"user manual"

USER MANUAL
SPEEDPACK 110
Prinzen B.V.
Weverij 18
7122 MS AALTEN
P.O. Box 85
7120 AB AALTEN
NEDERLAND
Website:
www.prinzen.com
TABLE OF CONTENTS
TABLE OF CONTENTS
CHAPTER
UM-SP-1.3-E/04-2010
BOOK
INTRODUCTION
I
1
SAFETY
I
2
MACHINE DESCRIPTION
I
3
OPERATION
I
4
MAINTENANCE
I
5
SPARE PARTS
I
USER MANAUL SPEEDPACK 110
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TABLE OF CONTENTS
INDEX
INTRODUCTION ................................................................................................................................................7
LIABILITY ............................................................................................................................................... 9
GENERAL ............................................................................................................................................... 9
COPYRIGHT ........................................................................................................................................... 9
GENERAL ............................................................................................................................................. 10
SAFETY REGULATIONS .......................................................................................................................... 10
LEGAL REGULATIONS............................................................................................................................ 10
HOW TO USE THIS MANUAL? ................................................................................................................. 11
WHO SHOULD USE THIS MANUAL? ......................................................................................................... 11
MANUAL INFORMATION ......................................................................................................................... 11
SERIAL NUMBER ................................................................................................................................... 11
SYMBOLS ............................................................................................................................................ 12
EC-DECLARATION OF CONFORMITY FOR MACHINERY .............................................................................. 13
1.
SAFETY..................................................................................................................................................15
GENERAL ............................................................................................................................................. 16
SAFETY REGULATIONS .......................................................................................................................... 17
SAFETY PROVISIONS ............................................................................................................................ 19
DEFINITION OF SAFETY DEVICES ............................................................................................................ 19
EMERGENCY BUTTON ........................................................................................................................... 20
SAFETY INSPECTION PROCEDURE ......................................................................................................... 20
WARNING LABELS ................................................................................................................................. 21
2.
MACHINE DESCRIPTION .....................................................................................................................23
SAFETY REGULATIONS .......................................................................................................................... 24
MACHINE DESCRIPTION ........................................................................................................................ 25
TIMELINE .................................................................................................................................................................................................... 25
POSTIONS SAFETY SWITCHES AND EMERGENCY BUTTONS ........................................................................................................................ 26
SPEEDPACK ................................................................................................................................................................................................. 27
UNIT DESCRIPTION ............................................................................................................................... 28
PACKER ....................................................................................................................................................................................................... 28
TRAY DENESTER ......................................................................................................................................................................................... 30
CURVE CONVEYOR ..................................................................................................................................................................................... 31
TRAY CONVEYOR........................................................................................................................................................................................ 32
OPTIONAL OUTFEED CONVEYOR ................................................................................................................................................................ 34
OPTIONAL AUTOMATIC TRAY STACKER ..................................................................................................................................................... 35
OPTIONAL BUFFER CONVEYOR ................................................................................................................................................................... 37
3.
OPERATION ..........................................................................................................................................39
SAFETY REGULATIONS .......................................................................................................................... 40
EXPLANATION OF THE OPERATION ......................................................................................................... 41
OPERATING PANEL...................................................................................................................................................................................... 41
INDICATOR LIGHT ....................................................................................................................................................................................... 42
BUZZER ....................................................................................................................................................................................................... 42
TRAY STACKER BUTTONS ........................................................................................................................................................................... 42
START-UP SCREEN ...................................................................................................................................................................................... 43
KEYPAD ...................................................................................................................................................................................................... 43
PRODUCTION SCREEN ................................................................................................................................................................................. 44
ALARM SCREEN .......................................................................................................................................................................................... 47
PRODUCTION TREND EGGS ......................................................................................................................................................................... 47
PRODUCTION TREND CASES ........................................................................................................................................................................ 47
ALARM MESSAGES ...................................................................................................................................................................................... 48
MANUAL MENU ........................................................................................................................................................................................... 50
PASSWORD SCREEN .................................................................................................................................................................................... 51
SPEEDPACK MANUAL SCREEN .................................................................................................................................................................... 52
TRAY STACKER MANUAL SCREEN .............................................................................................................................................................. 53
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TABLE OF CONTENTS
SERVICE MENU ........................................................................................................................................................................................... 54
MACHINE SETTINGS .................................................................................................................................................................................... 55
SIMULATION SCREEN .................................................................................................................................................................................. 56
TIMERS SCREEN .......................................................................................................................................................................................... 57
CONFIGURATION SCREEN ........................................................................................................................................................................... 58
SAVE MACHINE SETTINGS........................................................................................................................................................................... 59
USB STICK ................................................................................................................................................................................................... 59
PANEL SETTINGS ......................................................................................................................................................................................... 60
PRODUCTION TIME SCREEN ........................................................................................................................................................................ 60
DATE&TIME SCREEN .................................................................................................................................................................................. 61
CPU SCREEN ................................................................................................................................................................................................ 61
CONTRAST SCREEN ..................................................................................................................................................................................... 62
NETWORK SCREEN ...................................................................................................................................................................................... 62
CUSTOMER SETTINGS SCREEN .................................................................................................................................................................... 63
PRODUCTION COUNTERS ............................................................................................................................................................................ 64
LANGUAGE ................................................................................................................................................................................................. 64
I/O LIST ....................................................................................................................................................................................................... 64
SAFTEY RELAYS SCREEN ............................................................................................................................................................................ 65
SOFTWARE DEBUG SCREEN ........................................................................................................................................................................ 65
STARTING PRODUCTION ............................................................................................................................................................................. 66
STOPPING PRODUCTION .............................................................................................................................................................................. 67
OPERATION ADJUSTMENTS ................................................................................................................... 68
GATE BLOCKERS ......................................................................................................................................................................................... 68
GATE FLAPS ................................................................................................................................................................................................ 68
ON / OFF DELAY TIME ................................................................................................................................................................................. 69
OPERATING PANEL POSITION ..................................................................................................................................................................... 69
4.
MAINTENANCE .....................................................................................................................................71
GENERAL ............................................................................................................................................. 72
SAFETY REGULATIONS .......................................................................................................................... 72
MAINTENANCE UTENSILS ...................................................................................................................... 72
GENERAL CLEANING PROCEDURE .......................................................................................................... 73
REMOVING DRIP TRAYS .............................................................................................................................................................................. 74
REMOVING GATES STRIP ............................................................................................................................................................................. 76
REMOVING ROLLER TRACK GUIDES ........................................................................................................................................................... 77
REMOVING FILTER ELECTRICAL CABINET .................................................................................................................................................. 77
REMOVING GRIPPER SHAFTS....................................................................................................................................................................... 78
GENERAL MAINTENANCE PROCEDURE ................................................................................................... 80
AFTER MAINTENANCE ........................................................................................................................... 80
PREVENTIVE MAINTENANCE INSTRUCTIONS ............................................................................................ 81
DAILY MAINTENANCE ................................................................................................................................................................................ 81
WEEKLY MAINTENANCE ............................................................................................................................................................................. 82
MONTHLY MAINTENANCE .......................................................................................................................................................................... 84
½ YEARLY MAINTENANCE.......................................................................................................................................................................... 88
YEARLY MAINTENANCE ............................................................................................................................................................................. 89
LUBRICATION DIAGRAM ......................................................................................................................... 91
5.
SPARE PARTS ......................................................................................................................................99
LIST WITH RECOMMENDED SPARE PARTS ............................................................................................. 101
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INTRODUCTION
INTRODUCTION
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USER MANAUL SPEEDPACK 110
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INTRODUCTION
CAUTION:
This manual must be read by or to each person, before that person
operates, cleans, repairs, supervises the operation of, or uses this
machine in any way.
CAUCION:
Este manual debe ser leido por a cada persona antes de comenzar a
operar, limpiar, reparar, supervisar la operación de, o utilizar esta
maquina de cualquier manera.
ATTENTION:
Ce manuel doit être lu par, ou a, toute personne avant qu’elle ne mette
en route, nettoie, répare, supervise le fonctionnement ou utilise cette
machine, de quelque manière que ce soit.
VORSICHT:
Jeder, der diese Maschine bedienen, reinigen, reparieren, überwachen
oder auf irgendeine Weise benutzen soll, muß vorher diese Hinweise
lesen oder vorgelesen bekommen.
ATTENTIE:
Een ieder, die deze machine bedient, reinigt, repareert, controleert of op
enige andere wijze gebruiken zal, dient vooraf deze
bedieningsvoorschriften te lezen.
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INTRODUCTION
LIABILITY
Prinzen BV cannot be held responsible for any costs, damage or personal injury if its system is not
used in accordance with the instructions as described in this manual.
The information provided in this manual is valid for the standard design of the system. Parts of your
system may differ from this standard design.
Since Prinzen BV is constantly improving its systems it may be possible that there are small
differences between your system and this manual.
Though this manual has been put together with the utmost care, Prinzen BV cannot accept any
responsibility for costs, damage or personal injury arising from any fault and/or incompleteness in the
content of this document.
GENERAL
This manual contains important information concerning safety, operation, adjustment, maintenance,
cleaning and repair of the Prinzen BV system. For uncomplicated functioning of the system, read this
manual carefully and work according to the directions in this manual.
Beside the design and the used materials also the operation and maintenance have great impact on
the functioning, the life span and the operational costs of our system. You, as the owner of the system,
are responsible for the execution of maintenance according to the directions and the intervals in this
manual.
This manual will help you to gain knowledge to use the system as it should be used: Correct operated
and excellent maintained.
A Prinzen BV system meets the demands, mentioned in the European machine guideline (CE).
COPYRIGHT
Prinzen BV ©
This document contains confidential information and information protected by
copyright of Prinzen BV. Reproduction or transmission of any part of this
document to third parties, or the use thereof is only permitted after express
written permission of Prinzen BV.
All rights rest with Prinzen BV, Aalten, The Netherlands.
Written by Visser Machine Services.
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INTRODUCTION
GENERAL
This manual contains important information concerning safety, operation, cleaning, maintenance and
breakdown remedies.
At all time this manual must be accessible for all personnel working with the system. Keep it in a
permanent place, close to the system. When the manual is lost or damaged, order a new copy as
soon as possible.
The user of the system should read and understand the total user manual before operating, cleaning,
maintaining and repairing the system.
Never change the sequence of procedures as described in this manual.
Beside this manual also knowledge about the installation and adjustments of the system may be
helpful for communication with the Prinzen service department or dealer. This information is described
in the English-language service manual, which is also delivered with this system.
SAFETY REGULATIONS
Before starting operation, cleaning, maintaining the system or before remedying breakdowns first read
this chapter and chapter Safety.
LEGAL REGULATIONS
-
-
-
All safety directions stated in this manual must be observed.
Along with the safety regulations in this chapter the instructions of the qualified trade
organization of your country must be observed to avoid accidents.
Before starting to repair or maintain the machine always consult your safety manager to
discuss if a work permit is required for this job.
All safety devices in the machine and the safety indications mentioned in this manual are
conditions to control the machine safely. The owner and his qualified personnel are in the end
the ones responsible for the safe use of the machine.
The owner is responsible for the ability of the qualified personnel to perform its duties
according to the safety measures.
