Professional Documents
Culture Documents
Unilever Brasil
C5000
Palletiser 1
Location
: Aguai
: 2225
: DO6936357
Date of issue
: July 2010
Project manager
Version
:
A. Swikker
prelim
Telephone
Fax
E-mail
Internet
:
:
:
:
Description
General Purpose
Owner
DJB
09-1-14
Version Date
Copyright
We retain the ownership of all images, catalogues, technical details and computer programs provided by us,
unless expressly stipulated otherwise in the order confirmation. The client is responsible for ensuring that this
information is not copied and / or put at the disposal of, or submitted for inspection to, third parties without our
permission. We are not obliged to issue detailed drawings.
Original instructions
The original instructions have been written in English. Other language versions are a translation of the original
instructions. In case of doubt or small deviations in the translation, the original instructions prevail.
CSi
September 1, 2014
Preface
This user manual contains important and useful information to enable
proper functioning and maintenance of your system / the machine(s). It
also contains important information on the prevention of accidents and
serious damage to the system / machine(s) before putting into operation,
ensuring safe and trouble-free operation.
Important instructions
Before putting the system / machine(s) into operation, please read the user
manual thoroughly.
Acquaint yourself with the operation, and strictly observe the instructions
and directions. In this context, please be referred to the safety regulations
and the importance of appropriate staff training to operate the system /
machine(s).
Store this user manual in a safe area near the system / machine(s).
K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Titelblad.fm
09-1-14
September 1, 2014
CSi
09-1-14
CSi
September 1, 2014
CONTENTS
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2
Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3
1.4
09-1-14
1.5
1.6
1.7
1.4.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4.2
1.5.2
1.5.3
1.5.3.1
1.5.3.2
1.5.3.3
1.5.4
Fencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.5.5
1.5.5.1
1.5.5.2
1.5.6
1.5.7
1.5.8
1.5.9
1.6.2
1.6.3
1.6.4
September 1, 2014
Subcontractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
3.3
3.4
3.5
Type RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2
Type RL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.3
Type LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.4
Type LL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.2
3.2.3
3.2.4
3.2.4.1
3.2.4.2
3.2.5
3.2.6
3.2.7
3.2.8
3.2.9
3.2.10
3.3.2
Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.3.3
Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.4.2
3.4.3
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
3.5.7
3.5.8
ii
3.1.1
CSi
September 1, 2014
3.2
09-1-14
3.1
4.2
4.3
4.2.1
4.2.1.1
4.2.2
4.2.3
4.2.3.1
4.2.4
4.2.4.1
4.2.5
4.2.5.1
4.3.2
4.3.3
4.3.4
Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2
6.3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.4
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5
6.6
09-1-14
6.5.1
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.6.1
Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.6.2
Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.6.3
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.7
6.8
Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.9
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.9.1
6.10.2
6.10.3
6.10.4
September 1, 2014
6.11.2
6.11.3
6.11.4
6.11.5
6.11.6
6.11.7
iii
Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.14.2
6.14.3
6.15.2
6.15.2.1
6.15.3
6.15.3.1
6.15.4
6.15.5
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.16.2
6.16.2.1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.17.2
6.17.2.1
6.17.2.2
6.17.3
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.18.2
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.19.2
6.19.2.1
6.19.2.2
6.19.2.3
6.19.2.4
iv
CSi
September 1, 2014
09-1-14
6.15.1
6.21.1
6.21.2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6.21.3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6.21.4
6.21.4.1
6.21.4.2
6.21.4.3
6.21.4.4
6.21.4.5
6.21.5
6.21.5.1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.21.5.2
6.21.5.3
Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.4
7.5
7.4.1
7.4.2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.5.2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.7
09-1-14
7.6
7.7.1
Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.7.2
7.7.3
7.7.4
7.7.5
7.8
7.9
7.13.2
September 1, 2014
7.14.1
Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.14.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.14.2.1
CSi
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.15.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.16.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.16.2.1
7.16.2.2
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.17.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.18.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.18.2.1
7.18.2.2
7.18.2.3
7.18.2.4
7.18.2.5
7.18.2.6
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.19.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.19.2.1
7.19.2.2
7.19.2.3
7.19.2.4
7.19.2.5
7.19.2.6
7.19.2.7
7.19.2.8
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.20.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.20.2.1
7.20.2.2
CSi
September 1, 2014
09-1-14
7.18.1
Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.22.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.22.2.1
Rowpusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.22.2.2
7.22.2.3
7.22.2.4
7.22.2.5
7.22.2.6
7.22.2.7
7.22.2.8
7.22.2.9
09-1-14
Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.23.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.23.2.1
7.23.2.2
7.23.2.3
7.23.2.4
September 1, 2014
7.24.1
Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.24.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
CSi
vii
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.25.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.25.2.1
7.25.2.2
7.25.2.3
7.25.2.4
7.25.2.5
7.25.2.6
7.25.2.7
7.25.2.8
7.25.2.9
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.26.2
Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.26.2.1
7.26.2.2
7.27.2
7.27.3
7.27.3.1
7.28.2
7.28.3
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.32.2
Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.32.3
7.32.4
Rowpusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
7.32.5
Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
viii
7.32.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2
8.3
CSi
September 1, 2014
09-1-14
8.4
8.4.2
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
10
09-1-14
September 1, 2014
CSi
ix
09-1-14
CSi
September 1, 2014
LIST OF FIGURES
09-1-14
fig. 1.1
September 1, 2014
fig. 1.2
fig. 1.3
fig. 3.1
fig. 3.2
fig. 3.3
fig. 3.4
fig. 3.5
fig. 3.6
fig. 3.7
fig. 3.8
fig. 3.9
fig. 3.10
fig. 3.11
fig. 3.12
fig. 3.13
fig. 3.14
fig. 3.15
fig. 3.16
fig. 3.17
fig. 3.18
C5000Ti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
fig. 3.19
fig. 3.20
fig. 3.21
optional:
Controlling peripheral equipment:Motor modules . . . . . . 3-23
fig. 3.22
fig. 4.1
fig. 4.2
fig. 6.1
fig. 6.2
fig. 6.3
fig. 6.4
fig. 6.5
fig. 6.6
fig. 6.7
fig. 6.8
fig. 6.9
Position 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
fig. 6.10
xi
Position 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
fig. 7.1
fig. 7.2
fig. 7.3
fig. 7.4
fig. 7.5
09-1-14
fig. 6.11
xii
CSi
September 1, 2014
LIST OF TABLES
tab. 4.1
tab. 4.2
tab. 5.1
tab. 6.1
tab. 6.2
tab. 6.3
tab. 6.4
tab. 6.5
tab. 7.1
tab. 7.2
tab. 7.3
09-1-14
tab. 1.1
September 1, 2014
CSi
xiii
09-1-14
xiv
CSi
September 1, 2014
Safety
SAFETY
1.1
Introduction
1.2
Fundamentals
09-1-14
1.3
Safety standards
The system / machine is in conformity with the Machinery Directive 2006/
42/EC. The relevant harmonised standards are followed as far as practical.
A system may consist of a number of consecutive machines. These
machines have their own CE declaration.
In principle, a II-A declaration is supplied for the system / machines.
If the system / machine is not designed or capable of independent
operation, a IIB self-issued declaration is provided. The user is
additionally responsible for:
September 1, 2014
CSi
1-1
Safety
1.4
1.4.1
Safety Instructions
General
The following safety instructions are based on conditions expected under
normal circumstances. Exceptions may occur. The person performing the
activities always is responsible for his own safety and the safety of others
in his immediate vicinity.
In case of doubt, CSi can always be consulted for additional advice.
1-2
Keep the system / machine(s) and the environment clean and free of
obstructions.
Only use safety switches, emergency stops, etc. for their intended
purpose.
CSi
September 1, 2014
09-1-14
Please read the users manual carefully and comply with all safety
instructions, for reasons of safety, health and environmental protection.
Safety
1.4.2
Cautionary tags
In the manual these tags are used to draw your attention:
Warning
This sign is used when a situation may occur, which, when not properly
paid attention to, may lead to serious physical injury or even death.
Caution
This sign is used when a situation may occur, which when not properly
paid attention to, may lead to malfunctioning of machinery, to damage to
machinery or product, or to physical injury.
n
1.5
Note
This sign is used to provide additional information
Safety features
The system is fitted with safety features:
Cautionary tags
Safety signs
09-1-14
September 1, 2014
Emergency stops
Door switches
Safety fencings
Main switch
CSi
1-3
Safety
1.5.1
Safety signs
09-1-14
Make yourself familiar with the safety signs of your system. These signs
have been mounted on or near the system and indicate a specific warning,
instruction or prohibition.
1-4
CSi
September 1, 2014
Safety
Warnings
Electrical voltage
Moving parts
Risk of Injury
Risk of getting
locked in
Danger
Risk of jam
Prohibitions
09-1-14
Access prohibited
Do not climb on
conveyor
Do not climb
Mandatory
Wear gloves
1.5.2
Wear a harnas
Area stops
The complete palletising system is split into different areas:
September 1, 2014
Case conveyors
CSi
1-5
Safety
1.5.3
Emergency stop
The emergency stop function is designed to prevent or minimise injury to
staff and/or damage to machinery and/or product.
1.5.3.1
1.5.3.3
1.5.4
09-1-14
Fencing
The palletiser is fenced off by safety fencing. This fencing can only be
removed with the aid of tools. The fencing is meant to prevent undesired
access to the robot cell.
The palletiser system is only accessible via the safety doors in the fencing.
To allow the infeed and outfeed of pallets to and from the palletiser system
automatic doors have been fitted. These are monitored by safety
lightscreens.
The system has four acces doors. These are located at or near:
1-6
Pallet lift
Palletiser infeed
row-former
CSi
1.5.3.2
September 1, 2014
Safety
1.5.5
Door switch
An AMLOK safety switch is located on the door giving access to the robot
cell. The safety switch has an unique key number.
09-1-14
Warning
The user must take the key into the fenced off area when entering. With
the key in the lock the area can be started with the user inside! This can
lead to serious injury or even death!
After closing the door, the doors circuit will reset itself automatically.
Turning the key in the door switch resets the system. Because the general
emergency stop circuit is interrupted as well, this circuit needs to be reset
also. It can be reset by the reset button on the operator panel.
1.5.5.2
September 1, 2014
CSi
1-7
Safety
7 Turn the key to the active position, to the right, to reset the circuit. The
light in the push button now flashes slowly.
8 Push the start button.
1.5.6
c
1.5.7
Caution
When running override, it is the responsibility of the operator that no one
passes the light screen and enters the dangerous zone.
n
1-8
Note
The air service units pressure should be set at 6 Bar.
CSi
September 1, 2014
09-1-14
Every safety light barrier is equipped with an operator panel with a reset/
override button. The operator panel is mouted on the safety fencing near
the light barrier.
Safety
1.5.8
1.5.9
Signal Beacon
To indicate the status of the installation a light beacon is fitted.
1.6
1.6.1
1.6.2
09-1-14
Ensure that clothing, hair and limbs are kept at a safe distance.
Be aware that moving parts are always dangerous, even when they are
not moving.
Also take the safety items in section 1.7.1 Subcontractors into account.
1.6.3
September 1, 2014
Never work on the system / machine on your own. Make sure that an
authorised person is present in the immediate vicinity, to provide
assistance in case of need.
