AUTOMATIC DEPALLETIZER

Transcription

1 AUTOMATIC DEPALLETIZER BEVCO MODEL: GENERIC DEPALLETIZER SEPTEMBER 20xx SERIAL NO: JXXXXX OPERATION AND CONTROL MANUAL

2 Table of Contents 1.0 General Operating Description General Controls Description Processor Operator Interface AC Frequency Inverters Safety Requirements General Requirements Electrical Interlocks Initial Programming Setup Main Screen Depal Speed Setup Line Control Product Selection Defining Pallet Height Automatic Control Sequence Initial Start up Pallet Infeed Conveyors Pallet Infeed Conveyor Pallet Hoist Conveyor Empty Pallet Conveyor Pallet Stacker Hoist to Start Sequence Automatic Unload Sequence Last Tier Removal Container Discharge Table Metering Table Automatic Operational Interlocks Manual Operation Initial Start Pallet Conveyors Hoist and Solenoid Control Carriage Control Auxiliary Control Manual Operational Interlocks Fault Messages Troubleshooting Depalletizer Allen-Bradley CompactLogix 1769-L32E Processor Pro-face AGP3500-S1-D24 Operator Terminal Preventative Maintenance Routine...34 Bevco Conveying Systems Page... 2

3 9.2 Start-up Daily Check List Regular Maintenance Requirements Shutdown Procedures:...35 Appendix I Device Functions...36 Bevco Conveying Systems Page... 3

4 1.0 General Operating Description The Bevco Depalletizer is designed to unload cans, bottles or jars from a full size pallet, with a high level discharge. The Depalletizer will accommodate two sizes of pallets, 56" wide x 44" long and 48" wide x 40" long. The equipment includes conveyors for handling full pallets: a pallet hoist/unload station, a container discharge/accumulation table and an empty pallet take away conveyor. An automatic tier sheet remover and a platform are included in the standard machine. Full pallets are loaded by forklift onto the pallet staging conveyor. Wrapping and strapping are removed at this time. Depending on the stability of the full pallet of containers, some strapping may be left for removal in the machine. The pallets are indexed on the pallet conveyors where two pallets are accumulated while a third pallet is being unloaded. A pallet is indexed into the elevator, where it is trapped by the elevator doors. The pallet is raised to the required height to remove any strapping, after which the operator initiates the unload sequence. After the operator initiates the unload sequence, the tier sheet and picture frame are removed from the top of the pallet, the pallet is lowered to the starting position, and the carriage shifts to position the tier sheet above the tier sheet bin. The pallet is raised to the level to unload the top tier and is stopped by an adjustable container height detector. The containers are pushed off the pallet onto the moving accumulation table. As the containers are unloaded, a set of tier sheet clamps hold the lower tier sheet in position on the pallet. The containers are held in position by a container stop until they have been moved onto the moving accumulation belt. When the tier has been unloaded, the tier sheet picker is positioned over the pallet and lowers and picks the next tier sheet. The tier sheet is held until the carriage shifts to position the tier sheet over the tier sheet bin. The hoist raises the next tier into position and the cycle is repeated down to the bottom tier on the pallet. Once the bottom tier is unloaded, the hoist takes the empty pallet down to the bottom, where it exits onto the empty pallet conveyor. The empty pallet is taken away to the pallet stacker, as a new pallet is indexed into the elevator. This restarts the entire unload cycle. Bevco Conveying Systems Page... 4

5 2.0 General Controls Description 2.1 Processor The Bevco Depalletizer uses a CompactLogix 1769 or later modular processor to control the sequence of operation of the Depalletizer. The input and output functions are handled with 24VDC input and 120VAC output modules of the modular controller. The AC frequency inverters are controlled using relay output modules. 2.2 Operator Interface A Pro-face AGP3500-S1-24 series operator interface is provided to allow the operator to monitor and control the sequence of operation of the depalletizer. The operator interface communicates to the CompactLogix 1769 processor over the Ethernet network and is integral to the operation of the depalletizer. 2.3 AC Frequency Inverters Allen-Bradley Powerflex series AC frequency inverters are provided to allow the smooth operation of the pallet elevator, carriage and discharge/accumulation table. The operation of the frequency inverters are controlled by the CompactLogix 1769 processor. Bevco Conveying Systems Page... 5

6 3.0 Safety Requirements Warning: Bevco depalletizers are automated and all equipment must be LOCKED OUT electrically and mechanically before any maintenance or work of any kind is performed on this equipment. 3.1 General Requirements a) All maintenance and repair work must be performed by qualified personnel. b) No equipment shall be operated with protective guards, covers or railings removed. c) No equipment shall be operated with electrical interlocks or safeties disconnected, removed or defeated. d) Worker s Compensation Board (Occupational Safety and Health of America) regulations shall be adhered to in all cases. e) Be aware, this equipment has many moving parts and pinch points, and extreme caution is advised when the depalletizer is in operation. f) Safety warning stickers have been affixed to this equipment and must not be removed. 3.2 Electrical Interlocks Warning: Bevco Depalletizers are automated and machine operation may start at any time, extreme caution is advised when the depalletizer is in operation. Electrical interlocks are provided to protect both the equipment and operating personnel, at no time shall the equipment be operated with the interlocks removed, disconnected or disabled. The following is a summary of interlocks provided. a) Emergency Stops Four emergency stops are provided, one located on the main control panel, one located on the operator interface panel, one located at the pallet infeed control station and one located at the pallet infeed control station, provision is made in the control panel to add an additional customer supplied emergency stop. The emergency stops provided are the push-pull type, depressing the emergency stop will de-energize the emergency stop relay and stop both the automatic and manual operation of the depalletizer. To reset, the emergency stop must be pulled out and the depalletizer switched back into manual or automatic operation. Bevco Conveying Systems Page... 6

