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Summary of Contents for Prinzen PSPC30
- Page 1 SERVICE MANUAL PSPC PSPC30 PSPC5 PSPC7 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...
- Page 3 TABLE OF CONTENTS TABLE OF CONTENTS CHAPTER BOOK INTRODUCTION SAFETY INSTALLATION COMPONENTS ADJUSTMENTS DESCRIPTION PACKER DESCRIPTION OUTPUT CONVEYOR DESCRIPTION 30 CELL TRAY DENESTER DESCRIPTION HATCH TRAY DENESTER TROUBLE SHOOTING GUIDE SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 3 of 83...
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Page 5: Table Of Contents
? ......................... 12 HOW TO USE THIS MANUAL ..........................13 TARGET GROUPS ............................13 SYMBOLS ......................14 EXPLANATION OF MACHINE TAG ..........................15 ADDRESS PRINZEN SAFETY..............................17 ............................. 18 GENERAL ......................18 SAFETY INSPECTION PROCEDURE .......................... 19 SAFETY REGULATIONS ..........................21 SAFETY PROVISIONS ...................... - Page 6 TABLE OF CONTENTS PACKER..............................41 .......................... 42 DESCRIPTION PACKER ........................47 ADJUSTMENTS PACKER ....................................47 INFEED BELT TENSION ....................................47 GATE EGG DETECTION .................................. 48 ROLLER TRACK STOP POSITION ..................................48 FLAP SHAFT STOP POSITION .................................. 49 CUP CONVEYOR STOP POSITION ..................................
- Page 7 TABLE OF CONTENTS SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 7 of 83...
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Page 9: Introduction
INTRODUCTION INTRODUCTION SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 9 of 83... - Page 10 Cualquier persona que ajusta esta máquina, debe leer este manual de manejo antes de ajustar. El uso de este manual de manejo es por su propio riesgo. Prinzen no puede ser responsible por daños al sistema a causa del uso de este manual de manejo. ATTENTION: Chacun qui règle cette machine doit lire le manuel en avant.
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Page 11: Liability
INTRODUCTION LIABILITY Prinzen BV cannot be held responsible for any costs, damage or personal injury if it’s 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. -
Page 12: General
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 dealer or the owner of the system. -
Page 13: Target Groups
INTRODUCTION TARGET GROUPS Dealer: The dealer is the person (concern) that represents Prinzen BV. The dealer must take care that it’s service engineers will read this manual. Professional: A professional is someone who can assess the duties appointed to him on account of his education, knowledge and experience and who can assess the dangers attached, thereby avoiding these dangers. -
Page 14: Explanation Of Machine Tag
EXPLANATION OF MACHINE TAG Each machine has a unique serial number printed on the machine tag, which can be found in the electrical cabinet. When contacting the Prinzen service department have this number available. Machine type: This is the name of the system followed by the layout of the system: Rated voltage: This is the required power supply for this system: wires/frequency/power. -
Page 15: Address Prinzen
INTRODUCTION 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 SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 15 of 83... -
Page 17: Safety
SAFETY 1. SAFETY SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 17 of 83... -
Page 18: General
SAFETY GENERAL Only persons meeting the following requirements are authorized to work with the system. These persons should be: - Skilled and specifically trained for their duties. - Familiar with the contents of this manual. - Familiar with the locations of the emergency buttons and other safety devices. - 18 years old or above. -
Page 19: Safety Regulations
When the safety devices are put out of operation, the machine must be switched off and secured against accidental switching on. Work inside the electrical cabinet may only be undertaken by skilled personnel like Prinzen service engineers or its dealers service engineers. - Page 20 SAFETY Several parts inside the electrical cabinet maintain voltage even when the main switch is turned off (main switch, main power supply, terminals for egg collecting belts, etcetera). DANGER! Failure to obey safety regulations may result in permanent personal injury or death. ATTENTION! Failure to obey safety regulations may result in damage to the system.