1-9
Safety
Warning
Be particularly aware of dangers and risks when testing, checking,
adjusting and commissioning functions that require a supply of energy.
Warning
Be aware of sources of potential energy.
1.6.4
When lubricant has been spilled or leaked, the lubricant must be mixed
with sawdust, sand or absorbent granules. All used lubricants and
residual wastes must be disposed of in accordance with legal and
environmental standards.
1-10
Prepare plan of action and a hazard analysis and take the necessary
precautionary measures.
Remove all products that may fall, turn or become dislodged before
shutting off energy supply.
CSi
September 1, 2014
09-1-14
b Close the valves and lock the relevant switches / shut-off valves
with a padlock.
Safety
1.7
1.7.1
Shut off all supplies of electricity, compressed air, vacuum and hydraulic
fluids (where applicable).
Warning
Be aware of residual energy.
Detach and remove all power supply cables and supply lines.
Drain all lubricants and liquids and disassemble and sort all the parts
according to type of material, and dispose of them in accordance with
legal and the environmental standards.
Grind flat uncovered fixing points on the floor and clean the floor.
Additional instructions
Subcontractors
09-1-14
September 1, 2014
CSi
1-11
09-1-14
1-12
Safety
CSi
September 1, 2014
Project/Product/machine data
PROJECT/PRODUCT/
MACHINE DATA
09-1-14
September 1, 2014
CSi
2-1
09-1-14
2-2
Project/Product/machine data
CSi
September 1, 2014
Functional specification
FUNCTIONAL SPECIFICATION
3.1
Introduction C5000i
The palletiser is available in a number of standard versions.
3.1.1
Type RR
In this version, seen from the conveying direction, the packets are moved
to the right by the row pusher. (specification R...)
09-1-14
Seen from the direction of movement of the row pusher, the empty pallets
are fed in from the right. (specification ...R)
3.1.2
Type RL
In this version, seen from the conveying direction, the packets are moved
to the right by the row pusher.(specification R...)
Seen from the direction of movement of the row pusher, the empty pallets
are fed in from the left.(specification ...L)
September 1, 2014
CSi
3-1
Functional specification
3.1.3
Type LR
In this version, seen from the conveying direction, the packets are moved
to the left by the row pusher.(specification L...)
09-1-14
Seen from the direction of movement of the row pusher, the empty pallets
are fed in from the right. (specification ...R)
3.1.4
Type LL
In this version, seen from the conveying direction, the packets are moved
to the left by the row pusher. (specification L...)
Seen from the direction of movement of the row pusher, the empty pallets
are fed in from the left. (specification ...L)
3-2
CSi
September 1, 2014
Functional specification
3.2
3.2.1
09-1-14
Data line
September 1, 2014
Conveyor type
Skewed section
CSi
3-3
Functional specification
n
3.2.2
Note
The zero pressure conveyor is not part of the machine. Because of the
operational interface between this conveyor and the machine, the
interface needs to be incorporated in the specification.
Belt conveyor
The packets are kept apart on the braking section so that the photocell can
count them, and to create an interruption so that the packets can be turned
or put together.
The conveyor transports the packets to the feed row- forming conveyor
BC 90
Speed
Drive
09-1-14
Conveyor type
The packets are fed into the machine by a brake-metering belt conveyor.
This conveyor blocks the packets on the zero pressure conveyor and
distributes them across the two conveyor belts using the difference in belt
speeds. A photocell is fitted at the end to count the correct number of
packets.
3.2.3
3-4
CSi
September 1, 2014
Functional specification
The packets are lined up in rows on the row forming section. The row is a
logical component of the stacking pattern. The packets can be separated
on the row forming section with a stop plate, in accordance with the
stacking pattern. The stop plates are lowered and the row is pushed from
the row forming section when the last parcel is in the defined position.
All rollers in the row forming section are pressureless when the last parcel
is ready. The pressure zones are de-activated once the row pusher has
pushed the packets from the row forming section. A timer is located above
the last parcel to detect the end of the row. The row pusher will start once
the last parcel is in the correct position. This device is known as the 'row
ready" timer.
09-1-14
Band Conveyor
Clamp
Turn cam
September 1, 2014
Conveyor type
Speed
Drive
Pressure zones
The row forming section can be made pressureless in zones. These zones are able to
operate independently and are programmed
for each package type. They are operated
with a pneumatic cylinder. The operational
timing of a pressure zone is carried out via a
timer in the IPC control. This timer can be
programmed for each package type.
CSi
3-5
Functional specification
Stop plate
3.2.4
Turning unit
Depending on the package type and machine version, a clamp and / or a
turn cam can be applied.
It is a freely programmable turning facility with servo drive.
3.2.4.1
Clamp (optional)
The arm can be adjusted for all package types and is a machine setting.
Under no circumstances should this setting be changed, as this will affect
all package types.
You can select in the IPC whether a package needs to be turned using the
clamp. The clamp operates via a timer on the basis of a photocell fitted to
the conveyor, with which the following settings can be programmed for
each package type:
speed;
angle;
acceleration;
delay time;
box delay.
09-1-14
The axle, onto which the arm is fitted with the pusher plate, is driven by a
motor reductor.
3.2.4.2
3-6
CSi
September 1, 2014
Functional specification
3.2.5
The drive powers a crank mechanism. Linear movement is carried out with
four linear bearings. The mechanism and servo drive ensure smooth
operation. The package pusher operates via a timer based on a photocell
fitted on the belt conveyor.
The following settings can be programmed for each package type:
start delay times;
speed;
travelling distance;
acceleration.
09-1-14
3.2.6
Row pusher
When the row on the row forming section is complete, the row pusher
pushes the row in the direction of the load platform. Once the row pusher
has pushed the row from the row forming section, a new row can be
formed.
The row pusher pushes the rows in the direction of the load platform until
there are enough rows to form a pallet layer.
Three sliding bars are fitted between two parallel moving chains. When one
of the sliding bars has pushed a row to its end position, the other sliding bar
will be in the starting position to move the next row.
September 1, 2014
CSi
3-7
Functional specification
3-8
collision area;
CSi
09-1-14
September 1, 2014
Functional specification
09-1-14
3.2.7
September 1, 2014
CSi
3-9
Functional specification
When the last layer has been placed on the load platform, the stops are
placed in their end position in accordance with the dimensions of the
stacking pattern. This can be done to the nearest millimetre. Once the load
platform is open, the stops will return to their starting position. It is possible
to program a start delay, causing the row pusher and the rear pusher to
move forward to prevent the edges of the packets coming into contact.
Motor driven linear guided system. The driving mechanism has a double gear wheel gear rack transmission. The guide is connected to two linear guides. The stops are
driven in such a way that they will always
push against the entire layer (finger interface
on the sides). The position is adjusted with
an encoder. The motor is controlled with an
frequency inverter, while speed and acceleration are machine settings.
09-1-14
Drive
3-10
CSi
September 1, 2014
Functional specification
Side stop
Side stop
09-1-14
Rear stop
3.2.8
Load platform
Once a layer with the correct dimensions has been formed, it can be
stacked on a pallet. The pallet is placed underneath the load platform, and
the load platform ensures that a properly aligned pallet layer is formed on
the pallet.
Once a complete layer has been formed on the load platform, and the stops
have positioned the packets, the load platform will open in the centre, one
section of the load platform will slide underneath the row pusher, while the
other section slides underneath the rear stop. This will create a solid,
properly aligned pallet layer.
Once the layer has been placed on the pallet, the pallet lift will move the
layer below the level of the load platform.
September 1, 2014
CSi
3-11
Functional specification
As soon as the layer is below the load platform, the load platform will be
closed. This process is controlled using the height detection photo cells on
the pallet lift. A special photocell has been fitted, which checks that closing
is not hindered. The start- and stop positions are controlled with proximity
switches. The driving mechanism is operated with an AC/DC converter.
Speed and acceleration are machine settings.
3.2.9
Pallet lift
To enable packets to be stacked at a high level, the pallet has to be brought
to just below the level of the load platform and positioned there.
The lift trolley has to be positioned in such a way that the forks are below
the level of the rollers, and the stop plate is above, so that an empty pallet
can be fed in. The pallet will be fed into the loading zone, touch the stop
plate, and be aligned.
The lift will raise the empty pallet at great speed. During lifting, the pallet
will be aligned with a centring unit. Once the photocell for high / low speeds
detects the top of the pallet, it will slow down the lift. The lift will stop in a
certain position. This is controlled from the servo drive.
If a layer is stacked on to the pallet, it will be lowered at great speed so that
the load platform can close, and the top of the pallet layer can be moved to
below the level of the load platform.
All pallet layers will be stacked using this method. When the last layer has
been stacked on to the pallet, the lift will lower the pallet in such a way that
the forks and the stop plate are below the level of the rollers. The pallet can
then be transported to the pallet conveyor, where the loaded pallet is fed
out. It is possible to feed in an empty pallet and feed out a loaded pallet
(partially) simultaneously.
3-12
CSi
September 1, 2014
09-1-14
Drive
Functional specification
During infeed of an empty pallet and outfeed of a full pallet, the stop
position is operated using the resolver on the servo drive.
Pallet lift
Lift trolley
Centring unit
Drop lock
09-1-14
The drop lock of the lift trolley is spring operated. This spring tension can
be tightened with a pneumatic cylinder. The drop lock is activated when the
air pressure drops.
3.2.10
September 1, 2014
CSi
3-13
Functional specification
The lift trolley is equipped with forks which can be lowered between the
rollers of the pallet conveyor. This enables an empty pallet to be placed
onto the conveyor. When the empty pallet touches the stop plate, the lift will
raise the pallet to the load platform. The pallet is aligned during lifting. The
full pallet is lowered onto the conveyor. The forks will be lowered below the
level of the rollers.
The full pallet is then transported to the outfeed conveyor and an empty
pallet will be fed in.
The drives are controlled with an AC/DC converter. Speed and acceleration
are machine settings.
1
n
3.3
Conveyor type
CPRC
Drive
Note
This conveyor is not part of the machine. It is mentioned in these
specifications because its operation is closely related.
3-14
CSi
September 1, 2014
09-1-14
An empty pallet has stopped near the photocell (1). Start the infeed
conveyor (empty pallets) and the outfeed conveyor (full pallets) when the
machine gives the appropriate command. The empty pallet is transported
by the photocell (2) and aligned against the stop plate. When the pallet has
stopped and the photocell (2) is free, the pallet will be raised with the lift.
Functional specification
Belt conveyor
Divider
3.3.1
Belt conveyor
The packets should preferably be fed by an accumulation conveyor. They
are then distributed and counted by the brake- metering belt conveyor.
Conveyor type
3.3.2
BC90
Divider
The divider distributes the packets across two lines. Distribution is based
on the number of packets needed to build up the stacking pattern for each
row.
Divider
09-1-14
3.3.3
3.4
September 1, 2014
CSi
3-15
Functional specification
3.4.1
Container
The interleaving sheets are located in the container. To prevent the sheets
sticking to one another or being badly aligned, the sheets have to be placed
manually into the container. Depending on how the interleaving sheets are
put in the container, they are also placed onto the pallet.