7 The emergency stop circuit when activated will de-energize all outputs stopping all motors and de-energizing all solenoids. The solenoids on the depalletizer are double acting and will remain in the last position. If an air device is operating when the emergency stop is depressed, the device will continue to operate until the full stroke is reached. Warning: Emergency stops must not be used as a LOCK OUT device, proper disconnecting and lock out procedures must be adhered to. Bevco Conveying Systems Page... 7

8 4.0 Initial Programming Setup 4.1 Main Screen The Bevco depalletizer human-machine interface (HMI) will display a main screen as shown in figure #1 below. From this screen all other screens can be accessed. Additionally, a toggle switch is defined on this screen to show the display in Spanish. The main screen will be displayed when operating the depalletizer in automatic mode. figure #1 Main Screen 4.2 Depal Speed Setup From this screen press the Depal Setup button located to the lower left. The system will prompt the user for a password (default password: 1234). The HMI will then display Depal System Speed Setup as shown in figure #2 below. From here, the speed settings of the Sweep Forward Speed, Table 1 and Table 2 Forward Speed can be set. Touch the number display to Bevco Conveying Systems Page... 8

9 show the keypad. Key in the desired value and press Enter. This can be accessed to adjust as necessary. figure #2 Depal System Speed Setup Screen 4.3 Line Control From the Bevco depalletizer main screen select the Line Control button on the left portion of the display. The Line Control screen will be displayed as shown in figure #3 below. Bevco Conveying Systems Page... 9

10 figure #3 Line Control Screen From the Line Control display, the Line Sensors screen (figure #4), the Line VFD Status (figure #5), Product Selection (figure #6) and Line Setup (figure #7) as shown below can be accessed. Bevco Conveying Systems Page... 10

11 Figure #4 Line Sensors Screen Bevco Conveying Systems Page... 11

12 Figure #5 Line VFD Status Screen Bevco Conveying Systems Page... 12

13 Figure #6 Product Selection Screen (1 of 2) In the Line Control screen, press the LINE SETUP button in the lower right portion of the display. The user will be prompted for a password (default password: 5678). The Line Setup (Recipe) screen will be displayed as shown in Figure #X below. Bevco Conveying Systems Page... 13

14 Figure #7 Line Setup (Recipe) Screen The speed reference must be set up first. Press the SPEED REF button located in the lower right portion of the screen. The user will be prompted for a password (default password: 0868). The Filler VFD Speed Reference Selection screen will be displayed as shown in figure #8 below. Bevco Conveying Systems Page... 14

15 Figure #8 Filler VFD Speed Reference Selection Screen Select the button labeled PRESS TO USE FILLER AUTO SPEED FEEDBACK. This will store the current filler speed data. Press EXIT. *Note The button labelled PRESS TO USE THE ABOVE SPEED REFERENCE is for debugging purposes only, and should not be used for normal operation. The display will return to the Line Setup (Recipe) screen. Depending on the recipe, the multiplier will need to be adjusted to ensure smooth and uninterrupted flow to the downstream filler. *Note Ensure that the Filler VFD Speed Reference Selection has been performed at least once prior to this step. To adjust the multipliers for any recipe first select the desired recipe button on the left hand side. This does not need to be the current recipe; any recipe can be setup even if it is not the current product. Bevco Conveying Systems Page... 15

16 Touch the number display to show the keypad. Key in the multiplier value and press ENTER. This will need to be done for every recipe, and all 6 values. This can be accessed again when a new product is added. Press EXIT to return to the previous screen. 4.4 Product Selection In the Line Control Screen press PRODUCT SELECTION. The system will prompt for a password (default password: 5678). The Product Selection screen will be displayed as in figure #6. To name a recipe, touch the black banner area to the right of the SEL button and the text entry keypad will appear. Type in the desired recipe name for the appropriate line and press ENTER when finished. To select a recipe, press the SEL button to the left of the text. The current product is displayed in the banner area at the top of the page. Press EXIT to return to the previous screen 4.5 Defining Pallet Height Pallet layer height is defined through the Main Screen as shown in figure #1. Under Layer Height touch the number display to show the keypad. Key in the layer height and press ENTER. CURRENT LAYER displays the layer in progress. SET CURRENT LAYER TO 0 will bring up a flashing button display. CONFIRM RESET LAYER will reset the machine current layer to layer 0. EXIT RESET LAYER will discard the change attempt (no reset to layer 0). Bevco Conveying Systems Page... 16