Technical changes, which influence the safety working of the machine, may only be executed
by the service department of Prinzen.
Do not change controls, and/or PLC programs, without written permission from Prinzen
because this may affect the safety of the machine.
Only use genuine Prinzen parts or CE-certified parts for replacement.
Prinzen cannot be held responsible for any consequential damages to the system or other
installations that were caused by technical changes, unprofessional maintenance and repairs
on our system, which were executed by the customer.
Warranty becomes invalid when consequential damages to the system, caused by technical
changes, unprofessional maintenance and repairs, were executed by the customer.
DANGER!
Failure to obey legal regulations may result in permanent personal injury or death.
ATTENTION!
Failure to obey legal regulations may result in damage to the system.
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INTRODUCTION
HOW TO USE THIS MANUAL?
The manual is constructed to provide a maximum amount of information with a minimum amount of
searching. The key to easy reference is the Table of contents. Familiarize yourself with it and you
won’t have any trouble locating information from any area of machine.
WHO SHOULD USE THIS MANUAL?
Owner:
The owner (contractor, concern) is the person that owns or hires the machine and puts this machine
into production. The owner must take care that the users of the system will read the manual.
Operator:
The operator is the person who operates the system as ordered by the owner. The operator must read
the chapters Introduction, Safety, Machine description, Operation.
Professional:
A professional is someone who can assess the duties appointed to him on account of his education,
knowledge and experience and who can assess the dangers attached, thereby avoiding these
dangers.
Maintenance engineer:
The maintenance engineer is the professional who is deemed qualified by the owner to perform
certain duties. The qualification only applies to those assigned duties. The maintenance engineer must
read the total manual.
MANUAL INFORMATION
Machine type:
Manual revision:
Speedpack 110
1.3 (April 2010)
SERIAL NUMBER
Each machine has a unique serial number printed on the machine tag, which can be found in the
electrical cabinet. Note down this serial number to have it available when contacting the Prinzen
service department.
Speedpack 110
3~N 50Hz 400/230V
3 x 16A
S1012
01-2010
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INTRODUCTION
SYMBOLS
Symbols are used in the manual when special attention/caution is required while working on the
system. The special symbols and their meaning are depicted in the below table.
Symbol:
Meaning:
DANGER!
This symbol is used when instructions should be followed to the letter. If not they may result in permanent personal
injury or death.
CAUTION!
This symbol is used when instructions should be followed to the letter. If not they may result in permanent personal
injury.
ATTENTION!
This symbol is used when instructions should be followed to the letter. If not they may cause damage to the
system.
NOTE!
This symbol advises to use edible products and to work in a hygienically way. Disregarding this advice may cause
illness.
TIP!
This symbol is used as a helpful hint to simplify the execution of certain tasks.
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EC-DECLARATION
EC-DECLARATION OF CONFORMITY FOR MACHINERY
Concerning the machinery directives:
Prinzen B.V.
Weverij 18
7122 MS AALTEN
The Netherlands
1
Herewith declares that we are the manufacturer of the egg-packing machine on
which this declaration applies:
Brand:
Type:
Serial number:
Prinzen
Speedpack 110
2
The machine is developed in compliance with the demands of the machinery
directive 2006/42/EC (most recent).
3
The machine meets the provisions of the following directives:
The low voltage equipment directive 2006/95/EC (most recent).
The EMC-directive 2004/108/EC (most recent).
4
The machine is developed and constructed according the following standard:
NEN-EN-IEC 60204-1: 2006 Electrical equipment of industrial machines.
Signed in:
Date:
Aalten
Signed by:
G.J. van Eerden
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SAFETY
1. SAFETY
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SAFETY
GENERAL
Only persons meeting the following requirements are authorized to work with the system. These
persons should be:
- Skilled and specifically trained for their duties.
- Familiar with the contents of this manual.
- Familiar with the locations of the emergency buttons and other safety devices.
- 18 years old or above.
- Familiar with the national and regional regulations regarding safety.
These persons should have reached the minimum legal age required to perform this work.
These persons are NOT under influence of any drug, medicine or alcoholic drink.
DANGER!
Keep children and incompetent persons away from the system!
The system is only to be used for the purpose it was designed for. See the chapter Machine
description for details.
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SAFETY
SAFETY REGULATIONS
Do not use the system when safety devices have been removed. This system may contain sharp
edged parts, moving parts and rotating parts.
When protective covers are removed, sharp edges and pinch points may be exposed. Use extreme
caution and avoid touching or striking these areas with your hands or body because they may cause
injuries.
Do not enter parts of your body or objects into openings in the system. This may lead to serious
physical injury or damage to the system. It is dangerous to be in, on or under the system while it is
operational.
Loosely hanging clothing, wide sleeved clothing, ties, chains or rings are prohibited. Long hair should
be worn tied back.
Make sure that there is sufficient light around the machine.
Do not touch or come near moving or rotating parts. Physical contact with these parts is dangerous.
Do not stand or walk on any of the system parts.
Do not work alone on the system. At least one other person should be present
Before starting to clean, maintain or inspect the machine or before remedying breakdowns follow the
steps mentioned below:
- Switch off the machine and secure it against accidental switching on.
- Post “Do not switch on” warning sign on the main switch:
- Operate the nearest emergency button.
- Make sure that no components are moving.
Before switching on the machine, you must check the following:
- All safety devices are in place and are functioning.
- No other persons are in, underneath or above the system.
- No tools or objects are in the system.
- No other persons are at risk.
Do not use water to clean electricity cabinets and other electronic components.
For save and easy operation keep the area and floor around the machine clean, free of oil, grease or
obstacles. Remove superfluous fat and greasing oil after greasing duties.
When an extension cable is used for power supply, make sure that the cable diameter in relation to
the length of the cable is correct. Make sure the cable is completely unrolled
Manual activation of safety switches is forbidden.
When the safety devices are put out of operation, the machine must first be switched off and secured
against accidental switching on.
Work inside the electrical cabinet may only be undertaken by skilled personnel like Prinzen service
engineers or its dealers service engineers.
Always switch off the main switch before opening electrical cabinets.
After switching off the main switch, parts inside the electrical cabinet remain live for approximately 1
minute. The frequency inverters may hold a high voltage charge during this time. Do not touch parts
inside the electrical cabinet as long as displays of frequency inverters are on.
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SAFETY
Several parts inside the electrical cabinet maintain voltage even when the main switch is turned off
(main switch, main power supply, terminals for egg collecting belts, etcetera).
DANGER!
Failure to obey safety regulations may result in permanent personal injury or death.
ATTENTION!
Failure to obey safety regulations may result in damage to the system.
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SAFETY
SAFETY PROVISIONS
Before operating the machine the safety
devices must be checked for correct
functioning. Also the protective covers must be
mounted before starting to use the system.
Repair or replace safety devices before using
the system if they do not work properly.
Never rely solely on safety devices. Always
switch off the system and lock up the power
source (1) before working on the machine.
1
DANGER!
Protective covers safeguard dangerous
machine areas. These covers are of utmost
importance to operate the machine safely.
Never operate the machine when protective
covers are removed because serious injury or
death may occur!
2
DEFINITION OF SAFETY
DEVICES
Safety devices are: lockable doors (2),
emergency buttons (3), safety switches (4) and
protective covers (5).
3
The emergency button prevents the machine
from operating and should stop the machine
immediately when it is pressed. Safety
switches are provided to prevent the operation
of the machine or should stop the machine
immediately when a door is opened. Protective
covers shield off dangerous moving parts.
These covers cannot be removed without
tools.
Lockable doors are doors that can only be
opened with a key. The key should only be in
possession of a supervisor.
4
5
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DANGER!
Lockable doors safeguard dangerous
machine areas. These doors are of utmost
importance to operate the machine safely.
Never operate the machine when doors are
open or not locked because serious injury or
death may occur!
USER MANAUL SPEEDPACK 110
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SAFETY
EMERGENCY BUTTON
To stop the machine in case of an emergency, the system has one or more emergency buttons.
Only use the emergency button in case of an emergency. When the emergency button is pressed, the
system stops immediately. The button stays mechanically locked so the machine cannot start until it is
considered safe to do so. Release the emergency button by turning it clockwise.
Do not release the emergency button when it is not certain why and by whom it was pressed.
Personnel working with the system must know the positions of the emergency buttons.
SAFETY INSPECTION PROCEDURE
Before starting the machine all protective covers must be in place, all doors must be closed and safety
switches and emergency buttons must be operating. Trained personnel must check safety devices to
assure proper operation.
1.
Check that all protective covers are in place and all doors are closed.
2.
Start and stop the system.
3.
Wait until the system has completely stopped and open a door.
4.
Push the start button, the machine should not start.
5.
Close the door.
6.
Repeat the above steps 3, 4 and 5 for each door.
7.
Make sure that the machine does not start with a door opened.
8.
Check that all doors are closed and push an emergency button.
9.
Push the start button, the machine should not start.
10. Release the emergency button.
11. Repeat the above steps 8, 9 and 10 for all emergency buttons.
12. Make sure that the machine does not start when any emergency button is pressed.
If the machine operates with any of the doors opened or when an emergency button is pressed, this
machine is not safe to operate. Immediately call a qualified technician to repair the defective safety
switch or emergency button.
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SAFETY
WARNING LABELS
The Prinzen system makes dangerous
movements. The system also contains
dangerous parts when they contact the body.
The following labels are posted as a warning.
Understand and remember the meaning of the
warning labels.
DANGER!
Keep the warning labels clean. When labels become
unclear, replace them.
The flashlight label is used to warn for
dangerous voltage inside a cabinet. Contacting
parts inside this cabinet may result in
permanent personal injury or death.
This sign is used to warn for dangerous
movements. Keep a safe distance to those
parts. Disregarding this warning may result in
permanent personal injury.
This sign is used to warn for the danger of
limbs being pulled in. Keep a safe distance to
those parts. Disregarding this warning may
result in permanent personal injury.
This sign is used to warn for crushing danger.
Keep a safe distance to those parts.
Disregarding this warning may result in
permanent personal injury.
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MACHINE DESCRIPTION
2. MACHINE DESCRIPTION
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MACHINE DESCRIPTION
SAFETY REGULATIONS
Before starting operation, cleaning, maintaining the system or before remedying breakdowns first read
the chapters Introduction and Safety.
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MACHINE DESCRIPTION
MACHINE DESCRIPTION
The machine description gives information about the complete system.
It is possible to build a timeline with the speedpack and some optional systems. Below description is
the most complete version of a timeline. It is possible that your system does not contain all the
described optional systems, but since most of the systems in the timeline are described in this manual,
also a general description of the timeline is part of this manual.
For detailed information of the speedpack see the Speedpack description below.
For detailed information of all the units of the timeline see the Unit description in this chapter.
TIMELINE
Use:
The Prinzen timeline consisting of a speedpack, a tray stacker and a buffer conveyor is used to
assemble a random supply of eggs, coming from an egg collecting conveyor and pack these eggs into
trays with the pointed end downwards, and stack these trays. Optionally it is possible to place a printer
unit in the timeline.