The container is placed onto the container lift with a fork lift truck. This is
done via the access door. (permission needed). The container can only be
positioned one way. This is checked by the photocell. The lift raises the
container with interleaving sheets to the correct level. Once the sheet
inserter has picked up a sheet, the lift will be lowered by approx. 5 cm to
make room for the grab head to take away the sheet. Once the grab head
is in the lifting position, the lift will raise the stack again.
This process is repeated until the container is almost empty. A warning will
sound when the container is almost empty and needs filling up.
3.4.3
Lift
The lift with the container is located above the empty pallet infeed.
3.5
Control specifications
Standard E-cabinet;
I/O-bus control;
09-1-14
Control of the machine is based on the CSi machine control system. This
is the standard system for controlling machines and optional peripheral
equipment. It is made up of the following parts:
Package infeed
Empty pallet infeed
3-16
CSi
Palletiser
Machine
3.4.2
September 1, 2014
Functional specification
The control elements are always divided into the following four groups:
Standard
optional
optional
optional
Belt conveyor
Motor drive.
Controlled with frequency regulator.
The control can be programmed for each
package type via the field bus system. The
index photocell is connected to a PROFIBUS
module.
Motor drive.
Controlled with frequency regulator.
The control can be programmed for each
package type via the field bus system.The
photocell which checks whether the push
section is empty, is connected to a PROFIBUS box.
Clamp (optional)
Stop plate
Pressure zones
Row pusher
Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
09-1-14
September 1, 2014
CSi
3-17
Functional specification
Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O, and positioning can
be programmed for each layer.
Positioning is determined via an A+B
encoder connected to a PROFIBUS box..
Load platform
Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via four proximity
switches connected to a PROFIBUS box.
Pallet lift
Lift:
Servo motor drive.
Starting sensor on the lowest setting:limit
switch connected to a PROFIBUS box.
Positioning is determined with photocells and
a limit switch connected to the PROFIBUS
box, high / low speed photocell (empty pallets), photocell for scanning the top.
All other positions are detected via a
resolver-servo system.
Lift trolley with centring unit:
Pneumatically controlled centring mechanism:
Monostable valve connected to a PROFIBUS box.
Reed contacts with starting detection connected to a PROFIBUS box.
Reed contact for detecting pallet size, connected to a PROFIBUS box.
Protection against slackening/breaking of the
chain with the aid of two limit switches connected to a PROFIBUS box.
Drop lock:
The lift trolley is secured with a drop lock. In
the event of an emergency stop or safety
stop, the lift trolley will be mechanically
blocked.
The safety system is kept open with compressed air and is put in the blocking position
using spring tension.
Open detection using reed contacts on the
cylinders connected to a PROFIBUS box.
Blocking detection via limit switches connected to a PROFIBUS box.
An emergency stop or safety stop is generated via a safety relay, set at a certain time
3-18
CSi
September 1, 2014
09-1-14
Rear stop
Functional specification
Optional modules
Ti (double infeed)
Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via photocells connected to a PROFIBUS box.
Divider
Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via photocells connected to a PROFIBUS box.
Switching via a bistable pneumatically controlled valve.
Switching synchronisation via a proximity
switch connected to a PROFIBUS box.
Protection via a locked swing door.
Accumulation conveyors
Lift:
Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via photocells connected to a PROFIBUS box.
09-1-14
3.5.1
Sheet inserter:
Vacuum via an ejector:Vacuum on switch,
vacuum OKE switch, blow-off switch All are
September 1, 2014
CSi
3-19
Functional specification
HMI software
Hardware:
Software:
09-1-14
3.5.2
Connection via a RS422 or PROFIBUS connection using the IPC (integrated process
control) 24 V feed.
K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-03.fm
Barcode scanner (1 or 2)
3-20
Eagle control;
CSi
September 1, 2014
Functional specification
3.5.3
Eagle Control
This component consists of a graphic real-time interface for the machine.
The actual real-time status of the different parts of the machine is displayed
on different screens. The situation displayed on the screen is always the
current real-time status of the machine, with the current packets in their
current position, as graphically shown. All counters are displayed live,
including the current task.
Errors and faults are displayed in the 'error messenger' using the following
tools:
pallet ID;
3.5.4
Step 2
Step 3
09-1-14
Step 1
The control element calculates default values for all settings during
programming. These settings can be altered during fine adjustment and
are saved in the current program.
3.5.5
September 1, 2014
CSi
3-21
Functional specification
The program is based on a modular design. Each module collects the data
required for the current package. Once the package has been processed
in the module, the module will receive new data for the next package.This
enables the machine to work fully automatically with different packages,
and also enables package tracing.
Four Soft PLCs are active within the IPC:
1st PLC:
Palletiser
2nd PLC:
3rd PLC:
4th PLC:
This process ensures that the software will always be structured and used
in modules (see figure below).
S/PLC2
Case
S/PLC2
S/PLC1
S/PLC1
Palletiser
Conv.
Case
Conv.
Palletiser
3.5.6
09-1-14
3-22
128 MB
UPS
CSi
September 1, 2014
Functional specification
3.5.7
Standard E-cabinet
The machine has a standard control cabinet based on a modular design.
The base cabinet contains all the control elements for the basis machine.
You can choose from the following options:
09-1-14
1
Pallet
2
Case
September 1, 2014
CSi
3-23
Functional specification
3.5.8
3-24
Cable:
400 V: 4 mm2.
PROFIBUS:M12 connector cable with plug or female plug.
24 V: Flat cable with click module (Asi) and M12 connector.
All control mechanisms are connected to the connecting point with M12
connectors.
CSi
September 1, 2014
09-1-14
Each module has its own local control section. For complex modules such
as destackers, this could be a CSi local control mechanism.
Operator manual
OPERATOR MANUAL
4.1
Introduction C5000i
09-1-14
Tasks (assignments).
Eagle Editor:
-
Eagle services:
-
September 1, 2014
CSi
4-1
Operator manual
4.2
4.2.1
Start button
Press the start button to start the machine. The machine will start section
wise from backwards on. The machine is ready to palletize when it has an
active palletiser assignment, and when there are no error messages. The
start mode is not available in the event of:
4.2.2
Hardware faults such as: thermal faults, profibus faults, and supply
voltage faults;
Flashing
09-1-14
4.2.1.1
Stop button
The stop button is used to stop the machine. After the stop button is
pressed the machine will go into a controled stop. All positions will stop
when they are in a defined state. In case a section cannot stop in a defined
position because of a failure, the movement will stop after a delay time.
4.2.3
Reset button
Press this button to rest all alarms and/or warnings detected by the system.
w
4.2.3.1
Warning
Do not press the reset button casually. Always determine the reason for
an alarm/warning, and repair/remove/clear the cause before resetting the
alarm.
Indicator light (blue)
Flashing
4-2
CSi
September 1, 2014
Operator manual
4.2.4
Manual button
When automatic mode is active
Press the manual button to change from automatic mode to manual mode.
The machine will perform a controlled stop, i.e. all parts of the machine will
finish their current action and then stop.
Manually operating the machine is only possible when the machine is also
in stand-by mode (has been started). The machine is operated manually by
selecting specific devices in Eagle.
Note
During manual mode, counters and other software parameters are not
updated. Any palletizing operation in manual mode will upset the active
program on resumption of automatic mode.
When manual mode is active
4.2.5
Flashing
Stop Infeed
Press this button to stop products being input through channel 1. Press this
button again to restart the infeed.
4.2.5.1
09-1-14
Continuously lit
September 1, 2014
CSi
4-3
Operator manual
4.3
4.3.1
4.3.2
4-4
CSi
09-1-14
September 1, 2014
Operator manual
4.3.3
A safety light barrier is an optical entry point. Entering the system through
the light barrier will result in an immediate shutdown of the system. The
barrier will trip and needs to be reset via the local reset button near the light
barrier.
Location of safety light barriers is indicated in Fig. 1.1.
Every safety light barrier is equipped with an operator panel with a reset/
override button. The operator panel is mouted on the safety fencing near
the light barrier.
Push button (blue)
09-1-14
c
4.3.4
Caution
When running override, it is the responsibility of the operator that no one
passes the light screen and enters the dangerous zone.
Safety lock
The access door to the lift is fitted with a safety lock.
September 1, 2014
CSi
4-5
Operator manual
09-1-14
4-6
CSi
September 1, 2014
Fault-finding
FAULT-FINDING
5.1
Msg24=Assignment Failure;Packs
allready divided
Msg26=Assignment Failure;Amount
packs or layer = 0
Msg25=Assignment Failure;Pallet or
LayerID not found
Msg23=Assignment Failure;Sequention
number not found
Msg21=Assignment
Message;Assignment Accepted
09-1-14
FAULT MESSAGE
September 1, 2014
CSi
5-1
Fault-finding
5-2
CAUSE / SOLUTION
Msg39=Communication Failure;%s to
PLC.
Msg2147217887=Database
failure;DbMessage = %s
Database error.
Msg54=Error;DataBase cannot be
opened....
CSi
September 1, 2014
09-1-14
FAULT MESSAGE
Fault-finding
09-1-14
September 1, 2014
FAULT MESSAGE
CAUSE / SOLUTION
Msg31=Failure;PackLength, width or
height too smal. (<10mm)
Msg51=Failure;Wrong Password.
CSi
5-3
Fault-finding
5-4
CAUSE / SOLUTION
Msg2147217900=Input failure;Record
cannot changed because of field-input
failure. ***** DbaseMessage = %s
Database error.
Msg40=Mode failure
Palletiser in manual mode.
Msg204=No Read
Msg203=Reader Error
CSi
September 1, 2014
09-1-14
FAULT MESSAGE
Fault-finding
09-1-14
September 1, 2014
FAULT MESSAGE
CAUSE / SOLUTION
Msg100=Warning Overwrite
dimensions;Old values = LayerWidth
'%s' , LayerLength '%s' Accept new
values?
CSi
5-5
Fault-finding
5-6
CAUSE / SOLUTION
Msg42=Warning;Record cannot be
deleted because it is used by Palletizer.
CSi
September 1, 2014
09-1-14
FAULT MESSAGE
Fault-finding
FAULT MESSAGE
CAUSE / SOLUTION
09-1-14
September 1, 2014
CSi
5-7
09-1-14
5-8
Fault-finding
CSi
September 1, 2014
Maintenance
MAINTENANCE
6.1
Introduction
Note
We suggest you only consult those sections of the general instructions
that apply to the conveyors and machines supplied to you.
The maintenance instructions of equipment supplied by subcontractors
can be found in Chapter 9.
Keep the conveyors and machines in tip-top condition by carrying out the
prescribed maintenance. This is necessary to keep the machine
functioning correctly and safely.
Maintenance work may be carried out by authorised personnel only.
09-1-14
6.2
September 1, 2014
CSi
6-1
Maintenance
Warning
Safety devices should be operated with utmost vigilance and alertness as
they ensure the safety of staff.
Warning
Improper use, faulty installation or operation, improper removal or
switching-off of safety devices and opening of protective covers without
taking safety precautions can result in serious injury or death as well as
major material damage.
Work, of whatever nature, should be carried out by qualified and authorized
personnel only. The safety instructions as mentioned in Chapter 1 "Safety"
should have been read first and all necessary safety precautions should
have been taken prior to the start of work.
Familiarize yourself properly with safety instructions before carrying out
maintenance work or repairs.
Safety instructions must be strictly observed, in particular those described
in Chapter 1 ("Safety") under paragraph "Safety in the event of
maintenance, faults, repairs and adjustments".
