Dentech Line 1B Packaging Operation And Maintenance Manual

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Operation and

Maintenance Manual for

Line 1B Packaging

Last updated 09/20/2024

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Page 1 Operation and Maintenance Manual for Line 1B Packaging Last updated 09/20/2024...
Page 2 Edition notice DenTech Industrial 1975 N. Reading Rd. Denver, PA 17517, USA For customer support, please contact our service technicians. Phone: (717) 335-4899 Email: service@dentechindustrial.com Or visit dentechindustrial.com/customer-support Manual ID: C129911 LINE 1B PACKAGING MANUAL...
Page 3: Table Of Contents
3. Troubleshooting…………………..………………………………………………………….………...38 4. Fault clearing……………………………………………………………………………………………….39 4.1 Machine state messages…………………………………………………………..39 4.2 Warnings and alarms……………………………………………………………….…40 5. Maintenance……………..……………………………………………….…………………………….….49 For detailed information on machine components, please see the manufacturers’ manuals. See lists provided by DenTech Industrial for recommended spare parts. LINE 1B PACKAGING MANUAL...
Page 4: Safety Notice
DenTech Industrial is not liable for any consequences arising from misuse of this system. If you are unsure of whether you are qualified to use or maintain this system, please contact a Costco supervisor or manager or other qualified professional for assistance.
Page 5: Equipment Overview
1. Equipment overview Line 1B Packaging receives bags from upstream equipment, collates bags into a uniform stream, and then feeds bags into a case packer. The line runs two products: trail mix (28 count) and variety pack (30 count, 10 each of 3 flavors).
Page 6: Operation And Safety
2. Operation and safety This section covers how to operate Line 1B Packaging and includes safety information. Detailed information about each component in the machine is available in manufacturers’ manuals. 2.1 Button functionality Each cell in the line has operation buttons and an HMI screen on either side of the cell.
Page 7 3. Stop: Press to stop the machine cycle. 4. Start: Press to place the machine in Auto Mode and to start operation. 5. Request to enter: Stops the air valves and bleeds air. When conditions are safe to enter, the doors unlock. LINE 1B PACKAGING MANUAL...
Page 8 • Line Start – Green • Line Fault Reset - Blue (Note: This button will reset alarms BUT NOT safety devices. Use the physical Reset button on each cell to reset safety devices for the specific cell.) LINE 1B PACKAGING MANUAL...
Page 9 • Feeder 1 Start – Green • Feeder 1 Fault Reset - Blue (Note: This button will reset alarms BUT NOT safety devices. Use the physical Reset button on each cell to reset safety devices for the specific cell.) LINE 1B PACKAGING MANUAL...
Page 10: Light Stack And Interior Lighting
• Solid white – Guard stop is enabled, and a door is open Note: If machine conditions would indicate two different light colors in the cell, the interior light will be the color of the more severe status. LINE 1B PACKAGING MANUAL...
Page 11: Hmi Overview
Tap on the cell you want to operate and then use the soft buttons for Line Guard Stop, Line Stop, Line Start, Line Fault Reset, and Line Sys Reset. Home screen – Shows the machine status and navigation menu. Includes status and fault banner. LINE 1B PACKAGING MANUAL...
Page 12 Home screen while running – While the line is running, the feeder cells and case packer cell are outlined in green. LINE 1B PACKAGING MANUAL...
Page 13 Cell overview screens – Tap on a cell to select it and see the overview screen for that cell. Feeder 1 overview Feeder 2 overview LINE 1B PACKAGING MANUAL...
Page 14 Feeder 3 overview Feeder 4 overview LINE 1B PACKAGING MANUAL...
Page 15 Case packer overview LINE 1B PACKAGING MANUAL...
Page 16 Home screen with navigation – Tap the menu button in the top-right corner (three blue lines) to view the navigation menu. Home screen in system navigation – Tap the menu button in the top-right corner (three blue lines) to view the navigation menu. Then tap “System” to access system information. LINE 1B PACKAGING MANUAL...
Page 17 Tap on the U.S. flag to view the HMI screens in English. Tap on the Mexican flag to view the HMI in Spanish. Machine Info window – Tap i button in the toolbar to view machine info. This screen includes network information and the phone number to call for parts and service. LINE 1B PACKAGING MANUAL...