Process:
Eggs are entering the speedpack that takes care of assembling the eggs and placing them into trays
with the pointed end downward. The trays are transferred from the speedpack to the tray stacker. An
optional printer marks the eggs. The tray stacker continuously stacks 6 trays and places these stacks
onto the buffer conveyor.
Chapters and Manuals:
See below mentioned chapters or manuals for detailed information:
This chapter for unit information.
Chapter operation for operation details.
Chapter maintenance for cleaning and maintenance information.
Service manual for information about adjusting the system.
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MACHINE DESCRIPTION
Security:
The security of the system is created through a balance between safety and workability: An optimal
workable situation is created for the operating personnel but safety was kept in mind.
Dangerous movements of the system are mostly protected with protective covers or safety doors, but
there are exceptions. On a lot of places in the system it is possible to sustain injuries. The system is
not completely secured with protective covers and makes unexpected starts and stops. Therefore be
cautious with loosely hanging clothes and long hair, do not come too close to the system and do not
touch it when the system is running production.
Read the safety instruction of the units in the chapter unit descriptions.
CAUTION!
Do not enter objects or body parts into the system when it is running production.
ATTENTION!
Do not enter objects or body parts into the system when it is running production.
POSTIONS SAFETY SWITCHES AND EMERGENCY BUTTONS
See below picture for position of the emergency stop (1) and the safety switches (2).
2
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USER MANUAL SPEEDPACK 110
1
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MACHINE DESCRIPTION
Use:
The Prinzen speedpack is designed to pack a
random supply of eggs into 30-cell trays with
the pointed end downwards.
SPEEDPACK
Construction:
The speedpack is a 6 rows system, consisting
of:
1 Packer
2 Tray denester
3 Curve conveyor
4 Tray conveyor
Optional it is possible to execute the
speedpack with an infeed extension (5).
Process:
Eggs are entering the speedpack on the
packer that takes care of the pointed end
downward setting, assembly of eggs into a
fixed pattern and the transfer of those eggs to
the tray on the tray transport conveyor.
The tray denester supplies the empty trays.
The curve conveyor transports these empty
trays from the tray denester towards the tray
conveyor. On this conveyor the trays receive
the eggs after which the full trays are
transferred to the optional outfeed conveyor or
the optional tray stacker.
5
1
4
3
2
10
11
Safety:
The security of the system is created through a
balance between safety and workability: An
optimal workable situation is created for the
operating personnel but safety was kept in
mind.
Dangerous movements of the system are
mostly protected with protective covers or
safety doors, but there are exceptions. On a lot
of places in the system it is possible to sustain
injuries. The system is not completely secured
with protective covers and makes unexpected
starts and stops. Therefore be cautious with
loosely hanging clothes and long hair, do not
come too close to the system and do not touch
it when the system is running production.
Read the safety instruction of the units in the
chapter unit descriptions.
See alongside pictures for position of the
emergency stop (10) and power switch (11).
CAUTION!
Do not enter objects or body parts into the
Speedpack when it is running production.
ATTENTION!
Do not enter objects or body parts into the
Speedpack when it is running production.
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MACHINE DESCRIPTION
Use:
The Packer is designed to receive a random
supply of eggs and assemble these eggs into a
row of 6 eggs and place them with the pointed
end downwards into a tray.
UNIT DESCRIPTION
PACKER
Construction:
The packer consists of:
1 Infeed conveyor
2 Infeed gate
3 Main drive
4 Roller track
5 Gripper transport
Attached to the packer are:
6 Electrical cabinet
7 Operating panel
1
2
4
5
6
3
11
7
12
13
10
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Process:
Eggs are entering the packer on the infeed
conveyor where the eggs may be graded. On
this belt oversized-, misshapen-, cracked- or
dirty eggs should be manually removed.
A start/stop delay sensor (10) above the infeed
conveyor prevents accumulation of eggs on
the infeed conveyor.
The eggs run into the infeed gates where they
are detected (11). When all gates have
detected an egg, the roller track moves one
step forwards receiving the eggs from the
gates in between 2 roller shafts. Because of
the rotating movement of the roller shafts,
during each step forwards, the eggs move with
their pointed ends more towards the egg
guides.
At the end of the roller track (roller track
gripper transport transfer position), the pointed
ends of the eggs are touching guide flaps,
which results in the round ends of the eggs
gliding downwards towards the open grippers
of the gripper transport.
In between the grippers a cushion flap
prevents damaging eggs while they are gliding
into the grippers. A double egg in grippers
sensor (12) stops the downward movement of
the gripper transport when it detects an egg to
prevent damaging the egg and contaminating
the gripper transport. The grippers are closing
around the eggs during the downward
movement towards the tray conveyor where
they open again to drop the eggs into the tray.
An egg in grippers sensor (13) starts the tray
conveyor when it detects eggs in the grippers.
When eggs unintentionally remain in the
grippers, ejector pens push them out before
the grippers move up to receive a next row of
eggs.
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
MACHINE DESCRIPTION
Safety:
The packer is not completely secured with
protective covers or safety doors. Therefore be
cautious with loosely hanging clothes and long
hair, do not come too close to the packer and
do not touch it when it is running production.
Pay special attention to:
- The infeed conveyor.
- The roller track.
- The bottom side of the packer.
Never touch or come near these parts of the
packer when it is running production.
The cover above the gripper transport (transfer
position of eggs from roller track to grippers)
and both side covers have safety switches
(14). Opening one of these covers stops the
packer immediately.
14
CAUTION!
Do not enter objects or body parts into the
packer when it is running production.
ATTENTION!
Do not enter objects or body parts into the
packer when it is running production.
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 29 of 101
MACHINE DESCRIPTION
TRAY DENESTER
Use:
The tray denester separates a single 30-cell
tray from a stack of trays and drops this tray on
the curve conveyor.
Construction:
The 30-cell tray denester consists of:
1 Bunker
2 Top grippers
3 Lower grippers
4 Denester blocks
5 Drive mechanism
6 Mobile frame
The tray denester has a mobile frame and is
positioned above the curve conveyor (7).
1
2
3
4
5
Process:
Trays are manually supplied into the bunker
and rest on the top grippers.
When the start denester sensor (10),
positioned at the exit of the denester on the
curve conveyor, is OFF, the lower grippers
remove 1 tray from the bottom of the stack of
trays and drop this tray onto the curve
conveyor, which transports the trays towards
the tray conveyor.
Safety:
The denester is not completely secured with
protective covers. Therefore be cautious with
loosely hanging clothes and long hair, do not
come too close to the denester and do not
touch it when it is running production.
The lower grippers make unexpected fast and
powerful movements. Never touch or come
near this part when the packer is running
production.
7
10
7
CAUTION!
Do not enter objects or body parts into the
denester when it is running production.
Keep distant to the lower grippers! These make
unexpected fast and powerful movements!
ATTENTION!
Do not enter objects or body parts into the
denester when it is running production.
Page 30 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
MACHINE DESCRIPTION
CURVE CONVEYOR
Use:
The curve conveyor receives trays from the
denester and transports these trays towards
the tray conveyor.
Construction:
The curve conveyor consists of:
1 Curve belt
2 Drive mechanism
3 Stopper mechanism
The curve conveyor is positioned underneath
the packer.
Process:
Trays are supplied by the tray denester and
are transported towards the tray conveyor. At
the end of the curve conveyor a stopper stops
the supplied trays. On request of the tray
conveyor the stopper releases a tray. This way
a space is created between the trays on the
tray conveyor.
2
3
1
Safety:
The curve conveyor is not completely secured
with protective covers. Therefore be cautious
with loosely hanging clothes and long hair, do
not come too close to the curve conveyor and
do not touch it when it is running production.
Pay special attention to the belt. Never touch
the belt when the conveyor it is running
production.
CAUTION!
Do not enter objects or body parts into the
curve conveyor when it is running production.
ATTENTION!
Do not enter objects or body parts into the
curve conveyor when it is running production.
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 31 of 101
MACHINE DESCRIPTION
TRAY CONVEYOR
Use:
The tray conveyor receives empty trays from
the curve conveyor and eggs from the packer.
It transports the empty trays towards the
position underneath the gripper transport
where it receives a row of eggs, and full trays
towards the position where they are removed
(automatically).
Construction:
The tray conveyor consists of:
1 Roller conveyor
2 Drive mechanism
The tray conveyor is positioned underneath the
packer.
2
1
10
Page 32 of 101
11
Process:
Trays are supplied by the curve conveyor,
which continuously runs. The tray conveyor
runs start/stop, making steps according to the
following steps:
1. The 1st tray on the tray conveyor reaches
the start egg transfer sensor (10).
2. When eggs are present in the grippers,
during a step of the tray conveyor and the
gripper transport, the 1st row of eggs are
dropped in the tray.
3. After dropping the 2nd row of eggs into the
tray, the stopper of the curve conveyor
stops the next tray on the curve conveyor
to create a space between the trays.
4. The stopper moves out again, so the next
tray enters the tray conveyor, the 3rd row of
eggs is dropped into the tray.
5. The 4th row of eggs is dropped in the tray.
6. While dropping the 5th row of eggs into the
tray, the start next tray sensor (11) no
longer detects the 1st tray.
7. The tray conveyor makes a longer step to
move the 2nd tray towards the correct
position for receiving the 1st row of eggs.
8. The 2nd tray reaches the start egg transfer
sensor (10).
At the end of the tray conveyor the full trays
are removed (automatically).
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
MACHINE DESCRIPTION
Safety:
The tray conveyor is not completely secured
with protective covers. Therefore be cautious
with loosely hanging clothes and long hair, do
not come too close to the tray conveyor and do
not touch it when it is running production.
Pay special attention to the roller conveyor;
never touch it when the tray conveyor is
running production.
CAUTION!
Do not enter objects or body parts into the tray
conveyor when it is running production.
ATTENTION!
Do not enter objects or body parts into the tray
conveyor when it is running production.
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USER MANAUL SPEEDPACK 110
Page 33 of 101
MACHINE DESCRIPTION
OPTIONAL OUTFEED
CONVEYOR
Use:
The optional outfeed conveyor receives trays
from the packer.
It is possible to position an Ovo-printer above
this conveyor for marking the eggs.
Construction:
The outfeed conveyor consists of:
1 Belt
2 Drive mechanism
3 Optional printer
The outfeed conveyor is positioned
downstream of the packer.
3
2
1
Process:
Trays are supplied by the tray conveyor.
The outfeed conveyor runs continuously. A
sensor (4) near the end of the conveyor stops
the belt when it detects a tray. A sensor (5)
near the entrance of the conveyor stops the
upstream packer when it detects a tray while
the belt is not running.
When a printer is attached to the outfeed
conveyor it will mark the eggs when a tray with
eggs passes this printer.
Safety:
The outfeed conveyor is not secured with
protective covers. Therefore be cautious with
loosely hanging clothes and long hair, do not
come too close to the outfeed conveyor and do
not touch it when it is running production. Pay
special attention to the belt. Never touch the
belt when the conveyor it is running production.
CAUTION!
Do not enter objects or body parts into the
outfeed conveyor when it is running production.
ATTENTION!
Do not enter objects or body parts into the
outfeed conveyor when it is running production.
