Home

user manual smartpack

1. 1 Constant 2 Variable 3 A1c1 e 1 Device Type gt 4 Alic 5 A1v5 6 A5c1 3 Technician o 7 A33c6 v Y 2 Heads channel Setnesof Beads Set Pincode Y gt Set no of prints Y gt 3 No of prints d Indicate which sensor 1 Basic parameters OO 4 Sensor Y Indicate no of digits S 1 No of digits 2 Print parameters gt Set Print length 2 Print length E Set Print speed p 3 Speed m Get time after print puls p 4 Print start gt Not applicable 5 Print distance M Not applicable gt 6 v scale gt 222 7 vp scale e 1 from left gt 8 Print direction P 2 from left upside down 3 from right Y 4 from right upside down BN Testprint 3 Diagnosis gt 1 Normal gt 2 Pixel test Print parameters Speed Sensor Display Keyboard watchdog v E 1 DE German 4 Settings g qitanguaga p 2 EN English 3 NL Dutch 4 FR French Set cartridge power LN 2 Printstrength ER gt supply p Jet use R L Visight LN 2 Left _ 3 Both p 4 Both Flash gt Pincode USER MANUAL SMARTPACK UM SMP 04 E 10 2013 e e PRINTER p nnzen LIST WITH RECOMMENDED SPARE PARTS OVOPRINT CPUMut 24Z 690020003 Prnarm 1 1 2
2. DEN es ILI ES de M eoo corro ee Be DH H SE EEN Geer eee raa RK HN eorr eror De DD MENGN SiS oS i rite o Emergency button Main power switch mm Safety switch z5 4 Safety screen USER MANUAL SMARTPACK Page 39 of 126 Page 40 of 126 p rinzen WARNING LABELS The Prinzen system makes dangerous movements The system also contains dangerous parts when they contact the body The following labels are posted as a warning Understand and remember the meaning of the warning labels DANGER Keep the warning labels clean When labels become unclear replace them The flashlight label is used to warn for dangerous voltage inside a cabinet Contacting parts inside this cabinet may result in permanent personal injury or death This sign is used to warn for dangerous movements Keep a safe distance to those parts Disregarding this warning may result in permanent personal injury These signs are used to warn for the danger of limbs being pulled in Keep a safe distance to those parts Disregarding this warning may result in permanent personal injury USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen SAFETY These signs are used to warn for crushing danger Keep a safe distance to those parts Disregarding this warning may result in permanent personal injury This sign is used to warn for dangerous movements of a lift Keep a safe distance to
3. TIP Only lubricate the roller track transport chain Make sure the black rubber supporting guides remain free of lubricants Lubricant on the black rubber supporting guides causes malfunctioning of the rollers NOTE Keep rollers on roller track free of lubricants to prevent contamination of the eggs NOTE Keep cups of cup conveyor free of lubricants to prevent contamination of the eggs Page 100 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 PREVENTIVE MAINTENANCE p VAST Monthly Maintenance Interval hours Apply teflon spray on the optional tray stacker grippers PN og 5 2 transport chains 2x III vf Check the optional tray stacker grippers transport chains for wear 2x Check the optional tray stacker grippers transport chains tension 2x Apply teflon spray on the optional tray stacker grippers leveling chains 2x Check the optional tray stacker gripper leveling chains for wear 2x Check the optional tray stacker gripper leveling chains tension 2X Apply teflon spray on the optional tray stacker gripper drive chains 2x Check the optional tray stacker gripper drive chains for wear 2X Check the optional tray stacker gripper drive chains tension 2x Apply teflon spray on the optional tray stacker main drive chain Check the optional tray stacker main drive chain for wear Check the optional tray stacker main drive chain tension A
4. Apply teflon spray on the optional stamping unit rod ends 4x Apply silicon spray on the optional stamping unit plain bearings 2x Refill the stamps with ink Apply teflon spray on the optional tray stacker pusher plain bearings 2x Apply silicon spray on the optional trays stacker pusher wheels 4x Page 98 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 PREVENTIVE MAINTENANCE P nnzen MONTHLY PREVENTIVE MAINTENANCE Monthly Maintenance Interval hours Clean motor fans with compressed air 7x Check all belts for correct tension 3x Check the filters of the electrical cabinet for contamination and replace if necessary Check the vacuum hose for damages CAUTION Wear eye protection during cleaning of the motor fans with compressed air UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 99 of 126 PREVENTIVE MAINTENANCE e OG rnnzen Monthly Maintenance Interval hours Apply Teflon spray on the roller track transport chains 2x Check the roller track transport chains for wear 2x Check the roller track transport chains tension 2x Apply Teflon spray on the cup conveyor transport chains 2x Check the cup conveyor transport chains for wear 2x Check the cup conveyor transport chains tension 2x Check the transfer lever timing belt tension Check the transfer lever timing belt for wear Replace all the stamping heads 6x
5. Cassida PL Cassida FL5 Aerosol Gleitmo 985 HR260 Silicone spray Aerosol Aerosol www fuchs com www griffon nl Fuchs Griffon UNISILKON M 2000 Aerosol www klueber com Kl ber Cassida Silicone fluid spray Aerosol Stabylan SI 210 ATTENTION When you want to use different types of lubricants than the lubricants used by Prinzen make sure that these lubricants do not form a harmful product when contacting the lubricants used by Prinzen Aerosol www fuchs com Fuchs NOTE Use H1 classified lubricants These lubricants are approved to use in the food processing industry NOTE Residues of lubricant must be discharged as chemical waste TIP UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Prinzen uses Interflon Fin Food Lube Teflon spray and Griffon HR260 Silicone spray Page 87 of 126 PREVENTIVE MAINTENANCE e p rnnzen GENERAL MAINTENANCE PROCEDURE Before actually starting to maintain the system first follow below steps See to it that all eggs are removed by letting the machine run empty Switch off the system and secure it against accidental switching on Perform the maintenance Check the condition of the system during maintenance Perform the maintenance according the advices and intervals as described in the Preventive maintenance instructions further on in this chapter TIP The maintenance advice
6. Use The tray conveyor receives empty trays from the tray denester and transports them towards the egg place position underneath the vacuum head and it transports full trays towards the end of the conveyor where they are manually or automatically removed Construction The tray conveyor consists of 1 Belt 2 Drive mechanism 3 Stopper mechanism The tray conveyor is attached to the packer Process When the denester sensor 10 does not detect a tray the denester drops a tray on the conveyor This tray is transported towards the stopper As soon as the tray is detected by the tray present sensor 11 the vacuum head places the eggs into the tray Now the stopper releases the full tray while at the same time stopping the next empty tray The full tray is transported towards the end of the conveyor where it needs manual removal or automatic removal by the PS4 tray stacker When the tray present sensor 11 does no longer detect the tray the stopper releases the waiting empty tray and stops it again at the tray set position 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 belt Never touch it when the system is running production CAUTION Do not enter objects or body parts into the tray conveyor when i
7. Make sure the safety door or safety cover remains open and make sure the system is not able to start when you are inside the system USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen d SAFETY SCREEN Because the transfer lever needs easy access itis equipped with a safety screens 6 that stop the transfer lever immediately when one of them is interrupted The other parts of the system remain running A safety screen consists of a transmitter 7 and a receiver 8 When the safety screen is uninterrupted only the green LED on the receiver is ON as shown in the alongside picture DANGER Make sure it is not possible to start the system when you are inside the system DANGER Make sure nobody is present inside the system before resetting an interrupted safety screen CAUTION Interrupting the safety screen only stops the transfer lever 1 TIP Never use the safety screen for a normal production stop This may cause start up problems UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 37 of 126 SAFETY p rinzen SAFETY INSPECTION PROCEDURE Before starting the machine all protective covers must be in place and doors should be locked The safety devices should be operating Trained personnel must check safety devices on a daily basis to assure proper operation Check emergency stop buttons 2 Start and stop the system Wait until the system has comp
8. TIP Store the ink in a room with a temperature in between 10 C and 35 C Do not store the ink near a direct source of heat UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 29 of 126 MACHINE DESCRIPTION p SE OPTIONAL ROUND END PRINTER A Use The printer is designed for coding eggs Construction The printer consists of 1 Print heads 2 Print heads frame The printer is placed above the cup conveyor close to the transfer position of eggs from roller track to cup conveyor Process After a step forward of the cup conveyor the codes a row of eggs Safety Although the printer makes no movements at all itis secured with a protective cover TIP Store the ink in a room with a temperature in between 10 C and 35 C Do not store the ink near a direct source of heat Page 30 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 SAFETY 2 SAFETY UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 31 of 126 SAFETY plazen GENERAL Only persons meeting the following requirements are authorized to work with the system These persons should be Skilled and specifically trained for their duties Familiar with the contents of this manual Familiar with the locations of the emergency stop buttons and other safety devices 18 years old or above Familiar with the national and regional regulations regarding safety These persons should have reached the minimum legal a
9. 4 The machine is developed and constructed according the following standard NEN EN IEC 60204 1 2006 Electrical equipment of industrial machines oigned in Aalten Date 25 10 2013 N Aflu Signed by Eric Borren General Manager UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 13 of 126 MACHINE DESCRIPTION 1 MACHINE DESCRIPTION UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 15 of 126 MACHINE DESCRIPTION e SAFETY REGULATIONS Before starting operation cleaning maintaining the system or before remedying breakdowns first read the chapters Introduction and Safety i Page 16 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen MACHINE DESCRIPTION MACHINE DESCRIPTION The machine description gives information about the complete system Below description also contains the optional units of the smartpack It is possible that your system does not contain all the described optional units For more detailed information of this system see the Unit description in this chapter SMARTPACK Use The smartpack is designed to assemble a random supply of eggs coming from an egg collecting conveyor code and pack these eggs in a fixed pattern of 30 eggs into trays with the pointed end downwards and stack these trays Construction The smartpack consists of 1 Packer 6 Optional round end printer A 2 Tray denester 7 Optional PS4 tray stacker 3 Tray conveyor 8 Optional buffer conveyor
10. ATTENTION It is not allowed to use the Prinzen password With the Prinzen operating level it is possible to change settings that may damage the system ATTENTION Never create the same password for 2 different operating levels Page 50 of 126 p rinzen PASSWORD SCREEN 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 5 shows the current operating level For the lower operating levels the passwords are also visible After touching a visible password 6 a keypad pops up in which it is possible to change the password After touching the password window 7 a keypad appears 8 After entering the correct password and confirming it with the V button 9 the operating level changes DANGER By working on a higher operating level you have more possibilities to control the system manually Before starting to move parts of the system you have to assure yourself 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
11. 5 In case you have a long egg collecting conveyor and you do not want to wait until the eggs arrive on the infeed conveyor first start the infeed conveyor and the egg collecting conveyor by touching the infeed button The infeed conveyor and the egg collecting conveyor start running and will stop automatically when the first eggs arrive on the infeed conveyor ON DANGER _ Never leave the system running unattended 6 Press the start button to start the complete system 7 Nowthe system is running Normally after a few seconds the egg collecting conveyor also automatically starts up Page 72 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 P rinzen OPERATION STOPPING PRODUCTION JANE Follow below steps to stop the system 2234 Mainmenu START STOP 1 First wait until no more eggs are supplied on the egg collecting conveyor Denester Outfeed Stacker PE Manually place the last eggs on the infeed Ex conveyor into the gates S 7 pol ss e 8 3 Touch the empty rol cup button 4 Wait until all eggs are placed into the ue trays No more eggs should be present wann inside the system gt TIP The last trays leaving the system may be only partially filled Remove these trays manually from the tray conveyor WARCHE ARRET REMISE HOT AUS ARRET DURGENCE _ 5 When all eggs are removed from the system touch the empty rol cup button o
12. Q690020005 Printarm including photocell 6900200000 5 6 head 100 cm 6900200008 Print cable 6900200010 Sensor 912 E2A M12 LS04WPB1 8001600014 O O UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 119 of 126 TROUBLE SHOOTING GUIDE 8 TROUBLE SHOOTING GUIDE UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 121 of 126 TROUBLE SHOOTING GUIDE GENERAL Only professionals who are familiar with the installation and its operation may remedying breakdowns Immediately consult the Service Department of Prinzen if any problems occur or questions arise during remedying breakdowns SAFETY REGULATIONS Before starting operation cleaning maintaining the system or before remedying breakdowns first read the chapters Introduction and Safety Mm Page 122 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 3 TROUBLE SHOOTIN IDE HARDWARE TROUBLE SHOOTING TIP For all electrical failures first check the circuit breakers motor protection switches and fuses When the system was not able to finish a certain movement within the allowed time given for this movement an alarm message appears on the upper line in the touchpanel 1 By touching the alarm button 2 the alarm screen appears 3 displaying the current alarm messages The below table shows the possible specific alarms that may pop up In the table beside the alarm the alarm code the possible cause and an action to solve the error
13. 4 Optional stamping unit 9 Electrical cabinet 5 Optional side printer B 10 Operating panel Process Eggs are entering the packer that takes care of assembling the eggs and placing them into trays with the pointed end downward The trays are transferred from the packer to the optional tray stacker by the tray conveyor The tray stacker continuously stacks 6 trays and places these stacks onto the optional buffer conveyor An optional printer or stamping unit marks the eggs 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 maintenance information Chapter cleaning for cleaning information Chapter printer for detailed printer information Electrical drawings for information about the control Service manual for information about installing and adjusting the system UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 17 of 126 _ MACHINE DESCRIPTION p EDS 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 safety doors or safety screens 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 pro