Please also read and adhere to the applicable safety instructions described
in this chapter.
Before carrying out any work, please ensure that electric power supply and
compressed air supply are switched and closed off at all times, and that the
switch / valve is padlocked.
These maintenance instructions include pictograms (see alongside) that
warn you about hazards, and draw your attention to necessary
precautions.
Safety devices have been fitted. This chapter outlines the mechanical
safety devices. Information on electric safety devices can be found in the
chapter "Safety".
When carrying out inspection and/or maintenance work, please ensure
that:
6-2
All safety devices are present, in working order and functioning properly.
CSi
September 1, 2014
Safety
09-1-14
6.3
Maintenance
Any defect, fault or flaw in any safety device should be put right before the
installation is put into operation.
6.4
Cleaning
Warning
External cleaning by spraying with water or a cleaning liquid is not
permitted, unless specifically mentioned otherwise.
Never use petrol or solvents to clean the machine.
Remove bulky rubbish like sticky tape, packaging and product remnants, glass fragments, wood splinters etc. immediately to
avoid damage, wear and tear and faults.
Every 3 months:
Note
After cleaning, some components may need to be re-lubricated. Check
and lubricate the relevant components in accordance with instructions.
09-1-14
Driving belts and conveyor belts may need to be cleaned to prevent e.g.
steering problems. Do this sparingly, using water and a neutral soap. Never
use corrosive cleaning agents.
6.5
Gear motors
Carry out maintenance work in accordance with the manufacturers
instructions (see chapter 9).
The type plate indicates the type of lubricant used to fill the gearbox and
the amount of lubricant in litres.
The lubricant used and the filling quantity depends on the type of gear
motor, its shape and operating conditions.
Never mix different types of lubricants.
6.5.1
Replacing
Read the manufacturers instructions carefully before replacing a gear
motor. Make sure that the new motors specification match the old ones
exactly, i.e. that you install the same motor.
A new gear motor can come with a screwed-in vent, fitted with a transport
seal. Remove the seal to put the gear motor into working order.
September 1, 2014
CSi
6-3
Maintenance
When replacing the gear motor, please check the alignment of the drive
and the oil level in the gearbox.
6.6
6.6.1
6.6.2
Tensioning
The chain is correctly tensioned if there is play in the unloaded part on the
half centre distance of the sprockets. This can be determined as follows:
When the full tensioning capacity of the chain has been used up, the
tensioning device should be returned to the starting position and the chain
either shortened or replaced.
It is not possible to re-tension the short roller drive chains.
6.6.3
Replacing
The resulting friction in the hinge points of the transmission chain causes
wear and tear, resulting in chain lengthening. The maximum permissible
length increase is 3%.
Do not replace transmission chain and sprockets separately; always
replace both.
Transmission chains come in standard length and must be brought to
correct length on-site, using disassembly tools.
When re-assembling the transmission chains and sprockets, please retain
the original running direction.
sprockets should be fitted and disassembled using special tools. Use the
special screw thread in the end of the shaft.
6-4
CSi
September 1, 2014
09-1-14
Maintenance
When replacing and adjusting, please check the alignment of the chain
transmission. The sprockets need to be parallel to one another and aligned
This can be checked by keeping a ruler along the sprockets of the
sprockets;
Take care! Loosen the socket screw of the sprocket when disassembling
and fasten when assembling.
For installment of the sprocket that must be installed via a key way
connection to a shaft, use an appropriate anti-oxidant lubricant, see
paragraph 6.12.1.
6.7
Clamping bushes
MAKE
Bikon
ETP Classic
Ringfeder
09-1-14
Taper-lock
TYPE NO.
Bikon 1006 / 020 - 047
Bikon 1006 / 055 - 085
Bikon 1006 / 065 - 095
Bikon 8000 / 060 - 077
ETP 20 / 028 - 022
ETP 25 / 034 - 027
ETP 70 / 090 - 072
RfN 7012 / 025 - 050
RfN 7013.1 / 035 - 060
RfN 7013.1 / 045 - 075
1008 / 1108
1210 / 1610 / 1615
2012
2517
3020 / 3030
TENSIONING
BOLTS
(NO. / DIM.)
MOMENT
5 / M6
8 / M8
9 / M8
9 / M8
3 / M5
4 / M5
6 / M8
9 / M6
9 / M6
9 / M8
2 / 1/4" BSW
2 / 3/8" BSW
2 / 7/16" BSW
2 / 1/2" BSW
2 / 5/8" BSW
17
41
41
41
8
8
32
14
17
41
6
20
31
48
90
TA (NM)
September 1, 2014
CSi
6-5
Maintenance
TollokClampex
BOLTS
(NO. / DIM.)
8 / M6
8 / M6
8 / M8
6 / M6
8 / M6
8 / M8
8 / M8
8 / M8
8 / M8
8 / M10
6 / M6
6 / M6
6 / M6
8 / M6
8 / M8
8 / M8
8 / M8
8 / M10
TENSIONING
MOMENT
TA (NM)
17
17
41
14
14
35
35
35
35
70
17
17
17
17
41
41
41
83
6.8
Rollers
Please replace the entire roller if there is too much radial and / or axial play,
if it produces noises, is damaged, or runs with difficulty.
As a rule, roller bearings are not adjustable and not removable.
6.9
Bearings
Please replace a bearing if there is too much radial and / or axial play, if it
produces noises, is damaged, or runs with difficulty.
In certain instances, it is difficult or impossible to replace bearings, and the
component will have to be replaced in its entirety. This applies to e.g. rollers
and wheels.
When replacing bearing blocks, please use an appropriate anti-oxidant
lubricant during installment, see paragraph 6.12.1.
6.9.1
6-6
CSi
September 1, 2014
TYPE NO.
09-1-14
MAKE
Maintenance
For safety purposes, bearing blocks fitted to the outside of the frame may
come with a detachable guard. If such a bearing block should be lubricated,
first remove the protective guard to let excess lubricant run off and once the
bearing block has been lubricated, re-attach the protective guard.
6.10
Pneumatic installation
Make sure that dirt can not enter the pneumatic system.
The compressed air that enters at the connecting point of the pneumatic
installation, should be dry, clean and pre-filtered.
The connecting point of the compressed air supply line must have an "air
service unit" installed to remove dirt particles from the pipe system and to
set the air pressure. This is a combination of water separator, air filter,
pressure regulator and manometer.
6.10.1
Water separator
The water separator comes equipped with a condensate drain. The
frequency of draining depends on the condition of the compressed air and
on operating conditions.
If there is too much moisture in the supply line, please check whether the
supplied air meets requirements.
6.10.2
Air filter
The filter element should be cleaned or replaced when dirty.
09-1-14
6.10.3
6.10.4
September 1, 2014
Please ensure that the piston rod(s) of the pneumatic cylinder(s) is/are
clean; this will prevent wear and tear and leakage.
Please check that the pneumatic valves are in proper working order.
Check the pneumatic hose and connections for leaks and damage.
Please ensure that the hosing isnt twisted or jammed.
CSi
6-7
Maintenance
6.11
w
6.11.1
Electrical installation
Warning
Work, of any nature, on the installation should be carried out by qualified
and authorised personnel only. Please read Chapter 1 ("Safety") and
take all necessary precautions.
Control cabinet
Please close the cabinet door properly always so that dust and moisture
cannot enter.
If the control cabinet is equipped with a ventilator, please check the filter
element for dirt and clean or replace when necessary. The air inlets and
outlets must remain easily accessible i.e. kept free of obstacles.
Please take particular care to check security switches and other switches
that are used now and again only.
Photo cells
09-1-14
6.11.2
The PLC is fitted with batteries and the IPC is fitted with a UPS
(Uninterrupted Power Supply)
Every 6 months:
Check UPS
Every 3 years:
Please ensure that all activities are carried out in accordance with
manufacturers instructions.
6.11.3
Operating panels
Keep the operating panel clean and check functioning of control elements
and indicator lamps on a regular basis.
6.11.4
6.11.5
Clean the lenses of photo cells and reflectors with a soft cloth.
The frequency of cleaning depends on environmental influences such as
dust, dirt, damp etc. You might therefore need to clean more often than
instructed.
6.11.6
Electrical cabling
Please ensure that cable ducts dont become damaged. Please keep
cable work of the control current separate from cable work of the main
current. Loops in cables must be avoided.
6.11.7
Cable tracks
Depending on the application, cable tracks are used free-bearing or in
combination with cable ductings.
Important when inspecting and carrying out maintenance work:
6-8
CSi
September 1, 2014
Maintenance
6.12
Please shut cable tracks correctly and insure that connections and
internal sections are not damaged or loose.
Cables and pneumatic hosings (if applicable) must not become twisted
or jammed. Please also ensure that there is enough play for lengthwise
movement in the cable track.
Cables and hosings must be secured with a pull relief on outer ends of
cable tracks.
Lubricants
09-1-14
The table below provides an overview of the lubricants for general use.
For components requiring specific re-lubrication, please read the relevant
maintenance paragraph.
Note
The frequency of re-lubricating is highlighted in the maintenance
diagram.
Different lubricants and regulations apply if the conveyors / machines are
connected to a central lubricating system, are set up in a dirty or corrosive
environment or in areas with high or low temperatures.
Different types of lubricant should not be mixed.
APPLICATION
Bearing blocks with a greased
lubrication nipple.
(see paragraph 6.9.1)
Transmission chains
(see paragraph 6.6)
LUBRICANT
METHOD
Grease:
NOCO -Fluid
(see SEW Eurodrive
manufacturer's instructions)
Tab. 6.2 Lubricant table
September 1, 2014
CSi
6-9
Maintenance
1) Registered by NSF (Class H1) and meet USDA H1 guidelines (1998) for
lubricants for use where there is a potential for incidental contact with food.
Made only from substances permitted under the US FDA Title 21 CFR 178.3570,
178.3620 and 182 for use in food grade lubricants.
6.12.1
Anti-oxidant lubricant
Use an appropriate lubricant when replacing e.g. a slip-on motor reductor,
bearing blocks or when replacing transmission components that are
installed via a key way connection to a shaft, see lubricant table Tab. 6.2.
Lubrication facilitates installment and prevents oxidation.
6.13
09-1-14
Keep the conveyors and machines in tip-top condition by carrying out the
prescribed maintenance. This is necessary to keep the machine
functioning correctly and safely. The maintenance frequency indicated is
based on 24 hours/day and 7 days/week operation.
Warning
If you wish to use another equivalent lubricant, please make sure it
doesnt contain lead or copper. These additives are not compatible with
parts that have received a chemically blackened surface treatment.
These additives can corrode the chemically blackened layer which
complicates future disassembly.
6-10
CSi
September 1, 2014
Maintenance
Energy powered moving parts can cause hazardous situations and may
lead to serious injury or even death. Make sure to always switch off power
supply, shut down air supply and secure the particular switch / valve with
a padlock, before carrying out any work on the machine.
Inspection and maintenance work highlighted in the columns need to be
carried out while the conveyor is in operation. You must therefor be extra
vigilant and aware about the risks and the consequences.
Cleaning
Every 3
months
General inspection
I
I
Cleaning
Gear motors
Chain transmission
Rollers
Bearings
ICL
ICL
ICL
ICL
ICL
ICL
ICL
ICL
RUNNING WARM
SEE PAR.