5
4
Page 34 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
MACHINE DESCRIPTION
Use:
The optional automatic tray stacker receives
full 30 cell trays from the packer and
automatically stacks those trays. It is possible
to position an Ovo-printer above the infeed
conveyor for marking the eggs.
OPTIONAL AUTOMATIC TRAY
STACKER
Construction:
The automatic tray stacker consists of:
1 Infeed conveyor
2 Transfer lift
3 Stacker plate
4 Pusher
5 Drive mechanism
6 Optional printer
7 Electrical cabinet
7
6
1
2
4
3
5
Process:
Trays are supplied by the tray conveyor on the
infeed conveyor and run against a lever (8) at
the end of the infeed conveyor.
The lever movement is detected by an
inductive sensor which starts the movements
of the tray stacker. The tray stacker makes one
complete cycle and stops again. During this
cycle, the transfer lift lifts the tray from the belt.
When the next tray arrives at the lever, the
next cycle starts.
During the cycles the trays are transported
vertical up, horizontal forwards and vertical
down where it is placed on the stacker plate.
During each cycle this plate turns; 90° during
one cycle and 90° back during the next cycle.
The 1st tray is placed on this plate, it turns 90º.
After receiving the 2nd tray it turns back 90º.
This sequence is continued for 6 cycles.
During the 6th cycle the pusher moves forwards
to push the stack (with 6 trays) on the
downstream buffer conveyor. When the stack
is removed it moves backwards again and the
1st tray of the next stack is placed on the plate.
8
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USER MANAUL SPEEDPACK 110
Page 35 of 101
MACHINE DESCRIPTION
The infeed conveyor runs continuously. A
sensor (9) near the end of the conveyor stops
the belt when it detects a 2nd tray when the 1st
tray is still present at the lever (8). A sensor
(10) near the entrance of the conveyor stops
the upstream packer when it detects a tray
while the belt is not running.
When a printer is attached to the infeed
conveyor it will mark the eggs when a tray with
eggs passes this printer.
10
9
11
Safety:
The optional automatic tray stacker is
equipped with protective covers and safety
doors. The entry for the trays and the exit of
the stacks is protected by a cover. The infeed
conveyor is not secured with protective covers.
Therefore be cautious with loosely hanging
clothes and long hair, do not come too close to
the infeed conveyor and do not touch it when it
is running production. Pay special attention to
the belt. Never touch the belt when the
conveyor it is running production.
The cover above the entry and the cover
above the exit of the tray stacker have safety
switches (11). Opening one of these covers
stops the tray stacker immediately.
CAUTION!
Do not enter objects or body parts into the
infeed conveyor and the entry or the exit of the
automatic tray stacker when the system is
running production.
Keep distant to the tray stacker! It makes
unexpected fast and powerful movements!
ATTENTION!
Do not enter objects or body parts into the
infeed conveyor and the entry or exit of the
automatic tray stacker when the system is
running production.
Page 36 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
MACHINE DESCRIPTION
OPTIONAL BUFFER
CONVEYOR
Use:
The optional buffer conveyor receives stacks
with trays from the tray stacker and buffers
these stacks or transfers them towards the
downstream transport (for example pallet
loader).
Construction:
The buffer conveyor consists of:
1 Belt
2 Drive mechanism
The buffer conveyor is positioned downstream
of the tray stacker.
2
1
Process:
Stack with trays are supplied by the tray
stacker. As long as stacks of trays are
transferred to a downstream system the buffer
conveyor runs continuously. When the
downstream system cannot receive stacks, the
buffer conveyor stops and starts to buffer the
stacks.
Process buffering:
As soon as the sensor (3) at the entrance of
the belt detects a stack of trays the belt starts
to run until the stack has passed this sensor.
Then the belt stops again. This sequence is
repeated until the sensor (4) at the end of the
belt detects a stack, the belt stops. The tray
stacker pushes one more stack of trays on the
entrance of the belt. When the next stack is
ready for unloading the tray stacker also stops.
After removal of stack from the buffer
conveyor, the buffer conveyor starts again.
Safety:
The buffer conveyor is not secured with
protective covers. Therefore be cautious with
loosely hanging clothes and long hair, do not
come too close to the buffer conveyor and do
not touch it when it is running production. Pay
special attention to the belt. Never touch the
belt when the conveyor it is running production.
CAUTION!
Do not enter objects or body parts into the
buffer conveyor when it is running production.
3
UM-SP-1.3-E/04-2010
4
ATTENTION!
Do not enter objects or body parts into the
buffer conveyor when it is running production.
USER MANAUL SPEEDPACK 110
Page 37 of 101
OPERATION
3. OPERATION
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 39 of 101
OPERATION
SAFETY REGULATIONS
Before starting operation, cleaning, maintaining the system or before remedying breakdowns first read
the chapters Introduction and Safety.
Page 40 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
EXPLANATION OF THE OPERATION
OPERATING PANEL
In the operating panel the touchpanel with PLC is situated. The PLC controls the speedpack. The
touchpanel shows information about the status of the system. By touching buttons on the screen, the
speedpack is controllable.
DANGER!
Although a lot of safety measures are built into the control of the system, Prinzen cannot guarantee that no
dangerous situations will occur. Before you start the system, make sure no persons are in danger.
DANGER!
By working on a higher operating level, you have more possibilities to control the system manually. Before starting
to move parts of the system, you have to assure yourself no other persons are in danger. Make sure nobody is
around the part you intend to move.
ATTENTION!
By working on a higher operating level, you have more possibilities to control the system manually. When you
move parts manually, it may be possible that parts will collide, resulting in damage of the system.
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 41 of 101
OPERATION
ATTENTION!
It is not necessary to press real hard on the Touch Panel. We advise against doing this because it may damage
the Touch Panel. It is forbidden to press on the Touch Panel with (sharp) objects because this may also damage
the Touch Panel.
Emergency button:
After pushing the red button, the complete system stops. Only use this button in case of emergencies.
Start:
By pressing the start button, the system starts to run. The light inside the button turns ON.
When you start to move parts of the system manual (see the manual screen), the light inside the
button starts flashing.
Stop:
By touching the stop button, you will stop the system. The system stops after finishing certain internal
controlling cycles. Thus it may take some time before the system is completely stopped. This is the
normal procedure to stop the system.
Reset:
After a breakdown, first the breakdown needs to be solved. During a breakdown, the light inside the
reset button turns ON and the buzzer starts beeping. By pressing the reset button the first time the
buzzer stops beeping. After solving the breakdown and pressing the reset button again, the controller
verifies if all breakdowns are solved. When this is the case, the light inside the reset button turns OFF.
Now it is possible to start the system by pressing the start button again.
After pressing an emergency button, one of the reset buttons on one of the systems connected to the
speedpack must be pressed before it is possible to start the system again.
INDICATOR LIGHT
Above the electrical cabinet an indicator light
indicates the status of the speedpack:
Green:
Speedpack is running.
Red:
Breakdown.
Yellow:
System is in the manual mode.
BUZZER
Underneath the operating panel a buzzer is
positioned to attract the operators attention.
After starting the system, the buzzer beeps
once.
During a breakdown the buzzer starts beeping.
After pressing the reset button the buzzer
stops.
TRAY STACKER BUTTONS
After opening a safety door of the tray stacker
it is possible to start the tray stacker again by
closing the door, pressing the local reset
button and subsequently the local start button.
After pressing an emergency button, you also
have to press this reset button.
Page 42 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
START-UP SCREEN
After switching on the speedpack with the main
switch the start-up screen appears.
After touching this (1) button the production
screen appears.
1
KEYPAD
After touching yellow windows, the alongside
keypad appears. Enter a correct value and
confirm it with the V button.
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 43 of 101
OPERATION
5
PRODUCTION SCREEN
2
4
3
7
6
8
9
10
In the production screen the operator is able to
control the speedpack. On the production
screen the following information is visible:
2 Alarm message line, see alarm messages.
3 Average amount of packed eggs per hour.
4 Average amount of packed cases per
hour.
Alarm screen (5):
On all screens the alarm screen button is
available. After touching this button you will
enter the alarm screen.
Production trend (6):
After touching this button, the production trend
screen appears which gives information about
the performance of the system.
Eggs Infeed:
After touching the eggs infeed button, the
infeed conveyor starts to run. When the button
is activated, its color changes to green.
Tray chain:
After touching the tray chain button, the curve
conveyor starts to run and the tray conveyor is
able to run. Now by touching the Tip Tray
chain button, the tray conveyor moves 1 step
forwards.
Egg chain:
After touching the egg chain button, the roller
track and gripper transport are able to run.
Now by touching the Tip Egg chain button the
roller track and gripper transport move 1 step
forwards.
Denester:
After touching the Denester button, the
denester is able to run. Now by touching the
Tip Denester button, 1 tray is supplied from
the denester onto the curve conveyor.
Stacker:
After touching this button the optional tray
stacker starts to run.
100%:
With this button it is possible to change the
speed of the infeed conveyor. Normally this
button is used when a lot of damaged or dirty
eggs are entering the speedpack. Touching
this button immediately lowers the infeed
speed of the eggs, which make it easier to
remove bad eggs.
It is possible to toggle between 100% and a
speed set in the customer settings screen.
When the text inside the button shows 100%,
the infeed belt runs with its maximum speed.
When the text inside the button displays
another percentage, for example 70%, the
infeed belt runs with that percentage of its
maximum speed (in this example 70%).
Page 44 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
Clear outfeed:
In case an optional buffer conveyor is present
downstream of the optional tray stacker and no
further downstream systems, with this button it
is possible to toggle between buffering stacks
of trays or sending the stacks of trays directly
to the end of the conveyor.
When the button is colored white, the conveyor
is buffering.
When the button is colored blue, the conveyor
immediately sends stacks of trays to the end of
this conveyor.
TIP!
The last trays leaving the system may be only
partially filled! Remove these trays manually
from the tray conveyor.
TIP!
The reset button must be pressed before it is
possible to start the speedpack again!
UM-SP-1.3-E/04-2010
Packer manual submenu (7):
After touching this button the manual submenu
appears in which it is possible to manually
control parts of the system.
This submenu is not available for the operator.
Empty speedpack (8):
This button is used to remove all eggs out of
the system.
Normally all gates need to be filled with eggs
before these eggs are transported towards the
tray. When no more eggs are entering the
system on the infeed conveyor, the system
waits for eggs and the eggs on the roller track
and gripper transport remain on the system.
When the empty speedpack button is touched
it colors green and the eggs in the system are
transported towards the trays even though no
eggs are detected at the gates. The grippers
remain filling trays until all eggs are removed
from the speedpack. When the last tray is
leaving the tray conveyor, a message appears
on the display: remove the tray manually and
press the reset button to return to normal
operation. The empty speedpack button colors
white again.
Empty tray stacker (9):
This button is used to remove all stacks out of
the optional tray stacker.
Normally a stack of 6 trays is needed before
the stacker pushes it out. When no trays are
entering the stacker, it waits for trays and the
trays in the transfer lift and on the stacker plate
remain in the tray stacker.
When the empty tray stacker button is touched,
it colors green and for 3 seconds the tray
stacker waits for trays. When no more trays
are entering the tray stacker, the remaining
trays in the transfer lift are transported towards
the stacker plate and are pushed out even
though no trays are detected at the infeed of
the tray stacker.