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Page 21: Safety Provisions
SAFETY SAFETY PROVISIONS Before operating the machine the safety devices must be checked for correct functioning. Also the protective covers must be mounted before starting to use the system. Repair or replace safety devices before using the system if they do not work properly. Never rely solely on safety devices. -
Page 22: Warning Labels
SAFETY WARNING LABELS The Prinzen system makes dangerous movements. The system also contains dangerous parts when they contact the body. The following labels are posted as a warning. Understand and remember the meaning of the warning labels. This sign is used to warn for dangerous voltage inside a cabinet. -
Page 23: Installation
INSTALLATION 2. INSTALLATION SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 23 of 83... -
Page 24: Safety Regulations
ASSEMBLY AND INSTALLATION The assembly and installation must be carried out by personnel of Prinzen, or by engineers assigned by Prinzen, trained for this purpose. They also see to initial operation of the installation and the training of the operators. -
Page 25: Preparation
INSTALLATION PREPARATION Before actual assembly and installation, the buyer must see to the proper preparations to facilitate correct installation. The connection of the system to the electricity grid has to be done by a licensed electrician. All activities must be carried out according to local and national regulations, the requirements of the company and the required provision for the installation. -
Page 26: Installation
INSTALLATION INSTALLATION SAFETY REGULATIONS Before starting to install the system first read the chapters Introduction and Safety. PACKER Follow the below adjustment procedure for installation of the packer: 1. Place the packer with the infeed belt in front of the egg-collecting belt. The distance between the strip of the infeed belt and the egg-collecting conveyer should be a few mm. -
Page 27: Output Conveyor
INSTALLATION OUTPUT CONVEYOR 4. Place the supporting beams into the cut- away close to and above the feet of the packer. 5. Fasten the beam on the other side of the packer to the packer. 6. Place the output conveyor on the beams and hand tighten it to the beams with the bolts. -
Page 28: Mobile Output Conveyor
INSTALLATION MOBILE OUTPUT CONVEYOR A mobile output conveyor is designed for a fast changeover to a different type of tray by means of repositioning of the conveyor. When a mobile output conveyor is delivered, follow the below steps: 4. Place the supporting beams into the cut- away close to and above the feet of the packer. -
Page 29: Electrical Connection Output Conveyor To Packer
INSTALLATION ELECTRICAL CONNECTION OUTPUT CONVEYOR TO PACKER 10. Place the cables from the output conveyor into the electrical cabinet of the packer. 11. Put the 4 plugs into their belonging connector. The connectors are positioned in the right top corner of the electrical cabinet. -
Page 30: Power And Air Supply
INSTALLATION POWER AND AIR SUPPLY 15. Connect the air to the air regulator underneath the output conveyor. 16. Connect the main power to the main power terminals in the left top corner of the electrical cabinet. Connect the phase lines to L1, L2 and L3. -
Page 31: Direction Of Rotation Output Conveyor
28. When the rotation direction of the output conveyor is wrong contact the service department of Prinzen. TESTING 29. Push the emergency button. Make sure the systems stops immediately. -
Page 32: First Egg
INSTALLATION FIRST EGG 31. Set the tray selector to 1 32. Set the clear button to 1 33. Start the system by pressing the start button twice. 34. Place an egg onto the packer and wait until the egg is transported towards the end of the cup conveyor. - Page 33 INSTALLATION 42. The vacuum head stops at its tray set position. The tray set position depth is factory adjusted with a hatch tray. See adjustment procedure of the vacuum head tray set position. 43. The suction cups of the vacuum head must fit into the tray.