17 5.0 Automatic Control Sequence 5.1 Initial Start up Before switching the depalletizer to the automatic mode the operator should ensure that the power and air supplies are turned on, all emergency stops are reset and the depalletizer is in the home position. Home Position: 1) Hoist doors and side walls are open. 2) Pallet stop closed. 3) Pallet hoist is at bottom of tower. 4) Carriage is located fully forward, with the tier sheet picker located over the hoist opening. 5) Tier sheet picker is in the up position, with the vacuum off. 6) Upper and lower tier sheet grippers are open. 7) Squeeze clamp is in the open position. 8) Ensure all steps in the Initial Programming Setup (Section 4) have been completed. 5.2 Pallet Infeed Conveyors The forklift loads the full pallet of containers on the end of the pallet infeed conveyors, and the shrink wrapping and some strapping is removed. Once the sequence is initiated by the operator, the pallet will advance. The pallet will stop at pallet infeed conveyor #1 photocell (PEC1), if there is a pallet at the infeed conveyor #2 photocell (PEC2), or at the elevator doors photocell (PEC3) on pallet infeed conveyor #3. The pallet also will not index ahead if a pallet is in transit between the pallet infeed conveyor #1 and the pallet infeed conveyor #2 (PEC1 and PEC2), between the pallet infeed conveyor #2 and the hoist door position on pallet infeed conveyor #3 (PEC2 and PEC3) or between the hoist door position and the pallet in hoist position (PEC3 and PEC4). 5.3 Pallet Infeed Conveyor The pallet infeed conveyor #3 (M3) will hold a full pallet at the infeed position (PEC3) while a pallet is being unloaded. The elevator door open limits (LS7 and LS8) must be made and pallet at doors photocell (PEC8) must be blocked by the doors for the pallet to index ahead. The pallet at the pallet infeed conveyors #1 & #2 will be held in position until no pallets are present on the pallet infeed conveyor #3. Bevco Conveying Systems Page... 17

18 5.4 Pallet Hoist Conveyor The pallet hoist conveyor (M4) positions the full pallet in the pallet elevator. After a pallet has been unloaded, the pallet hoist lowers the pallet to the bottom position and the pallet is transferred to the empty pallet conveyor through the open pallet stop. At the same time, the full pallet held at the pallet door position is indexed into position in the elevator (PEC4). The incoming pallet will be stopped part way in if the pallet stop has not returned to the down and locked position (PRS1) by the time the incoming pallet first reaches PEC4. This is done to prevent the incoming pallet from being trapped under the pallet stop. After the pallet reaches PEC4, the pallet hoist conveyor will run for a time to square the pallet to the pallet stop. The pallet hoist conveyor will not start if the pallet hoist is not in the lower position (LS3). 5.5 Empty Pallet Conveyor The empty pallet conveyor (M5) transfers the pallet from the pallet hoist discharge through the open pallet stop, to the empty pallet stacker. When the empty pallet passes the pallet discharge photocell (PEC5), the pallet stop is energized to close (SOL8). The empty pallet conveyor will stop when the pallet reaches the pallet at stacker photocell (PEC6). 5.6 Pallet Stacker Empty pallets are lifted into a stack at the end of the pallet stacker. When the pallet arrives in position under the stack (PEC6), the empty pallet conveyor stops and the pallet stacker air bag solenoid is energized (SOL17) to raise the pallet into the stack. When the air bag reaches its full extension, the stacker up limit (LS1) is made and the solenoid (SOL17) is de-energized. When the pallet stack is full as indicated by the pallet stacker full photocell (PEC7), the stacker is disabled from lifting any more pallets. When the stacker is full, it will also lockout the pallet lift conveyor to prevent further pallets from being discharged. The pallet unloading at the time will continue to unload until the empty pallet is lowered to the bottom position and the automatic sequence will pause. 5.7 Hoist to Start Sequence After the pallet has entered the hoist tower and has been squared against the pallet stop, the hoist tower doors (SOL12) and side walls (or squeeze panels) (SOL9) will be energized to close. The hoist (M6) will then raise the pallet to the strap cutting position (PEC18). At this point the automatic sequence pauses to allow the operator to remove the remaining strapping from the load. After the strapping has been removed, the operator then initiates the automatic unloading sequence. The hoist will not raise the pallet to the strap cutting position if the carriage is not in the forward position (LS10), the tier sheet picker is in the up position (PRS3) and the pallet hoist doors are closed (PEC8). Bevco Conveying Systems Page... 18

19 5.8 Automatic Unload Sequence After the operator has initiated the continue sequence, the tier sheet picker vacuum generator will energize (SOL2) and the picture frame clamps will extend (SOL16) to remove the picture frame and tier sheet from the pallet. At the same time, the picture frame carriage will retract towards the hoist tower (SOL18) to catch the picture frame. The hoist will then lower to the load up slow photocell (PEC17). After the hoist has lowered, then the carriage will reverse (M7) to position the tier sheet over the tier sheet bin. With the carriage in the reverse position (LS9), the vacuum generators will be energized to release the vacuum (SOL1). The bottle height detector will be lowered (SOL19) into position and the hoist (M6) will raise the load. After a time delay for the vacuum to break, the picture frame catchers will close (SOL13) to catch the picture frame. When the load makes contact with the bottle height detector, it is deflected to activate the bottle height detector proximity (PRS5). The bottle height detector is adjustable to allow the operator to set the position where the hoist will stop the load. This unit should be set to stop the load with the load at ¾ above the dead plate on the discharge accumulation table. If the hoist does not stop, there are two safeties on the carriage to prevent damage to the carriage. A second proximity (PRS4) is set on the bottle height detector, that if made will drop the machine out of auto and stop the hoist. A limit switch (LS15) is mounted on the carriage which detects the position of the tier sheet picker assembly. The tier sheet picker assembly is hinged on the carriage and when the hoist over-travels, the tier sheet picker assembly will deflect with the load and release LS15. When LS15 is released, the machine will drop out of auto and stop the hoist. This safety is used to prevent damage to the tier sheet assembly and the tier sheet picker air cylinder. After the bottle height detector proximity (PRS5) has been made and the hoist stopped, the tier sheet grippers (SOL11) will be energized to grip the bottom tier sheet. At the same time, the bottle height detector will be de-energized to retract (SOL19) out of the way and the squeeze clamp will be energized (SOL6) to contain the tier of containers and then the picture frame clamps will retract (SOL15) to drop the picture frame. The carriage then moves forward to sweep the tier of containers onto the moving discharge table (M8). The picture frame carriage will also retract at this time. When the carriage reaches the squeeze clamp open limit switch (LS11), the squeeze clamp is energized to open (SOL5), and the carriage continues to sweep the containers onto the moving discharge table. The picture frame catchers are opened to drop the picture frame into the picture frame bin. The carriage stops when it reaches the full forward position (LS10), the vacuum assembly is lowered (SOL4), the vacuum generator Bevco Conveying Systems Page... 19