When all trays are removed, the transfer lift
makes 4 steps without trays and stops and the
button color changes into white.
USER MANAUL SPEEDPACK 110
Page 45 of 101
OPERATION
Service submenu (10):
After touching this button the service submenu
appears. In this menu the operator is able to
change a number of settings using submenus.
Not all submenus are available for the
operator.
Page 46 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
ALARM SCREEN
21
20
22
23
24
The Alarms current screen shows all present
alarms from the speedpack.
By touching the up- or down arrows (20) it is
possible to scroll through the alarm list.
An active alarm is colored red.
By touching the R button (21) the 1st time, the
operator acknowledges the alarm. The beeper
stops and the alarm colors yellow. After
touching the R button the 2nd time, the alarm is
reset. When the breakdown causing the alarm
is not solved, the alarm immediately pops-up
again.
After touching the alarm history button (22) the
alarm history screen appears.
Submenu Alarm history:
The Alarm history screen shows the history of
all alarms from the speedpack.
By touching the up- or down arrows (23) it is
possible to scroll through the alarm list.
Previous (24):
On most of the screens in the right bottom
corner this up-arrow button is present. After
touching this button the previous screen
appears.
PRODUCTION TREND EGGS
25
26
In this screen a graphic of the amount of eggs
(x1000) that are packed in the past hour is
displayed.
The average amount of eggs that have been
packed is displayed in the left bottom corner
(25).
After touching the down-arrow button (26) the
production trend cases screen appears.
PRODUCTION TREND CASES
27
UM-SP-1.3-E/04-2010
In this screen a graphic of the amount of cases
that are packed in the past hour is displayed (1
Case = 2 stacks of 6 trays = 360 eggs).
The average amount of cases that have been
packed is displayed in the left bottom corner
(27).
USER MANAUL SPEEDPACK 110
Page 47 of 101
OPERATION
ALARM MESSAGES
When the system is stopped, the upper line of the touchpanel shows the reason for stopping. The
following messages may appear on the display:
Alarm:
Main
Message
Emergency stop
Main
Main
Main
Denester
Denester
Denester
Denester
Denester
Communication error Omron (Event)
Communication error Omron (Open)
Communication error Omron (Step)
Mode fault
Fault frequency controller
Monitoring time denester motor
Monitoring time tray transport
Too many retries getting trays
Egg transport
Egg transport
Egg transport
Egg transport
Tray transport
Tray transport
Tray transport
Tray transport
Tray transport
Tray transport
Egg belts
Egg belts
Egg belts
Outfeed belts
Outfeed belts
Outfeed belts
Tray transport
Mode fault
Fault frequency controller
Monitoring time chain
Double egg
Mode fault
Fault frequency controller chain
Fault frequency controller curve
Monitoring time chain
No free space between trays
Double tray detection
Mode fault
Fault frequency controller 1
Fault frequency controller 2
Mode fault
Fault frequency controller 1
Fault frequency controller 2
Outfeed full
Tray transport
Simulation tray present switched on
Tray transport
Egg transport
Outfeed too long occupied
Simulation eggs at infeed switched on
Egg transport
Simulation eggs in chain switched on
Infeed
Pressure control active
Main
Main
Main
Temperature touchpanel too high (cabinet)
Temperature touchpanel too high (CPU)
Battery PLC empty
Page 48 of 101
Description
Emergency button is pressed.
Release emergency button.
Denester did not drop a tray on the
denester conveyor.
Clear the fault or place a new stack of
trays in the denester.
Double egg in grippers
The output conveyor is full with trays.
Remove the trays from the output
conveyor.
Tray present set to ON.
Roller track and gripper transport run
regardless of the presence of a tray.
Egg’s at infeed set to ON.
Roller track and gripper transport run
regardless of the presence of eggs.
Eggs present set to ON.
Roller track and gripper transport run
regardless of the presence of eggs.
Egg-collecting conveyor is stopped
because too many eggs are supplied.
Contact Prinzen
Contact Prinzen
Do not turn off the main power.
Replace the battery.
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
Outfeed
No release from machine in front
UM-SP-1.3-E/04-2010
System is stopped because there is no
release signal from downstream
system.
USER MANAUL SPEEDPACK 110
Page 49 of 101
OPERATION
MANUAL MENU
Password screen (29):
After touching this button the password screen
appears in which it is possible to change the
operating level of the system.
29
After touching the Speedpacker button, the
speedpack manual screen appears. After
touching the Stacker button, the tray stacker
manual screen appears. Both screens are not
available for the operator.
In those screens it is possible to control parts
of the speedpack or tray stacker manually.
With the manual screens it is also possible to
verify correct functioning of sensors and
motors. These are depicted in these screens.
Whenever a sensor detects something or a
motor is activated, it colors yellow or green.
DANGER!
Before starting to move parts of the system,
you have to assure yourself no other persons
are in danger. Make sure nobody is around
the part you intend to move.
ATTENTION!
When you move parts manually, it may be
possible that parts will collide, resulting in
damage of the system.
ATTENTION!
Using the manual buttons may result in
damaging trays, eggs and machine parts. We
advise you to remove all trays from the
system before starting to use these buttons.
ATTENTION!
The manual screen should only be used by
advanced users of the system like Prinzen
engineers for testing the system.
Page 50 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
PASSWORD SCREEN
31
30
32
Here you can enter your password. Depending
on the operating level you get the possibility to
change settings of the system and/or move
parts of the system manually. Passwords will
be handed over to certain dedicated persons
within your company.
The level window (30) shows the current
operating level. For the lower operating levels
the passwords are also visible. After touching a
visible password (31), a keypad pops up in
which it is possible to change the password.
After touching the password window (32) a
keypad appears (33). After entering the correct
password and confirming it with the V button
(34) the operating level changes.
33
34
DANGER!
By working on a higher operating level, you
have more possibilities to control the system
manually. Before starting to move parts of the
system, you have to assure yourself no other
persons are in danger. Make sure nobody is
around the part you intend to move.
ATTENTION!
By working on a higher operating level, you
have more possibilities to control the system
manually. When you move parts manually, it
may be possible that parts will collide,
resulting in damage of the system.
ATTENTION!
By working on a higher operating level, you
have more possibilities to control the system
manually. Using the manual buttons may
result in damaging trays, eggs and machine
parts. We advise you to remove all trays from
the system before starting to use these
buttons.
ATTENTION!
By working on a higher operating level, you
have the possibilities to change parameter
settings. This may result in malfunctioning
and even damage of the system.
ATTENTION!
The manual screens should only be used by
advanced users of the system like Prinzen
engineers for testing the system.
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USER MANAUL SPEEDPACK 110
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OPERATION
SPEEDPACK MANUAL
SCREEN
41
44
Page 52 of 101
40
45
42
46
43
Tray denester (40):
Touching this arrow button shortly activates the
denester. When touching it for a longer time,
the denester makes one complete cycle. When
trays are present, one tray is placed on the
curve conveyor underneath the denester.
Curve conveyor (41):
After touching this arrow button, the curve
conveyor starts to run as long as this button is
touched.
Tray conveyor (42):
Touching this arrow button shortly activates the
tray conveyor. When touching it for a longer
time, the tray conveyor makes one step
forwards.
Optional outfeed conveyor (43):
After touching this arrow button, the optional
outfeed conveyor starts to run as long as the
button is touched.
Optional (extended) infeed conveyor (44):
After touching this arrow button, the optional
infeed conveyor starts to run as long as this
button is touched.
Infeed conveyor (45):
After touching this arrow button, the infeed
conveyor starts to run as long as this button is
touched.
Roller track gripper transport (46):
Touching this arrow button shortly activates the
roller track and gripper transport. When
touching it for a longer time, the roller track and
the gripper transport make one complete step
forwards.
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
TRAY STACKER MANUAL
SCREEN
50
UM-SP-1.3-E/04-2010
53
51
52
Infeed conveyor tray stacker (50):
The infeed conveyor tray stacker transfers
trays from the speedpack towards the tray
stacker.
After touching this arrow button, the infeed
conveyor starts to run as long as the button is
touched.
1st buffer conveyor (51):
After touching this arrow button, the optional
1st buffer conveyor starts to run as long as the
button is touched.
2nd buffer conveyor (52):
After touching this arrow button, the optional
2nd buffer conveyor starts to run as long as the
button is touched.
Tray stacker (53):
After touching this arrow button, the tray
stacker makes one complete step. When trays
are present, the trays are transferred one step
forwards from the outfeed conveyor towards
the stack of trays.
USER MANAUL SPEEDPACK 110
Page 53 of 101
OPERATION
SERVICE MENU
In this menu the user of the system is able to
change a number of settings using submenus.
Not all submenus are available for the operator
or the supervisor.
ATTENTION!
Changing parameter settings may result in
malfunctioning and even damage of the
system.
ATTENTION!
The service screens should only be used by
advanced users of the system like Prinzen
engineers for testing the system.
CAUTION!
Be sure not to enter limbs between rotating
parts when cleaning or maintaining machine
parts while they are running.
We strongly advise you NOT to clean or
maintain the machine while it is running.
ATTENTION!
Remove all eggs and trays from the system
before touching the maintenance button.
Otherwise touching this button results in
damaged eggs, trays and machine parts.
Page 54 of 101
Adjust machine settings:
After touching this button the machine settings
menu appears in which it is possible to set the
system into a simulation mode, change a few
timers that control the system and enter the
correct configuration of the system. These
submenus are not available for the operator
and the supervisor.
Save machine settings:
With this button you can enter the save
machine settings submenu. In this menu it is
possible to save the machine settings. This
screen is not available for the operator and the
supervisor.
Panel settings:
After touching this button you will enter the
panel settings submenu in which it is possible
to change touchpanel settings. This submenu
is not available for the operator.
Customer settings:
After touching this button, the customer
settings screen appears in which it is possible
to change some timers and settings that
control the system. This submenu is not
available for the operator.
Production counters:
After touching this button the production
counters screen appears in which the amount
of processed eggs is shown.
Language:
After touching this button the language screen
appears. In this screen it is possible to select
the language of the touchpanel.
Maintenance:
After touching this button, it colors yellow.
Pushing the start button now, starts the
speedpack movements without the supply of
eggs. This functionality is not available for the
operator and the supervisor. It gives the
possibility to clean or lubricate certain parts of
the speedpack which are normally difficult to
reach. We advise you NOT to clean or
lubricate machine parts while they are running,
but let it run for a short distance, clean or
lubricate the parts while they are stopped, and
run the machine again for a short distance.
This way the machine is cleaned or lubricated
step by step until it is completely cleaned or
lubricated. Before using this button, remove all
eggs and trays from the system.
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
I/O list:
After touching this button the I/O screen
appears. In this screen it is possible to view the
status of all the inputs (sensors) and outputs
(motors).
Software debug:
After touching this button the software debug
screen appears. This screen shows
information about the status of the software.
MACHINE SETTINGS
ATTENTION!
Changing parameter settings may result in
malfunctioning and even damage of the
system.
Simulation:
After touching the Simulation button, the
simulation screen appears in which it is
possible to set (parts of) the system in the
simulation mode, making it is possible run the
system without eggs and trays.