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Page 34: Connection Egg Collecting Conveyor
INSTALLATION CONNECTION EGG COLLECTING CONVEYOR 47. A volt free contact is available for a start / stop signal from the packer to the egg collecting conveyor. Maximum contact load permitted is 230Vac, 4 Amps. Connect a cable from the egg collection conveyor to connections 29 and 30 of terminal X1 in the top center of the electrical cabinet. -
Page 35: Disassembly
If, for reasons of maintenance, service or alterations the installation or a part of it must be disassembled, we advise you to have this done by Prinzen personnel or its official dealers. When disassembling parts and materials, take note of the applicable environmental regulations. -
Page 37: Components Adjustments
COMPONENTS ADJUSTMENTS 3. COMPONENTS ADJUSTMENTS SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 37 of 83... -
Page 38: General Adjustments
Before starting to adjust the system first read the chapters Introduction and Safety. PHOTO SWITCHES In the Prinzen systems, often Carlo Gavazzi photo switches are used for detecting eggs or trays. The detection distance of these sensors are adjustable: First make sure that the photo switch is mechanically positioned correct. -
Page 39: Air Supply
COMPONENTS ADJUSTMENTS AIR SUPPLY Normally the Prinzen systems need an air pressure of approximately 6 bars. Adjust this air pressure with the primary pressure regulator. Pull the knob (1) up and turn it to change the air pressure. Press the knob down to lock it again. -
Page 40: Frequency Inverters
COMPONENTS ADJUSTMENTS FREQUENCY INVERTERS ATTENTION! The parameters of the frequency inverters are factory set. We advise you to consult Prinzen before changing these parameters. − Press the menu key (1) until the PRGM indicator (2) is lit. − Press the up (3) or down arrows (4) to view a certain parameter. -
Page 41: Packer
PACKER 4. PACKER SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 41 of 83... -
Page 42: Description Packer
PACKER DESCRIPTION PACKER Use: The Packer is designed to receive a random supply of eggs and assemble these eggs into fixed patterns of 25, 30, 36 or 42 eggs and place them with the pointed end downwards into a tray. Construction: The packer consists of: Infeed conveyor... - Page 43 PACKER Construction Infeed gate: The infeed gate consists of a shaking fork (30), gate blockers (31) and egg detection. The shaking fork movement is controlled by a cam (32) mounted on the infeed belt’s drive roller. Above each gate a sensor (33) detects eggs. Construction Main drive: A frequency-controlled motor (40) situated underneath the roller track is directly mounted...
- Page 44 PACKER Construction Cup conveyor: The cup conveyor drive shaft drives 2 transport chains (60) on both sides of the packer, transporting shafts (61) with cups (55). On the top- and bottom side the transport chains are guided. The cups are able to slide on the shafts.
- Page 45 PACKER Construction vacuum head: The vacuum head is available in 3 executions: 80 Fixed vacuum head 81 Combination vacuum head 82 Zigzag vacuum head The fixed vacuum head is used to place eggs into the common plastic or paper trays. The vacuum head is mechanically attached to the vacuum head holder of the transfer lever (83) and via a vacuum hose (84) to the...
- Page 46 PACKER Construction Vacuum system: The vacuum head is connected with the vacuum pump (90) via the vacuum hoses and pipes, the vacuum filter (91) and the vacuum valve (92). The valve takes care of the vacuum during carrying the eggs and the blow off during placement of the eggs in the tray.
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Page 47: Adjustments Packer
PACKER ADJUSTMENTS PACKER INFEED BELT TENSION Adjust the tension of the belt in such a way that it won’t slip on the drive roller during start up and during normal production with full load. Loosen up the tensioning roller lock bolt (1). Turn the tensioning bolt (2) Clock Wise for more belt tension and Counter Clock Wise for less belt tension. -
Page 48: Roller Track Stop Position
PACKER ROLLER TRACK STOP POSITION When the machine is normally stopped (stop sensor must be ON), 1 shaft with rollers (11) must be at the position of the mark in the frame (12). To adjust this position, adjust the position of the drive shaft of the roller track (13) in the main drive. -
Page 49: Cup Conveyor Stop Position
PACKER CUP CONVEYOR STOP POSITION When the machine is normally stopped the 2 rollers (20) of the roller track and the edge of a cup (21) must be positioned in a straight line. Normally when the 2 rollers and the edge of a cup are in a straight line, the slots in a cup (22) are at the position of the marks in the frame (23). -
Page 50: Main Drive Chain Tension
PACKER MAIN DRIVE CHAIN TENSION The chain tensioner (30) of the main chain is spring loaded. Because of the position of the fixation bolts (31), when the tensioner is completely to the right it is still possible to push in the tensioner with 10 mm (by the chain). When the chain tension is too low move the complete chain tensioner to the left. -
Page 51: Egg Lifter Position
PACKER EGG LIFTER POSITION When the machine is stopped, the distance between the star shaped cam and the next roller must be approximately 10 mm (50). To check and to adjust this, measure it or use a block with a 10 mm thickness (51). When adjustment is needed follow below steps: 52. -
Page 52: Vacuum Head Horizontal Position
