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Black—Standard prox output lead. This lead provides a 24VdC (high) signal each
time the prox detects a divert shoe. This is an optional output and is to be used at
the discretion of the controls provider.
HIGH-SPEED SOLENOID AIR VALVE
The solenoid air valve is used to receive the smart prox output signal and provide
air to the proper end of the divert switch cylinder to move and hold the switch in
either the "home" or "divert" positions. The valve used is specially designed for the
high speed operation necessary for proper divert switch timing.
The two inputs of the solenoid are non-polarized, allowing either lead to be used as
input or ground for the valve. The solenoid requires 24VdC, 4W to operate.
The solenoid air valve is controlled directly by the smart prox. direct control of this
valve by the controls package is not required or advised.
Other Control Components Supplied with the Conveyor
VARIABLE FREQUENCY DRIVE CONTROLLER
The variable frequency drive (Vfd) is a motor controller that has three functions:
1. It provides a smooth acceleration of the drive motor, allowing the sorter to slowly
"ramp up" to full speed. This protects the sorter components from the stress of a
full-speed start up.
2. It allows the speed of the sorter to be adjusted to match speed requirements of
the system. Also, it allows the sorter to be operated at a very slow speed during
installation "debugging" and when certain mechanical components are checked
after servicing.
3. It allows the sorter to be operated at a slower speed during "off-peak" seasons,
reducing energy consumption, noise, and wear.
Refer to the Vfd manufacturer's installation manual, provided with the sorter, for
wiring and adjustment instructions.
AIR PRESSURE SWITCH
The air pressure switch (fig. 5A) is used to detect low operating air pressure.
Operation of the sorter at air pressures under 50 PSI can cause erratic switching
and potential switch damage. If air pressure falls below this level, the sorter must
be shut down until the cause of the pressure drop has been found and remedied.
The pressure switch provides a contact-type output which closes at pressures at
or above about 48 PSI and opens below that air pressure. The system controls
provider should use this switch to monitor air pressure at the sorter and should shut
down the sorter if an open (low) output is detected from the pressure switch.
Refer to the pressure switch manufacturer's installation manual, provided with the
sorter, for wiring instructions.
SAFETY PROXIMITY SWITCHES
There are safety switch devices located at various locations in the sorter to indicate
when a divert shoe is out of place, an obstruction has entered the sorter, or when
some other event has occurred that could cause damage to the sorter or danger to
personnel. These safety switches use normal inductive proximity switches as the
electrical interface to the system controls.
There are two types of safety switches in the sorter:
1. Shoe position safety switches are switch mechanisms inside the sorter that trip
if a divert shoe passes them that is not in its proper track. They are also used to
detect foreign objects that might fall between the slats and enter the interior of the
sorter. They are made to detect problems on both the upper and return portions
of the sorter.
There is one shoe position safety switch located at the infeed end and one at the
discharge end of the sorter. There are additional switches included for every 30
feet of sorter length after the first 30 feet. for example, a sorter 50 feet long will
have a total of 3 switches, a sorter 80 feet long will have a total of 4 switches and
so on. These additional switches are spaced evenly along the sorter's length.
2. The pop-up transition roller safety switch is used to detect when the transition
rollers on the discharge end of the sorter are in the "up" position. These rollers are
designed to pop up if a stray divert shoe or a foreign object makes contact with
them.
The normal state of the output of the safety proximity switch is"on" (high). If a switch
detects a problem the signal is changed to "off" (low). The system controls must
be configured to go to an "emergency stop" condition and shut down the sorter
and related equipment when a problem is detected. Restart must not be possible
until the problem is corrected and the safety switch that detected the problem is
again "on" (high).
Refer to the proximity switch manufacturer's installation manual, provided with the
sorter, for wiring instructions.
CATENARY TAKE-UP PHOTO EYE
The catenary take-up photo-eye monitors the amount of chain sag occurring in
the drive's catenary area. The photo-eye is a retro-reflective, light-operated type,
positioned in the catenary so that if the carrying chains allow the slats to sag below
a certain level, the beam of the eye is blocked.
The system controls must be configured to stop the sorter when the photo-eye
beam is blocked (photo-eye output is "off" or "low") and provide an indication to
the sorter operator that the chains must be taken up or shortened before operating
the sorter further.
Refer to the photo-eye manufacturer's installation manual, provided with the sorter,
for wiring instructions.
