribution pipes The water separator needs manual drain off Check the regulator daily and drain off the water if necessary 11 Check the filter inside the water separator half yearly and clean or replace it if necessary UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 121 of 167 PREVENTIVE MAINTENANCE gt p PREVENTIVE MAINTENANCE INSTRUCTIONS DAILY PREVENTIVE MAINTENANCE Daily Maintenance Interval hours Observe for abnormal sounds vibrations and heat Check complete air supply for leakage Drain off water separator air regulators Check the functionality of the emergency stop buttons Check the functionality of the optional safety switches Check the functionality of the safety screens Page 122 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 PREVENTIVE MAINTENANCE WEEKLY PREVENTIVE MAINTENANCE Weekly Maintenance Interval hours Apply Teflon spray on rod ends gripper cylinders 4x Apply Teflon spray on rod end tilting cylinder Apply Teflon spray on rod end venturi frame cylinder Apply Teflon spray on rod ends venturi frame tie rod 2x Apply Teflon spray on rod end side shift cylinder Apply Teflon spray on plain bearings grippers 8x Apply Teflon spray on plain bearings tilting mechanism 2x Apply Teflon spray on plain bear
151. re open or not locked because serious injury or death may occur PROTECTIVE COVER Protective covers 4 shield off dangerous moving parts These covers cannot be removed without tools and should be attached to the system before starting to use it DANGER Protective covers safeguard dangerous machine areas These covers are of utmost importance to operate the machine safely Never operate the machine when protective covers are removed because serious injury or death may occur Page 22 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 o AFETY rinzen z SAFETY SCREEN In systems where easy access to openings is necessary a safety screen 5 is provided to stop the system immediately when it is interrupted A safety screen consists of a transmitter 7 a receiver 8 and occasionally mirrors When the safety screen is uninterrupted the LED s on the receiver are green as shown in the alongside picture 7 74 St E uu 242 E x 5 m eru 4 2 me 2v 2 P y Eor X Interrupting the safety screen stops the fork carrier fork support and the pallet outfeed conveyors immediately When the pallet outfeed conveyors are running in the manual mode they remain running when the safety screen is interrupted After interrupting a safety screen and after switching the power ON it is necessary to reset the safety screen
152. re starting to move parts of the system you have to assure yourself no other persons are in danger Make sure nobody is around the part you intend to move ATTENTION By working on a higher operating level you have more possibilities to control the system manually When you move parts manually it may be possible that parts will collide resulting in damage of the system UM PLV2 02 E 10 2011 USER MANUAL PALLET LOADER V2 Page 63 of 167 OPERATION 5 rinzen ATTENTION Do not damage parts of the system with pallets dividers or trays during manual control of the system Parts may start to move so that pallets dividers and trays are jammed which may damage these parts ATTENTION It is not necessary to press real hard on the Touch Panel We advise against doing this because it may damage the Touch Panel It is forbidden to press on the Touch Panel with sharp objects because this may also damage the Touch Panel Emergency stop button After pushing the red button the system stops immediately Only use this button in case of emergencies TIP Only use the emergency stop button for real emergencies Follow the normal stop procedure to stop the system When somewhere on the system an emergency button is pressed you have to reset and start the system again by pressing the reset and the start button on this main operating panel Start By pressing the start button the system starts to run The light inside the
153. rinzen USER MANUAL PALLET LOADER V2 Prinzen B V Weverij 18 7122 MS AALTEN P O Box 85 7120 AB AALTEN NEDERLAND Phone 31 0 543 490060 Fax 31 0 543 476205 e mail service prinzen com Website www prinzen com e 5 KG UM PLV2 02 E 10 201 1 TABLE OF CONTENTS CHAPTER INTRODUCTION SAFETY QUICK REFERENCE GUIDE MACHINE DESCRIPTION OPERATION CLEANING PREVENTIVE MAINTENANCE ADJUSTMENTS SPARE PARTS TROUBLE SHOOTING USER MANUAL PALLET LOADER V2 TABLE OF CONTENTS BOOK Page 3 of 167 TABLE OF NTENT ONES podia INTRODUCTION aH c 9 IL 11 GENERAU E 11 COP Y RIGHT EE T Eda 11 GENERAU e m G 12 SAFE Y REGULATIONS E E 12 LEGACREGUOULATONS T 12 HOW TOUSE THIS MANUAL 13 WHO SHOULD USE THIS MANUAL 13 E TOTUM NO Ed PORE UD du 13 mai Esai
