Related Manuals for Tomra AUTOSORT
Summary of Contents for Tomra AUTOSORT
- Page 1 English AUTOSORT with FLYING BEAM® technology USER MANUAL A GLOBAL PIONEER IN SENSOR-BASED SORTING...
- Page 2 Japan Korea Poland Russia TOMRA Sorting K.K. TOMRA Sorting Co., Ltd. TOMRA Sorting Sp. z o.o. "TOMRA Sorting" LLC 3-2-5 Magamoto, Minami-ku #404-1, Central Building, 762-4, Ul. Ligocka 103 Bakhrushina str. 32 bld. 1 Saitama-shi, Saitama 412-222 Haengsin-dong...
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Page 3: Table Of Contents
Commissioning the machine ........................12 Personal protective equipment ..................13 Personnel requirements ....................14 Device description ......................... Functional description ..................... 15 TOMRA Sorting scope of delivery ..................16 Technical data ......................... Ambient conditions ......................17 Dimensions and weights ....................17 Power supply ........................18 Compressed air supply .....................19... - Page 4 User Manual Installation and commissioning ..................Requirements for installation ..................26 Installation ........................27 Commissioning .......................27 6.3.1 Installation ..............................28 6.3.2 Commissioning ............................28 6.3.3 Optimization during production ......................29 Electrical connections ......................Electrical welding ......................31 Power connection ......................32 Signal interface and operating conditions ................ 33 7.3.1 Terminal list ..............................
- Page 5 User Manual Cleaning valve block cover for nozzles ................51 Cleaning valves ......................52 Cleaning VBPS ........................ 52 Cleaning the gap between valve block and conveyor ............52 Cleaning touchscreen ..................... 52 9.10 Cleaning heat exchanger ....................53 Troubleshooting ........................10.1 Operational fault conditions ....................
- Page 6 User Manual UM-KO-0026-REV0.0-en...
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Page 7: Introduction
+ Rated output in kilowatts Machinery Directive The AUTOSORT is certified as partly completed machine according to the specification the Machinery Directive (2006/42/EC) Annex II B No. 3 and is intended for incorporation into the final machinery. Due to this no CE mark must be applied to the partly complete machine. A declaration of incorporation according to the Annex II B will be provided by TOMRA Sorting. -
Page 8: Copyright
User Manual Introduction The incorporation of the AUTOSORT is carried out by TOMRA Sorting or by an authorized third- party. For incorporation of the machine an installation guideline in English is available on request (IM-KO-0002). Copyright The content of this manual is confidential and remains the unalienable property of TOMRA Sorting GmbH and copyright ©... -
Page 9: Layout Of Safety Messages
User Manual Introduction Abbreviation Description Kilogram Kilowatt Pound m³ Cubic meter Meter Milliampere Milligram Minute Millimeter Near infrared Programmable Logic Controller Red-Green-Blue (color model) Sorting Control System V AC Voltage of Alternating Current VBPS Valve Block Positioning System V DC Voltage of Direct Current Visual spectrum Watt... -
Page 10: Safety
The AUTOSORT must only be operated indoors. The AUTOSORT components are intended to be integrated into a sorting machine including a conveyor belt and a separation chamber. Only after this integration, a complete machine is build and ready for the industrial separation of recyclable materials. -
Page 11: Important Safety Messages
User Manual Safety Important safety messages The following safety messages apply throughout the life cycle of a machine and must be observed at all times. 2.2.1 General safety messages DANGER Danger due to bypassing the safety devices. Danger to life! –... -
Page 12: Safety Precautions
+ To provide a notice stating who is responsible for the installation. + To provide a notice describing the first aid procedure at the work place. + To inform the TOMRA Sorting personnel installing the machine of the internal safety regulations, and to document this with a signature list. -
Page 13: Personal Protective Equipment
User Manual Safety Personal protective equipment When operating, cleaning or maintaining the machine, wear suitable protective clothing. For details, refer to the warning signs. The following protective equipment must be provided: Safety gloves Safety footwear, according to DIN EN ISO 20345, category S3, or in compliance with local regulations. -
Page 14: Personnel Requirements