PLAY
TRACKING
TENSION
DIRT
OPERATION
DAMAGE
FASTENING
NOISES
POSITIONING
FUNCTIONAL OPERATION
LEAK
OIL LEVEL
Every day
General maintenance
09-1-14
6.4
6.3
I
I
6.4
I 6.5
I I-L
I-A
6.6
6.8
I 6.9
September 1, 2014
CSi
6-11
Maintenance
I
I
General inspection
Control cabinet
I
6.11.1
Cable tracks
6.11.2
6.11.3
ICL
ICL
ICL
ICL
RUNNING WARM
PLAY
TRACKING
TENSION
6.11.5
ICL
ICL
ICL
6.11.4
6.11.6
6.11.7
6.11.2
DW
I- I
CL
6.10.1
I
6.14
6.14.1
6.14.2
Machine construction
The machine consists of the following main groups:
6-12
CSi
Every 3
years
Every week
Every 3
months
Photo cells
SEE PAR.
09-1-14
Installation
Every 3
months
Every 6
months
OPERATION
DAMAGE
FASTENING
NOISES
POSITIONING
FUNCTIONAL OPERATION
LEAK
OIL LEVEL
DIRT
September 1, 2014
Maintenance
The modules:
-
Rotating unit
Row pusher
Load platform
Pallet lift
(Optional)
Pusher
Interleaving sheet module
Glue module
The machine can be extended with one or more optional extras and have
customer specific alterations. The optional extra is part of the machine if the
control of the optional extra is integrated in the control of the machine.
09-1-14
6.14.3
September 1, 2014
Fixed guards that can only be removed with the aid of tools for
maintenance purposes.
One entrance door for the product infeed zone and one door for the
row forming zone. Both have a lock in accordance with CE safety
class 3.
To gain access, the STOP button on the local control panel must be
pressed.
CSi
6-13
Maintenance
6.15
6.15.1
6.15.2
Accessible via a lockable door which can be opened and closed with
a safety key.
The entrance is cleared and the lock can be unlocked when the
machine has been turned off correctly. After closing the door, it must
be locked again using a key and the machine must be restarted via
the local control panel beside the entrance door.
The pallet lifts lift wagon is equipped with a mechanical drop lock.
Warning
Safety devices which are not assembled and/or not closed, or which are
not in working order or which do not function correctly, will cause
dangerous situations which may result in serious physical injury or death.
Drive belt
Continuously welded with a V-belt on the bottom. The belt can be tensioned using a
moveable tensioning pulley.
Rollers
Pressure unit
6-14
CSi
September 1, 2014
09-1-14
Maintenance
6.15.2.1
7 Remove the tension in the belt by rotating both tensioning bolts the
same number of turns in the correct direction.
8 Draw a linear measurement of 1,000 mm on the top of the belt.
9 Tension the belt by turning both tensioning bolts an equal number of
turns in the correct direction until there is an 2 mm increase in the length
of the line. This is equal to the required pre-tensioning of 0.2%. When
tensioning, check whether the drive belt is correctly positioned with
respect to the pulleys
10 Measure to see whether the tensioning pulley is positioned at right
angles in the frame.
11 Fit the rollers and tension springs.
12 Assemble the drive belts bottom guard.
13 Unlock the main switch and turn it to ON / 1 position.
14 Start the machine and test whether it functions correctly
09-1-14
6.15.3
6.15.3.1
September 1, 2014
CSi
6-15
Maintenance
Note
It is recommended to inspect the pulleys for dirt and wear before
beginning the assembly.
7 Assemble the continuous belt.
8 Tighten the belt and assemble in the correct order, see points 8 to 12 of
paragraph 6.15.2.1.
9 Unlock the main switch and turn it to ON / 1 position.
10 Bring into operation and test the functional operation.
6.15.4
3 Remove the two bolts used to secure the pressure unit to the ruler and
remove the pressure unit from the ruler via the bottom of the ruler.
4 Replace the cylinder.
5 Fit the pressure unit into the ruler and fix the air connections.
6 Assemble the bottom guard.
7 Unlock the main switch and turn it to ON / 1 position.
8 Bring into operation and test the functional operation.
6.15.5
6.16
6.16.1
6-16
Row pusher
Description
Drive
Chain guide
Chain tensioners
The chains which are connected to the pusher bars are automatically kept at the correct
tension by a spring tensioner. The drive
chains are tensioned by adjusting a tensioning wheel.
CSi
September 1, 2014
09-1-14
Maintenance
6.16.2
6.16.2.1
Tensioning bolts
9 pcs. M6
17 Nm
09-1-14
230
6.17
6.17.1
6.17.2
Load platform
Description
Drive
Guide
September 1, 2014
CSi
6-17
Maintenance
6.17.2.1
Tension gauge
In order to check and adjust the pre-tension, you must have a Gates Sonic
Tension Meter, model type 507C.
Read the tension gauges instruction manual and follow the instructions.
The tension gauge only has to be calibrated once by inputting the weight,
width and span length and saving the data in the memory of the tension
gauge. (see table Tab. 6.4)
WEIGHT
(M=G/M/MM)
WIDTH
(W=MM/#R)
SPAN
(S=MM)
004,5
025,0
0771 (fully
closed)
004,5
025,0
0660 (fully
closed)
004,5
025,0
0682 (fully
closed)
004,5
025,0
1011 (fully
closed)
004,5
025,0
004,5
025,0
In the SPAN column, the span length between two fixed points is indicated
(see Fig. 6.2) over which the timing belt can freely move up and down and
where the pre-tension must be measured.
The load platform must be fully closed for measurements 1 to 4. The load
platform must be fully open for measurements 5 and 6.
1750,5
771(1341 full open)
682
660
6-18
CSi
September 1, 2014
09-1-14
SELECT
Maintenance
6.17.2.2
8 Read the measured tension when the green LED goes out.
9 If the tension is higher or lower, correct the tension to a value of 400 N.
10 Check and tension the other timing belt as described in points 5 to 9.
11 Carry out measurement 2, followed by measurements 3 and 4 (see
table Tab. 6.4) as described in points 5 to 10.
12 Turn the motors fan by hand until the load platform is fully open.
13 Carry out measurement 5 followed by measurement 6 as described in
points 5 to 10..
14 Repeat the measurements, see points 5 to 13.
The tension values obtained must not differ greatly.
15 Unlock the gear motors brake by unscrewing the handbrake releaser
and assemble the motors fan cover.
16 Unlock the main switch and turn it to ON / 1 position.
17 Switch the machine on and test the whether it is working properly.
09-1-14
6.17.3
Note
It is recommended to inspect the pulleys for dirt and wear before starting
the assembly.
5 Adjust both tensioners to the start position.
September 1, 2014
CSi
6-19
Maintenance
6.18.1
Lubricant
6.18
Lubrication method
09-1-14
Frequency
6.18.2
6-20
CSi
September 1, 2014
Maintenance
6.19
09-1-14
6.19.1
6.19.2
Pallet lift
Description
Pallet lift
Lift wagon
Centring unit
Drop lock
September 1, 2014
CSi
6-21
Maintenance
6.19.2.1
Pallet lift
The lift chains and the bearing blocks of the drive axle should be relubricated, see paragraph 6.12.
Position of the lubrication points
The lubrication nipples for the bearing blocks
are connected to the bearing block via a
lubrication line and are located on the outside of the frame.
Frequency
6.19.2.3
Lubricant
Method
Frequency
Centring unit
The chains should be re-lubricated, see paragraph 6.12.
Frequency
The chains are correctly tensioned if the chains do not make much noise
when rolling onto and off of the chain wheels, have almost no free
movement and if it is not possible for the chains to touch the top of the
pneumatic cylinder (see Fig. 6.4).
Drop lock
Always first support the counterweight and the lift wagon if you must carry
out work on the drop lock
6-22
CSi
September 1, 2014
Lift wagons
09-1-14
6.19.2.2
09-1-14
September 1, 2014
Maintenance
CSi
6-23
Maintenance
6.20
conveyor
Infeed row-forming
6-24
RUNNING WARM
TENSION
TRACKING
PLAY
LUBRICATION
DIRT
OIL LEVEL
LEAK
FUNCTIONAL OPERATION
POSITIONING
NOISES
FASTENING
DAMAGE
I
C
I
C
6.15.
4
6.8
Pressure unit
Rollers
I
C
Spacers / stop
plate
I
C
CSi
I
A
09-1-14
OPERATION
General maintenance
Electrical installation
Pneumatic installation
Drive belt
SEE
PAR.
COMPONENT
FREQUENCY
MODULE
6.15.
2
6.15.
3
6.15.
5
September 1, 2014
Maintenance
COMPONENT
I
C
I
C
I
C
I
C
Plates
Running wheels
I
C
Slide crank
mechanism
I
C
I
C
CSi
I
L
I
L
RUNNING WARM
TENSION
TRACKING
PLAY
LUBRICATION
timing belts
DIRT
OIL LEVEL
Chain guides
LEAK
FUNCTIONAL OPERATION
POSITIONING
FASTENING
Chain
transmission
NOISES
DAMAGE
Every 3 months
Every 3 months
Every 3 months
Row
Pusher
Load platform
Back- and
side dams
September 1, 2014
SEE
PAR.
OPERATION
FREQUENCY
MODULE
I
A
6.16.
2
I
A
6.17.
2
6.17.
3
6.18.
2
6-25
Maintenance
6.19.
2.1
Lift wagon
I
C
I
L
6.19.
2.2
Centring unit
I
C
I
L
Drop lock
I
C
TENSION
I
L
TRACKING
PLAY
I
C
DIRT
OIL LEVEL
LEAK
I
A
6.19.
2.3
6.19.
2.4
6.21
6-26
CSi
September 1, 2014
RUNNING WARM
LUBRICATION
FUNCTIONAL OPERATION
POSITIONING
FASTENING
Pallet lift
NOISES
DAMAGE
OPERATION
Every 3 months
Pallet lift
SEE
PAR.
09-1-14
COMPONENT
FREQUENCY
MODULE
Maintenance
09-1-14
6.21.1
Functional description
The lifting elevator function is integrated in the palletising function.
The lift function drive is designed for a specific maximum pallet weight of
1500 kg.
A pallet is positioned on a pallet roller conveyor.
This pallet roller conveyor is integrated on a lifting platform.
For optimal handling / energizing the unit is equipped with a guided
counterweight.
The pallet is lifted to a position under the loading platform (stripper table),
depending on the actual height of the pallet.
The loading platform opens and a layer is dropped on top of the pallet (or
pallet load).
Now the pallet(load) is lowered in high speed until the top of the pallet(load)
is under the loading platform.
September 1, 2014
CSi
6-27
Maintenance
Then it will raise the pallet(load) in slow speed back towards the platform
for the next layer to be accepted.
6.21.2
Description
Lift construction
Blocking pin
6-28
CSi
September 1, 2014
09-1-14
21 Counter weight.
Maintenance
6.21.3
w
6.21.4
w
K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm
6.21.4.1
Safety
Warning
Improper use, faulty installation or operation, improper removal or
switching-off of safety devices and opening of protective covers without
taking safety precautions can result in serious injury or death as well as
major material damage.
Electrical installation
Warning
Work, of any nature, on the installation should be carried out by qualified
and authorised personnel only. Please read Chapter 1 ("Safety") and
take all necessary precautions.