154. ripper cylinder Timeout gt movement of cylinder takes to long detected by sensor s on end of cylinder cause Mechanical Blockage Reedcontact end sensor s not well positioned loose or broken No air pressure Valve broken Mechanical Blockage Reedcontact sensor on end of cylinder PLO BRI 84B03 07 if well Reedcontact sensor s not well positioned loose or broken positioned loose or both broken No air pressure Air pressure see manometer Valve broken Valve Use if the situation makes it possible without danger the manual control to test the cylinder Panel Manual gt Loader gt Forks or Gripper Venturi or Servo Check For mechanical blockage and solve if needed the blockage Reedcontact sensor on end of cylinder PLO BRI 86B03 07 if well positioned loose or both broken Air pressure see manometer Valve Use if the situation makes it possible without danger the manual control to test the cylinder Panel Manual gt Loader gt Forks or Gripper Venturi or Servo UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 159 of 167 TROUBLE SHOOTING GUIDE p rnnzen 162 32 Alarm Loader timeout reedcontact fork in out cylinder Timeout 2 movement of cylinder takes to long detected by Check sensor s on end of cylinder cause For mechanical blockage and solve if needed the blockage Mechanical Blockage Reedcontact sensor on end of cylinder P
155. rt up screen to go to the main screen Wait 30 seconds before starting the system Start the system See page 100 for more information about starting the system 2 While running production watch the system and duly supply pallets and dividers and remove stacked pallets See page 102 for more information about dividers and pallets supply See page 103 for more information about removing full pallets 3 Stop the system See page 104 for more information about stopping the system Recipe selection See page 106 for selection a different recipe UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 35 167 QUICK REFERENCE GUIDE 5 oe Scanning After switching the power supply ON manually controlling the pallet loader or interruption the safety screens of the pallet outfeed conveyors the pallet loader starts scanning the pallet stack position to determine the next stack position for a row Sensors on the fork support perform the scan See page 54 for more information about the scan sensor On a complete top layer 3 rows the scan sensors are not able to determine whether there is a divider present on top of this layer When this is the case after scanning an operator assistance screen pops up asking the operator to confirm whether there is a divider present or not With this information the system starts stacking the next row immediately or it first places a divider on the stacked pallet When more than one safety
156. s immediately start to move ATTENTION Y When frequency inverters are manually controlled parts of the system immediately start to move This may result in collision of parts which may damage the system TIP After a frequency inverter has been controlled manually the system may have lost its sequence and a reboot of the system may be necessary power OFF and power ON TIP See the OMRON V1000 User manual for details about this frequency inverter rinzen FREQUENCY INVERTERS Changing parameter values Follow below procedure to change parameters values Press the up 1 or down 2 button until PAr is visualized on the display Press the enter key 3 to display the parameters Use the Reset button 4 to select a parameter digit Repeat this step and next step until the parameter you want to view is displayed Press the up 1 or down arrows 2 to change the parameter digit Repeat this step and previous step until the parameter you want to view is displayed Press the enter key 3 to display the parameter value Use the Reset button 4 to select a parameter digit Repeat this step and next step until the parameter value is changed Press the up 1 or down 2 button to change the parameter digit Repeat this step and previous step until the parameter is completely changed Confirm the change with the enter key 3 Press the escape key 5 until the DR
157. s infeed or infeed2 gt press calibrated calibration gt check calibration factor 0 427 PLO MAINS90FC08 81FC08 FCO8 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 Page 154 of 167 p rinzen TROUBLE SHOOTING GUIDE 152 Alarm Infeed2 mode timeout end auto Stop button has been pressed ones but could not finish its stop Check for other alarms or messages sequence Check machine for mechanical blockage 152 01 Alarm Infeed2 safety Machine safety is activated for example safety screen is or has Step1 First solve if needed the cause of the safety interruption for example been interrupted or door is or has been opened etc check if safety screen is not interrupted or the door is closed but make sure no persons are in danger Step2 The alarm can be resetten by pressing the nearest blue reset button If still after following the above instructions the alarm can NOT be resetted contact Prinzen See also 1 Safety of this manual 152 05 Alarm Infeed2 timeout infeed conveyor runs too long 1 Stack is stuck on infeed conveyor 1 Release the stucked stack and start up again 2 The lowest tray of a stack is empty or not complete full 2 If lowest tray is empty or not complete full remove all stacks on the 3 Sensor on infeed conveyor is loose broken or not adjusted infeed conveyor and startup again well 3 Check sensors on infeed conveyor PLO MAIN 90FCO03 90FC1