The table below summarizes the personnel requirements in each life cycle phase of the machine. Operating phase Requirements Explanation Transport Instructed personnel Assembly/ Specialist Performed by TOMRA Sorting Service or by an authorized third- Installation party. Setup/ Specialist By the manufacturer. Commissioning The operating company is permitted, after receiving appropriate instruction, to specify different settings for materials and run different sorting programs. -
Page 15: Device Description
Separation chamber Fig. 2: Functional principle Feedstock material is deposited evenly on a conveyor (1) where it is scanned by the AUTOSORT scanner unit and an optional EM sensor. During scanning, the complete width of the belt is scanned linearly. If a sensor detects material which needs to be sorted out, the control unit sends the command to blow the corresponding valves of the valve block at the end of the conveyor. -
Page 16: Tomra Sorting Scope Of Delivery
TOMRA Sorting scope of delivery The TOMRA Sorting scope of supply consists of the components shown in the illustration below. The optional features are shown in sea blue. The conveyor, scanner frame, support frame and VPBS adjustment are to be supplied by the customer if not bought as an option. -
Page 17: Technical Data
2.000 m a.s.l. Tab. 5: Ambient conditions Dimensions and weights The following table lists dimensions and weights for the machine components. For exact values please refer to the dimensioned drawing provided by the TOMRA Sorting project manager. Component Type - Assembly Weight... -
Page 18: Power Supply
TOMRA Sorting project manager. Power supply The AUTOSORT system has to be supplied continuously with an undisturbed electrical sine voltage. During normal operation, the system must not be switched off/on and has to be powered... -
Page 19: Compressed Air Supply
Typical values for air consumption are defined in the offer. Specific values should be defined in a contract. All AUTOSORT systems are delivered with a 1”x 40 mm hose nipple A. Customer scope of supply Compressed air tube Ball valve B. -
Page 20: Different Sensor Configurations
(figure 4, item 5). The interface is the inlet hose nipple of the air pressure regulator delivered by TOMRA Sorting. The customer has to provide a compressed air tubing or a hose with a connection length of min. 1000 mm (39.37 in.) up to the inlet, including the clamps to fix the hose. - Page 21 User Manual Technical data Depending on the sensor configuration a wide variety of standard applications is available. The AUTOSORT 4 can be used for the following sorting tasks: Standard application package Description POLYMER sorting Sorting of e.g. beverage cartons, PE, PP, PS, PET,...
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Page 22: Optional Features
Statistic Package including CCU with Statistic Explorer USB-Kit USB download kit for statistic data Control interface for Remote Task switch Control Interface via OPC Control Interface via TOMRA Central Control Unit PBUS Control Interface via Profibus ModBus Control Interface via ModBus... -
Page 23: Transport
Only use lifting and load-carrying equipment with the CE marking and a valid declaration of conformity. TOMRA Sorting employees are not permitted to operate load-carrying devices at the customer’s site. An operator employed by the customer must be on-site if necessary. -
Page 24: Damage And Claims
Lifting the machine The AUTOSORT components are delivered packed in wooden boxes. The amount of these boxes is depending on the size of the machine and the additional options. Each box must be lifted and arranged close to the place of installation. -
Page 25: Storage
Customer is obligated to ensure the goods are insured against loss. The buyer must demonstrate corresponding insurance coverage. TOMRA Sorting reserves the right to check proper storage if it has reasonable grounds to do so. All costs associated with any such check will be borne by the buyer. -
Page 26: Installation And Commissioning
The floor must be able to bear the entire weight of the machine and all further equipment (e.g. for motor maintenance) without deforming. For detailed information on the space requirements and dimensions and weight of the machine, refer to the dimensioned drawing provided by the TOMRA Sorting project manager. -
Page 27: Installation
User Manual Installation and commissioning Installation The incorporation of the AUTOSORT is carried out by TOMRA Sorting or by an authorized third- party. Commissioning DANGER Danger due to bypassing safety devices. Danger to life! – Safety devices must not be bypassed. -
Page 28: Installation
