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Operation Manual

Lantech Wrapper Upgrade ADM

South Port, NC

Spring/2010

Packaging Systems

Account Rep: Mark Wolschlag & Steve Gibson

Project Manager: Randall Sorrells

ADM Wrapper Upgrade xpedx Packaging Systems of 18

Table of Contents

General Wrapper Upgrade Description ............................................................................................ 3

Wrapper Area Layout ...................................................................................................................... 3

Component Description ............................................................................................................... 5

Safety .............................................................................................................................................. 8

Safety Precautions ....................................................................................................................... 8

Lockout / Tag-Out ....................................................................................................................... 8

General Operation using the Operator Interface ............................................................................. 10

Screen Navigation ..................................................................................................................... 10

HMI Overview/Automatic ......................................................................................................... 11

HMI Conveyor Jog .................................................................................................................... 12

HMI Alarms and Maintenance ................................................................................................... 14

Typical Startup .............................................................................................................................. 15

Control System ............................................................................................................................. 16

Referenced Files ........................................................................................................................ 17

Troubleshooting Guide .................................................................................................................. 18

Conveyor System ...................................................................................................................... 18


General Wrapper Upgrade Description Loads existing the two pallitizer areas are capable of being routed to various locations. It is

possible to use both wrappers, a combination of a wrapper and manual offload with a fork truck or

no wrapper at all. On the other hand, it is possible to onload with a fork truck thus routing a load

through a wrapper. The selections are made via the input on an HMI touch screen. There are two

fork truck points which serve as both onload and offload. There are three other fork truck points

which serve as offload points only.

Pallet Dimensions: Minimum Load 48 x 40 x 50

Maximum Load 48 x 45 x 50

Rate: Sixty (60) loads per hour maximum

Weight: 2000 lbs Typical

Wrapper Area Layout

The New Wrapper System consists of seven basic components. Of which, are broken into two

sections: Lantech and xpedx. This manual will focus on the xpedx system only. Please see Lantech

documentation for information on the Lantech Top Sheet dispenser and Stretch wrapper.

Xpedx section includes:

1. Con.2 = Conveyor 2 feeds loads in from the right palletizer.

2. Con. 3= Turntable rotates clockwise and counter clockwise and can move a load from Con.

2 to Con 4, Con 2 to Con 5 or Con 5 to Con 4.

3. Con. 4 = Conveyor 4 is on the right side on the turntable closest to the older wrapper.

4. Con. 5 = Conveyor 5 is on the left side of the turntable.

5. Con. 6 = Conveyor 6 is to the left of Con. 5 with both rollers and a popup chain.

Lantech Section:

1. Con. 8 = This is the entry point into the Lantech system. Itis called the Top Sheet Dispenser.

2. Con. 9 = This is the Stretch Wrapper.

3. Con. 10 = Conveyor 10 is the outfeed and staging area for loads exiting the Lantech

Wrapper system.


Component Description

The HMI pedestal is the point where the flow of

loads is configured and the line is

stopped/started. There is also an E-stop button

as well as a power on button.

Con.2 = Conveyor 2 feeds loads in from the

right palletizer.

The load will stop near the turntable on Con 2 if

the Turntable is not in the Home position at Con

2.

Con. 3= Turntable rotates clockwise and counter

clockwise and can move a load from Con. 2 to

Con 4, Con 2 to Con 5 or Con 5 to Con 4.

Con. 2 can be seen at the Top of this image

while Con 4 is to the Right and Con 5 is to the

Left.

***The turntable is seen here in the Home

position.

Con. 4 = Conveyor 4 is on the right side of the

turntable closest to the older wrapper. This

conveyor can pass a load on down to the old

wrapper or hold a load for offload by the fork

truck.

**You can see the red safety pull cord here as

well as the fork truck sensor underneath.


Here is the Older Wrapper to the right of the

Turn Table.

If a load passes through Con 4 traveling into the

wrapper, the wrapper is expecting the load to

arrive at its internal turntable.

Con. 5 = Conveyor 5 is on the left side of the

turntable. A load can be passed either left or

right depending upon the flow configuration.

Con 5 can be both an offload and an on load

point for loads.

**There is a sensor to detect fork trucks

underneath at the middle. Loads will not move

if this sensor is blocked.

Con. 6 = Conveyor 6 is to the left of Con. 5 with

both rollers and a popup chains. Loads can

come out of the left palletizer and travel either

left or right based on the flow configuration.

Loads can travel from Con 5 left to the new

wrapper if the flow is set up to do so.

**If a load is at Con 5 and Con 7 at the same

time, the Load from Con 7 always gets priority.

Con. 8 = This is the entry point into the Lantech

system and is called the Top Sheet Dispenser.