20 is turned on (SOL2) and the tier sheet grippers (SOL10) are energized to open and release the tier sheet. The picture frame removal latch is reset. The carriage is now in position with the tier sheet picker over the load to repeat the cycle for the next tier. The cycle is repeated until all tiers have been removed from the pallet. 5.9 Last Tier Removal The last tier of containers is detected when the pallet hoist is in the top position (LS5) and the bottle height detector (PRS5) has been activated. When the last tier is detected, the hoist tower doors (SOL12) and the side walls (SOL9) are de-activated and open. When the carriage has reached its forward position (LS10) and the tier sheet picker has removed the last tier sheet, the hoist starts a fast decent to lower the empty pallet. As the hoist descends, the pallet stop opens (SOL7) and the empty pallet conveyor (M5) starts. When the descending pallet hoist reaches the slow down limit switch (LS4), the pallet hoist will slow for the last few feet to the bottom position (LS3). At this point, the empty pallet is removed from the hoist, to (PEC6) at which point the pallet stop (SOL8) closes. At this point, infeed pallet conveyor #3 (M3) and hoist tower conveyor (M4) activate and the next full pallet is indexed into the elevator to restart the sequence Container Discharge Table The container discharge table (M8) will start when the depalletizer is in auto run mode or in manual run mode. The speed of the discharge table is determined by the discharge empty photocell (PEC14) and the discharge table backup photocell (PEC13). When the discharge table empty photocell (PEC14) is clear, the discharge table will run at the maximum speed to fill the line with containers. As PEC13 is blocked, the table will drop to a medium speed, to maintain container supply to the line, but reduce the back pressure on the containers. When the discharge table fills to the full photocell (PEC12), the table will drop to a slow speed to further reduce the back pressure on the containers. The discharge table full photocell (PEC12) will also cycle stop the unloading sequence at the point where the tier is ready to be swept onto the table. This is done to prevent overloading the table with containers and interfering with the container stop. When the full photocell (PEC12) clears, the unloading sequence will resume. The discharge table full photocell (PEC12) will prevent the carriage from moving forward in both the automatic and manual modes. Bevco Conveying Systems Page... 20

21 5.11 Metering Table The metering table will be controlled by two photocells (PEC15, PEC16) in order to obtain the optimum feed rate for both the metering table and the transfer table to the combiner infeed table Automatic Operational Interlocks The depalletizer will stop in the automatic mode if any one of the following conditions exists: 1) Emergency stop activated. If either emergency stop on the main control panel or the remote Operator interface panel are activated. The emergency stop relay will de-energize all motors and solenoid valves, with the solenoids being de-energized in their last position. 2) Motor fault. Any of the motor overloads trip or an AC frequency inverter faults. overloads must be manually reset. The inverters may be reset from the HMI. 3) Hoist over travel fault. The hoist over travels while lifting the load and the hoist carriage makes contact with the Hoist Over-travel Up (LS6) or the hoist over travels while lowering the load and the hoist carriage makes contact with Hoist Over-travel Down (LS2). 4) Container height over run. The hoist over travels while lifting the load and the bottle height detector makes contact with Height Over-travel Proximity switch (PRS4). 5) Low air pressure. The air supply to the depalletizer drops below the set point on the air pressure switch PS1. 6) Disconnect Switch Open. Activated if any of M6, M7 or M8 motor disconnect switches are opened. 7) Full Pallet Stacker. The pallet stacker photocell (PEC7) is blocked. 8) Vacuum Assembly Over-travel. The vacuum assembly has over-travelled and breaks LS15. 9) MCR (Master Control Relay) Failure. 10) Low PLC Battery. Bevco Conveying Systems Page The