158. scccsccssccsccsccsccsccscesccsscesseecesccsccsscuscesscsscescesscscescescessesscescesscescesscescesseescessesscescesceescenses 130 Page 6 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 TABLE OF CONTENTS T PU US ERR 131 3721 MR TANNIRENCPRTE PM e 132 SAFETY REGULATIONS EDU ERE ames Dor ctOPE I LDU PUR TES PU FOU SEEK PROS PUES PETERET 132 AFTER ADJUSTNVIENTS viru PE pruDiUPEE creda PRS HIT ROID 132 COMPONENT ADJUSTMENTS 52 adco DIS r RUE EP PEINE EP rreS ES 133 PHOTO SWITCHES wsccascsnavaacivsetinseevesaacieteheasnenondicieveiuswenesanciebeniasvanessuctehaninsdoucnavedesakinsanneniciesobiaweananaieisbalianasnnnareiebebiananeaeaisieanianasaneansies 133 cack aes seca ct aiid len ana 133 PD30 RETRO REFLECTIVE TR CERTOS E 133 TT TETTE 134 QS IO BY 0 4 24 WAS RELE JUR ASAP 134 QS 134 PA
159. screen appears in which it is possible to determine the speed of the fork carrier and fork Support during its various movements Servo Acceleration Deceleration O tt After touching this button the acceleration deceleration screen appears in which it is possible to view or change the speed up and slow down settings of the fork carrier and the fork support during its various movements General servo positions After touching this button the positions screen appears in which it is possible to view and change the various stop positions of the fork carrier and fork support Factory settings After touching this button the factory settings of the loader are restored These settings are not immediately used but are used after switching the system OFF and ON again Then all changed parameter settings are lost LOADER SERVO SPEEDS 012 01 AlarmText 012 01 AlarmText 22345 Settings loader speeds 22 01 59 semi semi semi In the alongside screen the speeds of the fork carrier horizontal and fork support vertical during their movements to particular positions Gripper eH or during particular movements are displayed 1245 ac Velocity STEM Normally this setting is 10096 For testing Mena purposes it is possible to set this value in between 1 and 100 When this value is set Tough venturi on divider i t
160. screen is present the controller knows which safety screen is interrupted When entering a part of the system through a safety screen only adapt the part of the system that is protected by this particular safety screen because only this area is scanned after resetting this safety Screen See page 23 for more information about the safety screens Page 36 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 MACHINE DESCRIPTION 3 MACHINE DESCRIPTION UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 37 of 167 MACHINE DESCRIPTION SAFETY REGULATIONS Before starting operation cleaning maintaining the system or before remedying breakdowns first read the chapters Introduction and Safety BA Page 38 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 2011 MACHINE DESCRIPTION MACHINE DESCRIPTION The machine description gives information about the most complete pallet loader It is possible that your system does not contain all the described units For detailed information of all the units of the pallet loader see the Unit description in this chapter PALLET LOADER 27 df P z i 8 lt v 7 gt m p Y 2 _ B 11 S 524 S n 2 ox ns M 5 ET
161. sed in accordance with the instructions as described in this manual The information provided in this manual is valid for the standard design of the system Parts of your system may differ from this standard design Since Prinzen BV is constantly improving its systems it may be possible that there are small differences between your system and this manual Though this manual has been put together with the utmost care Prinzen BV cannot accept any responsibility for costs damage or personal injury arising from any fault and or incompleteness in the content of this document GENERAL This manual contains important information concerning safety operation adjustment maintenance cleaning and repair of the Prinzen BV system For uncomplicated functioning of the system read this manual carefully and work according to the directions in this manual Beside the design and the used materials also the operation and maintenance have great impact on the functioning the life span and the operational costs of our system You as the owner of the system are responsible for the execution of maintenance according to the directions and the intervals in this manual This manual will help you to gain knowledge to use the system as it should be used Correct operated and excellent maintained A Prinzen BV system meets the demands mentioned in the European machine guideline CE COPYRIGHT Prinzen BV e e This document contains confidential inform