Con. 9 = This is the Stretch Wrapper.

**Please see Landtech documentation for

further details.


Con. 10 = Conveyor 10 is the outfeed and

staging area for loads exiting the Lantech

Wrapper system.

**There is a sensor to detect fork trucks. Loads

will not move if this sensor is blocked.


Safety

Safety Precautions

Before working on the xpedx and Lantech systems disconnect all incoming power.

Turn off all electrical and air connections to the equipment and all Interfaced Equipment before

repairing or cleaning.

Do not put hands or tools in the equipment or any Interfaced Equipment while in operation.

Do not wear neckties, jewelry, loose clothing, or other items that can become caught in moving

parts or mechanisms in the vicinity of equipment or Interfaced Equipment.

Do not operate, troubleshoot, or maintain the equipment or Interfaced Equipment while under the

influence of any type of drugs or alcohol.

Do not operate the equipment or any of the Interfaced Equipment without all guards and safety

mechanisms in place.

Always observe all safety warnings and notices on all equipment and in this manual and all

Interfaced Equipment manuals.

Do not use flammable or toxic cleaning fluids such as gasoline, benzene, or ether when cleaning

and maintaining the equipment or any other Interfaced Equipment.

Wear all company-specified protective equipment while operating the equipment or any Interfaced

Equipment.

Lockout / Tag-Out

Follow ADM safety procedures and follow the Lockout / Tag-Out procedures as defined by

OSHA, before servicing the machines.

The xpedx system has a single control panel with a lockable disconnect beside the door as well as

an upstream safety switch mounted to the HMI pedestal and another upstream safety disconnect

mounted near the control cabinet on the column. Any of the three disconnects will de-energize the

following devices:

� All conveyor motors on Con. 2, 3, 4, 5, 6

� All solenoid valves on Con 6

� All sensors on Con. 2, 3, 4, 5, 6

The potential for stored energy on this line exists because of the use of pneumatic controls. Follow

ADM safety procedures and follow the Lockout / Tag-Out procedures as defined by OSHA. Be sure

to bleed off air pressures before servicing the Con 6. Always bring up the air pressure slowly to

avoid fast movement of devices as the air pressure increases.

The xpedx equipment has been equipped with several devices to help enhance the overall safety of

Please read all manufacturers Manuals and Training Guides of equipment

interfaced with the Transfer Table. Please read all manufacturers Manuals and Training Guides of equipment

interfaced with the xpedx equipment.


the system. The control system was designed with a Category I safety control circuitry.

The HMI panel is equipped with a xpedx system

Only E-stop Button. Once all E-stops are

cleared this is also the only point the control

circuitry can be reset.

Three safety pull cords were also provided to

surround the perimeter of the xpedx conveyors

giving the operators the ability to stop the

equipment in the event a controlled stop from

the HMI is not possible.

** Pull cords are Red and run along the outside

of the conveyors.

Large yellow barriers were provided by ADM to

prevent entry into areas of moving parts.

Please Note: The equipment is designed to hold pallets up to 40”x48” at near 2000 lbs. Anything

outside of this could exceed the weight and size capacity causing the conveyor to collapse and/or

jam.

Warning: The conveying equipment is not made to sit, stand or place anything other than loaded

pallets onto.

Failure to comply can cause personnel and equipment damage.


General Operation using the Operator Interface

Screen Navigation

Screen

Navigation

Start Screen Flow

Configuration

Jog Select

Screen

Alarm Screen Maintenance

Screen

Flow Status

Screen

Jog 2 and 3 Jog 5 and 6 Jog 3 and 4 Jog 3 and 5

PLC Inputs &

Outputs

HMI Shutdown


\

HMI Overview/Automatic

When the system is first powered up, this

will be the screen displayed. Each screen

area can be selected here. Choosing “Flow

Config” will open the screen necessary to

select load directions.

While the system is in Stop, select the

direction you want the loads to flow. You

can also select if you want loads to be held

on Con 5 or Con 4 instead of allowing them

to flow to the next area. Pass/Hold can be

changed at any time.

Selecting the “Return” button will send you

back to the “Screen Navigation” screen.

The line can be operated with any

component in Auto or Manual. Any

component can be changed from

Auto/Manual in both the stopped or

Running mode.

Starting the line activates a warning buzzer

and lights the amber light on the main

control cabinet. 20 seconds will pass

before fully in the Run Mode. Bothe the

Green and Amber light will be lit.

**Note a conveyor cannot operate manually

if in auto on this screen.

**Cycling from Auto/Manual is a good way

to reset a conveyor


This is just a verbal representation of the

setup configuration for load flow.