22 6.0 Manual Operation Although these conditions will stop the machine, if the depalletizer was in the automatic unload sequence, the machine will restart from the last step of the sequence when the fault has been cleared and the automatic run mode re-enabled. 6.1 Initial Start Before switching the depalletizer to the manual mode the operator should ensure that the power and air supplies are turned on and all emergency stops are reset. 6.2 Pallet Conveyors To enter manual operation of the Bevco depalletizer, the appropriate button PALLET STACKER, CARRIAGE, HOIST or INFEED must be pressed in the Main screen. To jog a conveyor, the appropriate jog button is depressed and held. Due to the nature of a touch screen control, only one button may be depressed at one time. Additional jog forward and reverse push buttons are provided to jog the pallet staging and infeed conveyors, or the pallet infeed and lift conveyors together when transferring one conveyor to the next. The manual infeed pallet conveyor operation screen is shown in figure #9. This screen contains the manual jog forward and reverse for the pallet infeed conveyors (M1, M2 & M3) and the hoist (M4) conveyor. Bevco Conveying Systems Page... 22

23 Figure #9 Infeed Screen The manual outfeed pallet conveyor operation screen is shown in figure #10 below. This screen contains the manual jog forward and reverse for the hoist (M4) and pallet outfeed (M5) conveyors as well as the empty pallet stacker control. Bevco Conveying Systems Page... 23

24 Figure #10 Pallet Stacker Screen The pallet outfeed conveyor requires the hoist to be in the bottom position (LS01) in order to manually jog forward and reverse. 6.3 Hoist and Solenoid Control The manual hoist and solenoid operation screen is shown in figure #11 below. This screen contains the manual operation of the hoist (M6), the closing of the hoist doors, and the opening and closing of the sidewalls. *Note: In the manual mode there are certain functions that are NOT allowed if not in a safe position to allow the functions without damaging the machine. Bevco Conveying Systems Page... 24

25 figure #11 Hoist Screen 6.4 Carriage Control The manual carriage operation screen is shown in figure #12 below. This screen offers control on all carriage related components within the limitations of sensor control The carriage will be disabled in the manual mode from jogging in forward or reverse if the tier sheet picker is not in the up position (PRS3). The carriage will also be disabled from jogging forward if the discharge table is full (PEC12). Bevco Conveying Systems Page... 25

26 figure #12 Carriage Screen 6.5 Auxiliary Control Not Applicable. 6.6 Manual Operational Interlocks The depalletizer will stop in the manual mode if any one of the following conditions exists: 1) Emergency stop activated. If either emergency stop on the main control panel or the remote Operator interface panel are activated. The emergency stop relay will de-energize all motors and solenoid valves, with the solenoids being de-energized in their last position. 2) Motor fault. Any of the motor overloads trip or an AC frequency inverter faults. overloads and inverters must be manually reset. The Bevco Conveying Systems Page... 26

27 3) Elevator over travel fault. The hoist over travels while lifting the load and the tier sheet picker breaks contact with LS6. This fault must be manually reset with the fault reset push button on the HMI. 4) Container height over run. The elevator over travels while lifting the load and the bottle height detector make contact with PRS4. This fault must be manually reset with the fault reset push button on the HMI. 5) Low air pressure. The air supply to the depalletizer drops below the set point on the air pressure switch PS1. Bevco Conveying Systems Page... 27

28 7.0 Fault Messages The following is a listing of the fault messages displayed on the Pro-face Operator interface. Msg. #1 Msg. #2 Msg. #3 Msg. #4 Msg. #5 Msg. #6 E-Stop 1 Pushed Emergency Stop 1 at the Main Panel (1CP) has been activated. E-Stop 2 Pushed Emergency Stop 2 at the Operator s Console (2CS) has been activated. E-Stop 3 Pushed Emergency Stop 3 at the Pallet Infeed (3CS) has been activated. E-Stop 4 Pushed Emergency Stop 4 at the Pallet Discharge (4CS) has been activated. MCR Fault The Master Control Relay (MCR) is not energized. Motor Overload 1, 2 or3 The full pallet infeed conveyors (M1, M2 or M3) thermal overload(s) has tripped. This fault must be reset in the Main Panel (1CS). Msg. #7 Motor Overload 4 or 5 Msg. #8 Msg. #9 Msg. #10 Msg. #11 Msg. #12 The hoist (M4) or empty pallet conveyor (M5) thermal overload(s) has tripped. This fault must be reset in the Main Panel (1CS). VFD M6, M7 or M8 Fault One of the AC frequency inverters has electronically tripped. The drive(s) may be reset from the front panel of the faulted drive in the Main Panel (1CS). Disconnect M6, M7 or M8 open One or more of the motor disconnect switches for the hoist (M6), the carriage (M7), the accumulation table (M8), and metering table (M9) is in the OFF position. Hoist Up Over-Travel The hoist has over traveled in the UP direction and LS6 on the tier sheet picker has been activated. Hoist Down Over-Travel The hoist has over traveled in the DOWN direction and LS2 at the bottom of the hoist has been activated. Bottle Height The bottle height detector disc has over run and PRS4 is activated. Bevco Conveying Systems Page... 28

29 7.0 Fault Messages (contd.) Msg. #13 Msg. #14 Msg. #15 Low Air Pressure The air supply pressure to the depalletizer (PS1) is low. Empty Pallet Stacker FULL The empty pallet stacker photocell (PEC7) is activated. spare Msg. #16 Msg. #17 Msg. #18 Vacuum Assembly Over-travel The hoist has over-traveled and activated the vacuum arm assembly overtravel limit switch (LS15). Low PLC Battery The PLC s internal battery is LOW and needs to be replaced. spare Msg. #19 Msg. #18 to Msg. #32 PLC Math Overflow Error Check Setup There has been an internal math Overflow Error and the PLC program needs to be checked for math errors. Spare fault messages. Bevco Conveying Systems Page... 29