Control cabinet
Please close the cabinet door properly always so that dust and moisture
cannot enter.
If the control cabinet is equipped with a ventilator, please check the filter
element for dirt and clean or replace when necessary. The air inlets and
outlets must remain easily accessible i.e. kept free of obstacles.
6.21.4.2
6.21.4.3
Photo cells
Clean the lenses of photo cells and reflectors with a soft cloth.
09-1-14
Electrical cabling
Please ensure that cable duct do not become damaged. Please keep
cable work of the control current separate from cable work of the main
current. Loops in cables must be avoided.
6.21.4.5
Cable tracks
Depending on the application, cable tracks are used free-bearing or in
combination with cable ducts
September 1, 2014
CSi
6-29
Maintenance
6.21.5
Please shut cable tracks correctly and insure that connections and
internal sections are not damaged or loose.
Cables and hoses must be secured with a pull relief on outer ends
of cable tracks.
Warning
The counterweight must be blocked mechanically.
For that reason a blocking provision (See Fig. 6.8 Safety Blockage
Positions 4/5 & 29/30) has been fitted on each side of the frame.
Each blocking provision has two blocking pins. ( See Fig. 6.7 Safety
blockage lift platform positions 3) In total four counterweight blocking pins
have been fitted.
Check prior to works
1 Check that the platform is empty.
(No load allowed on the conveyor.)
2 Bring the lift platform up and the counter weight down (Using the manual
control on the main operator panel)
Required:
w
6.21.5.2
6-30
Operation
09-1-14
6.21.5.1
General
Warning
The work must always be carried out by two persons.
Tools required:
-
Two padlocks.
CSi
September 1, 2014
Maintenance
6.21.5.3
Chain
Lift chain needs to be exchanged if the elongation is more than 3 %
1 Open the door
The safety cylinders will go out (on spring actuation) and at least one of the
cylinders will be captured in the safety profile. (See Fig. 6.7 Safety
blockage lift platform)
On each side of the elevator frame a blocking provision is mounted on the
outside (see Fig. 6.8 Safety Blockage Positions 4/5 & 29/30).
2 Remove the two dummy bolts M20 positioned in the provisions (one
each) side and approx 700 mm height. holes in the elevator frame will
occur.
3 The locking pin (See Fig. 6.9 Position 2 ) can now be taken from the
blockage provision. (see Fig. 6.8 Safety Blockage Positions 4/5 & 29/
30).
09-1-14
2 Remove the four (4) protection plates (See Fig. 6.9 Position 2) on the
lifting mechanism inside the palletiser.
w
September 1, 2014
Warning
The counterbalance weight must be secured!
CSi
6-31
Maintenance
One person to Lower the lift platform and raise the counterweight in
manual operating of the elevator.
One person on the outside of the fencing to visually check when the
bolt slot(s) become free. The counter weight must be above the bolt
slots.
Warning
Normally we will be needing some kind of slack of the chain
In order to work safely the strong hold of the lifting platform on the lifting
chain should be eliminated!
Create slack on the chains to the lifting platform.
09-1-14
Note
See Fig. 6.6 Overview Palletiser positions 7.1 and 7.2
1 Lift by hand the brakes of the elevator drive so that the platform will drop
downwards until the lift blockage system will stop the movement.
One of the safety cylinders is now against the bottom of the hole in the
safety catching profile.
Note
The chain is to be slack on both sides!
2 Switch off the air supply.
a Make sure surplus air is let off.
b Padlock the main air valve in order to work safely.
3 Switch off the entire system electrically.
a Padlock the main switch on the related panel.
4 Secure access around the drives on higher level.
6-32
CSi
The pin to enter into the profile of the moving area of the counterweight.
September 1, 2014
Maintenance
09-1-14
Note
The C5000 has one elevator drive.
6 Liftmotor removal/weight
a Expected weight 85 kg . Always check the actual indicated weight
on the available drive.
b Use sufficient lifting gear (hoist or crane) for safe handling of the
drive.
c Use sufficient and lifting rope(s) in combination with lifting gear .
d Only use equipment rated for the load required.
Note
Use tested and validated lifting equipment.
7 Lift rope(s)
September 1, 2014
CSi
6-33
Maintenance
For removal of the drive the lift a rope must be tightened in such a way that
it can be shifted to one side.
Note
Make sure the drive does not drop down when it comes off the shaft!
Torque arm
After the drive is secured we can now safely remove the torque arm
support.
Note
The shaft will not start turning because the blocking mechanism prevents
the chains to move the shaft.
If you only want to exchange the drive it is not required to use the
counterweight mechanical blockage system.
1 Lift drive motor and lift chains
a Lift drive motor is to be removed from the shaft before the lift
chains can be accessed.
b Pull the drive from the shaft (Use pulley wrench if necessary).
Note
See item 8 and make sure the drive is held properly by the lifting
equipment and rope(s)!
c Replace lift chain on the drive motor side.
2 Remove the bracket (16) from the top frame on the drive motor side.
This is one of the connections between the lift frame and top part.
Now the lifting chain on the drive motor side of the elevator is free.
Warning
Mind the weight of the chain!
3 Visually check the chain for wear and tear.
If necessary exchange the chain.
Note
If chains and or bearings need to be replaced always exchange both
bearings and or chains during the stop.
a Check the status of the chain sprockets.
When chain sprockets are worn (and or if there is play between the
key connections and the chain sprocket and drive shaft) and they
need to be replaced continue with item 18.
6-34
CSi
September 1, 2014
Note
The drive still remains on the shaft.
09-1-14
n
n
Maintenance
To access and remove the bearings the drive shaft must be supported.
4 Support the shaft from the top frame ( See Fig. 6.10 Position 22 using
ropes and ratchet belts.
n
n
Note
Only use equipment rated for the load required.
Note
Use tested and validated lifting equipment.
Bearing on drive side.
1 Untighten bearing and slide bearing sideways of the shaft.
2 Slide new bearing in position.
3 Tighten.
4 Loosen and remove ropes (etc) on this side.
5 On the driven side all checks are executed.
a Lift chain on the non-driven side.
Note
On the drive side the bracket is still not connected.
09-1-14
September 1, 2014
CSi
6-35
Maintenance
This bracket (24) is the second of the connections between the lift frame
and top part.
Now the lifting chain at the non-driven side is free.
Note
Mind the weight of the chain!
a Check the chain on visual damage and on the actual elongation.
If necessary exchange the chain.
Note
Reminder if to be exchanged always exchange the pair.
b Check the status of the chain sprocket.
- When chain sprocket is worn and needs to be replaced go to item
18.
c Bearing on non-driven side.
7 Untighten and slide sideways of the shaft.
8 Slide new bearing in position.
9 Tighten.
10 Loosen and remove ropes (etc) on this side.
11 Reassemble.
6-36
CSi
September 1, 2014
09-1-14
6 Remove the bracket ( See Fig. 6.11 Position 24) from the top frame at
the non- driven side.
Maintenance
09-1-14
CSi
6-37
Maintenance
09-1-14
6-38
CSi
September 1, 2014
Installation
INSTALLATION
7.1
Introduction
7.2
Safety
The system / machine has been designed and manufactured in such a way
that it can be installed and commissioned safely. Ensure that installation is
carried out solely and exclusively by authorised and qualified personnel.
Please read the Safety chapter carefully. Safety regulations must be
adhered to strictly.
7.3
General
It is advisable to have, at the very least, a CSi supervisor present during
installation. He can carry out installation work, instruct and assist others,
and coordinate during start-up and commissioning.
09-1-14
September 1, 2014
Mechanical, electric and pneumatic hand tools, such as a set of ring and
open-end spanners, socket wrenches and Allen keys, tape measures,
screwdrivers, spirit level, drills, rotary grinder, etc., in the number
required by the installation team.
Fork lift truck or side loader, matched to the required lifting height and
lifting capacity.
CSi
7-1
Installation
Connection points for electric power and air and adequate lighting at the
installation site.
7.4
7.4.1
Check the materials delivery against the packing list. Report any
damage and / or shortage to CSi immediately.
7.4.2
Procedure
Depending on the design, complexity and operating conditions, minor
differences may occur; hence this procedure should be regarded as a
guideline.
1 Bring the materials to the place of use with a forklift truck and / or a side
loader.
2 Define the fixed coordination points according to the layout drawing and
on the basis of these points, erect the conveyors with the aid of a laser
measuring instrument.
3 Raise the conveyors to the correct belt height with a forklift truck or a
hoist and fit the supports and / or hangers. The correct belt height can
be found on the layout drawing.
7-2
CSi
September 1, 2014
09-1-14
Installation
09-1-14
7.5
7.5.1
Note
Certain adjustment work cannot be done until the system is ready for trial
operation. Additional adjustment of belt height may be necessary to
ensure trouble-free operation at junctions between conveyors.
Adjustment of lateral guides may also be necessary.
Warning
Avoid severe jolts, vibrations and shaking during transport in order to
prevent damage to the machine.
The machine is equipped with hoisting and lifting points. Use only these
points for loading, unloading and erecting the machine.
September 1, 2014
CSi
7-3
Installation
7.5.2
Procedure
Depending on design, complexity and operating conditions, minor
differences may occur; hence this procedure should be regarded as a
guideline.
1 Transport machine parts to the place of use with a forklift truck and / or
a side loader.
2 Position machine parts in relation to each other and assemble.
3 Set machine to correct height and level, using a level and a jack. Height
adjustment of supports is accomplished with threaded adjusting legs.
Take care that an adequate length of thread remains in the frame and
that all locking nuts are secured.
n
7.6
Note
Certain adjustment work cannot be done until the machine is ready for
trial operation.
Pneumatic installation
Our systems and machines are generally designed for a compressed air
pressure of 6 bar.
The connection points for air are shown in the layout drawing.
An air service unit should be installed as close as possible to the air
equipment as to ensure that the quality of the compressed air meets the
defined requirements.
Install and connect cylinders, valves, air service units and piping in
accordance with the pneumatic diagram.
7.7
w
7-4
Electrical installation
Warning
Ensure that installation of the electrical equipment is carried out solely
and exclusively by authorised and qualified personnel.
CSi
September 1, 2014
09-1-14
5 Fit lateral guides and adjust them in height and lateral direction,
according to the products to be processed.
4 Fix supports to the floor. Fixing holes are provided in the baseplates of
the adjusting legs and anchor bolts are included in the supply. The
anchors are usually fixed in concrete by adhesive bonding. The
packaging contains installation instructions.
Installation
7.7.1
Study
Before commencing installation of the electrical equipment, the functional
specification and the electrical documentation should be studied.
The electrical documentation comprises:
7.7.2
Front sheets
I/O sheets
7.7.3
Motor drives
The rated voltage and frequency of the motors (see the rating plate on the
gear motor) must correspond to those of the supply system.
09-1-14
7.7.4
Control cabinet
The following components are installed in the control cabinet:
September 1, 2014
Main switch
Fuses
Power supply
Operating equipment
Motor contactors
Thermal relays
CSi
7-5
Installation
Terminals
Interface relay
PLC/IPC
7.7.5
7.8
Warning
When testing, checking and adjusting certain functions that require a
supply of energy, please be particularly aware of dangers and risks.
13 Test manual operation.
14 Download the PC software.
15 Test the communication between the PLCs and IPCs and between the
IPCs.