The material flow will be interrupted by TOMRA Sorting Service for optimization of the sorting tasks. A specialist with the knowledge of the required sorting tasks must be on site allowing TOMRA Sorting Service to set the proper sorting tasks. -
Page 29: Optimization During Production
It is often during this stage that customers also realize the benefits of having selected one or both of our financial offerings. We offer our best so that you can, too. Fig. 6: TOMRA Care For more information about TOMRA Care please contact TOMRA Service. UM-KO-0026-REV0.0-en... -
Page 30: Electrical Connections
User Manual Electrical connections Electrical connections Observe the following requirements for the electrical connections of the machine: + Only electrical technicians may work on the electrical system. + Determine the mains voltage according to the local regulations. The connection for the power supply is located in the control unit. -
Page 31: Electrical Welding
Electrical connections Electrical welding If welding should be done on a TOMRA Sorting system, please consult the detailed safety rules for welding in advance in order to prevent injury or damage of machinery like PE wires! Recommended minimum guideline is the German information of the employer’s liability insurance coverage of metal workers, called Berufsgenossenschafts-Information BGI 553. -
Page 32: Power Connection
3 Wire Fig. 10: AUTOSORT power connection - 480V transformer The AUTOSORT system has to be supplied continuously with an undisturbed electrical sine voltage. During normal operation, the system must not be switched off/on and has to be powered uninterruptedly! The fluctuations in the main supply voltage must not exceed +/-10% of the nominal supply voltage! UM-KO-0026-REV0.0-en... -
Page 33: Signal Interface And Operating Conditions
Electrical connections Signal interface and operating conditions The flex outputs are configured by TOMRA Sorting service according to the customer requests. In case of special options like an AUTOSORT with the two pressure control system the outputs are reduced. “Option satellite”... -
Page 34: Terminal List
+ 24 VDC From customer PLC. 5/6: 5/6: closed contact Sorter ready AUTOSORT is ready to sort (computer has finished 24 V DC 13:2 A or start-up). 230 V AC 15:3 A Direct connection + 24 VDC From customer PLC. -
Page 35: Flex Signals
7.3.2 Flex signals In accordance with the customer TOMRA Service can configure three flexible outputs and the output “Common Warning”. Each signal can be set to each output. The output “Common Warning” can be used for one signal or to combine several signals. Each Flex output is limited to one signal. -
Page 36: Sequence Diagram
To switch sorting on/off by remote control. The signal must be set when the belt moves, and reset before the belt is stopped. 4. Internal error: In case of an internal error of the AUTOSORT causing a stop of the sorting, the “Running” signal is set to off. Then usually a user action is necessary. -
Page 37: Operation
User Manual Operation Operation DANGER Danger due to bypassing safety devices. Danger to life! – Safety devices must not be bypassed. WARNING Danger due to valve block movement. Injuries caused by crushing! – Keep hands and feet away from the valve block and stay out of the moving range of the VBPS as long as the system is pressurized. -
Page 38: Before Commencing Operation
User Manual Operation CAUTION Danger due to elevated work places. Injuries from falling! – Only carry out work in safe areas that are safeguarded by a guard rail. We recommend a minimum height of 110 cm (43 in) for the rail and a width of 80 cm (31 in) for the gangway, and local regulations must always be complied with. -
Page 39: Operating And Display Elements
Figure 13. For exact information on the control panel, please contact the TOMRA Sorting project manager. If the AUTOSORT works as a standalone unit and is not remote operated, the control unit is the only operational user interface. -
Page 40: Operating Software
The operating software allows the operator to use the machine functions and sorting program features included in the purchased application package. Fig. 14: Start screen The operating software is described in detail in the user manual for the UM-KO-0020 “Common User Interface for AUTOSORT & FINDER”. UM-KO-0026-REV0.0-en... -
Page 41: Vbps
User Manual Operation VBPS 8.3.1 Setup The system consists of two shafts mounted at the sides of the valve block, lever, brackets and pneumatic air cylinder with stop valve, a control valve, connection tubes, air pressure regulator unit with manometer and an electrical switch to operate the control valves. VBPS power VBPS key switch VBPS push button... -
Page 42: Valve Block Movement