14. Changing machine settings may result in malfunctioning and even damage of the system ATTENTION The machine settings screens should only be used by advanced users of the system like Prinzen engineers for testing the system OPERATION MACHINE SETTINGS MENU Here it is possible to select a certain unit and in the appearing menus view or change the parameters that control that unit Line After touching this button the line settings screen appears Infeed After touching this button the infeed settings screen appears Rolcup After touching this button the roller track cup conveyor settings screen appears Transfer After touching this button the transfer lever settings screen appears Denester At the moment there is no settings screen for denester Output After touching this button the outfeed settings screen appears Stacker After touching this button the stacker settings screen appears UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 61 of 126 OPERATION 01201 AlarmText 01201 AlarmText 2534 Settings line 17 01 58 01201 amp larmText 234 Settings line LOAD Load settings from CFizcompact Flash to PL Existing settings on to CFi 2 Compact Flash Existing file on CF will be the PLC will be overwritten overwritten LE D D Factory Actual Factory Petual CFz PLC CF PLC PLC 3CF PLO CF 01201 amp larmText neen AA 2234 Settings line 17 01
15. Here it is possible to select a certain unit and in the appearing screen view or change the recipe settings of that unit Infeed At the moment there is no recipe for the infeed Rolcup After touching this button the change recipe roller track cup conveyor screen appears Transfer After touching this button the change recipe transfer screen appears Denester After touching this button the change recipe denester screen appears Outfeed After touching this button the change recipe outfeed screen appears Stacker At the moment there is no recipe for the tray stacker CHANGE RECIPE ROL CUP OvoPrint Side printer ON OFF Here it is possible to determine if the side printer should be used Stamping ON OFF Here it is possible to determine if the stamping unit should be used UM SMP 04 E 10 2013 p rinzen 01201 AlarmText 01201 AlarmText 2734 Change recipe transfer 17 01 59 encoder ATTENTION Before starting manual control make sure it is safe to do so transfer cannot collide with eggs trays with other machine parts ATTENTION Make sure the saved value is a correct value Incorrect values result in collisions between the transfer trays eggs or machine parts resulting in damaged machine parts trays and eggs 01201 amp larmText 01201 amp larmText 22734 Change recipe denester 17 01 53 Maximum number af tries denesting 2 01201 AlarmText 01201 AlarmText 2234
16. communication between the machine and via the internet an external computer This screen is not available for the operator and the supervisor 01201 AlarmText A LANGUAGE 01201 amp larmText 2234 Language 17 01 59 In this screen it is possible to select the language of the touchpanel Touch the flag that represents your native language Page 66 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen 2234 Date Time settings 17 01 59 year month day hour minute accept date amp time ok Temperature EN 25 0 g Backup battery status Power Up cycles 234 UM SMP 04 E 10 2013 OPERATION DATE amp TIME SCREEN After touching year month day hour or minute a keypad appears Enter the correct date and time and confirm this with the V button Now touch the button accept date amp Time to activate the correct date and time CPU SCHEEN 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 bac
17. frequency inverters may hold a high voltage charge during this time Do not touch parts inside the electrical cabinet as long as displays of frequency inverters are on UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 33 of 126 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 B Page 34 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 P rinzen SAFETY SAFETY PROVISIONS Before operating the machine the safety devices must be checked for correct functioning Repair or replace safety devices before using the system if they do not work properly Never rely solely on safety devices Always switch off the system and lock up the power source 1 before working on the machine Safety devices are Emergency stop buttons Lockable doors Protective covers Safety switches Safety screens Trolley switches QUO ore 59 Ze EMERGENCY STOP BUTTON To stop the machine in case of an emergency the system has one or more emergency stop buttons 2 Only use the emergency stop button in case of an emergency When the emergency stop button is pressed the system stops immediately The button stays mechanicall
18. is selected the stack of trays from the tray stacker is transferred to the end of the buffer conveyor or to a downstream system When YES is selected the buffer conveyor runs start stop to buffer the stacks UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 65 of 126 OPERATION p SE 01201 AlarmText PANEL SETTINGS HO AEN P 3 TAREE SELIS 2234 Panel settings 17 01 59 In this menu the user of the system is able to change touchpanel settings using submenus i Some of these submenus are not available for anguage CPU Network the operator and some are also not available for the supervisor DatesTime Touch screen Language After touching this button the language screen appears In this screen it is possible to select Alz i mel the language of the touchpanel Date amp Time After touching this button the Date amp Time screen appears In this screen it is possible to set the correct date and time This screen is not available for the operator CPU After touching this button the CPU screen appears This screen shows information about the status of the control system Touch screen After touching this button the touch screen settings screen appears In this screen it is possible to adjust the contrast the brightness and the orientation of the display This screen is not available for the operator Network After touching this button the Network screen appears In this screen it is possible to adjust the
19. or drying of the suction cups with compressed air CLEANING VACUUM HEAD Once a month clean the inside of the vacuum head 11 For this remove the 4 wing nuts 12 and remove the vacuum head from the vacuum arm Use compressed air to clean the inside of the vacuum head In case of extremely contamination cause by egg yolk let the head soak in warm water maximum 40 C until the dirt becomes soft this may take a few hours After this flush out the head with water or compressed air Dry up the head with compressed air before placing it back CAUTION Wear eye protection during cleaning or drying of the vacuum head with compressed air CLEANING VACUUM FILTER Remove the filter 13 and use compressed air to clean it In case of extremely contaminated filters cause by egg yolk let the filter soak in warm water maximum 40 C until the dirt becomes soft this may take a few hours After this flush out the filter with water or compressed air Dry up the filter with compressed air before placing it back CAUTION Wear eye protection during cleaning or drying of the filters with compressed air UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 81 of 126 MC p pem CLEANING VACUUM HOSES In case of extremely contaminated vacuum head because of broken eggs it may be possible that egg yolk contaminates the vacuum head all the way into the vacuum hose 14 In that case remove the vacuum hos
20. testing the system UM SMP 04 E 10 2013 USER MANUAL SMARTPACK OPERATION MANUAL MENU Here it is possible to select a certain unit and with the appearing screen control parts of that unit manually TIP The background color of this screen is yellow Touching a button in this screen sets the selected unit immediately into the manual mode Infeed After touching this button the infeed manual screen appears RolCup After touching this button the roller track cup conveyor manual screen appears Transfer After touching this button the transfer manual screen appears Denester After touching this button the denester manual screen appears Output After touching this button the outfeed manual screen appears Stacker After touching this button the tray stacker manual screen appears With the manual screens it is also possible to verify correct functioning of sensors motors and valves These are depicted in these screens Whenever a sensor detects something or a motor or a valve is activated it colors yellow or green Password screen 30 After touching this button the password screen appears in which it is possible to change the operating level of the system Page 55 of 126 OPERATION 01201 AlarmText 01201 AlarmText 2234 Manual Infeed 17 01 59 eqqbelts SE d contact i S O E eo Bes Ti Infeecd Infeed S bet belt 01201 amp larmText neen AA 253
21. touching a particular recipe the parameter settings of this recipe are used to control the system After touching a recipe name a keypad pops up after which it is possible to change the recipe name Ten recipes are available Use the arrow button to scroll to the next 5 recipes COPY RECIPE SCREEN Here it is possible to copy the settings of a particular recipe to another recipe This way it is possible to make a new recipe First copy an existing recipe to a new recipe and after that start to change the new recipe settings via the change recipe menu To copy a recipe follow the below procedure 1 Select the source recipe 2 Select the destination recipe 3 Touch the copy recipe button Now the settings of the source recipe are copied to the destination recipe Change the name of the new recipe in the choose recipe Screen USER MANUAL SMARTPACK Page 69 of 126 OPERATION 01201 AlarmText 01201 AlarmText 234 Change Actual Recipe 17 01 53 Infeed Rolcup vene one Outfeed Stacker Salz 79 8 is ATTENTION Changing parameter settings may result in malfunctioning and even damage of the system TIP Normally the parameters in these screens are factory set and do not need to be changed 01201 A amp larmText 01201 A amp larmText 2234 Change recipe rolcup COvaPrint Sideprinter Ott Stamping Ott Page 70 of 126 USER MANUAL SMARTPACK p rinzen CHANGE RECIPE MENU
22. with Now you can set the text 2 3 Lex 4 ABC DEF 9 T 9 3DEFdef 4 5 6 is 7 s8 9 6 26MNOmno PQRS TUV WXYZ 7 27PQRSpqrs 8 8TUVtuv Salaire Q9 9WXYZwxyz D 0 7 1 amp x Back or Escape Ok or Enter Page 114 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen PRINTER SET PRINT LENGTH Press followed by to access the submenu Now press 2 user functions and press 5 print length Here you can set the desired length of the text in mm For example large eggs on 22 mm and smaller eggs on 18mm length The numbers in the display can be overwritten and confirmed with 22mm 22mm cb SET FONT Press followed by to access the submenu Now press 2 user functions and press 1 Font Now you can choose 1 Standard normal set up 2 Bold e g dark eggs need more ink 3 3 Small preferred for smaller eggs 4 4 Times more ink other font If a choice has been made confirm this with Now press 3 times to return to the menu Standard 1 Bold 2 omall 3 Times 4 ry 3099 UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 115 of 126 PRINTER p rinzen SETTING OF TWO ROWS Press followed by to access the submenu Now press 2 user functions and press 2 Print rows Now you can choose 1 One row 2 Two rows Press 2 and confirm with Now press 3 times to return to the menu The d
23. 2013
24. 4 Manual Ralcup 17 01 53 Stamping Startsignal __ C Param signal z Fi Cvobrirt a IC gt w CED ss EN d belt Qum gt a 01201 amp larmText 01201 amp larmText 2534 Manual transfer 17 01 58 eg 100 p homed HCh PLACE ATTENTION Before starting manual control make sure it is safe to do so Make sure the vacuum head cannot collide with eggs trays or machine parts TIP When the vacuum head carries eggs and the vacuum is switched OFF the eggs fall down Page 56 of 126 USER MANUAL SMARTPACK EJ e rnnzen INFEED MANUAL SCREEN Egg belts contact After touching and holding this button a release signal is sent to the egg collecting conveyor which starts this conveyor Infeed belt After touching this button the optional extra infeed conveyor upstream of the Smartpack starts running as long as this button is touched Infeed belt After touching this button the infeed conveyor starts running as long as this button is touched ROL CUP MANUAL SCREEN Infeed belt After touching this button the infeed conveyor starts running as long as this button is touched Stamping After touching this button the stamping unit makes one complete step including coding the eggs OvoPrint motor After touching this button the printer makes one complete step including coding the eggs RolCup belt By touching this button the roller track and cup conveyor start running
25. 58 LOAD Backup settings from LISB to CF 2 compact Flash Existing file on CF will be overwritten BACKUP Load settings from CFizcompact Flash to USB Existing settings on the USB will be overwritten Di T xxx ED LE xxx Factory Actual USB CF USB gt CF Page 62 of 126 USER MANUAL SMARTPACK D e rnnzen LINE SETTINGS Directory 40 After touching this button the save machine settings screen appears USB stick 41 After touching this button the save machine settings to USB stick appears SAVE MACHINE SETTINGS Load Factory CF to PLC After touching this button all the machine settings are restored to the factory settings Load Actual CF to PLC After touching this button all the saved machine settings are restored Backup Factory PLC to CF After touching this button the machine settings are saved as the factory settings This button is only available for the Prinzen service and software engineers and is normally only used in the factory Backup Actual PLC to CF After touching this button the actual machine settings are saved USB STICK Inside the operating panel on the rear side of the touchpanel it is possible to plug in an USB stick 42 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 Load Factory USB to CF After touching this button the factory settings are copied fro
26. 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 Smartpack Manual revision 04 October 2013 This manual is originally written in English Should you come across unforeseen language or editorial errors please inform us 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 Weverij 18 7122 MS Aalten Netherlands 1 Tel 31 0 543 490060 P rinzen Fax 31 0 543 476205 Machine type ABCDE Rated voltage 3 N 50Hz 400 230V Max prim fuse 3x 995A Serial number AB1234 Date 08 2010 www prinzen com UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 11 of 126 INTRODUCTION p rinzen SYMBOLS Symbols are used in the manual when special attention caution is required while working on the system The special symbols and their meaning are depicted in the below table Meaning DANGER This symbol is used when instructions shoul