Page 18 Network Info window – Tap “Network Information” button to view IP addresses for machine components. LINE 1B PACKAGING MANUAL...
Page 19 Login window – Tap the person icon in the toolbar (far right) to access login settings. LINE 1B PACKAGING MANUAL...
Page 20 Statistics screens – Shows machine statistics. Main statistics – Shows overall stats for feeder cells and case packer. Feeder statistics – Shows stats for each feeder cell. LINE 1B PACKAGING MANUAL...
Page 21 Case packer statistics – Shows statistics for the case packer cell. LINE 1B PACKAGING MANUAL...
Page 22 IO Rack screens – Navigate to System and the IO Rack to view the IO Rack screens. Use the up and down arrows on the left side of the screen to scroll up and down the list. Press “Enter” to select item. With inputs: With VFD: LINE 1B PACKAGING MANUAL...
Page 23 PLC Time Control screen – Navigate to System and “PLC Time Control” to view the date time settings for the PLC. Use the column on the right to set the new date time. Then press “Set PLC Clock.” LINE 1B PACKAGING MANUAL...
Page 24 Alarms overview screen – Tap on one of the cells to select it and view the alarm log for that cell. LINE 1B PACKAGING MANUAL...
Page 25 Alarms screen – Shows a list of alarms and corresponding messages. Scroll up and down the list using the up and down arrows on the left side of the screen. LINE 1B PACKAGING MANUAL...
Page 26 Manual control overview screen – Select one of the cells to manual control it. Note: To jog main conveyors, press “Main Belt Manual.” Then the main line conveyors can each be controlled manually to move forward or in reverse. LINE 1B PACKAGING MANUAL...
Page 27 Press the “Vision Lights” button to toggle the vision lights on or off. Manual feeder control screen (when enabled) – When “Manual Mode” is enabled, robot 1, robot 2, the bagger conveyor, and the vision conveyor in the cell can be controlled manually. LINE 1B PACKAGING MANUAL...
Page 28 Manual feeder control screen (when enabled) – When “Manual Mode” is enabled, robot 1, robot 2, CP cassette servos, CP Fixture Conveyor Servo, and CP Full Case Conveyor, and CP Empty Case Conveyor in the case packer cell can be controlled manually. LINE 1B PACKAGING MANUAL...
Page 29 Product Selection screen – Shows products to select. Use the up and down arrows on the left side of the screen to scroll up or down the list. When a product is selected, photos of the product and the required end tool are displayed. Note: Machine must be guard-stopped to change product. LINE 1B PACKAGING MANUAL...
Page 30: Startup Procedure
Note: If a bagger is not performing up to rate, the other equipment in the line needs to be slowed down to match the lowest rate in the system. There are two ways to start Line 1B Packaging. Perform a sequential start when powering up the line for the first time or after a changeover.
Page 31 To clear out the cassettes on the case packer, press the ‘Empty Cassette #’ button on the Case Packer overview screen. This will push out an incomplete case, as long as there is a robot presenting a box to the cassette. LINE 1B PACKAGING MANUAL...
Page 32: Changeover Procedure
• When the variety packs are selected, Feeder 4 will be idle and the rest of the cells will run. • Different cases are used for each recipe, but no physical adjustments are needed when changing products. LINE 1B PACKAGING MANUAL...
Page 33: Shutdown Procedure
E-Stop button for an added layer of protection. 4. If the operator intends to change project, they can remove bags from the buffer zones. 5. Turn off the electrical disconnects and the air disconnect. LINE 1B PACKAGING MANUAL...
Page 34: Emergency Stops: Locations And Recovery
There are also E-stop buttons on each robot controller. When an E-stop is triggered, the stack light and interior cell light will be red. When conditions in Line 1B Packaging are safe, follow these steps for E-stop recovery: 1. Ensure all E-stop buttons are out.
Page 35: Safety Lockouts And Interlocks
2.8 Safety lockouts and interlocks Each cell has an electrical lockout on the side opposite the baggers. Each cell has a pneumatic lockout on the side with the baggers. LINE 1B PACKAGING MANUAL...