Timers/speed:
After touching the Timers button, the timers
screen appears in which it is possible change
the timers that control the system.
Configuration:
After touching the Configuration button, the
configuration screen appears in which it is
possible to enter the correct configuration of
the system. Normally this is done in the factory
by Prinzen engineers.
TIP!
Normally the parameters in these screens are
factory set and do not need to be changed.
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USER MANAUL SPEEDPACK 110
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OPERATION
SIMULATION SCREEN
Egg’s at infeed:
When egg’s at infeed is set to Auto, the roller
track and gripper transport will only make a
step when eggs are detected in all gates.
When egg’s at infeed is set to Simulation,
when the system is started, the roller track and
gripper transport will continuously run
regardless of the presence of eggs in the
gates.
Eggs in chain:
When egg’s in chain is set to Auto, the roller
track and gripper transport will only make a
step when eggs are detected in the grippers at
the egg transfer position.
When egg’s in chain is set to Simulation, when
the system is started, the roller track and
gripper transport will continuously run
regardless of the presence of eggs in the
grippers.
Tray present:
When tray present is set to Auto, the roller
track and gripper transport will only make a
step when a tray is detected at the egg transfer
position.
When tray present is set to Simulation, when
the system is started, the roller track and
gripper transport will continuously run
regardless of the presence of a tray at the egg
transfer position.
Tray present at infeed stacker:
When tray present at infeed stacker is set to
Auto, the optional tray stacker only makes a
step when a tray is detected at infeed of the
tray stacker.
When tray present at infeed stacker is set to
Simulation, when the system is started, the
optional tray stacker continuously runs
regardless of the presence of a tray at the
infeed of the tray stacker. The infeed conveyor
in between the speedpack and the tray stacker
does not run in the simulation mode.
Page 56 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
TIMERS SCREEN
Delay tray chain full:
This timer determines the timing for stopping
the tray conveyor after detecting a tray on the
downstream conveyor (outfeed conveyor
(stand alone system) or the infeed conveyor
tray stacker). When this timer is too short the
speedpack stops and starts too often. When
this timer is too long the (full) trays will collide
on the downstream conveyor resulting in
damaged eggs.
Delay outfeed full:
This timer is only available when the
speedpack is used as a standalone system
with an outfeed conveyor.
It determines the timing for stopping the
speedpack after detecting a tray on the outfeed
conveyor. When this timer is too short the
speedpack stops and starts too often. When
this timer is too long trays will collide on the
outfeed conveyor resulting in damaged eggs.
Show no release warning:
When another brand of tray stacker is used
instead of the Prinzen tray stacker, this stacker
sends a release signal to the speedpack.
When the speedpack does not receive this
release signal, a message appears on the
speedpack touchpanel.
Here it is possible to enable or disable the
appearance of this message.
When Yes is selected, the message appears
when no release signal is received.
When No is selected, the message will not
appear.
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OPERATION
CONFIGURATION SCREEN
Because of the possibility to run the speedpack
with a few optional systems, controlled by the
speedpack, the software of the speedpack is
able to control several configurations of the
speedpack.
With this screen it is possible to enter the
correct configuration of the system.
Normally this is done in the factory by Prinzen
engineers and the user of the system should
not change these parameters.
TIP!
Normally the parameters in the configuration
screen are factory set.
Serial number:
Here the serial number of the speedpack is
displayed.
Machine type:
Here it is possible to select the machine type,
with a tray stacker, a pallet loader or both.
Speedpack number of infeed conveyors:
Here the amount of infeed conveyors of the
speedpack is displayed, including the standard
1st infeed conveyor.
Speedpack number of outfeed conveyors:
Here the amount of optional outfeed conveyors
is displayed. These conveyors are placed
downstream of the tray conveyor and can only
be present when the speedpack is used as a
standalone system.
When the tray stacker is present, 0 is
displayed here and it is not possible this.
Outfeed direction stacker:
Here the direction of the outfeed conveyor to
the tray stacker is displayed. There is a straight
and a 90° angle outfeed conveyor available.
Stacker number of outfeed conveyors:
Here the amount of optional buffer conveyors
downstream of the tray stacker is displayed.
These conveyors may transport stacks of trays
to downstream systems not controlled by the
speedpack.
Page 58 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
SAVE MACHINE SETTINGS
71
72
73
In this menu it is possible to create, save, open
or delete a machine settings file.
A machine settings file is a file which contains
all the machine settings.
74
70
75
Create (70):
After touching this button, a keypad pops up in
which it is possible to enter a file name. After
confirming the name with the enter button, the
file is created and its name appears in the file
name list (71)
Save (72):
After selecting a file name from the file name
list and touching this save button, all the
machine settings are stored in this file.
Open (73):
After selecting a file name from the file name
list and touching this button, all machine
settings of this file are read and will be used by
the speedpack.
Delete (74):
After selecting a file name from the file name
list and touching this button, this file is deleted.
USB (75):
After touching this button you will enter the
USB stick submenu in which it is possible to
load or store machine setting files.
79
USB STICK
80
Inside the operating panel, on the rear side of
the touchpanel, it is possible to plug in an USB
stick (76). To store machine setting files on an
USB stick, or to load Machine setting files from
the USB stick, first plug in the USB stick.
78
77
76
UM-SP-1.3-E/04-2010
After touching the Directory button (77) on the
left side of the screen, all the machine setting
files of the speedpack appear in the left list.
After touching the Directory button (78) on the
right side of the screen, all the machine setting
files on the USB stick appear in the right list.
After selecting a file in the left list and touching
the right arrow button (79), this file is stored on
the USB stick.
After selecting a file in the right list and
touching the left arrow button (80), this file is
loaded from the USB stick and stored in the
PLC. To use the settings in the file it has to be
opened by using the open button (73)
USER MANAUL SPEEDPACK 110
Page 59 of 101
OPERATION
PANEL SETTINGS
In this menu the user of the system is able to
change touchpanel settings using submenus.
This submenu is not available for the operator
and some of the screens in this submenu are
also not available for the supervisor.
Machine production times:
After touching this button the Machine
production time screen appears. This screen
shows the performance of the system.
Date&Time:
After touching this button the Date&Time
screen appears. In this screen it is possible to
set the correct date and time.
CPU:
After touching this button the CPU screen
appears. This screen shows information about
the status of the control system.
Contrast:
After touching this button the Contrast screen
appears. In this screen it is possible to adjust
the contrast, the brightness and the orientation
of the display.
Network:
After touching this button the Network screen
appears. In this screen it is possible to adjust
the communication between the machine and
(via the internet) an external computer.
PRODUCTION TIME SCREEN
Here the performance of the system is visible.
Power on over all:
The power on over all shows the time that the
system power was ON.
Production active:
Production active shows the time that the
system was running production (filling trays
with eggs).
Production in standby:
This parameter is for future use and is
currently not used in this system.
Machine stopped:
Machine stopped is the time that the system
was not running production (stop button
pressed).
Page 60 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
DATE&TIME SCREEN
After touching year, month, day, hour or minute
a keypad appears. Enter the correct date and
time and confirm this with the V button. Now
touch the button “accept date & Time” to
activate the correct date and time.
CPU SCREEN
This screen shows information about the status
of the control system.
Serial number:
Here the serial number of the CPU is
displayed. During contact with a Prinzen
service engineer to solve a breakdown, you
may be asked to pass on this serial number.
Temperature CPU/ENV:
Here the temperature of the CPU (Central
Processing Unit) and its surrounding
temperature is displayed.
Whenever the temperature rises too high, a
message appears on the screen and the
cabinet of the CPU needs to be cooled
immediately.
Backup battery status:
The back-up battery status shows the status of
the battery. When the battery becomes
exhausted, not OK appears. In that case do
not power off the system and contact Prinzen
for the exchange procedure of the battery.
Power up cycles:
The amount of power up cycles (switching ON
the system) is displayed here.
Operation hours:
The time that the system was running
production (filling trays with eggs) is displayed
here.
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USER MANAUL SPEEDPACK 110
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OPERATION
90
91
92
93
CONTRAST SCREEN
With the contrast buttons (90) it is possible to
adjust the contrast of the display.
With the brightness buttons (91) it is possible
to adjust the brightness of the display.
After touching the orientation button (92) you
can calibrate the touchpanel part of the
display. Dots appear on the screen. Touch
these dots with a pointed (but not sharp!)
object (93). After touching the last dot, the
touchpanel part of the display is calibrated.
Another way to activate the calibration of the
touchpanel is by simultaneously pressing the
stop and the reset button (94) for at least 2
seconds.
ATTENTION!
It is forbidden to press on the Touch Panel
with sharp objects because this may also
damage the Touch Panel.
TIP!
The touchpanel is calibrated in the factory.
Because of this, normally it is not necessary
to calibrate the touchpanel.
94
NETWORK SCREEN
In this screen it is possible to enter the IP
addresses to be able to communicate with an
external computer via an Internet connection.
Normally these addresses are entered by
Prinzen engineers and are for information only.
In case it is necessary to change these
addresses ask your network administrator to
do this.
Page 62 of 101
USER MANUAL SPEEDPACK 110
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OPERATION
CUSTOMER SETTINGS
SCREEN
In this screen it is possible to change some
settings that control the system.
Egg belt low speed:
Here it is possible to change the low speed of
the infeed conveyors. This speed is used when
the 100% button on the production screen is
touched. The infeed conveyors will use the
speed as entered in this screen.
When for example 70% is entered, after
touching the 100% button on the production
screen, the infeed conveyors will run with 70%
of their maximum speed.
On delay pressure control:
The on delay is the time between the start/stop
delay sensors both detecting eggs and the
stop of the egg-collecting conveyor. When this
on delay is too short, the egg-collecting
conveyor stops just after an egg is detected.
When this timer is too long, too many eggs
enter the infeed conveyor causing too much
pressure on the gates.
After an egg collecting conveyor stop, the
below conditions must be met before this
conveyor is allowed to restart again:
- First the roller track makes a certain
amount of steps.
- Then one of the start/stop delay sensors
no longer detects eggs.
- And at last the pressure control off timer
has passed.
Pressure control off:
This parameter determines the time between
one of the start/stop delay sensors no longer
detecting eggs and the restart of the egg
collecting conveyor. When this time is too short
the egg-collecting conveyor stops and starts
too often. When this timer is too long, the
speedpack stops once in a while because it
takes too long before eggs are present in all
gates.
Steps pressure control off:
This parameter determines the amount of
steps that the roller track has to make after an
egg collecting conveyor stop.
Speed belt 1:
This speed setting determines the speed of the
optional infeed conveyor (infeed extension).
Speed belt 2:
This speed setting determines the speed of the
infeed conveyor.
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USER MANAUL SPEEDPACK 110
Page 63 of 101
OPERATION
PRODUCTION COUNTERS
101
In this screen the amount of packed eggs since
the last reset is displayed.
By touching the R button (100) all counters are
reset. The date and the time of the last reset is
displayed on the upper part of the screen
(101).
100
LANGUAGE
In this screen it is possible to select the
language of the touchpanel. The flags with
dotted lines around it are the languages which
are available in this system.
I/O LIST
In this screen it is possible to view the status of
all the inputs (sensors) and outputs (motors).