30 8.0 Troubleshooting 8.1 Depalletizer The Following Fault Exists Probable Cause Recommended Action Machine will not start in Auto Machine starts in auto, but hoist will not rise Any alarm is active. Low air pressure Emergency stop activated Motor overload or AC inverter trip Any alarm is active. Carriage is not fully forward (LS10) or fully reversed (LS9). Strap cut height photocell is blocked (PEC18). Pallet lift not fully in bottom position (LS3) Hoist doors not closed (PEC8). Correct the problem. Check air turned on and adequate supply to machine. Reset all emergency stops. Reset overloads inverter. Check for obvious reasons for trip, such as debris jamming motors. Correct the problem. Manually jog carriage forward or reverse to correct position. Check that photocell is clear and operating correctly. Manually jog lift to bottom position. Manually close doors. Hoist Up limit switch (LS5) or Check that both limit Up Over-travel limit switch (LS6) is switches are clear and activated. operating freely. Pallet stops part way into hoist. Bottle height Over-travel prox. (PRS4) is activated. Any alarm is active. Pallet lift not fully in bottom position (LS3) Check that proximity switch is clear and operating correctly. Correct the problem. Manually jog lift to bottom position. Bevco Conveying Systems Page... 30

31 8.1 Depalletizer (contd.) The Following Fault Exists Probable Cause Recommended Action Carriage will not travel Any alarm is active. Correct the problem. forward in Auto. Carriage Forward limit switch (LS10) is activated. Check that limit switch is clear and operating correctly. Pallet is in hoist and doors do not close. Empty pallet conveyor does not start. Pallet stacker keeps rising and dropping. Tier Sheet Assembly Up proximity switch (PRS3) is activated. Accumulation table full (PEC12) condition. Accumulation table full (PEC12) photocell misaligned. Any alarm is active. Pallet present in elevator photocell (PEC4) blocked. Hoist not in the full down position (LS4) Any alarm is active. Empty pallet discharge photocell (PEC5) is blocked. Pallet stacker is full (PEC7). Pallet not fully on dogs. Pallet present at stacker photocell (PEC6) misaligned. Check that proximity switch is clear and operating correctly. Normal condition. Carriage will re-activate when backup condition clears. Realign photocell. Correct the problem. Realign photocell. Manually jog lift to bottom position. Correct the problem. Check that photocell is clear and operating correctly. Remove empty pallets from stacker. Check pallet is fully on dogs. Check to ensure no broken boards. Realign photocell. Bevco Conveying Systems Page... 31

32 8.2 Allen-Bradley CompactLogix 1769-L32E Processor Refer to Allen-Bradley CompactLogix 1792 Modular Hardware Style - Installation and Operation Manual for more detailed information. Processor Led When It Is Indicates That On (steadily) The processor is in run mode. RUN (Colour: green) FLT (Colour: red) BATT (Colour: red) FORCE (Colour: amber) Flashing (during operation) Off Flashing (at power up) Flashing (during operation) On (steadily) Off On (steadily) Off Flashing On (steadily) Off The processor is transferring a program from RAM to the memory module. The processor is in a mode other than Run. The processor has not been configured. The processor detects a major error either in the processor, expansion chassis or memory. A fatal error is present (no communications). There are no errors. The battery voltage has fallen below a threshold level, or the battery or the battery jumper is missing or not connected. The battery is functional, or the battery jumper is present One or more input or output addresses have been forced to an On or Off state but the forces have not been enabled. The forces have been enabled. No forces are present or enabled. Bevco Conveying Systems Page... 32

33 8.2 CompactLogix 1769-L32E Processor (contd.) Processor Led When It Is Indicates That On (steady) ENET (Colour: green) Flashing The Ethernet port is functioning properly and is connected to an active Ethernet network. The Ethernet port is functioning properly and is connected to an active Ethernet network, and is transmitting packets. RS232 (Colour: green) Off On (steady ) DF1/ASCII Mode Off DF1/ASCII Mode On (steady) DH485 Mode Flashing DH485 Mode Off DH485 Mode No Ethernet connection or the processor halted. The 1769-L32E is transmitting on the network. The 1769-L32E processor is not transmitting on the network. The Channel 0 Communications Active Bit (S:33/4) is set in the System Status file and the processor is actively communicating on the network. The processor is trying to establish communications, but there are no other active nodes on the DH-485 network. A fatal error is present (no communications) Bevco Conveying Systems Page... 33