27. An error occurred during saving the network IP address Contact Prinzen 1 MININ Message line network set netmask incorrect An error occurred during saving the network subnet mask Contact Prinzen 106 Message line network set gateway incorrect An error occurred during saving the network gateway address Contact Prinzen Message line network get IP adress incorrect An error occurred during reading the network IP address Contact Prinzen 108 Message line network get netmask incorrect An error occurred during reading the network subnet mask Contact Prinzen 109 Message line network get gateway incorrect An error occurred during reading the network gateway address Contact Prinzen Message line network get node number incorrect An error occurred during reading the node number of the PLC Contact Prinzen Flash 7 Message backup directory file not present on USB Stick or The USB stick is not present or not present in the required port is not placed 312 00 Error infeed mode watchdog end auto 315 00 Message egg infeed full pressure control Therearetoo many eggs at the infeed gates Decreasetheeggflowtotheinfeed S O 322 Error Rolcup mode watchdog end auto The stop button has been pressed but the roller track and cup Check proximity switch for defects conveyor remain running This may be cause by the step Check drive motor for defects detection proximity switch or by the drive motor Check frequency inver
28. Change recipe outteed 17 01 53 Bottom tray mechanism Ott UM SMP 04 E 10 2013 USER MANUAL SMARTPACK OPERATION CHANGE RECIPE TRANSFER Arrow buttons 70 With the left right arrow buttons it is possible to manually move the transfer to the correct position for picking up or placing eggs The stop positions of the transfer are displayed in degrees Pick This parameter determines the position of the transfer for picking up the eggs from the cup conveyor The suction cups of the vacuum head should firmly touch the eggs Pick Wait This parameter determines the position of the transfer when it is waiting above the cup conveyor for eggs Place Wait This parameter determines the position of the transfer when it is waiting above the tray conveyor for placing eggs in a tray Place This parameter determines the position of the transfer for placing the eggs in the tray The vacuum head should be able to gently place the eggs in the tray without damaging eggs Place 71 This parameter determines the position for switching OFF the vacuum suction valve It is the number of degrees before the transfer reaches its place position CHANGE RECIPE DENESTER Maximum number of tries denesting It may happen that the denester fails to place a tray on the tray conveyor at its first attempt This parameter determines the amount of repetitions the denester makes try to release a tray before the system malfunctions CHANGE R
29. E e p rnnzen PRINTER Problem There is no ink coming out of the cartridge If there is still ink in the cartridge and looks liquefied it may be that the nozzle of the print head is dehydrated Solution Put the cartridge with the print head up and sprinkle some drops of Prinzen Cartridge Clean on the print head Leave the liquid for a few minutes then dab dry with kitchen tissue If this doesn t give you the expected result leave the cartridge for an hour in a dish with some Prinzen Cartridge Clean Please note that only the print head should be in the liquid Prinzen Cartridge Clean is specially designed for cleaning the print head without impairing it Other cleaning products may dissolve the components shortening the life span of the cartridge ROLLER TRACK ACCESS For cleaning and maintenance purposes it is possible to remove the roller shafts from the bottom side of the roller track 1 Push the transport chain towards the side of the system 2 Pushthe roller shaft towards the other side of the system and remove it Page 92 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 P rinzen UM SMP 04 E 10 2013 PREVENTIVE MAINTENANCE FILTER ELECTRICAL CABINET On some systems an air inlet and air outlet may be present A filter is placed in these inlets and outlets When this is the case check the filters once a month for contamination and replace them with a clean fi
30. ECIPE OUTFEED Bottom tray mechanism ON OFF Here it is possible to determine if the optional bottom tray mechanism should be used Page 71 of 126 OPERATION p nen SWITCHING THE SYSTEM ON START UP PROCEDURE 01201 AlarmText 01201 AlarmText 2234 Mainmenu START STOP O EU 20000 EG DANGER On a daily basis the operator has to check the safety provisions before starting the machine Make sure no persons are in danger CAUTION Make sure no persons are working near the p machine before you start it up Pe STOP Make sure all protective covers are in place ATTENTION Make sure no tools or other objects are present inside the system ARRET REMISE WARCHE HOT AUS j ARRETDURGEHCE ATTENTION Before starting the system make sure maintenance is performed according to the maintenance instructions further on in this manual Follow below steps to power on and start up the system 1 Switch the system ON 2 Fil the denester bunker with trays Place the trays with the tray grip pointing towards the front rear side of the denester TIP When the trays in the stack are packed tightly haet r into each other knock the stack loose before 127 ae filling the bunkers denester See 3 Make sure all emergency buttons are 6651 released and all safety screens are not interrupted 4 Press the reset button
31. H 01201 A amp larmText 01201 A amp larmText 234 Software Infeed 17 01 59 o kA D Page 60 of 126 USER MANUAL SMARTPACK p rinzen SERVICE INTERVAL In this screen it is possible to enter a service action message and an interval counter for this message Service description After touching this window a key pad appears Enter a service action message for example grease rod ends Set point Enter the service interval This is an amount of handled eggs After the entered amount of eggs has passed the service action message appears on the touchpanel Egg counter Here the amount of handled eggs since the last reset is displayed Reset When a service action message appears on the touchpanel first perform the service action and after this touch the corresponding reset button Its egg counter will be reset SOFTWARE MENU Here it is possible to select a certain unit and in the appearing screen view information about the status of the software The software screens show information about the status of the software and are intended to be used by experienced users of the system like software engineers or Prinzen service engineers During contact with a Prinzen service engineer to solve a breakdown you may be asked to pass on information from these screens UM SMP 04 E 10 2013 p rinzen 01201 AlarmText 01201 AlarmText 2234 Machine settings 17 01 58 e 7 9 5 is tt ATTENTION
32. MARTPACK UM SMP 04 E 10 2013 P rinzen MACHINE DESCRIPTION Safety The packer is not completely secured with protective covers 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 cup conveyor Transfer lever with vacuum head Never touch these parts of the packer when it is running production The cover above the flap shaft transfer position of eggs from roller track to cup conveyor has a safety switch Opening this cover stops the packer immediately The transfer lever with vacuum head makes unexpected fast and powerful movements Never touch or come near this part when the packer is running production CAUTION Keep distant to the transfer lever with vacuum head It makes unexpected fast and powerful movements 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 SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 21 of 126 MACHINE DESCRIPTION p rinzen VACUUM HEAD Use The vacuum head is designed to pick up eggs from the cup conveyor and place those eggs into the trays on the tray conveyor Construction The vacuum head consists of 1 Vacuum head holder 2 Vacuum hose connecti
33. TASTOP 17 01 53 2UUUUU feles 01201 A amp larmText 01201 A amp larmText 2534 Manual 17 01 58 01201 AlarmText 01201 AlarmText 5534 Service menu VO list Software Service Panel settings UM SMP 04 E 10 2013 OPERATION TOUCHPANEL COLORS The background color 2 of a screen represents the possibility of changing the mode of units Dark gray This color is only present on the main screen Touching a button in this screen immediately Starts or stops a unit Yellow This color is only present on the manual menu Touching a button in this screen immediately sets a unit into the manual mode Light grey This color is present on all other screens Touching a button in this screen does not change the mode of a unit The color of the buttons 3 in the screens except the main screen represent the operating level of the buttons White When a button is white the current operating level is high enough for entering the submenu or activating the button s functionality Black When a button is black the current operating level is too low for entering the submenu or activating the button s functionality To be able to use black button you have to change the operating level USER MANUAL SMARTPACK Page 49 of 126 OPERATION 01201 AlarmText 01201 AlarmText 2534 Password 17 01 58 supervisor level 5 D B S perator ervice nnzen
34. TIVE MAINTENANCE INSTRUCTIONS eerste gege Eed Ee Eege see 95 DAILY PREVENTIVE MAINT gcr M c 95 WEEKLY PREVENTIVE TAIN le 96 MONTHLY PREVENTIVE MAINTENANCE ssc cuicteeastetetetnebtstcaads eege eege 99 ve YEARLY PREVENTIVE MAINTENANCE eege 102 Mz YR a EEN Ne GE 103 CAE AREY PREVENTIVE MAINTENANCE ee 104 6 SEENEN 105 LIST WITH REGCOMMENDED SPARE PARTS sassicnsnitacennnmsnnsanadsensinmesnsnesahecanteuneceneteacaeenebivannetiitanseeennaenndas 107 T xl TE fee 109 INS TUG TION nnn SSSGSCST 112 OPEBPBATION me 113 CPAN INO ETING e E 114 SETTING E 114 SET PAIN EE CIT 115 cle je 115 SE TUNG OF TWO ROWS 116 SERIES leegen 116 ER E 116 wahicizlzisccigi tme 117 MENUSTRUCTUUR cm T M 118 LIST WITH RECOMMENDED SPARE PARTS OVOPRINT esee III etree HH n nnn nennen nnn 119 8 TROUBLE SHOOTING RECETTE 121 GENE RAE ea E R ee 122 SAFETY REGULATIONS E 122 HARDWARE TROUBLE SHOOTING ET 123 Page 6 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 INTROD
35. Touching the button shortly starts and stops the roller track and cup conveyor When this button is touched and hold the roller track and cup conveyor make one complete step and then stop TRANSFER MANUAL SCREEN Pick Place With the left right arrow buttons it is possible to move the vacuum head towards the cup conveyor or towards the trays The vacuum head moves as long as the button is touched Vacuum pump on off With these buttons it is possible to switch the vacuum pump on or off The vacuum pump creates the vacuum which holds the eggs during transport from cup conveyor to tray Vacuum valve Suction Off Blow With these buttons it is possible to control the vacuum that is able to change the air flow direction created by the vacuum pump from suction to blowing Suction is used picking up eggs During placement of eggs in a tray blowing is used UM SMP 04 E 10 2013 p rinzen 01201 AlarmText 01201 AlarmText 2734 Manual denester 17 01 53 denester motor 01201 AlarmText 01201 AlarmText 5234 Manual output t Stopper solenoid Output end conveyor conveyor packer a 01201 amp larmText 01201 amp larmText 225734 Manual stacker 17 01 59 aL aL c Solenoid start 4 SE stacker ai C enable from palletlaader s Outputbelt Output stacker ate conveyor UM SMP 04 E 10 2013 OPERATION DENESTER MANUAL SCREEN Denester motor After touching and holding this
36. UCTION INTRODUCTION UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 7 of 126 INTRODUCTION p rinzen CAUTION This manual must be read by or to each person before that person operates cleans repairs supervises the operation of or uses this machine in any way PRECAUCION Este manual debe ser le do por cualquier persona encargada de hacer funcionar limpiar reparar supervisar el funcionamiento o utilizar esta m quina antes de llevar a cabo dichas operaciones ATTENTION Ce manuel doit tre lu par ou a toute personne avant qu elle ne mette en route nettoie r pare supervise le fonctionnement ou utilise cette machine de quelque maniere que ce soit VORSICHT Jeder der diese Maschine bedienen reinigen reparieren berwachen oder auf irgendeine Weise benutzen soll mu vorher diese Hinweise lesen oder vorgelesen bekommen ATTENTIE Een ieder die deze machine bedient reinigt repareert controleert of op enige andere wijze gebruiken zal dient vooraf deze bedieningsvoorschriften te lezen CAUTELA Il presente manuale deve essere letto da o ad ogni membro del personale prima che tale persona operi pulisca ripari diriga il funzionamento o utilizzi la macchina in qualsiasi modo AVISO Este manual deve ser previamente lido por ou para cada pessoa antes de operar limpar reparar supervisionar a opera o ou utilizar este aparelho de alguma forma BHMMAHME Kaxkgomy KTO coo upaercsa
37. aA 54 IAIN ISP EIN eege rege 55 SERVICE MEN UR ME 58 SWITCHING THE SYSTEM ON START UP PROCEDURE sseem I III n hn Ihn Innere rh h rn r nr rrr nns 12 STOPPING PRODUCTION WEE 13 OPERATION ADJUSTMENT KE 14 GATE BLOCKERS E 74 e Wer EEN 74 UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 5 of 126 TABLE OF CONTENTS p rinzen HERR Ap s C C r e 75 EINE ADIU EME EE 76 TOP EE 76 4 GLEANING geed 77 GERNER E een e E EA EE E ee eee EE REEE ee ee ee 78 SAFETY REGULA TON LE 78 CLEANING D RE ETC IER ELE ME 78 RECOMMENDED KK EE E VE 79 GENERAL CLEANING PROG E DURE wcniudutecnanmaceanesdedeicensedvannnde ARAR Seam AN AREAN ER ARAE AARONA AEAN DRE RENARE AAS 79 CCEA EE AT RVA EE 79 AFTER CLE ANING E 79 CLEANING COMPONENTS ssc nutcuecstactencutds quecnacennentgonteeusd trteaecttnandiactinannacnae quacntentoncantaaetdnbteenacauceteanntereancenes 80 Re Men e TIN e e m 83 CLEANING PACI EE 83 EENEG Tene 83 CLEANING E LE e 84 RE eegen 84 EENEG 84 5 PREVENTIVE MAINTENANIGE sis ceccececcc aut ce deer wceuccqre ces cen dEeEEESSE 85 GENERAL ee eee eer ere Cee nn ar rer ee eee rer ee er er er ee re eer 86 SAFETY REGULATIONS UOTE 86 MAINTENANCE EM E EE 86 RECOMMENDED E e EE 87 GENERAL MAINTENANCE PROCEDURE a 88 TR We Me 88 MAINTENANCE COMPONENTS Aa 89 SEENEN 91 SSC 92 Sief Hee 92 FETE RELE eng ey Be zm rere ere te re ert S 93 PLC BATTERY REPLACEMENT E 94 PREVEN
38. ad Vacuum system Attached to the packer are 9 Electrical cabinet 10 Operating panel CON O1 P W PO Process Eggs coming from the egg collecting conveyor of the house 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 Egg pressure control sensors 20 on the sides of the infeed conveyor prevent accumulation of eggs on the infeed conveyor The eggs run into the infeed gates where they are detected 21 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 on the roller track Because of the shape of the rollers and their rotating movement during each step forwards the eggs move with their pointed ends more towards the outside of the rollers At the main drive position the egg lifters lift the eggs on the round end up while flaps are guiding the pointed end into the cups of the cup conveyor A cup detection sensor 22 stops the system when remaining eggs are detected in between the roller track and the cup conveyor The cup conveyor transports the eggs towards the transfer lever position until the first line of eggs is detected by the start transfer sensor 23 The transfer lever moves down and the vacuum head picks up the eggs and transports them towards an empty tray on the tray conveyor Page 20 of 126 USER MANUAL S
39. alarm history screen appears O12 01 amp larmText 012 01 AlarmText O12 01 amp larmText O12 01 amp larmText 012 01 AlarmText Main screen 22 On some of the screens in the right bottom corner this home button is present After touching it the main screen appears History alarmz 28 09 2007 17 01 58 euDmeni Aarm Historye The Alarm history screen shows the history of all alarms from the system By touching the up or down arrows 23 it is Som d WH Sole D12 OF AlammText possible to scroll through the alarm list om 36d 96 SSH Sh D12 01 S amp TarmText im od S5 96H ch D1 2 01 ATarmText iem 5ed e S amp H seh 012 01 Alarm Text Previous 24 After touching this arrow button the previous screen appears ibm od S5 96H hu D 2 01 Alarm Test im od S5 96H Sev D1 2 01 amp TarmText UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 53 of 126 OPERATION p rinzen 01201 amp larmText 2234 Production 17 01 38 Here it is possible to select a certain unit and in the appearing screen view the performance data of the particular unit Besides this for some units it is possible to run the unit empty Infeed Transfer Stacker Outfeed Production 25 Rolcup Denester After touching the graph button the production trend screen appears in which the processed eggs are displayed in a graph Infeed At the moment there are no produc