162. setting the system to prevent unexpected fast movements of air cylinders The speed of the pressure built up is adjustable with the set screw 5 on the topside When the soft starter cannot build up the of the soft starter pressure there may be an air leak somewhere in the system SPEED CYLINDERS Some movements are controlled by air cylinders These cylinders have speed restrictors 6 to adjust the speed of the ingoing and outgoing stroke of the cylinder Normally the speed is adjusted with the outgoing air When adjusting these speeds it should not influence the cycle time of the complete system but the cylinder movements should be smooth and gentle CYLINDER AIR CUSHIONING The movement of the piston rod of an air cylinder is stopped by an air cushion 7 on both sides of the cylinder The air cushion absorbs the piston rod movement The air of this cushion is released through the air cushioning screw By adjusting this screw it is possible to stop the piston rod movement in a smooth and gentle way A correct adjustment of this air cushioning extends the life span of the air cylinders Adjust this screw in such a way that the air in the cushion is released slowly and the piston rod is stopped gently Page 136 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 TMENT rinzen 5 VALVES In the system valves are positioned to control the air cylinders Manual activation of
163. sition which is at the end of the belt When the 4 stacks are removed by the fork carrier fork support the above sequence is repeated A number of sensors control the supply of stacks towards the pick up position A Start belt When this sensor detects a stack the belt starts to run When the stack has passed this sensor the belt stops B Safety 5th stack When the fork support is ready to pick up the 4 stacks this sensor should not detect a stack C Stop infeed belt This sensor is used in combination with sensor E When both sensors E and C detect stacks within a certain time the belt stops D Stacks to pick up position When this sensor detects a stack 4 stacks are on the infeed belt The belt starts running until sensors E and C both detect stacks E Stop infeed belt This sensor is used n combination with sensor C When both sensors E and C detect stacks within a certain time the belt stops F Detection too low stack height Stacks should be 6 trays high This sensor prevents entering too low stack heights USER MANUAL PALLET LOADER V2 Page 45 of 167 MACHINE DESCRIPTION CAUTION Do not enter objects or body parts into the infeed conveyor when it is running production CAUTION Do not enter objects or body parts into the entry of the pallet loader when the system is running production CAUTION Interrupting the safety screen does not stop the infeed conveyor ATTENTION Do not enter o
164. ssing the stop button When stopped loader not in auto a pallet can be filled by hand on the outfeedposition Stop the loader by pressing the stop button When stopped loader not in auto a pallet can be filled by hand on the outfeedposition Stop the loader by pressing the stop button When stopped loader not in auto the pallet can be taken by hand from the outfeedposition ston the loader by pressing the stop button When stopped loader not in auto the pallet can be taken by hand from the outfeedposition Sto the loader by pressing the stop button When stopped loader not in auto the pallet can be taken by hand from the outfeedposition Stow the loader by pressing the stop button When stopped loader not in auto the pallet can be taken by hand from the outfeedposition Make the loaderhead free manually Panel Manual gt Loader gt Forks and or Grippers Venturi and or Servo Page 163 of 167 TROUBLE SHOOTING GUIDE p rnnzen 172 Alarm Outfeed mode timeout end auto Stop button has been pressed ones but could not finish its stop Check for other alarms or messages sequence Check machine for mechanical blockage 172 01 Alarm Outfeed safety Machine safety is activated for example safety screen is or has 1 First solve if needed the cause of the safety interruption for example been interrupted or door is or has been opened etc PAR if 2 screen is not interrupted or the door is closed but make sure
165. stem OPERATION SERVICE MENU In this menu the user of the system is able to change a number of settings using submenus Not all submenus are available for the operator or the supervisor list After touching this button the I O menu appears Via this menu it is possible to view the status of all the inputs sensors and outputs motors valves Service After touching this button the Service interval screen appears In this screen it is possible to enter service message which will appear on the touchpanel when its set interval counter has elapsed Software debug After touching this button the software debug screen appears This screen shows information about the status of the software Machine settings After touching this button the machine settings menu appears In the submenus of the machine settings menu it is possible to change parameters that control the system Most of these submenus are not available for the operator and the supervisor Panel settings After touching this button you will enter the panel settings menu in which it is possible to change touchpanel settings Some submenus are not available for the operator and supervisor UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 81 of 167 OPERATION rinzen 012 01 amp larmText nonam AN mE 22345 Input Output Menu 22 01 59 ar Here it is possible to select a certain unit and necs Loader feed with the appearing scre