User Manual Operation The VBPS is operated with the following components: Component Description AUTOSORT Main power switches 1 and 4 (see figure 13). control unit VBPS control unit One key switch 2 and a push button 3 (see figure 15). -
Page 43: Start-Up Sequence
User Manual Operation DOWN Working position UP Cleaning/maintenance position DOWN Fig. 17: Valve Block Positioning System Start-up sequence 8.4.1 Local or remote sorter control The sorter can be operated in two different modes, locally or remotely. Beware of the following when starting the sorter. The switch number shown in figure 18 is referring to numbering in figure 13 on page 39 and the Always activate lamps function is... -
Page 44: Local Start Up
This mode is intended to ensure operation in case the regular start up fails or when instructed to do so by TOMRA Service! For local start up do the following. The switch numbers shown in figure 19 are referring to... -
Page 45: Remote Start Up
User Manual Operation 8.4.3 Remote start up For remote start up do the following. The switch numbers shown in figure 20 are referring to numbering figure 13 on page 39s) and the Always activate lamps function is described in “ ”... -
Page 46: Central Control Room Functions
User Manual Operation 8.4.4 Central control room functions Remote operation enables the following functions to be read/executed from a central control room: + Automatic switching on and off of the entire system. + “Ready for operation” message is given from the sorter. Stop / emergency stop 8.5.1 Stop... -
Page 47: Emergency Stop For Vbps
User Manual Operation 8.5.4 Emergency stop for VBPS If anybody, against all security issues, is stuck between the valve block and the conveyor, the valve block can be moved down by doing as follows: Turn main power switch ON. Turn VBPS key switch 2 (figure 15) to DOWN (=1). Fig. -
Page 48: Operating Pressure For Different Applications
User Manual Operation Operating pressure for different applications The operating pressure should be chosen depending on the material selected for ejection. This ensures on the one hand that light material such as foil is ejected correctly and that swirling of material is avoided and on the other hand that heavy materials are propelled with sufficient force to pass over the splitter. -
Page 49: Cleaning
User Manual Cleaning Cleaning Prior to cleaning any part of the machine, under the machine or at the material inputs and outputs, the machine must be switched off! Check that the safety installations are in place and operational. CAUTION Danger due to moving material in the sorter and the compressed air flow. Danger of working on the sorter during the sorting process. -
Page 50: Cleaning Equipment
User Manual Cleaning Cleaning equipment Make sure the compressed air cleaner is properly attached to the hose before starting the sorter and before and after carrying out maintenance. Always wear safety glasses when working with compressed air. Cleaning intervals The cleaning intervals depend on the degree of soiling of the machine/components, which depends on the operating time and the material being processed. -
Page 51: Cleaning Heat Exchanger
User Manual Cleaning Remove dust, dirt and other soiling by lightly wiping the optical surfaces with a soft cloth. Do not calibrate the color camera or the NIR sensor when lamp modules are broken. If lamp modules are broken, the amount of reflected light is less which reduces the intensity of the signal received by the sensor. -
Page 52: Cleaning Valves
Cleaning procedure: 1. Switch off the conveyor and secure it against being switched back on. 1. Deactivate in the software “Always activate lamps”. Refer to the user manual “AUTOSORT & FINDER Common User Interface”, chapter “Lights”). 2. Move the valve block DOWN, see chapter 8.3.2. -
Page 53: Cleaning Heat Exchanger
User Manual Cleaning 9.10 Cleaning heat exchanger Cleaning the heat exchanger means to remove the dust deposit from the cover. Only the cover is cleaned from the dust that has settled. Never use compressed air to clean the heat exchanger! Fig. -
Page 54: 10 Troubleshooting
User Manual Troubleshooting 10 Troubleshooting DANGER Danger due to bypassing safety devices. Danger to life! – Safety devices must not be bypassed. WARNING Danger due to valve block movement. Injuries caused by crushing! – Keep hands and feet away from the valve block and stay out of the moving range of the VBPS as long as the system is pressurized. - Page 55 User Manual Troubleshooting CAUTION Danger of falling due to unexpected movements when removing obstructions. Contusion! – Do not interfere with the material flow using poles or sticks. – No manual valve test. CAUTION Danger due to elevated work places. Injuries from falling! –...