34 8.3 Pro-face AGP3500-S1-D24 Operator Terminal Refer to Pro-face Operator Manual, for detailed information. Cleaning the Display Window: Attention: Use of abrasive cleansers or solvents may damage the window. Do not scrub or use brushes. 1. Disconnect power from terminal at power source. 2. Using a clean sponge or soft cloth, clean the display with a mild soap or detergent. 3. Dry the display with a chamois or moist cellulose sponge to avoid water spots. 9.0 Preventative Maintenance 9.1 Routine There are three grease zerk banks on the depalletizer. Additionally, there are bearings located in accessible places which have not been plumbed out to the central grease banks and must be dealt with separately. All grease zerks on banks are individually labeled. All grease zerks require one pump stroke of the grease gun each week during continuous running. The two linear bearings on each linear shaft should have a good grade of light oil pumped into them twice a year. (Refer to Maintenance Manual). 9.2 Start-up Prior to start-up the all gearboxes should be checked for oil and brought up to the proper level with the correct oil. (Refer to the manufacturer information as supplied elsewhere in this manual for the correct levels and oil descriptions). Gearboxes should be checked twice a year for proper levels unless leakage is noted at which time the cause of the leak should be corrected and the gearbox topped up. 9.3 Daily Check List The following is a general daily checklist that outlines general areas to be monitored by operating staff. 1. Check all bearings - Keystone Pennwalt Nevastane HT-2, for food and beverage or equivalent lubrication should be used if required. 2. Check drive units for signs of oil leakage. If there is any evidence of leakage, check oil level and top off if required - For Eurodrive gearboxes, refer to information that was in the information packet supplied with your rinser and generally shipped in the control panel. 3. Lubricate all drive chains with SAE 30 non-detergent oil. Bevco Conveying Systems Page... 34

35 4. Check alignment of equipment and report broken / damaged parts. 5. Check & tighten all loose assemblies. 6. Ensure all safety guards and covers are in place. 7. Test run all pieces of equipment without load and inspect for proper operation prior to container flow. 8. Ensure all emergency stop switches are operational by running equipment and using emergency switches to shut down. 9.4 Regular Maintenance Requirements a) Bearings: Grease all bearings weekly during continuous operation - Keystone Pennwalt Nevastane HT-2 food grade grease or equivalent. b) Drives: Check the oil level in all drives monthly. If oil is contaminated, burned or waxed, flush the gearbox and change the oil immediately. Under normal operation conditions, change the oil every two (2) years, or as recommended by the manufacturer in his information. c) Chain: Tension on chains must be checked at a minimum of 1 month for stretch or mechanical issues and adjusted or replaced as necessary. For proper operation, chain should have 1 to 1-1/2 linear slack in it. DO NOT OVERTIGHTEN d) General: Maintain general cleanliness of machine areas and avoid any buildup of foreign matter. The depalletizer is designed to operate in a dry environment. Should any fluid come into contact with the machine, it must be cleaned and dried promptly. 9.5 Shutdown Procedures: Extended If the operation is to be shut down for an extended period of time, care must be taken to ensure problems are avoided on restart. a) Grease all regular bearings. b) Oil all linear bearings. c) Check oil levels in drive units. d) Lubricate drive chains. e) Lock out electrical system. f) Sweep down all components as required and clean and dry if necessary. Bevco Conveying Systems Page... 35

36 Appendix I Device Functions Table 1 Photocell Functions Device Description Function I/0 Reference PEC1 Pallet at Infeed Conveyor Holds pallet at this position on the infeed conveyor I:3.0/1 #1 #1 until the infeed conveyor #2 is clear to receive PEC2 Pallet at Infeed #2 Conveyor pallet. Holds pallet at this position on the infeed conveyor #1 until the infeed conveyor #2 is clear to receive pallet. PEC3 Pallet at Infeed #3 Conveyor Used to move next full pallet into position at the elevator doors. PEC4 Pallet in Hoist Indicates pallet is in hoist to be raised to strap cut position. PEC5 Pallet at Discharge Closes pallet stop after empty pallet has been ejected from the hoist. PEC6 Pallet at Stacker Initiates the pallet stacker air bag to raise the pallet into the stack. PEC7 Pallet Stacker Full Disables the ejecting of further pallets to the pallet stacker until the existing stack is removed from the stacker. PEC8 Pallet Doors Closed Ensures the hoist doors are closed during the auto cycle. If broken will cause the auto cycle to stop except during the last tier when they are required to be open PEC9 PEC10 Carriage Intrusion Safety #1 Prevents the operator from reaching into the machine while it is running. PEC11 PEC12 Accumulation Table Full Prevents the carriage from pushing a tier of containers onto a full Accumulation belt. PEC13 Accumulation Table Decreases the speed of the discharge belt to slow Backup container pressure onto Accumulation line. PEC14 Accumulation Table Increases the speed of the Accumulation belt to Empty bring containers ahead to fill the line. PEC15 PEC16 PEC17 Hoist Up Slow Makes the hoist go into slow speed after this point and stops the hoist going down after the strap cut step. PEC18 Pallet in Strap Position Stops pallet in upper hoist position to allow operator to cut the straps. PEC19 Metering Table Full PEC20 Metering Table Empty I:3.0/2 I:3.0/3 I:3.0/4 I:3.0/5 I:3.0/6 I:3.0/7 I:3.0/8 I:3.0/10 I:3.0/11 I:3.0/12 I:3.0/13 I:3.0/14 I:4.0/1 I:4.0/2 Bevco Conveying Systems Page... 36