16 Test the error messages.
17 Test the whole system with product under production conditions.
18 Test all control panels, manual operation and the reports print out.
7-6
CSi
September 1, 2014
09-1-14
Installation
19 Make an EPROM.
20 Test the system / machine with regard to capacity and functionality.
7.9
Operating manual
Once the system / machine is fully operational, the operating manual
should reflect the as built state.
7.10
Training
Put together a training programme and give training to operating,
production and maintenance personnel.
09-1-14
Explanation of layout via the product routing and by pass facilities (if
any).
Measures and instructions for working safely with the system / machine
(emergency stop protection, pull-cord switches, door switches, access
barriers, pneumatic switches, etc).
7.11
Measures and instructions for safe working with the system / machine,
such as emergency stop, pull-cord and access barriers, door switches,
pneumatic switches, shut-off valves, light curtains, etc.
Operation.
After commissioning
Continue to comply with all instructions as described in the operating
manual for reliable, safe operation of your system / machine(s).
Versie 2.0.1 - 2011-08-25
September 1, 2014
CSi
7-7
Installation
7.12
n
7.13
7.13.1
Note
The system parameters can only be changed by qualified employees.
Therefore you logged in on level 3 maintenance.
Description
5000Si
1 palletiser channel
5000Ti
2 palletiser channels
Tab. 7.1 Palletiser selection
7-8
CSi
September 1, 2014
09-1-14
Installation
7.13.2
Value
Description
7.14
7.14.1
Divider
Hardware
Switching moment control
The switching moment control prox is set in such a way that the prox fire
can be switched.
Air pressure
09-1-14
The air pressure is set to bar. The air pressure control switch is set to
bar.
7.14.2
Eagle
7.14.2.1
7.15
7.15.1
Accumulation conveyors
Hardware
The photocells are positioned so that there is still sufficient space between
the divider and the photocells to enable the divider to rotate when empty as
it rotates when full. The photocells are always positioned at an angle.
September 1, 2014
CSi
7-9
Installation
The belt guides are set so that the boxes run level alongside the machine
kicker
1 Set the guides on the breakfeeder(s) wide.
2 Adjust the accumulation belt guides so that the products run level
alongside the kicker.
3 Adjust the breakfeeder guides so that the products are just not touching.
7.15.2
Eagle
Not applicable. In the future, both the full and empty reporting times of the
photocells will be able to be set up.
Hardware
The photocell is positioned about 10-15cm before the end of the
breakfeeder. If products stop at the breakfeeder, the photocell causes it to
come to a stop a few cm before the end of the belt. The photocell should
not be set to high (consider tray edges, transparent bottles, holes in
products etc.).
If the direction of breakfeeder rotation is not correct, the machine
orientation has probably not been set up properly.
7.16.2
Eagle
7.16.2.1
7.16.2.2
7.17
7.17.1
Rotating cam
Hardware
Set the cylinder to as fast as possible. Set the microswitch to the cylinder
home position.
7.17.2
Eagle
Not applicable.
7-10
CSi
September 1, 2014
7.16.1
Breakfeeders
09-1-14
7.16
Installation
7.18
7.18.1
Kicker
Hardware
Set the arm length to no longer than the longest box. Set the home prox so
that it just burns in the minimum position of the kicker (the kicker is then
against the frame). When the direction of kicker rotation is not correct,
adjust it with the controller.
7.18.2
Eagle
The kicker only takes control of the changes when the machine is in the
Stop position.
7.18.2.1
The maximum speed of the kicker. This is the speed that the kicker goes
back to its home position. For forward movement, the assigned speed (in
%) increases with this speed. When this speed is adjusted, the kicker goes
slower or faster.
DEFAULT: 100%
7.18.2.2
7.18.2.3
7.18.2.4
09-1-14
The speed with which the kicker kicks during manual operation (0 - 100%)
Note
If 0% is input, it takes a long time for the rotation to be ready. Therefore
please avoid doing this.
DEFAULT: 60%
7.18.2.5
September 1, 2014
CSi
7-11
Installation
7.18.2.6
7.19
7.19.1
Packpusher
Hardware
7.19.2
Eagle
7.19.2.1
7.19.2.2
09-1-14
7.19.2.3
Note
If 0% is input, it takes a long time for the rotation to be ready. Therefore
please avoid doing this.
DEFAULT: 30 %
7-12
CSi
Select the stroke size of the packpusher equal to the greatest width of the
rotating products. The position of the reference prox is not important and
can be set up in Eagle. The direction of rotation is also not important.
September 1, 2014
Installation
7.19.2.5
7.19.2.6
7.19.2.8
09-1-14
7.20
7.20.1
Format area
Hardware
Direction of motor rotation is determined manually for the assigned
orientation.
7.20.2
Eagle
7.20.2.1
September 1, 2014
CSi
-1
7-13
Installation
Always control the speed evenly using the belt speed meter.
7.20.2.2
7.21
Spacers
09-1-14
Select Add/Rem from this screen. After you have selected the channel
number to see, you then get the following screen:
7-14
CSi
September 1, 2014
Installation
The spacers are configured by typing in the valve number for each spacer.
When there is no spacer at the position, a 0 should be input. A maximum
of 16 spacers can be configured for each channel. Where there are more
than 8 spacers in a channel, a second valve island should be set up. The
changes in the Eagle plates are changed just after Eagle restarts.
09-1-14
7.22
7.22.1
Rowpusher
Hardware
The position of the reference prox is not so important and can be set up in
Eagle. The row length monitoring photocell is set up so that it is not
positioned too high (consider tray edges, transparent bottles etc.). The
direction of motor rotation is adjusted by the controller.
7.22.2
Eagle
7.22.2.1
Rowpusher
Fig. 7.1 shows all of the adjustment positions. All positions can be
measured with respect to the 0 point. The 0 point is the position where the
rowpusher beam is just before the format area.
September 1, 2014
CSi
7-15
Installation
RP_C_Sliding_Table
Reference prox
RP_Ref_Pos
RP_Between_Dams
RP_Safe_Max
RP_PC_Check
Channel 2
RP_Input_All_Ch1
RP_Input_All_Ch2
0 position
Rowpusher beam
in 0 position
7.22.2.2
09-1-14
7.22.2.3
C5000Si
950 mm
C5000Ti
1550 mm
7-16
CSi
Channel 1
September 1, 2014
Installation
DEFAULT:
7.22.2.4
C5000Si
0 mm
C5000Ti
0 mm
7.22.2.5
C5000Si
1510 mm
C5000Ti
2350 mm
When the rowpusher has passed this position, the input of channel 1
indicates free. This is valid for the maximum rowpusher speed. When the
rowpusher speed is lower, this position is moved automatically.
The position is measured from the 0 point.
DEFAULT:
7.22.2.6
C5000Si
400 mm
C5000Ti
900 mm
09-1-14
DEFAULT:
7.22.2.7
C5000Si
200 mm
C5000Ti
250 mm
7.22.2.8
C5000Si
1010 mm
C5000Ti
1600 mm
September 1, 2014
C5000Si
1010 mm
C5000Ti
850 mm
CSi
7-17
Installation
7.22.2.9
7.22.2.10
7.22.2.11
7.22.2.12
7.22.2.13
7.22.2.14
7.22.2.15
7.22.2.16
C5000Si
2070 mm
C5000Ti
2735 mm
09-1-14
DEFAULT:
7.22.2.17
C5000Si
1515 mm
C5000Ti
2175 mm
7-18
CSi
September 1, 2014
Installation
7.22.2.18
7.23
7.23.1
C5000Si
280622 pulses/stroke
C5000Ti
638887 pulses/stroke
Side-, backdam(s)
Hardware
First check the directions of motor rotation. If these are incorrect, change
the motor rotation direction around (The 24VDC signals in the movimot).
Check the direction of encoder rotation. When the dams run to the middle
of the pallet, the encoder value in Eagle will be greater. If this is not the
case, then change round the encoder connection cables. The home prox
is adjusted so that the dam is in the home position, is far enough inwards,
and to ensure that no products can get caught behind.
7.23.2
Eagle
7.23.2.1
09-1-14
7.23.2.2
7.23.2.3
310 mm
September 1, 2014
CSi
7-19
Installation
7.23.2.4
Lift
Uitslag:
Sidedam 1 = Ref_distance - 1/2 Pallet_Length + 1/2 Load_Length - Length_Offset
Sidedam 2 = Ref_distance - 1/2 Pallet_Length - 1/2 Load_Length + Length_Offset
Backdam = Ref_distance - 1/2 Load_width + Width_Offset
50 mm
SD2 1258 mm
BD
7.24
7.24.1
616 mm
Load platform
Hardware
The proxes are controlled when they are first used with the load platform.
This is effected as follows:
1 Adjust the semicircular plates so that they have maximum slide with
respect to each other.
2 Close the load platform (only 1 prox now burns).
7-20
CSi
September 1, 2014
Ref
distan
ce
09-1-14
Ref distance
Sidedam in homepos
Ref distance
Sidedam in homepos
Backdam in homepos
Installation
3 Check that the load platform is also closed in Eagle. If this is not the
case, then turn the proxes around.
4 Now set the load platform to the middle position (this can possibly be
done using the hand control and emergency stop).
5 Now close the load platform using the hand control in Eagle. The load
platform now closes immediately. If this is not the case, turn around the
direction of rotation in the movimot and try again.
6 Now adjust the two semicircular plates so that the load platform stops
with a right crank. Only move the plate for which the prox does not burn
nearer to (to rotate further) or farther from (to stop earlier) the prox.
7.24.2
Eagle
Not applicable.
7.25
7.25.1
Lift
Hardware
1 First check the direction of rotation of the lift motor. Operate the lift using
the hand control in Eagle. If the direction of rotation is incorrect, change
it using the control.
2 Now check the direction of rotation using the control panel by the lift. If
the direction of rotation is incorrect, change the switch connections in
the control panel.
3 Check the lift limit switches and set them to the correct height (when the
lift runs in the limit switches, this can only be obtained through a reset).
Centring unit:
1 Set the home microswitches to the farthest position of the centring unit.
09-1-14
7.25.2
c
7.25.2.1
Eagle
Caution
Incorrect adjustment of the lift parameters can cause serious damage to
the sliding table.
Adjustment of Lift_Max_Speed(Int)
Maximum speed of the lift in mm/s. This is also the speed with which the lift
ascends with an empty pallet.
DEFAULT: 975 mm/s
7.25.2.2
Adjustment of Lift_Max_Acc(Int)
Maximum acceleration of the lift in mm/s. This is also the acceleration with
which the lift ascends with an empty pallet.
September 1, 2014
CSi
7-21
Installation
Adjustment of Lift_Man_Speed(Int)
Manual speed of the lift in mm/s.
DEFAULT: 150 mm/s
7.25.2.4
Adjustment of Lift_Man_Acc(Int)
Manual acceleration of the Lift in mm/s2.
DEFAULT: 500 mm/s2
7.25.2.5
Adjustment of Lift_Measure_Speed(Int)
Speed of the lift in mm/s with the measurement of pallet height.
DEFAULT: 100 mm/s
Adjustment of L_Pos_Infeed(Int)
This is the position of the lift, in mm, when it is in the infeed position. The
infeed position is shown in Figure 1-3. In this position, the pallet comes to
a stop above the pallet belt. The lift forks are just beneath the pallet belt.
