MOBA Farmpacker M100T Installation guide

Release 5
4 April 2013
Training manual
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MOBA Farmpacker M100T
MOBA b.v.
Stationsweg 117
P.O. Box 7
3770 AA BARNEVELD
The Netherlands
(T) +31 (0) 342 - 455 655
(F) +31 (0) 342 - 455 755
(E) [e-mail]
(I) http://www.moba.nl
Document number:

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Table of content
Table of content 3
1 MOBA Farmpacker M100T 7
1.1 The Controlled stop postion 7
1.1.1 Adjusting the Dropset Stop postion. . . . . . . . . . . . . . . . . . . . . . 8
1.2 Initialization of the packing lane 9
2 The linear Actuator 11
2.1 Unlock compensation depending on speed 12
3 The Unlock Unit 15
3.1 Section 1 Output side 16
3.2 Section 2 Input side. 17
3.2.1 Dipswitch configurations . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Unlock unit signals and commands 18
3.4 Error messages of the Unlock unit 18
4 Machine timing Synchronisation in 4 steps 21
5 The LUST controller 25
5.1 Technical subscription LUST program 25
5.1.1 The learning procedure: . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.2 Running the lane: . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2 LUST controller modes 25
5.2.1 LUST Indication LED’s. . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3 Communication schematics LUST Controller 28
5.4 Update LUST program 30
6 ABI controller for the main motor 31

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7 The MSW1 33
7.1 Extra functions of the MSW1 33
7.1.1 Power supply and automatic thermal fuses . . . . . . . . . . . . . . . . . . . 34
7.1.2 Emergency procedure defective Linear actuator Farmpacker M100T . . . . . . . . . . . 36
7.2 Software update of the MSW1 37
7.2.1 Different Version of the MSW1 . . . . . . . . . . . . . . . . . . . . . . . 38
7.2.2 Conversion kit MSW-5 (Machine number 18.5400 up) . . . . . . . . . . . . . . . . 38
7.2.3 General information regarding update possibilities. . . . . . . . . . . . . . . . . . 39
7.3 MSW1 Quick reference 40
8 Inkjet provision 41
8.1 Signals 41
8.2 Inkjet diagram 42
9 Touch screen 45
9.1 Touch screen calibration 45
9.2 Adjust Contrast 45
9.3 Factory Reset 45
9.4 Erase Firmware software 46
9.5 Erase Application software 46
9.6 Update Software Touch screen 47

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10 M100 Fault diagnostics 51
10.0.1 All eggs are not dropped in the receiverset but instead go to the end of the machine . . . . . . 51
10.0.2 Machine starts, Lineair actuator does not move, all eggs to the end of the machine and the machine is not
able to stop. (unless by emergency stop)51
10.0.3 Only the first egg in a row go to the end of the machine, error symbol on screen. . . . . . . . 51
10.0.4 Dropset go down and lane does not pull-up, all eggs are dropped on top of each other, machine does not
stop.51
10.0.5 Lane does not pull-up correctly, dropset moves down and pull-up too slow . . . . . . . . . 52
10.0.6 Dropset does not stop, eggs go to the end of the machine. . . . . . . . . . . . . . . 52
10.0.7 Lane does not Initialize . . . . . . . . . . . . . . . . . . . . . . . . . 52
10.0.8 White light blinks . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.0.9 Dropset does not move down or moves too slow. . . . . . . . . . . . . . . . . . 53
10.0.10 The dropset drops down on the Contra-pawl, brake seems not to work . . . . . . . . . . 53
10.0.11 Machine always drops eggs even the Check egg photocell does not see one. . . . . . . . . 54
10.0.12 How to disable the Tray stacker and run the Farmpacker. . . . . . . . . . . . . . . . 54
10.0.13 In some cases the Farmpacker does not start automatically. . . . . . . . . . . . . . . 54
10.0.14 Unlock system does drop eggs not in right sequence. . . . . . . . . . . . . . . . . 55
10.0.15 Last egg not dropped into dropset. . . . . . . . . . . . . . . . . . . . . . . 55
10.0.16 Eggs are ‘restless’ as they are arriving in the carrier. . . . . . . . . . . . . . . . . 55
List of figures 57
Index 59