PACKER VACUUM HEAD HORIZONTAL POSITION The position of the vacuum head must be horizontal in all positions (60). To adjust this, loosen up the 2 bolts (61) that hold the sprocket and reposition the sprocket. Tighten up the bolts afterwards. VACUUM LIFTER CHAIN TENSION The chain tension of the vacuum lifter is... -
Page 53: Vacuum Head Pick Up Position
PACKER VACUUM HEAD PICK UP POSITION Follow below steps to move the vacuum head to the pick up position: 70. Set the clear button to 1 71. Start the system by pressing the start button twice. 72. Place an egg onto the packer and wait until the egg is transported towards the end of the cup conveyor. -
Page 54: Speed Cylinder Vacuum Head
PACKER SPEED CYLINDER VACUUM HEAD Both the combination and the zigzag vacuum head have air-controlled cylinders. These cylinders have speed restrictors (79) to adjust the speed of the ingoing and outgoing stroke of the cylinder. Normally the speed is adjusted with the outgoing air. -
Page 56: Vacuum Valve Parts Replacement
PACKER VACUUM VALVE PARTS REPLACEMENT A replacement set for the vacuum valve consists of the following parts: 4x Filter 2x Spring large 1x Spring small 4x External retaining ring 4x Washer 1mm 2x Washer 0.5 mm 1x Washer 0.3 mm 3x O-ring 38x3 1x O-ring 30x3 Follow below procedure to replace the filter:... - Page 57 PACKER Follow below procedure to replace the o-rings and the spring on the cover 1 side: Remove Cover 1 by loosening the 3 bolts that fastens the cover to the casing. Remove the retaining ring. Remove the 1 mm washer Remove the 0.3 mm washer.
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Page 58: Position Blocking Shafts
(91) to block a different gate, this is not allowed and will result in a stop of the system. When another egg pattern is needed, we advise you to consult Prinzen, because for a different egg pattern new software to control the system is required. -
Page 59: Output Conveyor
OUTPUT CONVEYOR 5. OUTPUT CONVEYOR SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 59 of 83... -
Page 60: Description Output Conveyor
OUTPUT CONVEYOR DESCRIPTION OUTPUT CONVEYOR Use: The output conveyor transports empty trays from the denesters towards the tray set position underneath the vacuum head, and full trays towards the position where they are manually removed. Construction: The output conveyor consists of a tray transport system (1), a drive mechanism (2) for the transport belts and the 30-cell tray denester and a drive mechanism (3) for the... - Page 61 OUTPUT CONVEYOR Construction transport system: The transport system consists of 2 transport belts for the transportation of the trays. There are 2 side guides (20) to guide the hatch trays and 2 center guides (21) to guide the 30 cell trays.
- Page 62 OUTPUT CONVEYOR Construction optional easy stacker: The easy stacker consists of a tray stacker (30), a drive mechanism (31) for the tray stacking and an infeed stopper (32). The easy stacker is situated on top and below the output conveyor and has 2 fixed feet. Construction drive mechanism easy stacker: An AC motor (33) situated underneath the...
- Page 63 OUTPUT CONVEYOR Construction infeed stopper easy stacker: The infeed stopper is positioned in the output conveyor just before the trays of the output conveyor are entering the easy stacker. A solenoid (50) controls a lever (51). When the solenoid is activated it puts the lever in the position where it stops the tray at the entrance of the easy stacker (52).
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Page 64: Adjustments Output Conveyor
OUTPUT CONVEYOR ADJUSTMENTS OUTPUT CONVEYOR TRANSPORT BELT TENSION Adjust the tension of the transport belts in such a way that they won’t slip on the drive rollers during start up and during normal production with full load. Loosen up the tensioning roller lock bolts (1) on both sides of the output conveyor. -
Page 65: Hatch Tray Stop Position
OUTPUT CONVEYOR HATCH TRAY STOP POSITION TIP! Make sure the pick up position of the vacuum head is correct before adjusting the hatch tray stop position. Follow below steps to check the stop position of the hatch tray: 10. Place a hatch tray against the first stopper. -
Page 66: Adjustments Easy Stack
OUTPUT CONVEYOR ADJUSTMENTS EASY STACK LIFT GUIDES Adjust the 2 tray guides (30) on the lift (31) to guide the tray onto the lift. Loosen up the 2 bolts (32) and position the guides to fit into the slots of the tray. Tighten up the bolts after adjustment. -
Page 67: Infeed Sensor
OUTPUT CONVEYOR INFEED SENSOR The infeed sensor (43) detects a tray at the infeed of the easy stacker but also determines the start of the lift. Adjust the sensor in such a way that it detects (turns ON) a tray when it arrives at the infeed stopper (44). -
Page 68: Lift Bottom Position
TIE ROD ADJUSTMENT The tie rods (57 and 58) are factory set. We advise you to consult Prinzen before adjusting the tie rods! Page 68 of 83 SERVICE MANUAL PSPC... -
Page 69: 6. 30 Cell Tray Denester
30 CELL TRAY DENESTER 6. 30 CELL TRAY DENESTER SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 69 of 83... -
Page 70: Description 30 Cell Tray Denester
30 CELL TRAY DENESTER DESCRIPTION 30 CELL TRAY DENESTER Use: The tray denester separates a single tray from a stack of trays and drops this tray on the output conveyor. Construction: The tray denester (1) is placed on top of the output conveyor (2). - Page 71 30 CELL TRAY DENESTER Safety: CAUTION! The denester is not completely secured with Do not enter objects or body parts into the protective covers. Therefore be cautious with denester when it is running production. loosely hanging clothes and long hair, do not come too close to the denester and do not ATTENTION! touch it when it is running production.