HMI Conveyor Jog

To manually Jog any of the conveyors,

select the conveyor you wish to jog.

**Note a conveyor cannot operate

manually if in auto on the “Start Screen”.

**In Manual Jog there are little oversight

by the system to allow for safe movement

of loads. Take extra precaution.

To manually operate a conveyor make sure

the corresponding button is “Selected” and

is Green.

The Turntable can rotate clockwise and

counter clockwise.

The Turntable must be directed toward one

of the three positions to allow bed rollers to

activate.

**There are hard stops which will prevent

rotation passed 180 degrees. Damage can

occurred if manually jogged into the hard

stops




is Green.


counter clockwise.



activate.




stops



is Green.


counter clockwise.



activate.




stops



is Green.


HMI Alarms and Maintenance

The alarm screen displays in red the active

alarm. The buzzer on the main control

cabinet will also be active. The buzzer can

be silenced by the button in the middle of the

screen.

Alarms will disappear once the condition is

corrected.

The “Maintenance Screen” displays the

current system configuration. From here the

HMI can be shut down into its own operating

system.

Advancing to the next series of maintenance

screens allows for the viewing of all of the

system Inputs and Outputs.

**Shutdown of HMI should be done only by

qualified technicians.

Advancing to the next series of maintenance

screens allows for the viewing of all of the

system Inputs and Outputs.

Active I/O will be noted by the yellow

indicators


Typical Startup Power the main control panel using the main disconnect and/or upstream safety switches.

Give the HMI and PLC as much as 5 minutes to properly boot up into the run mode. Attempt to

reset the control power by pushing the control power reset button on the HMI pedestal. If no pull

cord conditions are active the green button will light up. If it does not, then check the listed alarms

on the HMI screen to see which pull cord and/or E-stop is active.

Once the E-stop and pull cord conditions are corrected, push the control power reset button

to turn on the control power for the xpedx system. Select the “Flow Config Screen”. Select the

direction you would like the loads to flow and whether or not you want the loads to be offloaded on

Conveyors 4 and/or 5.

Please note: it may be necessary to us a stylus to make selections on the HMI screen.

Navigate to the Start screen. Set the necessary conveyors in the Auto mode.

Select start.

It is best to empty the system of any loads and place Con 3 Turntable in the Home position.

However if that is not possible, make sure the load is sitting in a known position blocking a photo

eye. Make sure the Con 3 Turntable is at one of the three known positions.

Manual Jog While in the Run Mode, any conveyor can be placed into manual from the Start screen. Navigate to

the appropriate Jog screen. Select the appropriate conveyor and jog as needed.


Control System

The control system is housed in the Main

Control panel. This panel is located on the back

side of Con 5.

The HMI pedestal is located just to the left of

Con 3 Turntable. It is equipped with a touch

screen, E-stop Push button and a Power rest

push button. The safety switch mounted to the

back of the pedestal should be locked out before

crossing and or servicing associated conveyors.

The HMI is a AB Panel view Plus 600 which

talks to the PLC via RS-232.

The system is controlled by a AB Micro Logix

1500 PLC with two serial ports for connectivity.

The variable frequency drive is a AB general

purpose Power flex drive.


Referenced Files

Cad layout with Control Notes = ADM Layout 041510 with c notes.dwg

Electrical Cad Drawings = ADM Master Elect 041510.dwg

PLC File = ADM NEW7.RSS

HMI file = ADM TRANSITION CONVEYORS2.apa

HMI compressed file = ADM TRANSITION CONVEYORS.mer


Troubleshooting Guide

Conveyor System

Control power will not come on

Main Conveyor System will not

start

Any single conveyor will not start

Turntable will not move in Auto

Conveyor 5 is on and will not turn

off in Auto

Conveyor 5 will not start in Auto

Conveyor 4 will not start in Auto

� Push Control Power Reset on HMI panel

� Confirm Main Control Panel disconnects are on.

� Check all system E-stop push buttons/pull cords.

(Reset)

� Check circuit breakers

� System Control Power must be on.

� Push Control Power Reset on HMI panel

� Select Start button from the HMI Start Screen

� Ensure green light flashing on stack light. If not

clear faults

� Check Alarms page for active alarms and rectify

� Ensure system is configured correctly

� Check to see if it is in Auto on Start Screen

� Check for motor faults

� Check Circuit Breakers

� Cycle from Auto to Manual and back to Auto

� Not at a know position, put it in manual and jog

to Home (Con 2) make sure display says “Home”

� Cycle from Auto-Manual-Auto; It thinks a load is

still on it

� The load is not being seen by Photo Eye

� The fork truck sensor is blocked

� The load is not being seen by Photo Eye

� The fork truck sensor is blocked

�

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