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Page 56: Operational Fault Conditions
Check compressed air at the air pressure regulator for VBPS and sorter. Lack of electrical power. Check that AUTOSORT system is switched ON and that power is indicated on AUTOSORT sorter control unit and VBPS control unit. Tab. 19: Operational fault conditions... - Page 57 (refer to user manual “Common User Interface” (UM-KO-0020)). Contact TOMRA Sorting service if nothing above solves the problem. Remote control Fault in connection to remote Turn switches 4 and 5 (see “Operating and display does not work control.
- Page 58 Valves at the valve block are not Perform automatic valve test. If individual valves do working. not respond, test them manually and replace as necessary. Contact TOMRA Sorting service if nothing above solves the problem. Tab. 19: Operational fault conditions UM-KO-0026-REV0.0-en...
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Page 59: Messages
- Network switch switched off; switch on. - Network switch defective; replace or call TOMRA Sorting service. - Network port of computer defective; replace or call TOMRA Sorting service. - EM controller defective, call TOMRA Sorting customer service. Corrupt or missing classifier Restart the system, restore backup configuration, change sorting task or contact TOMRA Sorting service. -
Page 60: 11 Maintenance
Our systems incorporate cutting-edge technology and the latest developments in sensor-based sorting. To keep the machines running efficiently, the following basic requirements must be met: + All work on TOMRA Sorting equipment needs to be carried out strictly in accordance with this manual. - Page 61 User Manual Maintenance CAUTION Residual energy may still be present in power lines (frequency converter) and pneumatic pressure lines even if the machine is switched off. Injury from electric shock and compressed air! – All work on the electrical and pneumatic equipment of the machine may only be carried out by qualified personnel.
- Page 62 Only use original spare parts as otherwise the warranty will be rendered null and void. TOMRA Sorting offers training courses for operation and maintenance personnel. Please contact us for an offer tailored to your individual needs. We recommend using only TOMRA Sorting original parts.
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Page 63: Safety Equipment
To maintain high quality and performance, a calibration check must be performed from time to time. For detailed information on the calibration process, please refer to the user manual of the UM-KO-0020 “AUTOSORT & FINDER Common User Interface”, chapter “Sensor calibration”). When should a system be calibrated? TOMRA Sorting can only provide recommendations. -
Page 64: Replacing Halogen Lamp Unit
User Manual Maintenance 11.2.2 Replacing halogen lamp unit The “Lights” diagnosis dialog indicates the intensity of each lamp module at the optical sensor. Each module is equipped with two halogen lamp units. If both halogen lamp units are working, the light intensity should be around 95% to 100%. - Page 65 User Manual Maintenance All halogen lamps are calibrated by TOMRA Sorting in order to find the optimum sorting position. If the position of the lamp is changed, the sorting results will deteriorate significantly. Always exchange the entire halogen lamp unit.
- Page 66 User Manual Maintenance Scanner Heat exchanger Screw Spring washer Flat washer Cooling fins Lamp 2 Lamp 1 Lamp bracket 10 Halogen lamp module 11 Retaining screw (2x) Fig. 28: Exchanging halogen lamp module UM-KO-0026-REV0.0-en...
- Page 67 User Manual Maintenance Note that each time a halogen lamp unit is exchanged the lamp hours must be reset. 9. Turn the lamps on! 10. Tap the bulb icon for the corresponding lamp module in the “Lights” dialog to open the “Lamp exchange”...