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1 MOBA Farmpacker M100T
This training document subscribes the MOBA Farmpacker M100T functions and electrical layout.
NOTE
aIn this document: Read signal “0” as a low potential <0,5 Volt DC. Read signal “1” as a high
potential >5 Volts Dc. (Measured towards Gnd)
1.1 The Controlled stop postion
In case there are eggs in the farmpacker the machine has to stop following a specific procedure, called
Controlled Stop. A condition for a controlled stop is: Dropset must be in Up-position. To achieve this
condition the machine will not directly halt, but first the speed is brought back to a slow speed of 10 Hz.
The frequency converter will slowly drop the speed to 10 Hz. During this Ramp-down, the moving bar will
also follow to the zero position. During this process the egg dropping will not be disturbed or interrupted.
The Machine will now stop, see fig. 1 (1):
a. If the moving bar is in the 0-position (DL23 Bar OK)
b. The clutch is not activated. (Dropset does not move)
c. The dropset in up-position (Dropset Stop sensor just become “0” (DL21).
Or the machine will stop, see fig. 1 (2):
a. If the moving bar is in the 0-position
b. The clutch is activated (Moving dropset)
c. The Dropset Stop sensor is “0” and the Dropset Check sensor (DL20) just become active “1”.
Fig. 1 - Controlled stop (Dropset cycle)
1
2
3

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On the return-stroke of the Dropset movement Just after the falling edge “Check receiverset full” the
Dropset protection photocell is checking (3) if the dropset is made empty. If not, it will stop the frampacker.
1.1.1 Adjusting the Dropset Stop postion.
Following procedure is used to set the proxes of the dropset movement.
1. Set the Dropset Check Sensor (2) in the correct position Distance (3) is 26,5mm
2. Set the machine to Ghost-eggs function. See chapter 7.1.
3. Start on Full speed.
4. The dropset now starts to work. Check the stop postion-mark on the camb (4). Every stop this mark
must be in line with the center of the bal bearing, running in the camb.
5. If not move the Sensor (1) a little up or down to create the correct stop position.
Fig. 2 - Dropset Stop postion
1
2
3
4

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1.2 Initialization of the packing lane
Before the machine can start packing first the packing lane has to be initialized.
Initialization of the packing lane also take place if:
- The MSW1 is switched on
- The unlock unit has a failure
- The Oiling mode is activated
During initalisation the LUST controller “learns” where the lane has to stop in order to drop the eggs in the
correct position.
The machine start to initialize as the MSW1-output X11-5 (DL47 Init index) is “1” . Depending if the lane is
on error or the lane is set to Oiling mode, the lane will complete an initialisation or just run to the Home
position.
If the LUST controller has received all the information he needs, the MSW1-output X11-5 (Init Index) will
become “0” again.
Fig. 3 - Lane disc

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2 The linear Actuator
The linear actuator is used to move the unlock unit, and so the unlock moment of the carrier. Depending on
the speed of the machine the unlock position of the carrier has to be changed.
The linear actuator use 1 sensor to determine the position.
a. Moving bar 0K
A the machine starts, the signal, Start Moving Bar is send from the MSW1 to the MSW1. Output DL17
activated and the Linear actuator motor start to run. Depending on the speed, the motor will stop, setting
the Linear actuator in a specific position. This position secure correct dropping of the eggs into the
receiverset.
Fig. 4 - Linear actuator connections

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On the linear actuator motor a encoder is mounted. These pulses are counted as soon as the sensor
Moving Bar Ok is switched off. The MSW1 transforms this counter to a 4 Bit output signal (Barpos 1 to 4) to
the Unlock unit. This code is used to determine the correct start moment of the unlock magnet.
The E-stop relay (120K13) is used to switch off the power to the linear actuator during a E-stop.
2.1 Unlock compensation depending on speed
The Egg sensor detect if a carrier contains an egg. This signal is sent from the MSW1, 3 pitches (carriers)
later, to the Unlock unit. This signal is called “Eggselect Unlock” In the Unlock unit this signal arrives into a
shift register. and is taken over by the HiRes pulses of the machine. A certain amount of HiRes Pulses later
the unlock unit has to unlock the egg out of the carrier. The moment of unlocking and the position of the
Unlock magnet is depending on the speed of the machine See fig. 6.
Fig. 5 - Linear Actuator
Fig. 6 - Unlock at Low speed
Speed =
0,1K
Egg
Unlock unit
21mm
81mm
54 mm
Unlock unit HiRes
Eggselect Unlock
Chain
Egg Sensor
81mm
54mm
Command to
unlock Pos #1
Command to
unlock Pos #2
0 - Pos
Egg flow
Receiverset