166. stock 2 Press the stop button on the local operating panel the local start button starts flashing 3 Wait until the units are stopped the start button turns OFF 4 Place pallets in the pallet stock or a pallet with dividers in the divider stock 5 sure the stacks are not skew Push pallets or dividers against the guides Make sure the height of the stack remains below the top of the guide DANGER Make sure the safety screen remains interrupted when you are supplying pallets or dividers to the pallet stock or divider stock 6 Push the flashing reset button on the local operating panel until it stops flashing DANGER Make sure nobody is present inside the pallet loader before resetting an interrupted safety screen 7 Push the start button on the local operating panel it turns ON Now the system continues running production Page 102 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 o PERATION rinzen M FULL PALLET REMOVAL Follow below steps to remove a full pallet from the pallet outfeed conveyor 1 A full pallet is automatically transferred from the pallet stack position to the pallet discharge position 2 Roll the forks of a fork lift or a hand pallet truck underneath the pallet en lift the pallet The pallet outfeed button starts FLASHING 3 Carefully roll the pallet away from the pallet outfeed conveyor CAUTION Carefully
167. t 012 AlarmText 227345 Settings Infeed Calibration Siepz infeed conveyor ix empty again Then Start empty press button Start empty measurement measurement infeed can infeed conv Steps place calibration weight on em ieee 3 ply Start weight infeed conveyor and then press button 5 measurement Start weight measurement Stepi Typ calibration weight Calibration factor loadcell 71 2 UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 OPERATION INFEED SETTINGS SCREEN Delay time Start buffer conveyor after stack conveyor runs to transfer stack This parameter determines the timing for starting the buffer conveyor after the stacker conveyor starts running to transfer a stack of trays to the buffer conveyor Delay time Start infeed conveyor after buffer conveyor runs to transfer stack This parameter determines the timing for Starting the infeed conveyor after the buffer conveyor starts running to transfer a stack of trays to the infeed conveyor Delay time row at end infeed conveyor This parameter determines the time that the infeed conveyor remains running after a stack of trays is detected at the end of the conveyor Time stack conveyor has to be empty When the stack conveyor runs for the set time and no stack of trays is detected this conveyor is assumed to be empty Time buffer conveyor has to be empty When the buffer conveyor runs for the set time and no stack of trays is detected
168. the lift area lock the lift movement mechanically Disregarding this warning may result in permanent personal injury This sign is used to remind you to activate the Before entering the system safety key emergency button and to keep the Push the emergency button and lock it safety key in your pocket while you are inside with the safety key the system Keep the safety key in your possession while you are inside the system UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 29 of 167 QUICK REFERENCE GUIDE 2 QUICK REFERENCE GUIDE UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 31 of 167 QUICK REFERENCE GUIDE SAFETY REGULATIONS Before starting operation cleaning maintaining the system or before remedying breakdowns first read the chapters Introduction and Safety GENERAL This quick reference guide familiarizes you in a short time with the content of this manual and gives you the most important information about the system Read this guide and use the references to absorb this important information uN Page 32 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 6 QUICK REFERENCE GUIDE PALLET LOADER CONSTRUCTION The Pallet loader consists of 1 Pallet stock 9 Pallet outfeed 2 Divider stock 10 Electrical cabinet main 3 Infeed conveyor 11 Electrical cabinet fork carrier fork 4 Buffer conveyor support 5 Stacker conveyor optional 12 Main operat