By touching the + or – buttons (110) it is
possible to scroll through the list of Inputs and
Outputs.
110
Page 64 of 101
After touching the safety button, the safety
relays diagnose screen appears. In this screen
it is possible to view the status of all the safety
relays.
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
SAFTEY RELAYS SCREEN
In this screen it is possible to view the status of
the safety relays.
During contact with a Prinzen service engineer
to solve a breakdown, you may be asked to
pass on information from this screen.
SOFTWARE DEBUG SCREEN
The software debug screen shows information
about the status of the software.
During contact with a Prinzen service engineer
to solve a breakdown, you may be asked to
pass on information from this screen.
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USER MANAUL SPEEDPACK 110
Page 65 of 101
OPERATION
STARTING PRODUCTION
1
Follow below steps to start up the system:
CAUTION!
Make sure all protective covers are in place.
Make sure no persons are in danger.
ATTENTION!
Make sure no tools or other objects are present
inside the system.
ATTENTION!
Before starting the system make sure
maintenance is performed according to the
maintenance instructions further on in this
manual.
2
1. Switch the system ON.
2. Fill the denester bunker with trays. Place
the trays with the tray grip pointing towards
the front/rear side of the denester.
3. Push the start button to start the system.
The light inside the button turns ON.
4. Now the system is running. Normally, after
a few seconds, the egg collecting
conveyor also automatically starts up
3
Page 66 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
STOPPING PRODUCTION
Follow below steps to stop the system:
2
1. First wait until no more eggs are supplied
on the egg-collecting conveyor.
2. Manually place the last eggs on the infeed
conveyor into the gates.
3. Touch the empty speedpack button. The
button colors green.
4. Wait until all eggs are placed into the
trays. No more eggs should be present
inside the speedpack.
TIP!
The last trays leaving the system may be only
partially filled! Remove these trays manually
from the tray conveyor.
7
10
3
8
12
UM-SP-1.3-E/04-2010
5. A message appears on the screen to
remove partially filled trays from tray
conveyor / outfeed conveyor. The empty
speedpack button colors white again.
6. Manually remove the partially filled trays.
7. Press the reset button.
8. Touch empty tray stacker button. The
button colors green.
9. Wait until all trays are removed from the
optional tray stacker. The empty tray
stacker button colors white again.
10. Push the stop button.
11. Wait until all movements of the system are
stopped.
12. Switch the system OFF.
USER MANAUL SPEEDPACK 110
Page 67 of 101
OPERATION
OPERATION ADJUSTMENTS
1
GATE BLOCKERS
2
1
2
Gate blockers prevent the possibility of 2
smaller eggs entering 1 gate.
When smaller eggs are produced keep all gate
blockers in the infeed gates using the 15 mm
gate blockers (1).
When the produced eggs are becoming bigger
replace the 15 mm gate blockers by the 10 mm
gate blockers (2).
As soon as most of the produced eggs are big
and the infeed of eggs get stuck by the gate
blockers, remove the gate blocker (3).
GATE FLAPS
3
Gate flaps (4) prevent the possibility of a 2nd
egg rolling above the 1st egg in the gate at
roller track transfer position.
Adjust the height of the gate flaps with the
adjustment bolt (5). Turn the bolt counter
clockwise to lower the flap for smaller eggs.
Turn the bolt clockwise to raise the flap for
bigger eggs.
Adjust in such a way that the eggs are nearly
not touching the produced eggs.
5
4
Page 68 of 101
LET OP:
Item 5 moet met ander foto, met schroefknop!!!
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
OPERATION
ON / OFF DELAY TIME
Check the on delay pressure control and
pressure control off timers for the infeed
conveyor.
When the infeed conveyor of the speedpack is
full with eggs from the egg-collecting conveyor
the start/stop delay sensors (6) at the side of
the infeed conveyor are activated. When these
sensors both remain detecting eggs for a
certain time (on delay pressure control time), a
signal is sent to the egg-collecting conveyor to
stop supplying eggs.
6
After an egg collecting conveyor stop, the
below conditions must be met before this
conveyor is allowed to restart again:
- First the roller track makes a certain
amount of steps.
- Then one of the start/stop delay sensors
no longer detects eggs.
- And at last the pressure control off timer
has passed.
When one of the start/stop delay sensors is no
longer detecting eggs, a certain time later
(pressure control off time) a signal is sent to
the egg-collecting conveyor to supply eggs
again.
Adjust the delay times to get a smooth flow of
eggs without too much starting and stopping of
the egg-collecting conveyor.
For adjustment of the timers see the on delay
pressure control and pressure control off
parameters in the Timers screen in this
chapter.
OPERATING PANEL POSITION
The position of the operating panel is
adjustable. Loosen up both knobs (7) on the
rear side of the panel and turn the panel into
the required position. Tighten up the knobs
afterwards.
7
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MAINTENANCE
4. MAINTENANCE
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Page 71 of 101
MAINTENANCE
GENERAL
Only professionals who are familiar with the installation and its operation may perform maintenance,
cleaning, repairs and replacement of defective or worn out parts.
When during maintenance questions arise regarding the condition of the system, consult your Prinzen
dealer.
In case of difficult or special repairs consult your Prinzen dealer.
Inspections must be carried out before, during and after operation of the machine. Mechanical flaws,
such as loose bolts and ball bearings must be repaired upon discovery.
The operator is responsible for noticing and locating abnormal noises and other unusual signs
indicating flaws. If the operator cannot locate the flaw, he must stop the installation and inform his
superior.
Take preventive actions against vermin as they may cause failures to the electrical cables and such.
SAFETY REGULATIONS
Before starting operation, cleaning, maintaining the system or before remedying breakdowns first read
the chapters Introduction and Safety.
MAINTENANCE UTENSILS
In general we advise to have the following tools available for maintenance of the Prinzen systems:
- Padlock.
- Vacuum cleaner.
- Compressed air.
- Plastic scraper.
- Moistened cloth
- Water and neutral soap.
- Lubricants.
- Set of Allen keys.
- Set of wrenches.
- Set of screwdrivers.
NOTE!
Use H1 classified lubricants. These lubricants are approved to use in the food processing industry.
TIP!
Prinzen uses Interflon Fin Food Lube Teflon spray and Griffon HR260 Silicone spray
ATTENTION!
When you want to use different types of lubricants than the lubricants used by Prinzen, make sure that these
lubricants do not form a harmful product when contacting the lubricants used by Prinzen.
Page 72 of 101
USER MANUAL SPEEDPACK 110
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MAINTENANCE
GENERAL CLEANING PROCEDURE
Before actually starting to clean the system, first follow below steps:
-
See to it that all eggs are removed by letting the machine run empty.
Switch off the system and secure it against accidental switching on.
Clean the complete system with compressed air, a vacuum cleaner and a plastic scraper.
Remove persisting scrap with a moistened cloth.
Check the condition of the system during cleaning.
CAUTION!
When using warm water to moisten a cloth, make sure the temperature of the water is below 45°C. Above this
temperature it is possible to incinerate body parts.
ATTENTION!
Do not use abrasive cleaning detergents or utensils on non-longwearing parts.
ATTENTION!
Do not use aggressive cleaning products. Use cleaning product with a PH value between 6 and 8.
ATTENTION!
The system is NOT designed for wet cleaning. Do NOT clean the system with water and certainly NOT with a high
spraying pistol. Only use moistened cloths for cleaning.
Do NOT clean bearings, printers, robots, electrical parts and pneumatic parts with water.
Perform the cleaning according the advices and intervals as described in the Preventive maintenance
instructions further on in this chapter.
TIP!
The cleaning advices and intervals described in this manual are general. For your specific products and production
process the cleaning schedule may need alteration. During the first production months observe the performance of
the system and the influence of contamination on the product quality and production process and (if necessary)
change the cleaning methods and schedules.
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 73 of 101
MAINTENANCE
REMOVING DRIP TRAYS
2
1
3
The drip trays underneath the roller track (1)
and gripper transport (2) are positioned behind
a lockable door. Open the door to have access
to these drip trays.
The drip tray underneath the tray conveyor (3)
is directly accessible.
2
1
3
Page 74 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
MAINTENANCE
When an optional extended infeed conveyor is
part of the speedpack, underneath this
conveyor a drip tray (4) is present.
When the optional tray stacker is part of the
speedpack, underneath this tray stacker 2 drip
trays (5) are present.
4
5
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 75 of 101
MAINTENANCE
REMOVING GATES STRIP
1
For easy cleaning of the strip underneath the
gates in between the infeed conveyor and the
roller track, it is possible to remove this strip.
Follow below procedure to remove the strip:
1. Lift the complete gate upwards.
2. Open up the cover on one side of the
packer.
3. Pull the knob on the side of the packer
outwards and at the same time lift the strip
up from the strip holder.
4. Remove the strip.
8
Clean the strip with warm water and a brush.
3
1
9
7
8
Follow below procedure to place the strip back:
5. Position the strip into the strip holder on
one side of the packer.
6. Pull the knob on the other side of the
packer, place the strip into this strip holder
and loosen the knob.
7. When the strip is correctly placed into both
strip holders lower the gate.
8. Make sure the drive levers on both sides
of the packer fit into the slotted holes of
the drive beam of the moving gates.
9. It is possible to move the strip forwards or
backwards to position it above the drive
levers.
4
Page 76 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
MAINTENANCE
4
REMOVING ROLLER TRACK
GUIDES
For easy cleaning of the roller track the egg
guides (4) are removable.
To remove a guide, lift it up on the gripper
transport side (5), and pull it forwards away
from the infeed gate (6).
5
6
REMOVING FILTER
ELECTRICAL CABINET
3
On both sides of the electrical cabinet a filter is
placed in front of the air inlet and air outlet.
Check this filter once a month for
contamination and replace it with a clean filter
if necessary.
2
Follow below procedure to replace the
filters of the electrical cabinet:
1. Stop the packer.
2. Switch OFF the main switch on the
electrical cabinet.
3. Open up the filter holder by pulling the clip
on the topside.
4. Replace the contaminated filter in the filter
holder by a clean filter.
5. Close the filter holder again.
4
CAUTION!
Always switch OFF the main switch before
opening the filter holder!
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 77 of 101
MAINTENANCE
1
4
REMOVING GRIPPER SHAFTS
For easy cleaning of the gripper transport, it is
possible to remove the gripper shafts with
grippers from the gripper transport chain.
There is only access to a few gripper shafts in
the gripper transport. Because of this, after
removing a few gripper shafts, the gripper
transport needs to make a few steps before it
is possible to remove the next few gripper
shafts.
2
5
6
Follow below procedure to remove the gripper
shafts:
1. Open up the cover of the gripper transport.
2. Push the spring-loaded holder block
towards the grippers and move it away
from the transport chain.
3. Remove the gripper shaft.
4. After removing a few gripper shafts, close
the cover and press the reset button.
5. Touch the egg chain button.
6. Touch the tip egg chain button a few
times.
7. Open up the cover again and remove the
next few gripper shafts.
To clean the grippers, let them soak in warm
water (maximum 40ºC) until the dirt becomes
soft (this may take a few hours). After this rinse
off the grippers with water to clean them.