40. aning duties Padlock Vacuum cleaner Compressed air Plastic scraper Moistened cloth Water and neutral soap Lubricants CAUTION When using warm water to moisten a cloth make sure the temperature of the water is below 45 C Above this temperature it is possible to incinerate body parts ATTENTION Do not use abrasive cleaning detergents or utensils on non longwearing parts Do not use aggressive cleaning products Use cleaning products with a PH value between 6 and 8 Do not use chlorinated cleaning agents After cleaning with a cleaning product rinse off with plenty of water ATTENTION The system is NOT designed for wet cleaning Do NOT clean the system with water and certainly NOT with a high spraying pistol Only use moistened cloths for cleaning Do NOT clean bearings printers robots electrical parts and pneumatic parts with water NOTE Use H1 classified lubricants These lubricants are approved to use in the food processing industry TIP Prinzen uses Interflon Fin Food Lube Teflon spray and Griffon HR260 Silicone spray d Le E 3 OCA Page 78 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen CLEANING RECOMMENDED CLEANING AGENT Prinzen customers often use Hatchonet cleaning agent for hatcheries for cleaning their systems The supplier of this cleaning agent is Cid lines For safe and correct use of this cleaning agent contact Cid lin
41. are described When an alarm pops up use its alarm code 6 to find the corresponding cause and action in the below table 1012 AlarmText Current Alarms 25 09 2007 17 01 59 Giel 012 01 AlarmText gt O12 01 amp larmText O12 01 amp larmText Oi 01 amp larmText 012 01 AlarmText 3 O12 01 amp larmText 012 01 AlarmText t iA on xum line emergency stop WGA So aE not in eseu LE relay not activated e WS nr y TTS and eh the emergency buttons and press the reset button if this solves nothing check the emergency stop relay Alarm Line no recipe chosen This message only appears after changing over the Compact First select a recipe before starting the system Flash 100 Warning line temperature CPU too high Temperature PLC processor too high 101 Warning line temperature in ENV too high Surrounding temperature PLC too high 02 Warning line backup battery is empty Memory backup battery empty 03 Message line frequency controllers not Ok Thereis a problem with one of the frequency inverter 10 Message Line Password equal 1 j Bychanginga password an equal password was typed Makeupauniquepassword O UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 123 of 126 TROUBLE SHOOTING GUIDE lt o rnzen Message Line Service_Description6 A Prinzen or own defined service message has appeared Read the message Message line network set IP address incorrect
42. arts of the touchpanel depending on the chosen button or screen the system is controllable process settings can be changed or information becomes visible on the screen DANGER Although a lot of safety measures are built into the control of the system Prinzen cannot guarantee that no dangerous situations will occur Before you start the system make sure no persons are in danger DANGER By working on a higher operating level you have more possibilities to control the system manually 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 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 UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 45 of 126 OPERATION p EIDEM Emergency stop button After pushing the red button the complete system stops immediately Only use this button in case of emergencies TIP Only use the emergency stop button for real emergencies Follow the normal stop procedure
43. ay Do this after every 40 hours running production Lubricate other guides 6 monthly with teflon spray Do this after every 200 hours running production Before lubricating clean the guides with a solvent and a soft cloth Do not spray lubricant directly on the guides Use a cloth to apply a film of lubricant on the guides Guides that are cleaned with water need to be lubricated directly after cleaning Page 90 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 P rinzen UM SMP 04 E 10 2013 PREVENTIVE MAINTENANCE STAMPING UNIT INK REFILL Refill the stamps weekly with the special Prinzen ink 1 Pull the stamps from the shaft en place them on a cloth 2 Push the stamp completely down 3 Fill the stamp to 15 mm below the rim with ink 4 Place the stamp back on the shaft ATTENTION Only use the special Prinzen stamp ink It is especially developed for these stamps STAMP HEAD REPLACEMENT The stamp head is a wear part Replace it every 2 months 5 Pull the stamps from the shaft 6 Keep de topside of the stamp closed and compress the spring 7 The stamp head pops off the bellow 8 Clean the bellow with lotion wipes 9 Place the new stamp head on a cloth and position the bellow above it 10 Press the bellow into the stamp head 11 Refill ink as described above 12 Place the stamps back on the shaft USER MANUAL SMARTPACK Page 91 of 126 PREVENTIVE MAINTENANC
44. button the denester motor starts running moving the denester parts up and down OUTFEED MANUAL SCREEN Stopper solenoid As long as this button is touched the stopper solenoid is deactivated Output conveyor packer After touching this button the tray conveyor starts running as long as this button is touched End conveyor After touching this button the optional end buffer conveyor downstream of the tray conveyor starts running as long as this button is touched TRAY STACKER MANUAL SCREEN Solenoid start stacker As long as this button is touched the start stacking solenoid is activated Stacker After touching this button the tray stacker starts running as long as this button is touched Output conveyor After touching this button the tray conveyor Starts to run as long as the button is touched This is the conveyor that transfers the trays to the optional PS4 tray stacker Output belt stacker After touching this button the optional buffer conveyor downstream of the optional PS4 tray stacker starts to run as long as the button is touched USER MANUAL SMARTPACK Page 57 of 126 OPERATION p rinzen 01201 AlarmText SERVICE MENU 01201 AlarmText EE 2734 Service menu 17 01 58 In this menu the user of the system is able to change a number of settings using submenus u Adjust machine Not all submenus are available for the operator db settings or the supervisor Service Panel settings I O lis
45. ch 03 etc Once printing is finished switch off the printer You may then click the cartridge out of the holder by gently pressing the lock clip upwards and remove the cartridge Clean the cartridge and place it in the synthetic cartridge holder provided UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 113 of 126 PRINTER p SE CHANGING SETTINGS Menu In the entire menu stands for Back escape or cursor to left The stands for OK confirm or cursor to right By touching the followed by it is possible to get into the menu There you may change the print text save it under another number or change the font SETTING TEXT Press followed by to access the submenu Now press 1 print text The display asks in which row you would like to record the text The program allows you to program 50 texts or rows The first text you record in row 01 by pressing 01 and confirming with Now you can set the text For example 2 NL 1234501 This is done as follows Press 2 O twice to note a dash Confirm with 3 times 6 to note the N Confirm with 4 times 5 to note the L Confirm with 2 times 0 to note the dash Confirm with Now you press 1 2 3 4H 5 Ot 1 For returning to the menu press twice Now the printer will print the following text in row 01 2 NL 1234501 A second text e g 1 NL 9876502 must be recorded under row 02 1 followed by 02 and then confirming 02
46. ck the functionality of the safety switches Check the functionality of the optional safety screens UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 95 of 126 PREVENTIVE MAINTENANCE e p rnnzen WEEKLY PREVENTIVE MAINTENANCE Weekly Maintenance Interval hours Apply silicon spray on the guides of the moving gates 4x Clean the transport shafts of the cups with a solvent and a soft cloth Apply silicone spray on the shafts Do not spray direct on the shafts but use a cloth to apply a film of lubricant on these shafts TIP Use the dedicated oil holes to lubricate the guides of the moving gates NOTE Keep moving gates free of lubricants to prevent contamination of the eggs NOTE Keep cups of cup conveyor free of lubricants to prevent contamination of the eggs Page 96 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 PREVENTIVE MAINTENANCE P nnzen Weekly Maintenance Interval hours Check the suction cups for damages Apply Teflon spray on the denester rod ends 4x Apply silicon spray on the stoppers plain bearings 4x UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 97 of 126 PREVENTIVE MAINTENANCE e e p rnnzen Weekly Maintenance Interval hours Apply teflon spray on the optional printer rod ends 6x Apply silicon spray on the optional printer guides 2x Apply silicon spray on the optional printer plain bearings 2x
47. consumption Not applicable Air pressure Not applicable Connection Not applicable Weight omartpack 500 kg Tray stacker PS4 250 kg Dimensions Smartpack 300 I x 150 b x 170 h cm Tray stacker PS4 150 I x 70 b x 150 h cm Environment The climate around the machine must have a normal air moisture and a temperature in between 10 C and 30 C During transport and storage the temperature of the system should remain in between 0 C and 45 C The system is not suitable for outdoor use and should not be used in a surrounding containing items having a high flash point or an explosive nature Environment consequences Dismantling and disposal of the system must be carried out by a suitable disposal company which has the required licenses and permits for the state or the country concerned Dismantled materials should be sorted for disposal according to local rules and regulations that may apply Separate all materials like oil and lubrication fluids and discharge them as chemical waste UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 19 of 126 MACHINE DESCRIPTION p rinzen UNIT DESCRIPTION Use PACKER The Packer is designed to receive a random m supply of eggs and assemble these eggs in rows of 6 eggs and place them with the pointed end downwards into a 30 er tray Construction The packer consists of 1 Infeed conveyor Infeed gate Main drive Roller track Cup conveyor Transfer lever Vacuum he
48. cover above the stamping unit is equipped with a safety switch Opening this cover stops the system CAUTION Do not enter objects or body parts into the stamping unit when it is running production ATTENTION Do not enter objects or body parts into the stamping unit when it is running production TIP Do not store the stamps and ink into a room with a temperature below 12 C Below this temperature the ink becomes syrupy resulting in bad coding on the eggs Page 28 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen OPTIONAL SIDE PRINTER B MACHINE DESCRIPTION Use The printer is designed for coding eggs Construction The printer consists of 1 Print heads 2 Print heads frame 3 Drive mechanism The printer is placed above the roller track close to the transfer position of eggs from roller track to cup conveyor Process After a step forward of the roller track the frame with print heads moves backwards to code a row of eggs During the forward step of the roller track the frame with print heads moves forwards again to be ready for coding the next row of eggs Safety The cover above the printer is equipped with a safety switch Opening this cover stops the System CAUTION Do not enter objects or body parts into the printer when it is running production ATTENTION Do not enter objects or body parts into the printer when it is running production
49. ction The tray denester consists of 1 Bunker 2 Top grippers 3 Lower grippers 4 Tray lift 5 Drive mechanism The tray denester is placed on top of the tray conveyor 6 Process Trays are manually supplied into the bunker when the machine is stopped and rest on the top grippers When the start denester sensor 10 on the tray conveyor detects no tray the tray lift moves up while the lower grippers remove 1 tray from the bottom of the stack of trays The tray lift moves down with the tray and places it on 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 Only place new trays when the machine is stopped The grippers make unexpected fast and powerful movements Never touch or come near this part when the system is running production CAUTION Do not enter objects or body parts into the denester when it is running production Keep distant to the grippers These make unexpected fast and powerful movements CAUTION Only refill the bunker with trays when the system is stopped ATTENTION Do not enter objects or body parts into the denester when it is running production Page 24 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 P rinzen MACHINE DESCRIPTION TRAY CONVEYOR
50. d be followed to the letter If not they may result in permanent personal injury or death CAUTION This symbol is used when instructions should be followed to the letter If not they may result in permanent personal injury ATTENTION This symbol is used when instructions should be followed to the letter If not they may cause damage to the system NOTE This symbol advises to use edible products and to work in a hygienically way Disregarding this advice may cause illness TIP This symbol is used as a helpful hint to simplify the execution of certain tasks ADDRESS PRINZEN Prinzen BV Weverij 18 7122 MS AALTEN P O Box 85 7120 AB AALTEN The Netherlands Telephone 31 0 543 490060 Fax 31 0 543 476205 E mail info prinzen com Website www prinzen com Page 12 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 H E EC DECLARATION p rinzen Ge g EC DECLARATION OF CONFORMITY FOR MACHINERY Prinzen B V Weverij 18 7122 MS AALTEN The Netherlands Herewith declares that 1 We are the manufacturer of the egg handling machine on which this declaration applies Brand Prinzen Type omartpack Serial number 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
51. d materials also the operation and maintenance have great impact on the functioning the life soan 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 LE COPYRIGHT Prinzen BV s This document contains confidential information and information protected by FIN Zell 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 lt gt All rights rest with Prinzen BV Aalten The Netherlands S 9 3 Written by Visser Machine Services V wa Sser UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 9 of 126 INTRODUCTION p rinzen GENERAL This manual contains important information concerning safety operation cleaning maintenance and breakdown remedies At all time this manual must be accessible for all personnel working with the system Keep it in a permanent place close to the system When the manual is lost or damaged order a new copy as soon as possible The user of the system should read and understand the total user manual before operating cleanin
52. dry the stamp head at least 15 minutes TIP Depending on your specific production circumstances dab the stamps with lotion wipes before during and after using them ATTENTION Do not use cleaning detergents like thinners or benzene to clean the stamps CLEANING TRAY STACKER Clean the inside of the tray stacker 30 with a plastic scraper and a moistened cloth Remove the drip tray 31 from the tray stacker and clean it with water CLEANING BUFFER CONVEYOR Use compressed air to clean the belt 40 Clean the guides 41 with a plastic scraper and a moistened cloth CAUTION Wear eye protection during cleaning parts of the system with compressed air Page 84 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 PREVENTIVE MAINTENANCE 5 PREVENTIVE MAINTENANCE UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 85 of 126 PREVENTIVE MAINTENANCE e p rnnzen GENERAL Only professionals who are familiar with the installation and its operation may perform maintenance 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 re