169. these valves controlling the cylinders is possible by pressing on the manual activating pin 8 CAUTION Before manually activating valves make sure no persons are in danger Air cylinders immediately start to move ATTENTION When valves are manually activated parts of the system immediately start to move This may result in collision of parts which may damage the system REED SWITCH ON A CYLINDER When sensors are present on the cylinder to detect the piston position these sensors should be adjusted properly When only 1 sensor is used it is important to know if the ingoing or outgoing stroke of the piston rod has to be detected Below the general adjustment instruction for the sensors on the air cylinders is stated Loosen up the connection of the sensor to the cylinder Move the sensor to the outside of the cylinder until the sensor goes OFF A Move the sensor to the centre of the cylinder until the sensor goes OFF B Move the sensor to the position in between position A and B C Fasten the sensor again at position C UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 137 of 167 Page 138 of 167 ADJUSTMENTS ATTENTION The parameters of the frequency inverters are factory set We advise you to consult Prinzen before changing these parameters CAUTION Before manually controlling frequency inverters make sure no persons are in danger Motor
170. transport the full pallet Do not endanger other persons 4 When the pallet is completely removed from the pallet outfeed conveyor press the pallet outfeed button to confirm that the pallet is really removed DANGER Make sure the pallet is completely removed from the pallet outfeed conveyor A next pallet may knock down the previous pallet causing permanent injury to the operating personnel 5 light inside the button turns OFF 6 Now the pallet loader can discharge a next full pallet UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 103 of 167 OPERATION 5 rinzen MARCHE Page 104 of 167 ARRET STOPPING PRODUCTION 012 01 AlarmText 012 01 AlarmText 22345 Home Menu START STOP 22 01 59 STOPPING THE SYSTEM Follow below steps to stop the system 1 Push the stop button once on the main operating panel or all local stop buttons The start button s start flashing 2 Wait until all movements of the system are stopped The start button s turns OFF 3 Press an emergency button 4 Switch the power supply off by turning the main switch to OFF 5 Make sure the fork support is empty and switch OFF the air supply 6 Helease the air through the outlet valve 7 Atthe end of a production day clean the pallet loader EMERGENCY STOP NOODS TOP REMISE NOT AUS ARRET DURGENGE USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 2011
171. tray of a stack is empty or not complete full 2 If lowest tray is empty or not complete full remove all stacks on the 3 Sensor on infeed buffer conveyor is loose broken or not infeed conveyor and startup again adjusted well 3 Check sensors on infeed and buffer conveyors PLO MAIN 90FCO03 91FC08 Alarm Infeed2 too quickly a stack at end of buffer conveyor 1 A stack was placed by hand on infeed or buffer conveyor 1 Remove the stack and startup again detected 2 Sensor on infeed buffer conveyor is loose broken or not 2 Check sensors on infeed and buffer conveyors adjusted well PLO MAIN 90FC03 91F C08 Alarm Infeed2 row on end infeed conveyor but fourth stack not present 1 A stack was placed by hand on infeed conveyor 1 Remove the stack and startup again 2 The lowest tray of a stack is empty or not complete full 2 If lowest tray is empty or not complete full remove all stacks on the 3 Sensor on infeed conveyor is loose broken or not adjusted infeed conveyor and startup again l 3 Check sensors on infeed conveyors PLO MAIN 90FCO03 90FC17 152 12 Alarm Infeed2 stack at end and begin infeed conveyor 1 A stack was placed by hand on infeed or buffer conveyor 1 Remove the stack and startup again 2 Sensor on infeed buffer conveyor is loose broken or not 2 Check sensors on infeed and buffer conveyors adjusted well PLO MAIN 90FCO03 91FC08 wel UM PLV2 02 E 10 201 1 USER M
172. tween 8 and 10 bars System air regulator reduces it to 6 bars For more information see the pneumatic diagrams of your pallet loader Transport and Installation Height 300 The dimensions length x width and weight of the pallet loader depend on its execution For more information see the lay out drawing of your pallet loader Environment The climate around the machine must have a normal working temperature 10 C to 30 C During transport and storage the temperature of the system should remain in between 0 C and 45 C The system is not suitable for outdoor use and should not be used in a surrounding containing items having a high flash point or an explosive nature Environment consequences Dismantling and disposal of the system must be carried out by a suitable disposal company which has the required licenses and permits for the state or the country concerned Dismantled materials should be sorted for disposal according to local rules and regulations that may apply oeparate all materials like oil and lubrication fluids and discharge them as chemical waste Page 42 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 MACHINE DESCRIPTION UNIT DESCRIPTION PALLET STOCK Use The Pallet stock is used to place a stack of pallets for automatic supply of pallets to the pallet stack positions Construction The pallet stock consists of 1 Bottom guides 2 Side guides Process