ENCODER
An encoder is included with the sorter to provide a pulse signal to be used for
product tracking. The encoder provides a square-wave pulse signal of 30 pulses
per revolution of the sorter infeed shaft. This equates to one pulse for every 1.75
inches of sorter travel.
The encoder requires 24VdC power, and provides a 24VdC pulse output.
Refer to the encoder manufacturer's installation manual provided with the sorter,
for wiring instructions.
CHAIN OILER SOLENOID
The chain oiler is used to provide automatic lubrication of the carrying chains
during sorter operation. When the oiler solenoid valve is energized, oil is allowed
to gravity feed from the oiler reservoir, through metering valves, to brushes located
above the return chains in the sorter.
The system controls should be configured to activate the chain oiler solenoid for a
duration equal to one complete revolution of the carrying chains about every two
hours of operation. The actual amount of oil applied to the chains is controlled by
the metering screws (see "Conveyor Set-up" section of this manual). The chain
oiler solenoid requires 24VdC power to operate.
LOST BEARING DETECTION
The missing bearing block is used to detect a bearing missing from a divert shoe.
A divert shoe that does not have a bearing on the bottom can cause damage to
the sorter. The missing bearing block uses two proximity switches located in the
return section of the sorter to detect the presence of a bearing on the shoe. If one
prox detects a bearing being present but the other does not, the block removes
its output to indicate a missing bearing was detected. See figure 8A for location of
missing bearing prox switches.
The missing bearing block requires 24VdC power to operate. The prox switches
are plugged into the left two ports in no particular order. A reset signal of 24VdC
is needed to clear the missing bearing error in the block. The output from the block
is "on" or "high" when no error is detected.
Control Components Not Supplied with the Conveyor
In addition to the control components supplied with the ProSort sorter, there are
several components that must be supplied by the system control provider. Hytrol
recommends the following control components be used to protect the sorter from
damage due to product jams or other problems.
ADJUSTABLE INSTANTANEOUS MOTOR OVERLOADS
Instantaneous overloads provide protection against sorter "hang-ups" by turning
off the drive if a sudden increase in motor current is detected. By adjusting the
overload limit to slightly above the power required to operate the sorter, any
extra load on the motor, such as would be caused by a product jam or switch
malfunction, would cause the sorter to stop, possibly before significant damage is
done to the equipment.
The instantaneous overloads should be installed in the control panel for the sorter
and sized for the proper power requirements.
PHOTO-EYES
Photo-eyes are common components in systems controls. Hytrol recommends that
photo-eyes be installed at the following locations to perform listed functions. These
are, of course, in addition to other photo-eyes needed in the system.
Induction Photo-eye—A photo-eye
mounted at the infeed point of the
sorter. This eye is used to perform the
following functions:
1. Signal the system controls that a
particular package has entered the
sorter. from this point forward, the
package must be tracked using the
encoder pulses to determine when it
reaches the proper divert location.
2. measure the length of the package
so that the system controls may assign the proper number of divert shoes to the
package for diverting. Note: Shoes are to be assigned for the entire length of the
package plus one extra shoe is to be assigned to the trailing end of the package.
3. Check for the proper gap between packages for safe sorting. It is important to
check for the proper gap here, even if it has been set prior to this point, to insure
that the packages are truly spaced properly. Attempting to sort packages with
too little gap between them can cause jams. Note: The minimum gap necessary
for sorting a package is a function of the width of the package. The charts below
should be used in checking for proper gap.
Jam/Confirmation Photo-eye—Photo-eyes mounted on each take-away spur of
the sorter, as close to the sorter as possible. These eyes perform two functions:
1. detect a product jam at the sorter "exit point." If a package blocks this photo-eye
for a longer time than it would take for the package to travel past the photo-eye
normally, this indicated that the package is jammed. The sorter should be stopped
and the jam cleared before restarting the sorter.
2. divert confirmation. If a divert signal is given to a particular divert point, and no
package is detected by the associated jam/confirmation photo-eye, an error has
occurred. The sorter should be stopped and the error found and corrected before
restarting the sorter.
7
ProSort 421 (22° diverts)
ProSort 421 (22° Centros de desvio)
0" < W ≤ 13" Minimum gap = 10"
13" < W ≤ 26" Minimum gap = 16"
26" < W ≤ 40" Minimum gap = 20"
*W = Package Width
Note: When sorting to both sides, the
minimum gap from the above charts must
be increased by 6 in.
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