53. ds need lubrication weekly Apply Teflon spray after every 40 hours running production Rod ends that are cleaned with water need to be lubricated directly after cleaning UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 89 of 126 PREVENTIVE MAINTENANCE e OG rnnzen PLAIN BEARINGS In the Prinzen systems bronze 1 and plastic 2 plain bearings are used Both types of plain bearings need lubrication weekly Lubricate bronze plain bearings with teflon spray and plastic plain bearings with silicone spray Do this after every 40 hours running production Plain bearings that are cleaned with water need to be lubricated directly after cleaning CHAINS In the Prinzen systems different executions of chains are used transport chains 3 and drive chains 4 Transport chains are chains that transport product carriers for example egg grippers Check those chains monthly for wear and tension and lubricate them every 200 hours running production with teflon spray Drive chains are chains that transfer the rotating movement of one shaft to another Normally these chains have a chain tensioner Check those chains half yearly for wear and tension and lubricate them every 1200 hours running production with teflon spray Chains that are cleaned with water need to be greased directly after cleaning GUIDES In the Prinzen systems several types of linear guides are used Lubricate plastic guides 5 weekly with silicone spr
54. e from the vacuum head and flush it out with water Dry up the hose with compressed air before placing them back CAUTION Wear eye protection during cleaning or drying of the vacuum hose with compressed air TIP Only clean the vacuum hose in case of extreme contamination Page 82 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 P rinzen CLEANING CLEANING INSTRUCTIONS CLEANING PACKER CLEANING INFEED CONVEYOR Clean the infeed belt 1 with a plastic scraper and a moistened cloth or a brush Clean the rear side of the belt with compressed air CLEANING ROLLER TRACK Use compressed air to clean the roller track 2 Remove persisting scrap with a moistened cloth CLEANING CUP CONVEYOR Use compressed air to clean the cup conveyor 3 Remove persisting scrap with a moistened cloth CLEANING DRIP TRAYS Remove the drip trays 4 from underneath the packer and the transfer position and clean them with water CLEANING TRAY CONVEYOR Use compressed air to clean the belt 10 Clean the guides 11 with a plastic scraper and a moistened cloth CAUTION Wear eye protection during cleaning parts of the system with compressed air UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 83 of 126 CLEANING p rinzen CLEANING STAMPING UNIT Clean the stamp heads 20 daily before and after use with lotion wipes Clean extremely polluted stamp heads with warm water or spirit Afterwards
55. e plate Safety The PS4 tray stacker is equipped with protective covers and a safety door The entry for the trays is protected by a cover Be cautious with loosely hanging clothes and long hair do not come too close to the tray stacker and do not touch it when it is running production The door above the exit of the tray stacker is protected with a safety switch Opening this door stops the tray stacker immediately CAUTION Do not enter objects or body parts into the entry or the exit of the tray stacker when the system is running production Keep distant to the tray stacker It makes unexpected fast and powerful movements USER MANUAL SMARTPACK ATTENTION Do not enter objects or body parts into the entry or exit of the tray stacker when the system is running production UM SMP 04 E 10 2013 P rinzen MACHINE DESCRIPTION OPTIONAL BUFFER CONVEYOR Use The optional buffer conveyor receives stacks with trays from the tray stacker and buffers these stacks until they are manually removed Construction The buffer conveyor consists of 1 Belt 2 Drive mechanism Process Stack with trays are supplied by the tray stacker on the buffer conveyor which runs start stop to buffer as many stacks as possible As soon as the sensor 3 at the entrance of the conveyor detects a stack the belt starts to run until the stack has passed this sensor Then the belt stops agai
56. e safety switch opposite the safety screen The Banner Easyscreen may display 4 In that case it is not possible to reset the safety screen the system should be switched OFF 332 05 Error transfer power supply encoder is not OK Standard alarm for encoders The encoder board of the PLC has Check the counter boards DC1196 or DC 1396 for defects no 24 Vdc power supply 1332 06 Error transfer encoder has not detected movement At the moment this message is not in used and cannot appear At the moment this message is not in used and cannot appear appears Check the encoder for defects Check home sensor proximity switch for defects W Error transfer movement over software end switch According the controller the transfer arm is located underneath Check the encoder for defects the cup conveyor or transport conveyor When the transfer arm is manually moved beyond the software end switches move the transfer arm manually back The transfer arm position should be within 95 cup conveyor maximum position and 95 transport conveyor maximum position 332 10 Error transfer position data not set correctly The recipe data for the transfer arm positions stop above cup Contact Prinzen conveyor stop above transport conveyor etcetera is outside the limits 332 11 Error transfer Can t set zero position arm is not homed It is not possible to use the machine settings transfer screen Home the system before starting to r
57. e tray stacker again by closing the door pressing the local reset button and subsequently the local start button Stop By pressing the stop button you will stop the optional tray stacker It stops after finishing certain internal controlling cycles Thus it may take some time before this unit is completely stopped Pressing this stop button twice stops the system immediately Reset After opening the safety door of the tray stacker only the tray stacker stops Before it is possible to start it again first close the door and afterwards push this reset button When the blue reset light is ON the de stacker door is opened TRAY DENESTER TIP O0 AUTO es With this selector switch it is possible to switch the tray denester ON AUTO or OFF 0 Beside this it is possible to manually control the tray denester by activating the TIP button Q DENESTER UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 47 of 126 OPERATION D EN ono 1700 OPERATING SCREENS P rinzert After switching on the system with the main switch the start up screen appears SmartPack W212 After touching this 1 button the main screen appears 30 KEYPAD After touching yellow windows the alongside keypad appears Enter a correct value and confirm it with the V button m Page 48 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen 01201 amp larmText 01201 amp larmText 234 Mainmenu STAR
58. eneuesseunesnenenssaneeaes 17 SEET 17 KR Gelle TEE Oe Te ae 19 UNIT DESC iie Wii NEE 20 PACKER EE 20 VACWVUMIHE A NEE 22 VACUUM SYS IEM ee 23 TRAY DENESTER eege a a a A 24 MN eel e CO ENEE 25 EIERE IRAY STACKER Ee 26 OPTIONAL BUFFER CONVEYOR erster Seege 27 OPTIONAL cO deg H CIE 28 ei Gate UI Pra NIU ER 29 OPTIONAL ROUND END PRINTER ER 30 2 BA EE 31 GENERAU EE 32 SAFE IY Ee RK an Tei 33 SAFE IY PROVISIONS EE 35 SAFETY INSPECTION PROCEDURE EE 38 POSITIONS SAFETY DEVICES EE 39 WARNING LABELS EE EE 40 3 OPERATION WEE 43 SAFETY REGULATIONS cccccecccceeccceecceceenceeuneeeeeneeeuneeeeeneesaneeenaneeeuneeeanaeseunneennneeeunneeeuneeeanneeeunetennnenauaes 44 EXPLANATION OF THE ORBERATION m n In mmn Ihn hnhR mehr hrh hr hnrnrrne erue r rrr nennen nr rn 45 OPERATING S RE 45 LOCAL EMERGENCY STOP unt el LEE 46 Be erm NH Le im EE 47 OPTIONELE TRAY STACKER RE 47 TRAY IDEN ENEE MR O X PVME 47 POPE ING SN eege 48 eil d EE 48 uelle eso OO o 49 PASSWORD SCREEN MEE ETE 50 MAIN SCREEN eu EEN EE 51 ALARMS SGREEN RETE ee SC EE EE EE tates siecle DEER E ER EE EE ER cei utes enews AER E EE EAR EE EE e 53 PRODUGTION MENU rete n c n D D eni
59. erent recipes for different tray types After touching this button the recipe menu appears Via this menu it is possible to choose copy or change recipes UM SMP 04 E 10 2013 USER MANUAL SMARTPACK OPERATION In the main screen the operator is able to control the system On the main screen the following information is visible Alarm message line 10 On the top of the screen the alarm messages may appear when the system needs assistance See trouble shooting for possible alarms that may popup Alarm screen 11 On all screens the alarm screen button is available After touching this button you will enter the alarm screen Eggs hour Here the average amount of packed eggs per hour is displayed Eggs Here the Total amount of packed eggs is displayed With the reset button it is possible to reset this counter Buttons 12 With the buttons it is possible to switch parts of the system ON or OFF Beside this the buttons indicate the status of these units White Unit is not running Light green Unit is running Light green flashing Unit is stopping Dark green Unit is initializing Red Unit has a breakdown Yellow Unit is in manual mode infeed This button activates the infeed conveyor With this button it is also possible to start the egg supply from a long egg collecting conveyor After touching this button the infeed conveyor and the upstream egg collecting conveyor start running These conve
60. es Visit their website to find a local dealer www cidlines com Prinzen recommends this cleaning agent instead of others but we cannot verify the correct use of it and thus we cannot guarantee a good cleaning result and avoiding negative influences of it on our systems GENERAL CLEANING PROCEDURE Read the below general cleaning procedure to clean the system For specific cleaning instructions see the cleaning instructions further on in this chapter See to it that all products eggs trays are removed by letting the machine run empty Switch off the system and secure it against accidental switching on Clean the complete system with a vacuum cleaner compressed air a dry cloth and a plastic scraper Remove persisting scrap with a moistened cloth Clean the floor underneath and around the system Check the condition of the cleaned parts during cleaning CLEANING INTERVAL Remove all dirt inside and around the system after every 8 hours running production Clean the system thoroughly after every 40 hours running production and afterwards lubricate the moving parts according to the preventive maintenance instructions further on in this manual TIP The cleaning advices and cleaning intervals described in this manual are general For your specific products and production process the cleaning schedule may need alteration During the first production months observe the contamination of the system and the influence of t
61. eset the zero position of the vacuum because the system is not homed head transfer lever 332 12 Error transfer Can t set zero position machine not stopped It is not possible to use the machine settings transfer screen Stop the system before starting to reset the zero position of the vacuum because the system is not stopped head transfer lever 332 13 Error transfer Can t set zero position is the arm straight up It is not possible to reset the zero position of the vacuum head First move the vacuum head to its highest position or 5 degrees before transfer lever because the vacuum head is not in its highest touching the reset zero position button position 335 Message transfer no tray present The transfer arm is stopped at its waiting position above the Check why there is no tray present transport conveyor waiting for a tray 01 01 02 Message transfer simulation mode active The Simulation button in the change recipe transfer screen is After touching this button again the message disappears touched Erroroutputconv mode watchdog end auto The stop button has been pressed but the outfeed did not finish its Press the reset button and subsequently the start button movement Check why the outfeed conveyor is full with trays 01 Output conveyor is full The outfeed conveyor upstream the tray stacker is full Check why the outfeed conveyor is full with trays Output machine running clear and tray is
62. g 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 p
63. ge required to perform this work These persons are NOT under influence of any drug medicine or alcoholic drink DANGER Keep children and incompetent persons away from the system The system is only to be used for the purpose it was designed for See the chapter Machine description for details Page 32 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen 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 breakdown
64. ged appears on the screen In that case do not power off the system until you are going to replace the battery Battery replacement procedure 1 When the system is turned OFF turn the power ON and leave it ON for at least 10 minutes 2 After atleast 10 minutes power ON turn the power OFF Now within 10 minutes replace the old battery with the new one 3 Touch the housing or other ground connection to discharge any electrostatic charge from your body Remove the cover of the battery at the rear side of the touchpanel 4 Carefully pull the strip out to remove the old battery Do not touch the battery on its edges 5 Carefully place the new battery into the MEME TO AHNE ERST EMI MUR battery slot Make sure the strip remains CepbiiHblt HOMER underneath the new battery and sticks me Se of e slot for the next Medie 6 Close the cover and switch ON the power TeMneparwvpa ENY 25 BIS li Do T supply cocTo sme Darapen 7 Check the battery status in the CPU KONMYECTEO EKN H BEBIKPIOHSHHH screen Make sure OK is displayed CHETUMK AML Used batteries must be discharged as chemical waste Page 94 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 e PREVENTIVE MAINTENANCE p rnnzen PREVENTIVE MAINTENANCE INSTRUCTIONS DAILY PREVENTIVE MAINTENANCE Daily Maintenance Interval hours Observe for abnormal sounds vibrations and heat Check the functionality of the emergency stop buttons Che
65. his contamination on the product quality and production process and if necessary change the cleaning methods and schedules AFTER CLEANING When the cleaning duties are finished follow steps below Consult your maintenance engineer in case of questions about the condition of parts Blow dry the system the system must be absolutely dry before putting it back into operation Lubricate moving parts that have been cleaned Remove excess grease after lubrication Make sure all cleaning utensils are removed from the machine UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 79 of 126 CLEANING p rinzen CLEANING COMPONENTS CLEANING PHOTO SWITCHES Clean the lenses of the photo switches 1 and the reflectors 2 with a moistened soft fluff free cloth CLEANING SAFETY SCREENS Clean the lenses of the safety screens 3 and the surface of the accompanying mirrors 4 with a moistened soft fluff free cloth Page 80 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen CLEANING CLEANING SUCTION CUPS To clean the suction cups 10 remove them from the vacuum head and let them soak in warm water maximum 40 C until the dirt becomes soft this may take a few hours After this rinse off the suction cups with water to clean them Dry up the suction cups with compressed air before placing them back CAUTION Wear eye protection during cleaning