173. ually it may be possible that parts will collide resulting in damage of the system ATTENTION Using the manual buttons may result in damaging pallets dividers trays eggs and machine parts We advise you to remove all pallets dividers and trays from the system before starting to use these buttons ATTENTION The manual screens should only be used by advanced users of the system like Prinzen engineers for testing the system Page 76 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen OPERATION 012 01 amp larmText SCREEN 22345 Manual Toptray 22 01 59 Pusher denester back Pusher denester out 3 Pusher denester back Pusher denester out With these buttons it is possible to move the Decenter stack Center stack pusher above the stack out or back h the tray denest ee 4 underneath the tray denester ote Denester stack Center stack Rotate stack Rotate stack COW With these buttons it is possible to close the ci CS chy centering unit center stack of open the l centering unit denester stack Rotate stack CW rotate stack CCW With these buttons it is possible to rotate the centering unit Clock Wise CW or Counter Clock Wise CCW 012 01 amp larmText INFEED MANUAL SCREEN 22345 Manual Infeed 22 01 59 Infeed conveyor Buffer conveyor Stacker conveyor Stacker conveyor After touching this arrow button the conveyor under
174. ular height it starts to use the row 2 sensor 102 to detect the height for placing a plastic divider on top of the stacks The trigger divider value determines the distance in 0 1 mm the fork support moves down after the row 2 sensor has detected the top of the stacks for the exact height to place a divider on top of the stacks Off Here it is possible to disable the pallet outfeed conveyor This may be used when a pallet loader has 2 outfeed conveyors Page 97 of 167 OPERATION Page 98 of 167 5 rinzen No divider on pallet Divider on pallet With this button it is possible to determine if a carton divider should be placed on a wooden pallet before starting to place the stacks on this pallet When no divider on pallet is selected no divider will be placed on the pallet When divider on pallet is selected a divider will be placed on the pallet Number of layers Here you can enter the amount of layers to be placed on the pallet Normally it is possible to place a maximum of 5 layers on the pallet but optionally it is possible to place 6 layers on a pallet Top tray ON OFF Here you can determine if a top tray should be placed on the stacks of trays which enter the pallet loader Rotate ON OFF Here you can determine if the stack should be turned per layer Rows After touching this button you will enter the change rows recipe screen USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 2
175. uld be present on the infeed buffer conveyor TIP Never place stacks on the buffer conveyor during normal production of the pallet loader The system will malfunction Safety The infeed conveyor is positioned into the secured area of the pallet loader On all sides it is protected by fencing except the entry for stacks into the pallet loader The buffer conveyor is not completely secured with protective covers Therefore be cautious with loosely hanging clothes and long hair do not come too close to the infeed conveyors and do not touch them when the system is running production Never touch the belt or come near the entry of the pallet loader when the system is running production UM PLV2 02 E 10 201 1 MACHINE DESCRIPTION BUFFER CONVEYOR Use The buffer conveyor transports the supplied stack of trays from the upstream systems to the infeed conveyor Construction The infeed conveyor consists of 1 Transport belt 2 Drive mechanism Process During normal production the buffer conveyor receives 4 stacks from the upstream system and transfers these 4 stacks to the infeed conveyor according to the below sequence The buffer conveyor runs start stop As soon as a stack is detected at its entry it starts it stops as soon as this stack is completely on the belt This is repeated until 4 stacks are present on the belt As soon as the infeed conveyor request stacks the buffer conveyor