4
Page 78 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
MAINTENANCE
1
Follow below procedure to place the gripper
shafts back into the gripper transport:
1. Open up the cover of the gripper transport.
2. Make sure to position each gripper on the
correct position on the gripper shaft. The 4
center grippers must fit into the 4 gripper
guides.
3. The most left grippers must be positioned
on the left side of the most left guide.
4. The most right gripper must be positioned
on the right side of the most right guide.
9
13
3
2
2
2
2
ATTENTION!
Wrong position of one of the grippers in one of
the guides will immediately damage the
grippers when the system is started.
4
5. Put the holder block (not spring-loaded)
onto the pins of the right transport chain.
6. Push the spring-loaded holder block
towards the grippers and place it onto the
pins of the left transport chain.
7. Make sure the spring-loaded holder block
is placed on the left transport chain! This is
marked with a sticker!
8. When the gripper shaft is positioned the
other way around, the open/close
activation pin damages.
8
7
6
5
ATTENTION!
Wrong position of gripper shaft on the transport
chain will immediately damage the grippers
when the system is started.
9. Close the cover of the gripper transport.
10. After placing a few gripper shafts, close
the cover and press the reset button.
11. Touch the egg chain button.
12. Touch the tip egg chain button a few
times.
13. Open up the cover again and place the
next few gripper shafts.
11
12
10
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 79 of 101
MAINTENANCE
GENERAL MAINTENANCE PROCEDURE
Before actually starting to maintain the system, first follow below steps:
-
See to it that all eggs and trays are removed by letting the machine run empty.
Switch off the system and secure it against accidental switching on.
Perform the maintenance.
Check the condition of the system during maintenance.
TIP!
All motors are provided with lifetime lubrication and require no lubrication.
TIP!
All bearings are sealed and lubricated for life and require no lubrication.
Perform the maintenance according the advices and intervals as described in the Preventive
maintenance instructions further on in this chapter.
TIP!
The maintenance advices and intervals described in this manual are general. For your specific products and
production process the maintenance schedule may need alteration. During the first production months observe the
performance of the system and the influence of the maintenance and (if necessary) change the maintenance
methods and schedules.
AFTER MAINTENANCE
When the maintenance duties are finished, ensure the following:
-
All fasteners are secure.
All safety covers are in place and safety doors are closed.
All tools and cleaning utensils are removed from the system.
The system is absolutely dry before putting it back into operation.
Moving parts that have been cleaned are lubricated.
Excess lubricant is removed.
The system is tested before starting production.
NOTE!
Residues of lubricant must be discharged as chemical waste.
Page 80 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
MAINTENANCE
PREVENTIVE MAINTENANCE INSTRUCTIONS
DAILY MAINTENANCE
4
1
2
1
2
3
3
4
Daily Maintenance:
Interval (hours):
Observe for abnormal sounds, vibrations and heat
Remove all dirt, grease and feathers from the system
Clean the drip trays with water (3x)
Clean tray stacker drip trays with water (2x)
Clean the infeed conveyor with a moistened cloth.
3
3
3
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 81 of 101
h
8
8
8
8
8
MAINTENANCE
WEEKLY MAINTENANCE
1
1
1
1
1
2
2
2
2
2
3
3
Weekly Maintenance:
Interval (hours):
Clean all photo switches with a moistened cloth (14x)
Clean infeed conveyor tray stacker (or optional outfeed
conveyor) photo switches with a moistened cloth (2x)
Clean optional buffer conveyor photo switches with a
moistened cloth (2x)
Clean the mirrors with a moistened cloth (4x)
Clean infeed conveyor tray stacker (or optional outfeed
conveyor) mirrors with a moistened cloth (2x)
Clean optional buffer conveyor mirrors with a moistened
cloth (2x)
Check the functionality of the emergency button.
2
1
1
1
2
1
2
1
Page 82 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
h
40
40
40
40
40
40
40
MAINTENANCE
4
5
6
7
8
Weekly Maintenance:
Interval (hours):
Clean the transport shafts of the grippers.
Apply silicon spray on the transport shafts of the grippers
Clean the infeed conveyor tray stacker (or optional
outfeed conveyor) belt
Clean the optional buffer conveyor belt
Clean the optional tray stacker lever
4
5
NOTE!
Keep the grippers of the gripper transport free
of lubricants to prevent contamination of the
eggs.
6
7
8
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 83 of 101
h
40
40
40
40
40
MAINTENANCE
MONTHLY MAINTENANCE
1
1
1
1
Monthly Maintenance:
Interval (hours):
Clean all motor fans with compressed air (5x)
Clean infeed conveyor tray stacker (or optional outfeed
conveyor) motor fan with compressed air
Clean optional tray stacker motor fan with compressed air
Clean optional buffer conveyor motor fan with
compressed air
1
1
CAUTION!
Wear eye protection during cleaning of the
motor fans with compressed air.
1
1
1
Page 84 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
h
200
200
200
200
MAINTENANCE
2
3
4
5
2
6
3
7
8
9
10
4
Monthly Maintenance:
Interval (hours):
Apply Teflon spray on the gripper transport chains (2x)
Apply Teflon spray on the roller track transport chains (2x)
Apply Teflon spray on the tray conveyor transport chains
(2x)
Apply Teflon spray on the optional tray stacker gripper
transport chains (2x)
Apply Teflon spray on the optional tray stacker gripper
leveling chains (2x)
Apply Teflon spray on the optional tray stacker gripper
drive chains (2x)
Apply Teflon spray on the optional tray stacker main drive
chain
Apply Teflon spray on the optional tray stacker pusher
control chain
Apply Teflon spray on the optional tray stacker, stacker
plate rotating control chain
TIP!
Only lubricate the roller track transport chain.
Make sure the black rubber supporting guide
remain free of lubricants. Lubricant on the
black rubber supporting guide causes
malfunctioning of the roller shafts.
NOTE!
Keep roller shafts of roller track free of
lubricants to prevent contamination of the
eggs.
NOTE!
Keep grippers of gripper transport free of
lubricants to prevent contamination of the
eggs.
10
9
8
5
6
7
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 85 of 101
h
200
200
200
200
200
200
200
200
200
MAINTENANCE
11
12
13
14
15
11
Monthly Maintenance:
Interval (hours):
Apply silicon spray to the tray denester block up/down
guide (4x)
Apply silicon spray to the tray denester lower grippers
in/out guides (4x)
Apply silicon spray on the 30-cell tray denester upper
grippers plain bearings (8x).
Apply Teflon spray on rod ends 30 cell tray denester (4x)
Apply silicon spray on the infeed gate shaking fork plain
bearings (4x).
12
13
14
15
Page 86 of 101
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
h
200
200
200
200
200
MAINTENANCE
17
17
16
17
18
19
20
Monthly Maintenance:
Interval (hours):
Check the main drive chain for wear
Check the infeed conveyor drive chain for wear
Apply Teflon spray on the main drive chain
Apply Teflon spray on the infeed conveyor drive chain
Check the filters of the electrical cabinet for contamination
and replace if necessary (2x)
19
TIP!
When the yellow part on the chain tensioner
becomes visible, replace the infeed conveyor
drive chain.
18
16
20
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 87 of 101
h
200
200
200
200
200
MAINTENANCE
½ YEARLY MAINTENANCE
1
2
1
2
Page 88 of 101
½Yearly Maintenance:
Interval (hours):
Check all bearings for wear
Check complete system for loose parts, bolts, nuts,..etc
USER MANUAL SPEEDPACK 110
UM-SP-1.3-E/04-2010
h
1200
1200
MAINTENANCE
YEARLY MAINTENANCE
1
1
Yearly Maintenance:
Interval (hours):
Replace the touchpanel internal battery.
TIP!
See Service manual for replacement procedure
of the touchpanel battery.
TIP!
When the internal battery of the PLC is empty,
the speedpack will malfunction and needs to be
re-tuned by a specialist from Prinzen.
TIP!
Although the battery has a lifetime of
approximately 5 years, Prinzen advises to
replace the battery during a yearly
maintenance.
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 89 of 101
h
2400
MAINTENANCE
LUBRICATION DIAGRAM
M
W
M
Silicon spray
Sillicone spray
Siliconenspray
M
Teflon Spray
M
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
M = Monthly
W = Weekly
Page 91 of 101
MAINTENANCE
M
M
Silicon spray
Sillicone spray
Siliconenspray
Teflon Spray
M = Monthly
W = Weekly
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 93 of 101
MAINTENANCE
M
Silicon spray
Sillicone spray
Siliconenspray
Teflon Spray
M = Monthly
W = Weekly
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 95 of 101
MAINTENANCE
M
M
Silicon spray
Sillicone spray
Siliconenspray
Teflon Spray
M = Monthly
W = Weekly
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 97 of 101
SPARE PARTS
5. SPARE PARTS
UM-SP-1.3-E/04-2010
USER MANAUL SPEEDPACK 110
Page 99 of 101
SPARE PARTS
LIST WITH RECOMMENDED SPARE PARTS
Adv.
10
1
2
2
2
1
1
1
1
2
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
1
1
1
1
1
1
1
1
1
1
1
1
1
10
1
1
1
1
1
1
Description
Gripper shaft
Roller chain main drive
Transport chain roller track
Transport chain gripper transport
Hollow pin chain tray conveyor
Shackle hollow pin chain
Shackle chain
Chain tensioner big
Chain tensioner small
Rimmed bearing
Optocoupler
DC power supply
DC power supply
Photocell
Photocell transmitter
Photocell receiver
Photocell reflector
Reflector
Relay
Frequency inverter
EMC Filter for frequency inverter
Solenoid
Sensor proximity
Filter electrical cabinet
Infeed belt
Curve belt
Roller for tray conveyor
Motor curve conveyor
Motor tray conveyor
Motor roller track/gripper transport
Motor infeed conveyor
Motor tray denester
Gripper assembly Tray stacker
34
1
Gripper set plastic Tray stacker
UM-SP-1.3-E/04-2010
Type / Remarks
0,18kW 109rpm
0,25kW 46rpm
0,37kW 55rpm
0,18kW 68rpm
0,25kW 46rpm
PS4
Article code
6100100460
7000100069
7000100070
7000100071
7000100072
7000100063
7000100030
7001400003
7001400001
7001200045
8001000002
8001300004
8001300017
8001600069
8001600070
8001600071
8001600132
8001600133
8001000003
8001100036
8001100048
8000800038
8001600014
5702300190
7200100051
7200100061
4000400096
8500200022
8500400014
8500400030
8500400031
8500400014
6100100398
PS4
6100100364
1/2x5/16 08B-1 188 chain links
08B-1 4th pin 151 chain links
08B-1 2nd pin 75 chain links
10B-1 101 chain links
5/8x3/8
08B-1
UFL 004 SS
24DC RP1D060D4M1PD
24V/5A
5V/5W
PD30CNB15PPRT
PD30CNT15PMU
PD30CNT15PPRT
PD30CNP06PPRT
Reflector
G2R-1-SN 24VDC OMRON
V1000 0,4/0,75kW
V1000
DBMX6060.11.N210-39
E2A-M12LS04WP-B1
EFMP200
USER MANAUL SPEEDPACK 110
Page 101 of 101