DEFAULT: 250 mm
Adjustment of L_Pos_Outfeed(Int)
09-1-14
7.25.2.7
7.25.2.6
This is the position of the lift, in mm, when it is in the outfeed position. The
outfeed position is shown in Figure 1-4. In this position, the pallet stop and
the pallet forks are beneath the pallet belt. Ensure that this position is not
set too low by which the lift comes up against the limit switch.
DEFAULT: 210 mm
7-22
CSi
September 1, 2014
Installation
Adjustment of L_Pos_PC_Dec(Int)
Lift height
7.25.2.8
This adjustment is used to set the height of the deceleration photocell. The
deceleration photocell is the lowest photocell of the lift. The set height is the
distance, in mm, measured between the lowest limit switch and the
photocell with the lift height subtracted from it (see Figure 1-5). This
distance can also be determined with the lift empty by using manual
upward movements (the lift serving as a reference). The position in which
the lift photocell is just covered is the L_Pos_PC_Dec position. This
position can be read off from the operator panel (subtract the pallet height
from it).
DEFAULT: 1500 mm
7.25.2.9
Adjustment of L_Pos_PC_Max(Int)
This adjustment is used to set the height of the maximum photocell. The
maximum photocell is the highest photocell of the lift. The set height is the
distance, in mm, measured between the lowest limit switch and the
photocell with the lift height subtracted from it (see Figure 1-5). This
distance can also be determined by the empty lift by using manual upward
movements (the lift serving as a reference). The position by which the lift
photocell is just covered is the L_Pos_PC_Max position. This position can
be read off from the operator panel (subtract the pallet height from it).
DEFAULT: 2000 mm
09-1-14
7.25.2.10
Adjustment of L_Drop_Height(Int)
This is the distance, in mm, that the lift goes higher than the maximum
photocell.
DEFAULT: 30 mm
w
7.25.2.11
Warning
If this value is set too high, damage can be caused to the sliding table.
L_Max_Pos setting (mm)
This is the distance (in mm), where the lift slows down when carrying no
pallets, or when carrying too low a pallet. The Max-Pos distance is
determined by taking the distance between the top and bottom limit switch
and deducting the length of the skate on the lift ( 100 mm ).
7.25.2.12
September 1, 2014
CSi
7-23
Installation
w
7.26
7.26.1
Warning
Setting the value too high can damage the layer pad trolley.
Conveyors
Hardware
7.26.2
Eagle
7.26.2.1
7.26.2.2
09-1-14
DEFAULT: 4 sec
Pallet conveyor 2
Adjustment of C2_Time_Out(Int)
Time-out time of the pallet belt at the output of the pallet. Time is set in
seconds.
DEFAULT: 100 sec
Adjustment of C2_Time_Outf(Int)
Minimum time that the pallet belt remains running at the output of a pallet.
Just after this time has elapsed and the photocell is free, the belt is made
free and the data is copied.
DEFAULT: 6 sec
7-24
Check the direction of rotation of the conveyor belts. If they are incorrect,
turn them around in the movimot.
CSi
September 1, 2014
Installation
Movimot
09-1-14
7.27
CSi
7-25
Installation
7.27.1
09-1-14
7.27.2
7-26
CSi
off
September 1, 2014
Installation
Connection example:
n
7.27.3
Note
Use the correct type of EMC swivels.
Movimot LEDs
09-1-14
The following table applies to the LEDs on the movimot, not to those on the
field or profibus cabinets.
September 1, 2014
CSi
7-27
Installation
7-28
CSi
September 1, 2014
Fault codes
09-1-14
7.27.3.1
09-1-14
September 1, 2014
Installation
CSi
7-29
Installation
n
7.28
7.28.1
Note
The sys fault LED illuminates when the operating switch is off.
Movidrives
Downloading and uploading of parameters
The uploading and downloading of parameters is effected through
movitoolsThe downloading of parameters is only possible when the
machine is in emergency shutdown.
09-1-14
First start up the MT Manager. Set the radio button under the Connect to:
part of the screen to Single Inverter (Peer-to-Peer).
Connect the controller to your PC and press the update button. When this
has been accepted, a controller will be visible in the Connected Inverters
table. If this is not the case, check the cable and COM port number (this
must usually be set to COM 1).
Now click on the Shell button. The Movitools Shell now starts up.
Select Copy data from the Movitools Shell File menu (see also the
illustration).
7-30
CSi
September 1, 2014
Installation
09-1-14
Set the radio buttons as shown in the above screen to enable the
downloading of parameters to the controller. Use the Browse button to
search for the file to be downloaded.
When you want to upload parameters from the controller to a file, you must
set things up as follows:
September 1, 2014
CSi
7-31
Installation
09-1-14
When you want to download parameters you will see the following screen:
In this screen, check the All inverter data and Run IPOS Program
options. Now click the OK button. The downloading of parameters will now
begin.
If you had selected uploading of parameters, you would see the following
screen:
7-32
CSi
September 1, 2014
Installation
7.28.2
09-1-14
In the Parameters menu, select the Main Menu option. You will then see
the Main Menu (left-hand part of the following screen printout). In the Main
Menu, select the Motor parameters option. Now double-click on the 35.
Motor sense of rotation option (you will now also see the right-hand part of
the following screen printout). Set parameters 350 and 351 to ON when
they are set to OFF, otherwise turn them around. The changes to these
parameters are only possible when the machine is in emergency
shutdown. After the changes have been made, upload the parameters.
September 1, 2014
CSi
7-33
7.28.3
If there is a fault present, the red bar will illuminate and you may be able to
read what the fault message means. It is possible to reset the fault by
clicking the reset button.
7.29
Bus boxes
LEDs:
LED Indications
Bus
Module Status
Inputs
Short-circuit
Outputs
7-34
CSi
September 1, 2014
Installation
09-1-14
Installation
7.29.1
7.30
Connections
Valve islands
The green LED is constantly illuminated. If this is not the case, then one of
the two supply voltages has failed.
7.31
Profibus
09-1-14
September 1, 2014
CSi
7-35
Installation
7.32
7.32.1
7.32.2
Easy to synchronise.
Stable.
The rotations are made slowly which can cause the following products
to run inwards too early (this can possibly be resolved by utilising the
kicker as a rotational aid).
Spacers
Ensure that the spacer times are adjusted such that the spacer in the
middle between the boxes always goes upwards (the boxes must then
stand up against each other on the breakfeeder).
In the first instance, adjust the spacers on unrotated boxes. When the
spacers are correctly adjusted for unrotated boxes but are still not correctly
adjusted for rotated boxes, an offset time can be set for the kicker or
rotating cam (depending on whether it is used). This offset time is counted
up for all spacer times when the box is rotated. Through this offset, possible
rotational decelerations can be controlled.
7.32.3
Pressure zones
Regarding adjustment of the pressure zone times, two principles can be
adopted, namely:
1 Preset stroke
2 Extra long rotation
7-36
CSi
September 1, 2014
09-1-14
Installation
With heavy and/or breakable products, preset strokes are the best option.
Using preset strokes, set the pressure zones so that they go upwards
before the product runs against a spacer or against the preceding product.
With normal products it is usually better for the pressure zones to just
disconnect after the product has run against a spacer or against another
product. To prevent the product from rebounding, it is prudent to allow the
pressure zones to run a bit longer.
7.32.4
Rowpusher
Adjust the rowpusher spees so that the product is not damaged or breaks
loose during the pushover operation.
For each row, it is possible to set a RowReady time in the layer editor. The
default for this time is usually 3000 msec. The rowpusher starts after this
time as the last box in the row is run inwards. Try to make this time as low
as possible as the capacity is strongly dependent on such time. If this time
is set too high, products wait around needlessly. If this time is set too low,
the last product will not connect in time. It is also possible that the
rowpusher free check photocell will give a fault message.
7.32.5
Forming
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Always check that the layer is not formed too tightly on the pallet. If this is
the case, drop the layer just on the lift when the dams open. It is also
possible to not get any holes in the pattern. Adjust the dimensions of the
dams so that all products still have a bit of leeway on the pallet.
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Installation
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8.1
Introduction
This chapter has been compiled in order to identify and order spare parts
for the by CSi designed and manufactured conveyors and machines.
The mechanical and general electrical spare parts mounted on the
machine(s) are listed in this chapter 8. The remainder of electrical parts is
specified and listed in chapter 10. Refer to chapter 9 if you need to order
parts that originate from a subcontractor.
Before ordering any parts, please read this chapter carefully.
8.2
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8.3
Position number
Ordering procedure
The CSi installations and machines are subdivided into modules. These
modules all have a corresponding position number. These position
numbers are printed on the type plate or sticker mounted on the system or
machine.
In the index of spare part lists the position number refers to the list of spare
parts that are used in that particular position number. The spare part list is
ranged by position numbers. Under each position number all spare parts
used at that position number are listed.
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8-1
Look up this position number in the index of the spare part lists. The
position number refers to a page with a list of all spare parts used in
this particular position number, the so-called position numbers spare
part list.
In the list of spare parts on this page you will find the spare part you
seek.
Listed under that spare part you will find a description of the part and
an article number. Listed also, is the amount of parts of that particular
part used in the entire position number.
The information you have found is needed to order the particular part at
CSis: the CSi order number, the position number and the article number.
Example of how to identify and localise a spare part in the digital
users manual:
On the floor you notice a broken part.
-
First check where this part has come off from. Find the type plate or
sticker on the module concerned. On this type plate you will find the
CSI order number and the position number.
Keep the position number in mind and double click on this chapter 8.
This will lead you to the index of the spare part lists.
In the index, you double click on the position number you found on
the module. This position number is listed in the first column. This
will lead you to the position numbers spare part list.
In this postion numbers spare part list you will find the part you seek.
Listed under that spare part, you will find a description of the part and
an article number. Listed also is the amount of parts of that particular
part that is used in the entire position number.
The information you have found is needed to order the particular part at
CSis: the CSi order number, the position number and the article number.
The same information can also be obtained through the lay-out:
-
With this position number in mind, check the index of the spare parts
lists. In this list your position number refers to a page with a list of all
spare parts used in that particular position number.
On this page you will find the spare part you want to order.
Listed under that spare part you will find a description of the part and
an article number. Listed also is the number of parts of that particular
part used in the entire position number.
The information you have found is needed to order the particular part at
CSis: the CSi order number, the position number and the article number.
8-2
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8.4
8.4.1
8.4.2
In the mechanical spare parts list in Excel format it is quite easy to identify
and locate spare parts.
1 Open the spare parts list in Excel.
2 Go to the tab-page transport. In this page click in the left upper corner
(above 1 and left from the A). The list turns blue.
3 Click Data, Filter and Autofilter to activate this Autofilter.
4 Click CSi order no and select a level at will.
5 Before closing the file, de-activate the Autofilter. Excel has trouble
opening the file with the Autofilter on.
Another method is using the Find function (Control + F) to search for part
numbers.
1 Use Control + F.
2 Enter the part number you are looking for.
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3 Confirm with Enter. The line with the wanted spare part number
appears.
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8-4
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Attachments
ATTACHMENTS
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Attachments
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10
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Wiring diagrams
WIRING DIAGRAMS
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10-2
Wiring diagrams
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September 1, 2014