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Page 68: Valve Block
11. Move the valve block in up (working) position (see “VBPS” on page 41). 12. Confirm a correct air blow by performing a test of the valve block unit as described in the user manual “AUTOSORT & FINDER Common User Interface”, chapter “Ejector test”. UM-KO-0026-REV0.0-en... -
Page 69: Replacing Nozzles
10. Switch on the machine from the control unit. 11. Open the ball valve (figure 35/1) carefully. 12. Confirm a correct air blow by performing a test of the valve block unit as described in the user manual “AUTOSORT & FINDER Common User Interface”, chapter “Ejector test”. UM-KO-0026-REV0.0-en... -
Page 70: Replacing Valve Block Cover Of Housing
User Manual Maintenance 11.3.3 Replacing valve block cover of housing Tools: Locking key square 6 mm. 1. Close the ball valve (figure 35/1). 2. Move the valve block in down (maintenance) position (see “Valve block movement” on page 42). 3. Depressurize the system and check by reading off the values at the manometers (should be 0 bar). -
Page 71: Replacing Valves
User Manual Maintenance 11.3.4 Replacing valves Tools: Allen key size 4 mm. 1. Close ball valve (figure 35/1). 2. Move the valve block in down (maintenance) position (see “Valve block movement” on page 42). 3. Depressurize the system and check by reading off the values at the manometers (should be 0 bar). -
Page 72: Valve Test
Defective valves should be exchanged as quickly as possible to keep an optimal sorting performance. For this only use original TOMRA Sorting parts because they are temperature and speed optimized. -
Page 73: Pressure Setting
11.4.2 Pressure setting The setting of the VBPS is performed by TOMRA service. But in some rare cases (e.g. exchange of defective hoses) the pressure setting for the VBPS must be readjusted. The following steps describes how to ensure enough pressure to move the valve block to the upper position, but at the same time to maintain a pressure as low as possible in order to reduce the danger of crushing the hands or feet. -
Page 74: Pressure Equipment
User Manual Maintenance 11.5 Pressure equipment CAUTION Residual energy may be present in the pneumatic system even if the machine is switched off. Personal injuries caused by compressed air! – Always depressurize the pneumatic system before starting any maintenance work on it. Ball valve Output for cleaning pistol Knob for adjusting the main pressure... -
Page 75: Exchanging Pressure Regulator Filter
User Manual Maintenance 6. Disconnect all hoses (figure 35/7, 11 and 13). 7. Unscrew the pressure regulator from the support frame. 8. Fasten the new pressure regulator to the support frame. 9. Connect all air hoses. 10. Replace the solenoid connector (figure 35/5). 11. -
Page 76: Replacing Manometers
User Manual Maintenance 7. Pull the filter (figure 36/3) down and out and replace. 8. Attach the filter compartment and fasten the four screws. 9. Make sure that the compressed air system is properly sealed. 10. Open the compressed air feed carefully. 11. -
Page 77: Belt Speed Measurement
User Manual Maintenance 11.6 Belt speed measurement WARNING Danger due to body parts or objects being drawn into the system! Risk of serious injuries! – Make sure to wear suitable working clothes. – Do not work with loose clothing, long hair or dangling jewelry in the area around the infeed points. -
Page 78: 12 Maintenance Plan
Check status of the halogen lamps. Replace defective halogen lamp. Remove dust and dirt from the cooling fines Calibrate AUTOSORT [NIR1-VIS] and [NIR1-NIR2-VIS] Calibrate AUTOSORT [NIR1] and [NIR1-NIR2] Valve block Remove residues Clean the valve block cover for nozzles Cleaning the gap between valve block and... -
Page 79: 13 Decommissioning And Disassembly
Materials that are no longer required must be separated and disposed of according to national laws. We recommend that you contact TOMRA Sorting Service or TOMRA Sorting Sales. In consultation with TOMRA individual solutions for the decommissioning and disassembly of your machine can be discussed. - Page 80 User Manual Decommissioning and disassembly UM-KO-0026-REV0.0-en...
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Page 81: 14 Signs
User Manual Signs 14 Signs The customer must make sure that these sign are in use when necessary. 14.1 Sign “Do not operate” Do Not Operate! Danger of crushing! Personal are working on at the valve block! This sign must be removed only by: Date: Time: Fig. -
Page 82: Warning Sign - Operating Instructions
User Manual Signs 14.2 Warning sign - Operating instructions These instructions must be observed without fail! WARNING! Danger due to valve block movement Injuries caused by crushing! Switch the "Main power switch" and the "Plant ready" switch at the main control panel ON (switches 1 and 4). Open ball valve of the VBPS pressure regulator. -
Page 83: 15 Declaration Of Incorporation
User Manual Declaration of Incorporation 15 Declaration of Incorporation An example of a certificate for a AUTOSORT is shown below. The customer will receive a certifi- cate that is specific for the system delivered. The manufacturer TOMRA Sorting GmbH Otto-Hahn-Strasse 6 56218 Mülheim-Kärlich... - Page 84 User Manual Declaration of Incorporation UM-KO-0026-REV0.0-en...
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