37 Table 2 Limit Switch Functions Device Description Function I/0 Reference LS1 Stacker up Limit Indicates pallet stacker air bag in the full up I:4.0/3 position. Releases the air bag in the up position to allow scissor lift to lower. LS2 Hoist Over-travel Down I:4.0/4 LS3 Elevator in Bottom Lower limit of hoist travel. I:4.0/5 Position LS4 Hoist Decelerate In auto slows hoist from fast descent when I:4.0/6 approaching the lower limit. LS5 Hoist in Top Position Upper limit of hoist travel. Also used to initiate I:4.0/7 the last tier sequence LS6 Hoist Up Over-travel I:4.0/8 LS7 Hoist Door #1 Open Indicates that the left hoist tower door is open. I:4.0/9 LS8 Hoist Door #2 Open Indicates that the right hoist tower door is open. I:4.0/10 LS9 Carriage in Reverse Carriage in reverse position ready to sweep tier I:4.0/11 Position of containers. Tier sheet picker is over tier sheet bin in this position. LS10 Carriage in Forward Carriage in forward position after sweeping tier I:4.0/12 Position of containers onto accumulation belt. LS11 Squeeze Clamp Open Squeeze clamp opens when made during the forward sweep. I:4.0/13 LS12 Picture Frame Carriage I:4.0/14 Reversed LS13 Picture Frame carriage I:4.0/15 Forward LS14 Sweep Carriage Open I:2.0/14 Bottle Clamp LS15 Vacuum Arm Over-travel I:3.0/15 Bevco Conveying Systems Page... 37

38 Table 3 Proximity Switch Functions Device Description Function I/0 Reference PRS1 Pallet Stop Closed Confirms that the pallet stop is closed. I:0.0/11 PRS2 Tier Sheet Picker Down Indicates tier sheet picker in the down position. I:0.0/12 PRS3 Tier Sheet Picker Up Indicates tier sheet picker in the up position. I:1.0/13 PRS4 Bottle Height Overrun Stops auto sequence if hoist travels higher than I:1.0/15 the container height. PRS5 Bottle Height Detector Stops hoist at proper tier height. I:1.0/14 PS1 Low air pressure switch Will switch the depalletizer out of auto if main air supply pressure is low. I:2.0/15 Table 4 Motor List Device Description Function I/0 Reference M1 Pallet Infeed #1 Conveyor Conveyor where full pallets are initially loaded. Fwd. O:7.0/8 Rev. O:7.0/9 M2 Pallet Infeed #2 Conveyor Transport conveyor to transfer full pallets between staging and pallet hoist. Fwd. O:7.0/10 Rev. O:7.0/11 M3 Pallet Infeed #3 Conveyor Pallet conveyor located in hoist tower, to position pallet in hoist. Fwd. O:7.0/12 Rev. O:7.0/13 M4 Hoist Conveyor Pallet conveyor located in hoist, to position Fwd. O:7.0/14 pallet in lift. M5 Empty Pallet Conveyor Empty pallet accumulation conveyor to transport empty pallets from hoist to pallet stacker. Rev. O:7.0/15 O:8.0/0 M6 Pallet Hoist Hoist to raise pallet into position for tier removal. Up O:8.0/2 Dwn. O:8.0/3 M7 Carriage Container tier removal. Fwd. O:8.0/5 Rev. O:8.0/6 M8 Accumulation Discharge Table conveyor to discharge containers from O:8.0/8 Conveyor the depalletizer to the line. M9 Accumulation Metering Table conveyor metering container feed O:8.0/10 Conveyor between accumulation table and transfer Bevco Conveying Systems Page... 38

39 Table 5 Solenoid Valve Functions Device Description Function I/0 Reference SOL1 Vacuum Off De-energizes vacuum generators to release tier O:9.0/0 sheet. SOL2 Vacuum On Energizes vacuum generators to lift tier sheet. O:9.0/0 SOL3 Tier Sheet Picker Up Energizes to raise tier sheet picker with tier O:9.0/0 sheet. SOL4 Tier Sheet Picker Down Energizes to lower tier sheet picker to remove O:9.0/0 tier sheet from pallet. SOL5 Squeeze Clamp Up Energizes to raise squeeze clamp. O:9.0/0 SOL6 Squeeze Clamp Down Energizes to lower squeeze clamp to contain O:9.0/0 containers during sweep. SOL7 Pallet Stop Close Energizes to close pallet stop to position load in O:9.0/0 elevator. SOL8 Pallet Stop Open Energizes to open pallet stop to release empty O:9.0/0 pallet from elevator SOL9 Side Squeeze Close Energizes to position top of side panels for O:9.0/0 small pallets. De-energize to open. SOL10 Tier Sheet Grippers Off Energizes to release top tier sheet clamps to O:9.0/0 allow removal of tier sheet. SOL11 Tier Sheet Grippers On Energizes to close top tier sheet clamps to hold O:9.0/0 tier sheet during sweep. SOL12 Doors Open Energizes to close doors of hoist tower. Deenergizes to open. O:9.0/0 SOL13 Picture Frame Catcher - Energizes to close catcher and hold the picture O:9.0/0 Close frame. SOL14 Picture Frame Catcher - Energizes to open catcher and drop the picture O:9.0/0 Open frame. SOL15 Picture Frame Clamps Energizes to retract the pins to drop the picture O:9.0/0 Retract frame onto the picture frame catcher. SOL16 Picture Frame Clamps Energizes to extend the pins to lift off the O:9.0/0 Extend picture frame. SOL17 Pallet Stacker Up Energizes air bag to lift pallet scissor lift with O:9.0/0 empty pallet into pallet stack. De-energizes to lower. SOL18 Picture Frame Carriage Energizes to move picture frame carriage O:9.0/0 backwards to the picture frame bin. SOL19 Bottle Height Detector Down Energizes to lower bottle height detector. Deenergizes to rise out of the way during carriage movement. O:9.0/0 Bevco Conveying Systems Page... 39