Page 36 Doors of the cell are located on each side of every cell. Each set of doors has interlocks with lights to indicate status. • Blinking green – Door is not locked • Solid green – Door is locked • Red – Door is open LINE 1B PACKAGING MANUAL...
Page 37: Sensors
2.9 Sensors Line 1B Packaging does not have physical sensors. Sensor trigger positions along belts give the system virtual position data of products on belts. There are no light curtains in the system. 2.10 Potential hazards Take caution when using this equipment.
Page 38: Troubleshooting
Please note that for maintenance of this system, “lock out, tag out” safety protocol applies. This means that any time maintenance on this system is performed, the machine must be properly locked out and tagged out or labeled, explaining that maintenance is taking place. LINE 1B PACKAGING MANUAL...
Page 39: Fault Clearing
• MANUAL MODE: Machine is in a manual mode, turned on by the switch on the manual screen • FAULTED: Machine is in a faulted state • STOPPING...: Machine is moving to a cycle stop position • RUNOUT MODE: Machine is in runout mode. LINE 1B PACKAGING MANUAL...
Page 40: Warnings And Alarms
F# VISION CONV BIN The bin at the end of the Empty the bin at the end of the cell’s vision FULL vision conveyor is close to conveyor. full LINE 1B PACKAGING MANUAL...
Page 41 Select a valid product from the HMI NOT CONFIGURED that is not configured F# EMPTY VISION CONV Cell’s overflow bin has been Empty the overflow bin to continue. OVERFLOW BIN full for more than two minutes LINE 1B PACKAGING MANUAL...
Page 42 PLC has lost connection to Verify ethernet connection from vision ETHERNET FAULT the vision conveyor conveyor drive to PLC F# ROBOT FAILED TO Robot failed to change Re-select recipe from the product select CHANGE RECIPE recipe screen on the HMI LINE 1B PACKAGING MANUAL...
Page 43 AUTO RUN to clear warning. Case packer are not. will still run while this warning is active. CP MAIN CONV BIN The Case Packer’s main Empty the bin at the end of the main FULL conveyor bin is getting full conveyor. LINE 1B PACKAGING MANUAL...
Page 44 F4 CELL ENABLED AND This is a Variety Pack Use the LINE START HMI push button to put NOT RUNNING Specific Fault. The Case all enabled cells and The Case Packer into Packer entered Auto Run AUTO RUN. LINE 1B PACKAGING MANUAL...
Page 45 Exterior Empty Case Check VFD for error code, or press RESET SUPPLY CONV FAULTED Conveyor Drive has faulted EXT CASE ERECTOR Exterior Empty Case Check VFD for error code, or press RESET CONV FAULTED Conveyor Drive has faulted LINE 1B PACKAGING MANUAL...
Page 46 Perform a SYSTEM RESET on the cell to NOT RUNNING running. restart the robot program. CP ROBOT 3 NOT Robot 3 is not powered on or Power on robot or perform a SYSTEM BOOTED UP has not started it’s startup RESET program LINE 1B PACKAGING MANUAL...
Page 47 2 servo pusher 2 servo drive to PLC FAULT drive. CP ROBOT 1 FAILED TO Robot 1 failed to change Re-select recipe from the product select CHANGE RECIPE recipe screen on the HMI LINE 1B PACKAGING MANUAL...
Page 48 ETHERNET FAULT the external empty case conveyor drive to PLC conveyor. EXT CASE ERECTOR PLC has lost connection to Verify ethernet connection from full case CONV ETHERNET the external case erector conveyor drive to PLC FAULT conveyor. LINE 1B PACKAGING MANUAL...
Page 49: Maintenance
On a daily basis, the operator should perform a visual inspection of the components in Line 1B Packaging for any issues that would affect performance. The operator should perform general housekeeping to keep Line 1B Packaging and surrounding area clean.
Page 50 Vacuum filter for LR Mate 200iD robot For preventative maintenance of each component, see the manufacturers’ manuals. Maintenance schedules For maintenance schedules, see the manufacturers’ manuals for each component. LINE 1B PACKAGING MANUAL...
Page 51 Operation and Maintenance Manual for Label and Cartoner Loading Cell For customer support, please contact DenTech Industrial's service technicians. Phone: (717) 335-4899 Email: service@dentechindustrial.com Or visit dentechindustrial.com/customer-support 1975 N. Reading Rd., Denver, PA 17517 717-335-4820 | www.dentechindustrial.com Manual ID: C129911 ©2024 DenTech Industrial...