66. isplay now shows 2 different rows E g 11 1 NL 1234501 36 THT 21 07 These texts should be put in row 11 1 NL 1234501 And row 36 THT 21 07 These two rows should now work together thus 2 NL 1234501 THT 21 07 2 NL 1234501 THT 21 07 SET CLEANING TIME Press followed by to access the submenu Now press 2 user functions and press 3 Nozzle cleaning Now you can set the time in minutes so the printer will give a start pulse on its own This is a standard notation on 30 minutes and will give a start pulse just once Now press 3 times to return to the main menu SET SHORT KEY Press followed by to access the submenu Now press 2 user functions and press 4 Index print text Now you can choose 1 for 1 number 1 digit 2 for 2 numbers 2 digits After making a choice confirm with and 3 times to return to the menu If the programmed number needs to be changed often press just a 1 instead of 01 Page 116 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 e e PRINTER p nnzen CHANGE PRINTER SETTINGS Press followed by to access the submenu Now press 3 Technician Display asks for a Pin code You can get a pin code from your dealer to access the change of settings Warning Incorrect settings can cause the printer to malfunction Press pin code You are now in the technician menu 1 Basic parameters 1 Device Type 2 Heads Channel 3 N
67. k up battery status shows the status of the battery When the battery becomes exhausted not OK appears In that case do not power off the system and contact Prinzen for the exchange procedure of the battery or see PLC battery replacement procedure Power up cycles The amount of power up cycles switching ON the system is displayed here Egg counter The amount of processed eggs is displayed here USER MANUAL SMARTPACK Page 67 of 126 OPERATION OG pem TOUCH SCREEN SETTINGS SCHEEN 01201 A amp larmText 01201 A amp larmText 2534 Touch screen settings 17 01 53 With the contrast buttons 60 it is possible to adjust the contrast of the display With the brightness buttons 61 it is possible to adjust the brightness of the display After touching the orientation button 62 you can calibrate the touchpanel part of the display Dots appear on the screen Touch these dots with a pointed but not sharp object 63 After touching the last dot the touchpanel part of the display is calibrated ATTENTION It is forbidden to press on the Touch Panel with sharp objects because this may also damage the Touch Panel TIP The touchpanel is calibrated in the factory Because of this normally it is not necessary to calibrate the touchpanel NETWORK SCREEN UE T In this screen it is possible to enter the IP ip address addresses to be able to communicate with an netmask external computer via a
68. letely stopped and push an emergency stop button Push the start button the machine should not start Release the emergency stop button and reset the emergency circuit Repeat the above steps 2 3 and 4 for all emergency stop buttons Make sure that the machine does not start when any emergency stop button is pressed Check safety switches 5 Start and stop the system Wait until the system has completely stopped and open a safety door or safety cover Push the start button the machine should not start Close the door or cover and reset the emergency circuit Repeat the above steps 2 3 and 4 for all doors and covers Make sure that the machine does not start when a door or a cover is opened Check safety screens 6 1 Start and stop the system Wait until the system has completely stopped and Interrupt a safety screen Push the start button the machine should not start Reset the emergency circuit Repeat the above steps 2 3 and 4 for all safety screens Make sure that the machine does not start when a safety screen is interrupted GE s te Des OO Pe TO If the machine operates when a safety device is activated this machine is not safe to operate Immediately call a qualified technician to repair this defective safety device 4 Page 38 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen SAFETY POSITIONS SAFETY DEVICES See below picture for position of the safety devices UM SMP 04 E 10 2013
69. lter if necessary Follow below procedure to replace the filters of the electrical cabinet 1 Stop the system 2 Switch OFF the main switch on the electrical cabinet 3 Open up the filter holder by pulling the clip on the topside 4 Replace the contaminated filter in the filter holder by a clean filter 5 Take note of the filter orientation The arrows should point towards the electrical cabinet and the TOP text should be up 6 Close the filter holder again CAUTION Always switch OFF the main switch before opening the filter holder USER MANUAL SMARTPACK Page 93 of 126 PREVENTIVE MAINTENANCE e p rnnzen PLC BATTERY REPLACEMENT Battery replacement Parameter settings of the system are stored in the memory of the PLC When the system is not powered ON the power for the memory is supplied by a battery A 1 ATTENTION During normal circumstances never remove the battery Without battery data may be lost resulting in malfunctioning of the system To prevent loss of the parameter settings replace this battery of the PLC every 2 years Try to have a spare battery on stock before the 2 years have passed The battery is a long lead item but keep in mind that a battery on stock is leaking juice so do not keep a battery on stock for more than 1 5 years Battery type CR2477N 3V Prinzen part number 8001500340 In case the battery is exhausted the message Battery dischar
70. m the USB stick to the CF Load Actual USB to CF After touching this button all the saved machine settings on the USB stick are copied to the CF Backup Factory CF to USB After touching this button the factory settings are copied from the CF to the USB stick Backup Actual CF to USB After touching this button the saved machine settings are copied from the CF to the USB stick UM SMP 04 E 10 2013 p rinzen 234 Machine settings Packer kA Infeed stop delay Infeed start delay 22 5 infeed stop on 1 or 2 photasensorz smartpack infeed H 01201 AlarmText 01201 AlarmText 22534 Machine settings Packer Cupdetection with Photosensor Off Transfer with Photozensoar only 30 cell tray Ott Smartpack printer H UM SMP 04 E 10 2013 OPERATION INFEED SETTINGS SCREEN Infeed stop delay The infeed stop delay is the time between the egg pressure control sensors both detecting eggs and the stop of the upstream egg collecting conveyor When this timer is too short the egg collecting conveyor stops too often When this timer is too long too many eggs enter the infeed conveyor of the Smartpack causing too much pressure on the gates Infeed start delay The infeed start delay is the time between the egg pressure control 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 I
71. m valve use replacement set TIP See Service manual for replacement procedure vacuum valve seals and springs USER MANUAL SMARTPACK Page 103 of 126 PREVENTIVE MAINTENANCE e p rnnzen 2 YEARLY PREVENTIVE MAINTENANCE 2 Yearly Maintenance Interval hours h Replace the touchpanel internal back up battery 4800 TIP When the internal back up battery of the PLC is empty the system will malfunction and needs to be re tuned by a specialist from Prinzen TIP Although the back up battery has a lifetime of approximately 5 years Prinzen advises to replace the battery during a two yearly maintenance Page 104 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 SPARE PARTS 6 SPARE PARTS UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 105 of 126 p rinzen SPARE PARTS LIST WITH RECOMMENDED SPARE PARTS Part number Recommended Description 4000200073 4000200074 4100300006 5702300190 6201100003 6400400007 6400700013 7000100034 7000100036 8001000020 8001100036 8001300004 8001300017 8001500340 8001600014 8001600016 8001600017 8001600033 8001600160 i Egg holder Chain block Suction cup 40 shore black Filter electrical cabinet Vacuum hose 25mm Vacuum filter cartridge Seal kit vacuum valve Chain for roller track Chain for cup track Brake relay Frequency inverter V1000 Power supply 24V 5Amp Power supply 5V 1Amp Batte
72. n This sequence is repeated until the sensor 4 at the end of the belt detects a stack Then the belt stops The tray stacker pushes one more stack on the entrance of the belt When the next stack is ready for unloading the tray stacker also stops After removal of stacks from the buffer conveyor the buffer conveyor starts again Safety The buffer conveyor is not completely secured with protective covers Therefore be cautious with loosely hanging clothes and long hair do not come too close to the buffer conveyor and do not touch it when it is running production Pay special attention to the belt Never touch it when the system is running production CAUTION Do not enter objects or body parts into the buffer conveyor when it is running production ATTENTION Do not enter objects or body parts into the buffer conveyor when it is running production UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 27 of 126 MACHINE DESCRIPTION p SE OPTIONAL STAMPING UNIT Use The stamping unit is designed for coding eggs Construction The stamping unit consists of 1 Shaft with stamps 2 Hinging frame 3 Drive mechanism The stamping unit is placed above the cup conveyor close to the transfer position of eggs from roller track to cup conveyor Process After a step forward of the roller track and the cup conveyor the shaft with stamps moves down to code the row of eggs in the cup conveyor Safety The
73. n Internet connection gateway Normally these addresses are entered by eee errs T Prinzen engineers and are for information only In case it is necessary to change these addresses ask your network administrator to do this Page 68 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen 01201 AlarmText 01201 AlarmText 2234 Recent menu 17 01 58 01201 A amp larmText 01201 A amp larmText 2234 Choose Recipe 17 01 58 01201 amp larmText 01201 amp larmText 2234 Copy recipe 17 01 58 source recipenumber Destination DU Set JL recipenumber PSP UM SMP 04 E 10 2013 OPERATION RECIPE MENU In a certain recipe all the settings for a particular tray type are stored Via this menu the user of the system is able to select copy or change a recipe using submenus Choose recipe After touching this button the choose recipe screen appears where it is possible to select a recipe Copy recipe After touching this button the copy recipe screen appears where it is possible to copy the parameter settings of a particular recipe to another recipe This screen is not available for the operator Change actual recipe After touching this button the change recipe menu appears Via this menu it is possible to change the parameter settings of the current recipe This screen is not available for the operator CHOOSE RECIPE SCREEN Here it is possible to select a different recipe After
74. nce more to stop the roller track and cup conveyor 6 Manually remove the partially filled trays 7 Touch the empty tray stacker button 8 Wait until all trays are removed from the optional tray stacker 9 Wait until the optional tray stacker has stopped After the last incomplete stack is pushed out of the tray stacker the tray stacker makes a number of steps until it has completed its cycle Do not interrupt this cycle TIP The tray stacker has to finish its complete cycle to stop in the right position for the next production run 10 Press the stop button 11 Wait until all movements of the system are stopped 12 Switch the system OFF UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 73 of 126 OPERATION p GER OPERATION ADJUSTMENTS GATE BLOCKERS Gate blockers 1 and 2 prevent the possibility of 2 smaller eggs entering 1 gate As long as smaller eggs are produced keep the gate blockers on the stationary gates 1 and on both side guides 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 Gate flaps 4 prevent the possibility of a 2 egg rolling above the 17 egg in the gate at roller track transfer position Adjust the height of the gate flaps with the adjustment knob 5 Turn the knob clockwise to lower the flaps for smaller eggs S Turn the knob counter clockwise to raise the fla
75. nfeed stop on 1 or 2 photo sensors Here it is possible to select 1 or 2 When 1 is selected the infeed conveyor stops when 1 of the egg pressure control sensors detects eggs for a longer time the infeed stop delay time When 2 is selected both egg pressure control sensors have to detect eggs for a longer time the infeed stop delay time before the infeed conveyor stops ROL CUP SETTINGS SCHEEN Cup detection with photo sensor Here it is possible to switch the cup detection sensor OFF As a result the system no longer checks the correct transfer of eggs from roller track to cup conveyor Transfer with photo sensor Here it is possible to switch the start transfer sensor OFF Because the controller tracks the eggs on the cup conveyor still at the right moment the eggs will be transferred from the cup conveyor to the trays Smartpack printer Here it is possible to select the type of egg coding device that is present on the system Stamping unit cup printer or side printer When no egg coding device is present on the system none should be selected USER MANUAL SMARTPACK Page 63 of 126 01201 AlarmText 01201 AlarmText 2734 Machine settings transfer 17 01 58 encoder 29990 Reset Zeropos homed PICK LACE SERE RT DREES 2734 Machine settings packer autfeed conveyor 17 01 53 run time autfeed space between trays oso 5 run time outteed after taking tray oso 5 stopdelay at end 2nd belt os
76. not full Press The system is running empty and the last filled trays are not Remove the partially filled trays manually You can also press the start start to release tray completely filled button In that case the partially filled tray enters the tray stacker Eed Error denester mode watchdog end auto n stop n has been pressed but the denester did not finish its movemen UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 125 of 126 TROUBLE SHOOTING GUIDE lt o 352 Error denester max number retries no tray out The denester has made its set amount of repetitive movements Check why no tray has been dropped but still there is no tray detected Check the stack of trays Turn the stack of trays rnzen 07 Error denester watchdog denester motor runs too long The denester motor remains running Check the proximity switch for defects finish its movement within 10 seconds 62 The tray stacker is started but after a few seconds the start Check if the tray is dropped from the grippers stacking sensor is still detecting a tray Check the start stacking sensor for defects 62 02 Alarm stacker door not closed The safety door of the tray stacker is opened or its safety switch J Open and close the safety door subsequently press the reset button Check the emergency stop relay for defects The outfeed conveyor of the tray stacker is full with stacks Remove the stacks o ll Page 126 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10
77. o 5 Page 64 of 126 USER MANUAL SMARTPACK OPERATION p SE TRANSFER LEVER SETTINGS Transfer movement 45 With the left right arrow buttons it is possible to move the vacuum head to its Zero position This is the highest position in between the cup conveyor and the tray conveyor Reset Zeropos After positioning the vacuum head exactly in the top position touch this button reset the encoder OUTFEED SETTINGS SCREEN Run time outfeed This timer is used when an optional end buffer conveyor is present downstream of the tray conveyor It determines the space between the trays on this end buffer conveyor After a full tray is no longer detected on the infeed of the end buffer conveyor it remains running until this time has elapsed Run time outfeed after taking tray The end buffer conveyor stops running when a trays is detected at the end of this conveyor When no tray is coming this timer determines the time the end buffer conveyor remains running after the last full tray was removed from the end of the conveyor Stop delay at end 2 belt This timer determines the time that the end buffer conveyor remains running after a tray is detected at the end of this conveyor Smartpack outfeed Here it is possible to select the configuration of the outfeed of the system Tray stacker pallet loader or 277 outfeed conveyor When there are no systems or unit present downstream of the tray conveyo