176. veyor the top tray denester is positioned Process plastic trays On request of the buffer conveyor stacks are supplied by the upstream systems and transferred to the buffer conveyor Process paper trays Stacks are supplied by the upstream systems and are stopped underneath the top tray denester The top tray denester places a tray on top of the stack Depending on the destination layer of the stacks the stacks are immediately transferred layer 1 3 and 5 to the buffer conveyor or the stacks are first turned layer 2 4 and 6 before they are transferred to the buffer conveyor Safety The optional stacker conveyor is not completely secured with protective covers Therefore be cautious with loosely hanging clothes and long hair do not come too close to the conveyor and do not touch it when the system is running production Never touch the belt when the system is running production CAUTION Do not enter objects or body parts into the stacker conveyor when the system is running production CAUTION Interrupting the safety screen does not stop the conveyors ATTENTION Do not enter objects or body parts into the stacker conveyor when it is running production Page 48 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 MACHINE DESCRIPTION Use TOP TRAY DENESTER The optional top tray denester is only used when palletizing stacks with paper trays It plac
177. y a new pallet with dividers Safety The divider stock is positioned into the secured area of the pallet loader On all sides it is protected by fencing except the infeed side which is protected by a safety screen When the safety screen is interrupted the fork carrier fork support stops immediately DANGER Do not enter objects or body parts into the pallet stock when the system is running production ATTENTION Do not enter objects or body parts into the packer when it is running production Page 44 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 201 1 rinzen a E INFEED CONVEYOR UM PLV2 02 E 10 201 1 F MACHINE DESCRIPTION Use The infeed conveyor transports the supplied stack of trays from the buffer conveyor to the fork carrier fork support As an option an additional stacker conveyor and a top tray denester are available Construction The infeed conveyor consists of 1 Transport belt 2 Drive mechanism Process During normal production the buffer conveyor buffers 4 stacks and these 4 stacks are transferred to the infeed conveyor according to the below sequence The infeed conveyor runs start stop As soon as a stack is detected at its entry it starts it stops as soon as this stack is completely on the belt This is repeated until 4 stacks are detected on the belt Then the infeed conveyor starts to run until the 4 stacks are transferred to the pick up po
178. y parts into the transport conveyor when the system is running production ATTENTION Do not enter objects or body parts into the transport conveyor when the system is running production UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 59 of 167 OPERATION 4 OPERATION UM PLV2 02 E 10 201 1 USER MANUAL PALLET LOADER V2 Page 61 of 167 OPERATION SAFETY REGULATIONS Before starting operation cleaning maintaining the system or before remedying breakdowns first read the chapters Introduction and Safety BA Page 62 of 167 USER MANUAL PALLET LOADER V2 UM PLV2 02 E 10 2011 rinzen OPERATION EXPLANATION OF THE OPERATION OPERATING PANEL EMERGENCY STOP Hoobs Tar MARCHE ARRET REMISE HoT AUS ARRET CURGENCE In the operating panel the touchpanel with PLC is situated The PLC controls the Pallet loader The touchpanel shows information about the status of the system By touching certain parts of the touchpanel depending on the chosen button or screen the system is controllable process settings can be changed or information becomes visible on the screen DANGER Although a lot of safety measures are built into the control of the system Prinzen cannot guarantee that no dangerous situations will occur Before you start the system make sure no persons are in danger DANGER By working on a higher operating level you have more possibilities to control the system manually Befo
179. zontal position directly using the corresponding teach button The horizontal position value in the green numerical window is transferred to the corresponding yellow numerical window Height The vertical positions for placing the rows are determined in the loader servo positions screen Here it is possible to correct this position for placing stacks on carton dividers For a lower place position increase this height value For a higher place position decrease this value Trigger The trigger value determines the distance in 0 1 mm the fork support moves down after the row 1 sensor has detected the pallet or the divider for the exact height to place a row of stacks on this pallet or divider With the up down arrow buitons it is possible to change the value Don t feed pallet out at emptying line Feed pallet out at emptying line With this button it is possible to determine if the pallet on the pallet stack position should remain there or should be removed when the run empty button is touched on the main screen When don t feed pallet out is selected the pallet will remain on the pallet stack position When feed pallet out is selected the pallet outfeed conveyor will transfer the pallet from the pallet stack position to the pallet discharge position Page 99 of 167 OPERATION 5 STARTING PRODUCTION DANGER On a daily basis the operator has to check the safety provisions before start

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