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Facts:
1. 1 HiRes = 9 mm
2. 1 Carrier pitch = 81mm
3. 1 Unlock pitch = Receiver set pitch = 54mm
Because the Pitch of the Carriers is not equal with the pitch of the receiverset, the unlock moment of a
unlock pawl is controlled individually. If the pitch of the receiverset (= Pitch Unlock pawl) was the same as
the pitch of the carriers, all 6 unlock pawls could be ejected at the same time. This is not the case. After
The second unlock pawl has to be ejected 6 HiRes (6 HiRes= 54mm) Later because the pitch of the
receiverset is 54mm,
See fig. 6 and fig. 7 for following example:
In this example we only discuss the first drop position of the egg.
- On 0K speed postion the unlock pawl is controlled ejected
- On 36K speed the position of the unlock pawl is moved 96mm
- Depending on the position of the moving bar the MSW1 send a 4 bit number (Barpos 1 to 4) to the
Unlock unit. This number is used to eject the unlock pawl a certain number of HiRes earlier.
- On 36K speed the unlock pawl will be activated 11 HiRes pulses earlier.
Fig. 7 - Unlock at High speed
Egg
Unlock unit
96mm
81mm
54 mm
Unlock unit HiRes
Eggselect Unlock
Chain
Egg Sensor
81mm
54mm
Command to
unlock Pos #1
0-pos
Egg flow
Receiverset
11 HiRes compensation
Speed = 36K

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3 The Unlock Unit
The Unlock unit of the Farmpacker secures the egg is dropped at the correct position into the Receiverset.
On the circuit board all the inputs and outputs are indicated by LEDs
Fig. 8 - Unlock Unit & Receiverset
Fig. 9 - Unlock unit circuit

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.
For a subscription the board is split-up into two sections, Section 1 and 2
3.1 Section 1 Output side
Following LED’s are used in the Farmpacker configuration.
- D27 - Worm Error.
- D28 - Dropset Full.
- D29 to D38 Output to Unlock magnets 1 to 10.
Fig. 10 - Unlock Board
12
Fig. 11 - Unlock Board Section 1 Inputs

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3.2 Section 2 Input side.
Following LED’s are used in the Farmpacker configuration.
- D39 - Run LED.
- D58 - Bar position 3.
- D59 - Bar position 2.
- D60 - Bar position 1.
- D61 - Bar position 0.
- D62 - Packing lane ready.
- D63 - Reset Worm.
- D64 - HiRes clock
- D52- Eggselect
3.2.1 Dipswitch configurations
The Dipswitch on the board set the functionality of the unlock board.
- S17-3: On=Left machine configuration. Off=Right machine configuration
Fig. 12 - Unlock Board Section 2 Inputs
Tab. 1 - Dipswitch S17-1 and S172
S17-1 S17-2 S17-3 Function
On On XX 10 wide dropping (Hatchery trays)
Off On XX EOC (Manual lane)
On Off XX Automatic lane
Off Off XX Invalid

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3.3 Unlock unit signals and commands
Reset Unlock
- A Reset Unlock is given during power-up.
Dropset full
- If the receiverset contains 6 eggs the Unlock unit sent a Dropset full-command to the MSW1. The
Clutch is activated and the dropset makes one stroke.
Lane ready
- As the lane has moved a step, the lane-ready signal is generated in order to give the dropset free to
move down (again).
Unlock error
- In case of an error in the Unlock unit. this output becomes active See error messages of the Unlock
unit.
3.4 Error messages of the Unlock unit
On the Unlock circuit board you find a orange LED (D39 - Run LED). Depending on the situation, this LED
is indicating if there is an error.
• No unlock Error
The Orange Run LED blinks on 20Hz.
• Unlock Error
The Run LED will blink several times and this is repeated every 3 seconds.
a. 1x Blink
Wrong Input received (Software problem)
b. 2x Blink
A unlock pawl is activated while still activated
Defect in HiRes detection or MSW1
c. 3x Blink
Packing lane not ready
A Unlock pawl has to be activated but the Lane ready signal is missing
d. 4x Blink
This error appears when there are 6 eggs shifting in the memory for one unlock position. The
memory can only handle 5 eggs at the same time.
e. 5x Blink
Software problem
XX XX Off Right machine configuration
XX XX On Left machine configuration
Tab. 1 - Dipswitch S17-1 and S172
S17-1 S17-2 S17-3 Function

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f. 6x Blink
g. Dropset Full signal is still active. A unlock pawl is activated while the Dropset-Full signal is still
active. The PLC did not receive the “Dropset full” signal or the “lane ready” signal is not detected.

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