78. on 3 Stabilizer 4 Suction cups The vacuum head is attached to the transfer lever Process When eggs are detected at the transfer position the vacuum head moves towards the eggs The vacuum is ON and the suction cups pick up the eggs The vacuum head moves to the tray conveyor above a tray On this position the vacuum changes into blow off to place the eggs into the tray Safety The vacuum head is not secured with protective covers It makes unexpected fast and powerful movements Never touch or come near this part when the system is running production CAUTION Keep distant to the vacuum head It makes unexpected fast and powerful movements Page 22 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen MACHINE DESCRIPTION VACUUM SYSTEM Use The vacuum system supplies the vacuum for the vacuum head Construction The vacuum system consists of 1 Vacuum pump 2 Vacuum valve 3 Vacuum filter 4 Vacuum hoses and pipes Process Via vacuum hoses and pipes the vacuum filter and the vacuum valve the vacuum head is connected with the vacuum pump The valve controls the air flow vacuum during picking up eggs and blow off during placing eggs into trays UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 23 of 126 MACHINE DESCRIPTION p rinzen TRAY DENESTER Use The tray denester separates a single 30 cell tray from a stack of trays and places it on the tray conveyor Constru
79. 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 USER MANUAL SMARTPACK ATTENTION The manual screens should only be used by advanced users of the system like Prinzen engineers for testing the system UM SMP 04 E 10 2013 p rinzen MAIN SCREEN 34 Mainmenu START STOP r a m lranste 300000 Eggs TIP The background color of this screen is dark gray After touching a button in this screen starts or stops the selected unit immediately Production menu 14 After touching this button the production menu appears In this menu the performance of the system amount of packed eggs is visible Manual submenu 15 After touching this button the manual submenu appears in which it is possible to manually control parts of the system Service submenu 16 After touching this button the service submenu appears In this menu the operator is able to change a number of settings using submenus Recipe 17 All the settings that are used by the system to process eggs are stored in a recipe Itis possible to make several diff
80. onveyor Touch this empty roll cup button once again to stop emptying the system Empty tray stacker 19 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 the stacker waits another 3 seconds for trays Then 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 It is not possible to stop emptying the tray stacker After the last incomplete stack is pushed out the tray stacker makes a number of steps until it has completed its cycle and has the right start position for pushing out stacks of 6 trays when the next production run is started Page 52 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen OPERATION Current Alarms 28 09 2007 17 01 58 ALARMS SCREEN 12 01 amp larmText O12 01 AlarmText The Alarms current screen shows all present alarms from the system including its alarm code Use this alarm code to find this alarm and its corresponding cause and action to solve the error in the trouble shooting guide By touching the up or down arrows 20 it is possible to scroll through the alarm list An active alarm is colored red After touching the alarm history button 21 the
81. p for bigger eggs XL Adjust in such a way that the flaps are nearly not touching the produced eggs Page 74 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 P rinzen OPERATION START STOP DELAY Check the pressure control parameters infeed start delay and infeed stop delay for the infeed conveyor When the infeed conveyor of the smartpack is full with eggs from the egg collecting conveyor the egg pressure control sensors 6 at the side of the infeed conveyor are activated When these sensors both remain detecting eggs for a certain time infeed stop delay a signal is sent to the egg collecting conveyor to stop supplying eggs When one of the egg pressure control sensors no longer detects eggs a certain time later infeed start delay 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 infeed start delay and infeed stop delay parameters in the infeed settings screen in this chapter UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 75 of 126 P rinzen BUNKER ADJUSTMENT Make sure there is a free space for the stack of trays inside the bunker 10 It should be possible to easily move the stack of trays up and down inside the bunker 11 Normally a space of 3 mm between the trays and all the side strips is nece
82. paoorarb c naHHOli MALUNHOU YUCTUTb DeMOHTMDOBATE NPOBEPATb UNUM UCNONb3OBaTb ee kak n60 Hause pekoMeHnyercs npex 1e OSHAKOMUTbCA C D aHHHOM MHCTDpykLiAe no 3 cnnyarauM OSTRZEZENIE Niniejsza instrukcja musi zostac przeczytana przez kazda osobe zajmujaca sie obstuga czyszczeniem naprawami nadzorowaniem obstugi lub wykorzystujaca maszyne w inny spos b Page 8 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 o INTRODUCTION p rinzen GE 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 use
83. pply teflon spray on the optional tray stacker pusher control chain Check the optional tray stacker pusher control chain for wear Check the optional tray stacker pusher control chain tension Apply teflon spray on the optional tray stacker stacker plate rotating control chain Check the optional tray stacker stacker plate rotating control chain for wear Check the optional tray stacker stacker plate rotating control chain tension UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 101 of 126 PREVENTIVE MAINTENANCE e p rnnzen V2 YEARLY PREVENTIVE MAINTENANCE VALUA ALAT al Interval hours Check all bearings for wear Check complete system for loose parts bolts nuts etc Apply Teflon spray on the main drive chain Check the main drive chain for wear Check the main drive chain tension Apply teflon spray on the infeed conveyor drive chain Check the infeed conveyor drive chain for wear Check the infeed conveyor drive chain tension TIP When the yellow part on the chain tensioner becomes visible replace the infeed conveyor drive chain Page 102 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen UM SMP 04 E 10 2013 PREVENTIVE MAINTENANCE YEARLY PREVENTIVE MAINTENANCE Yearly Maintenance Interval hours Replace vacuum filter Replace seals and springs in the vacuu
84. r none should be selected Bottom tray stacker Here it is possible to choose between yes or no When the optional bottom tray stacker is present on your system select YES When the optional bottom tray stacker is not present on your system select NO UM SMP 04 E 10 2013 p rinzen space between stacks 1 00 5 run time autfeed after taking stack stopdelay at end output belt PS4 nutfeed Bufferind na OPERATION STACKER SETTINGS SCREEN Space between stacks This timer is available when a buffer conveyor is present downstream of the optional tray stacker It determines the space between the stacks on this buffer conveyor After a stack is pushed out of the tray stacker the buffer conveyor remains running until this time has elapsed Run time outfeed after taking stack The buffer conveyor stops running when a stack is detected at the end of this conveyor When no stack is coming this timer determines the time the buffer conveyor remains running after the last stack was removed from the end of the conveyor Stop delay at end output belt This timer determines the time that the buffer conveyor remains running after a stack is detected at the end of the conveyor PS4 outfeed Here the direction of the buffer conveyor downstream of the tray stacker is displayed There is a straight and a 90 angle buffer conveyor available Buffering Here it is possible to choose between yes or no When NO
85. rinzen USER MANUAL SMARTPACK Prinzen B V Weverij 18 7122 MS AALTEN P O Box 85 7120 AB AALTEN NEDERLAND Phone 31 0 543 490060 Fax 31 0 543 476205 e mail service prinzen com Website www prinzen com TABLE OF CONTENTS TABLE OF CONTENTS CHAPTER BOOK INTRODUCTION 1 MACHINE DESCRIPTION 2 SAFETY 3 OPERATION CLEANING l 5 PREVENTIVE MAINTENANCE 6 SPARE PARTS 7 PRINTER 8 TROUBLE SHOOTING l x ES ex e ES ES m amp E UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 3 of 126 p rinzen TABLE OF CONTENTS INTRODUCTION tunes 7 N E UE EE 9 TT 9 OP VAG NR 9 GENERAU EE 10 SAFETY REGULATIONS wre axes exEaxEtetEtunERE Um MakU PNEU ERE EEEE EAEE EEEE EEANN AINE 10 Bercher HIR Kult LEE 10 HOW TO USE THIS MANUAL EEN 11 WHO SHOULD USE THIS MANUALE 11 MANUAL INFORMATION gege uam a ERREEZERSEERUKSREEREEFRSRRTKNRaERATKEEKKTERRTZSRERRATEEWZERERRERR KRSTERXERERERZMRARSKRREERAYKERERTASKS 11 SERIAL NUMBER EE 11 SYMBOLES EE 12 PO DRE Te e EE 12 EC DECLARATION OF CONFORMITY FOR MACHINERY ssseen n m Ih RI Ihnen hne rne rne r nr nr rrr 13 1 MACHINE DESCRIPTION eorr nnnm EN ENEE EEN ENKEN RR RR RR RR EN ENKE EN ENNEN RR su sue nar ur 15 SAFETY REGULATIONS NE 16 MACHINE DESCRIPTION ccccccccccccccccccnccecanccccnctecauceecneteneneeseanseneueeeeunsenensesuanseneueeseane
86. rmText 01201 amp larmText A 2234 Inputs Line 17 01 59 E Stop relay active Safety Packer OK Inverters OK start button pressed Stop button pressed ee WE Lo EE Reset button pressed Lal e 01201 AlarmText 01201 AlarmText 2234 Outputs Line 17 01 59 Reset relay e stop circuit f gt Reset relay safety stacker Lamp reset button Lamp start button ay GS 2 0 g el H UM SMP 04 E 10 2013 OPERATION LO MENU Here it is possible to select a certain unit and with the appearing screen view the status of its inputs Sensors and outputs motors valves After touching a particular unit first the inputs of this unit are displayed With the left right arrow buttons it is possible to view the outputs of the particular unit As an example below the inputs and outputs of the line are shown In this screen it is possible to view the status of the inputs Sensors and outputs motors valves When the circle in front of the input is green then the input is ON for example the stop button is pressed When the circle in front of the input is not green the input is OFF for example the stop button is NOT pressed USER MANUAL SMARTPACK Page 59 of 126 01201 AlarmText 01201 AlarmText 234 Service 17 01 58 Reset Reset hh Reset Reset Reset Reset 01201 AlarmText 01201 AlarmText 234 Software menu 17 01 58 Infeed Rolcup Transfer Outfeed stacker bh
87. rograms without written permission from Prinzen because this may affect the safety of the machine Only use genuine Prinzen parts or CE certified parts for replacement Prinzen cannot be held responsible for any consequential damages to the system or other installations that were caused by technical changes unprofessional maintenance and repairs on our system which were executed by the customer Warranty becomes invalid when consequential damages to the system caused by technical changes unprofessional maintenance and repairs were executed by the customer DANGER Failure to obey legal regulations may result in permanent personal injury or death ATTENTION Failure to obey legal regulations may result in damage to the system Page 10 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen 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 WHO SHOULD USE THIS MANUAL Owner The owner contractor concern is the person that owns or hires the machine and puts this machine into production The owner must take care that the users of the system will read the manual Operator The operator is the person who operates the system as ordered by the owner The operator must read the chapters Introduction Safety Machine description Operation Cleaning Professional
88. ry for PLC CR2477N 3V Proximity switch Photocell transmitter Photocell receiver Photocell diff Single Photocell diff Double NO sch sch ech Lech o eck Leck 1 sch Jeck Leck NM IM Jeck Leck 1 UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 107 of 126 PRINTER 7 PRINTER UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 109 of 126 P rinzen PRINTER OVOPRINT UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 111 of 126 d PRINTER plazen INSTRUCTIONS Be sure that the printer is fitted on to a stable surface in a reasonably dust free environment Be sure to use a clean and dust free place to store the cartridges after use Do not place printer near any source of direct heat The room temperature should be between 10 C and 35 C The printer and ink cartridges must be kept dry at all times Clean the printer and print head with a dry and dust free cloth When connecting or replacing cables plugs print heads and or switches the power supply MUST be turned off m Page 112 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 e e PRINTER P nnzen OPERATION Ensure that the ink cartridges are clean and dry and that is no ink leakage Place the cartridge in the holder The printer will now print message number 1 To print message number 2 touch 02 on the keyboard for message number 3 tou
89. s 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 are removed from the system Excess lubricant is removed The system is tested before starting production Page 88 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 PREVENTIVE MAINTENANCE P nnzen MAINTENANCE COMPONENTS BEARINGS In the Prinzen systems normally bearings without a grease nipple are used These bearings have a life time lubrication No grease is needed TIP All bearings are sealed and lubricated for life and require no lubrication MOTORS AND REDUCTORS In the Prinzen systems normally motor reductors with a lifetime lubrication are used It is not needed to change the oil TIP All motors are provided with lifetime lubrication and require no lubrication GEARS In the Prinzen systems normally plastic gears are used These gears do not need lubrication 4 P MN All gears are made from plastic and require no 9 lubrication ROD ENDS Rod en
90. s follow the steps mentioned below Switch off the machine and secure it against accidental switching on Post Do not switch on warning sign on the main switch Operate the nearest emergency stop button Make sure that no components are moving Before switching on the machine you must check the following All safety devices are in place and are functioning No other persons are in underneath or above the system No tools or objects are in the system No other persons are at risk Do not use water to clean electricity cabinets and other electronic components For save and easy operation keep the area and floor around the machine clean free of oil grease or obstacles Remove superfluous fat and greasing oil after greasing duties When an extension cable is used for power supply make sure that the cable diameter in relation to the length of the cable is correct Make sure the cable is completely unrolled Manual activation of safety switches is forbidden When the safety devices are put out of operation the machine must first be switched off and secured against accidental switching on Work inside the electrical cabinet may only be undertaken by skilled personnel like Prinzen service engineers or its dealer s service engineers Always switch off the main switch before opening electrical cabinets After switching off the main switch parts inside the electrical cabinet remain live for approximately 1 minute The