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Page 72: Adjustments 30 Cell Tray Denester
30 CELL TRAY DENESTER ADJUSTMENTS 30 CELL TRAY DENESTER BUNKER ADJUSTMENT Make sure there is a free space for the stack of trays (20) inside the bunker. Adjust this space with the positions of the sides (21) of the bunker. Adjust the 4 sides in such a way that the trays are centered on the output conveyor. -
Page 73: Lower Grippers
30 CELL TRAY DENESTER LOWER GRIPPERS For several types of trays, Prinzen has tray denester conversion kits. Among others the following kits are available: Paper trays Plastic trays Hartmann egg tech unic trays The lower grippers for several conversion kits have different shapes of lower grippers. -
Page 74: Denester Stop Position
48. Place back the circlip to lock the cam ring on the clutch. Place back the cover TIE ROD ADJUSTMENT The tie rods (46) are factory set. We advise you to consult Prinzen before adjusting this tie rod! Page 74 of 83 SERVICE MANUAL PSPC... -
Page 75: Hatch Tray Denester
HATCH TRAY DENESTER 7. HATCH TRAY DENESTER SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 75 of 83... -
Page 76: Description Hatch Tray Denester
HATCH TRAY DENESTER DESCRIPTION HATCH TRAY DENESTER Use: The hatch tray denester separates a single hatch tray from a stack of trays and drops this tray on the output conveyor. Construction: This hatch tray denester (1) is placed on top of the output conveyor (2). - Page 77 HATCH TRAY DENESTER Safety: CAUTION! The denester is not completely secured with Do not enter objects or body parts into the protective covers. Therefore be cautious with denester when it is running production. loosely hanging clothes and long hair, do not come too close to the denester and do not ATTENTION! touch it when it is running production.
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Page 78: Adjustments Hatch Tray Denester
HATCH TRAY DENESTER ADJUSTMENTS HATCH TRAY DENESTER BUNKER ADJUSTMENT Make sure there is a free space for the stack of hatch trays (1) inside the bunker. Adjust this space with the positions of the sides (2) of the bunker. Adjust the 4 sides in such a way that the trays are centered on the output conveyor. -
Page 79: Denester Stop Position
16. Repeat 10 to 15 until the tie rod and crank are in the vertical position. TIE ROD ADJUSTMENT The tie rods (17) are factory set. We advise you to consult Prinzen before adjusting this tie rod! SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC... -
Page 81: Trouble Shooting Guide
TROUBLE SHOOTING GUIDE 8. TROUBLE SHOOTING GUIDE SM-PSPC-01-E/03-2008 SERVICE MANAUL PSPC Page 81 of 83... - Page 82 TROUBLE SHOOTING GUIDE TIP! For all electrical failures, first check the circuit breakers, motor protection switches and fuses! Failure Conditions Possible causes Possible solutions Machine not able to reset White light on start- 1 Emergency stop Unlock or replace /reset button is OFF button pushed or defective 2 Fuse F18 defective...
- Page 83 TROUBLE SHOOTING GUIDE Failure Conditions Possible causes Possible solutions 30 cell tray denester Machine is running 1 selector switch on Switch ON doesn’t start conveyor is OFF 2 Photocell “start Replace or adjust denester” defective or incorrect adjusted 3 Clutch is not activated Relay K9 defective 30 cell trays stuck on one 1 Upper grippers Adjust...
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