91. sfers eggs after every 5 step of the cup conveyor regardless of the presence of eggs initialized the cup conveyor cannot run It is possible to disable this sensor in the service menu 325 01 Printer Message Movement too long This message can only appear when the optional printer is used Check the proximity switch for defects The printer movement stops because the stop printer proximity switch did not detect a step within 2 seconds Page 124 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 o TROUBLE SHOOTING GUIDE p nnzen 325 10 Printer Message Movement too long This message can only appear when the optional printer is used Check the proximity switch for defects The printer movement stops because the stop printer proximity switch did not detect a step within 2 seconds 325 11 Stamping message Movement too long This message can only appear when the optional stamping unit is Check the proximity switch for defects used The stamping unit movement stops because the stop stamping oroximity switch did not detect a step within 2 seconds 332 Error transfer mode watchdog end auto The stop button has been pressed but the transfer arm did not Press the reset button and subsequently the start button finish its movement within 10 seconds 332 01 Error transfer Lightscreen The safety screen is interrupted Press the reset button When the message reappears check the emergency stop relay and th
92. sponsible for noticing and locating abnormal noises and other unusual signs indicating flaws If the operator cannot locate the flaw he must stop the installation and inform his superior Take preventive actions against vermin as they may cause failures to the electrical cables and such SAFETY REGULATIONS Before starting operation cleaning maintaining the system or before remedying breakdowns first read the chapters Introduction and Safety MAINTENANCE UTENSILS In general we advise to have the following tools available for preventive maintenance of the Prinzen systems Padlock Lubricants Set of Allen keys Set of wrenches Set of screwdrivers Page 86 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen RECOMMENDED LUBRICANTS PREVENTIVE MAINTENANCE Prinzen uses Interflon Fin Food Lube Teflon spray and Griffon HR260 Silicone spray See below table for alternative lubricants and their manufacturers On the websites of the manufacturers you can find a local dealer for your desired lubricant Component Chains Rod ends Guides Bronze plain bearings Plastic guides Plastic plain bearings Lubricant Fin Food Lube Supplied in Aerosol Fin Lube TF Aerosol TFO89 PTFE spray Aerosol www interflon com Interflon Food grade www griffon nl Griffon Kl beroil 4NH1 4 220N Aerosol Kl beroil CM 1 220 Aerosol www klueber com Kl ber
93. ssary 12 Adjust this space with the positions of the side strips 13 of the bunker Loosen up the handles 14 and slide the side strips inwards or outwards Adjust the side strips in sucha way that the trays are placed on the center of the tray conveyor TOP GRIPPERS ADJUSTMENT When you use different types of trays per tray type it may be necessary to adjust the position of the top grippers 20 on its base plate 21 For the correct height first place the stack of trays on the floor and measure the distance 22 between the floor and the space between the first and the second tray in the stack Use the engraving on the base plate 23 to position the top grippers on the same height as the measured distance 22 For example When the measured distance is 25 mm slide the top gripper to the 25 mm line CLEANING 4 CLEANING UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 77 of 126 CLEANING p rinzen GENERAL Only personnel who are trained to perform cleaning duties on this system are allowed to clean it When during cleaning duties questions arise regarding the condition of the system consult your maintenance engineer SAFETY REGULATIONS Read the chapters Introduction and Safety before starting operation cleaning maintaining the system or remedying breakdowns CLEANING UTENSILS AND DETERGENTS In general we advise to have the following tools cleaning utensils and detergents available during cle
94. t After touching this button the I O menu appears Via this menu it is possible to view the status of all the inputs Sensors and outputs motors valves Service After touching this button the Service interval screen appears In this screen it is possible to ATTENTION enter service message which will appear on Changing parameter settings may result in the touchpanel when its set interval counter malfunctioning and even damage of the has elapsed system Software ATTENTION After touching this button the software debug The service menu and its underlying screens screen appears This screen shows SDOUC ONY de Us ae ae alta Fe Gr INE information about the status of the software system like Prinzen engineers for testing the system Adjust machine settings After touching this button the machine settings menu appears In the submenus of the machine settings menu it is possible to change parameters that control the system Most of these submenus are not available for the operator and the supervisor Panel settings After touching this button you will enter the panel settings menu in which it is possible to change touchpanel settings Some submenus are not available for the operator and supervisor Page 58 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen 01201 AlarmText 01201 AlarmTert 2234 Input Output menu 17 01 59 Line Infeed Rolcup vene one Outfeed Stacker 01201 amp la
95. t is running production ATTENTION Do not enter objects or body parts into the tray conveyor when it is running production UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 25 of 126 MACHINE DESCRIPTION OPTIONAL TRAY STACKER Page 26 of 126 OG rinzen Use The optional PS4 tray stacker is designed to stack full 30 cell trays from the packer Construction The PS4 tray stacker consists of 1 Transfer lift 2 Stacker plate 3 Pusher 4 Drive mechanism Process Trays are supplied by the tray conveyor At the end of this conveyor the trays are detected by a sensor 10 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 sensor 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 1 tray is placed on this plate it turns 902 After receiving the 2 tray it turns back 902 This sequence is continued for 6 cycles During the 6 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 1 tray of the next stack is placed on th
96. tective 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 Page 18 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 o MACHINE DESCRIPTION p rinzen X odios TECHNICAL SPECIFICATIONS The construction of your system may differ slightly from the descriptions in this manual Because of this the data in the technical specifications may be incorrect and or incomplete for your system For complete and exact data see the lay out drawing the electrical drawings and the machine tag of your system Restrictions Dirty eggs and eggs with cracks should be manually removed from the infeed conveyor Speed Maximum capacity 30 000 eggs hour Electrical data Connection voltage 400V 230V 3 phase N PE 50Hz Pre fuse 3x20 Amp Power 4kVA Maximum voltage deviation 696 to 10 Electrical protection IP55 A ground fault circuit interrupter earth leak protection is not a necessity but if required or present it should have a minimum leakage current of at least 300 mA Pneumatic data Nominal air
97. ter for defects Check if roller track cup conveyor is jammed 322 01 Error Rolcup cover opened The cover above the transfer position of eggs from roller track to Close safety cover P cup conveyor is opened or its safety switch malfunctions Check the safety switch for defects Check the emergency stop relay for defects 322 04 Alarm Rolcup sensor rol cup blocked check sensor or It is not possible to start the roller track cup conveyor because Message appears when an egg is detected and the start button is pressed adjustment the cup detection sensor detects an egg in the roller track cup Remove the egg at roller track cup conveyor transfer position conveyor transfer position Check the sensor for defects In case of a defect it is possible to disable this sensor in the service menu detection proximity switch did not detect a step within 3 seconds 322 Alarm Rolcup double egg present at roll to cup transfer The cup detection sensor detects an egg in the roller track cup Remove the egg at roller track cup conveyor transfer position conveyor transfer position Check the sensor for defects In case of a defect it is possible to disable this sensor in the service menu 322 Alarm Rolcup egg left behind at vacuumtransfer The start transfer sensor detects an egg which the vacuum head Hemove the egg from the cup at transfer position left on the cup conveyor Check the sensor for defects In that case the transfer arm tran
98. the lift Before entering the lift area lock the lift movement mechanically Disregarding this warning may result in permanent personal injury UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 41 of 126 p rinzen This sign is used to warn for damaging the system during installation and start up of a new system It is only used in systems with a roller track To prevent roller shafts falling out of the roller track during transportation of the system a tie wrap holds the transport chains of the roller shafts together After installing the system remove the tie wrap Disregarding this warning not removing the tie wrap and starting the system will result in damaging the system ATTENTION _ Not removing the tie wrap will damage the system Page 42 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 OPERATION 3 OPERATION UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 43 of 126 OPERATION E SAFETY REGULATIONS Before starting operation cleaning maintaining the system or before remedying breakdowns first read the chapters Introduction and Safety B Page 44 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen OPERATION EXPLANATION OF THE OPERATION OPERATING PANEL START STOP RESET In the operating panel the touchpanel with PLC is situated The PLC controls the system The touchpanel shows information about the status of the system By touching certain p
99. tion screens for the infeed conveyor RolCup At the moment there are no production screens for the roller track and cup conveyor Transfer At the moment there are no production screens for the transfer Denester At the moment there are no production screens for the tray denester Outfeed At the moment there are no production screens for the tray conveyor Stacker At the moment there are no production screens for the PS4 tray stacker 01201 AlarmText A PRODUCTION TREND SCREEN Production trend In this screen a graph of the amount of eggs x1000 that are packed in the past hour is displayed The average amount of packed eggs is displayed in the left bottom corner 27 Page 54 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen 01201 AlarmText 01201 AlarmTert 2534 Manual 17 01 59 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 CUI Ele 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 screens should only be used by advanced users of the system like Prinzen engineers for
100. to stop the system Start By pressing the start button the system starts to run The light inside the button turns ON Stop By touching the stop button you will stop the system The system stops after finishing certain internal controlling cycles Thus it may take some time before the system is completely stopped This is the normal procedure to stop the system Pressing the button twice stops the system immediately Reset After a breakdown first the breakdown needs to be solved During a breakdown the light inside the reset button FLASHES After solving the breakdown and pressing the reset button the controller verifies if all breakdowns are solved When this is the case the light inside the reset button turns OFF Now it is possible to start the system by pressing the start button again LOCAL EMERGENCY STOP BUTTONS On the following parts of the system emergency stop buttons are present Optional PS4 tray stacker After pushing this emergency stop button the complete system stops Pull or rotate the emergency button to release the emergency stop TIP Only use the emergency stop button for real emergencies Follow the normal stop procedure to stop the system Page 46 of 126 USER MANUAL SMARTPACK UM SMP 04 E 10 2013 p rinzen OPERATION LOCAL OPERATING PANELS O D c O OPTIONELE TRAY STACKER ii SS Start After opening the safety door of the tray stacker it is possible to start th
101. umber prints 4 Sensor 2 Print parameters Number of digits Print length Speed Print start Print distance V scale VP scale Print direction pori a de GTI 3 Diagnosis Test print Print parameters Sensor Display Keyboard Watch dog Time Dp eI 4 Settings 1 Language 2 Print strength 3 Jet use R L 4 Flash UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 117 of 126 PRINTER MENU STRUCTURE Main display 1 Press set text Y Y 2 User functions Set line choice between 1 and 50 Y 1 Font Y Set text Page 118 of 126 y 2 Print rows 3 Print length 4 Index print text 5 Nozzle cleaning 1 Standard 2 Bold 3 Small 4 Times gt 1 row 2 rows gt Set length E 1 digit 2 digit Set time
102. y locked so the machine cannot start until it is considered safe to do so Release the emergency stop button by turning it clockwise Do not release the emergency stop button when it is not certain why and by whom it was pressed Personnel working with the system must know the positions of the emergency stop buttons LOCKABLE DOOR Lockable doors are doors that can only be opened with a key 3 The key should only be in possession of a supervisor DANGER Lockable doors safeguard dangerous machine areas These doors are of utmost importance to operate the machine safely Never operate the machine when doors are open or not locked because serious injury or death may occur UM SMP 04 E 10 2013 USER MANUAL SMARTPACK Page 35 of 126 SAFETY Page 36 of 126 p rinzen PROTECTIVE COVER Protective covers 4 shield off dangerous moving parts These covers cannot be removed without tools and should be attached to the system before starting to use it DANGER Protective covers safeguard dangerous machine areas These covers are of utmost importance to operate the machine safely Never operate the machine when protective covers are removed because serious injury or death may occur SAFETY SWITCH Safety switches 5 are provided on safety doors or safety covers to prevent the operation of the machine or to stop the machine immediately when this door or cover is opened DANGER
103. yors stop when all 6 infeed gates detect eggs or when both egg pressure control sensors detect eggs TIP Use the infeed button when you have a long egg collecting conveyor so you do not have to wait near the Smartpack until the eggs arrive RolCup This button activates the roller track and cup conveyor Transfer This button activates the transfer Denester This button activates the tray denester Outfeed This button activates the tray conveyor Stacker This button activates the optional PS4 tray stacker Page 51 of 126 OPERATION p SE Empty roll cup 18 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 cup conveyor remain on the system By touching this button the eggs in the system are transported towards the trays even though no eggs are detected at the gates The eggs are transferred to the trays while the controller tracks the not completely filled trays When the optional tray stacker is part of the system the controller warns for partly filled TIP trays Machine running clear and tray might be The last trays leaving the system may be only half filled press start to release tray partially filled Remove these trays manually diis from the tray conveyor Remove the partial filled trays manually from the tray c

user manual smartpack

Contents

Download Pdf Manuals

Related Search

Related Contents