Post PR21.56 User manual

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
OPERATOR MANUAL
DRUM CONDITIONER WITH MOBILE CART
POST MATERIAL HANDLING
SERIAL NUMBER PR21.56

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
Table of contents
INTRODUCTION ........................................................................................................................3
DESCRIPTION.............................................................................................................................3
PRINCIPLE OF OPERATION.....................................................................................................3
GENERAL SPECIFICATIONS...................................................................................................3
DRUM CONDITIONER OPERATION (Using Control Panel)..................................................4
MANUAL OPERATION (Using Control Panel).........................................................................5
DRUM CONDITIONER OPERATION (Using Pendant) ...........................................................5
ACCESSING MACHINE SETTINGS (HMI) .............................................................................6
ADJUSTING DRUM CONDITION SETTINGS (HMI).............................................................6
ADJUSTING PRESSURE SETTINGS (HMI) ............................................................................7
MAINTENANCE SCREEN (HMI) .............................................................................................8
MAINTENANCE REMINDER SCREEN (HMI)........................................................................9
ADVANCED SETTINGS SCREEN (HMI) ................................................................................9
EMERGENCY STOP.................................................................................................................10
SAFETY .....................................................................................................................................10
MAINTENANCE.......................................................................................................................10
REMOVING THE SLOT COVER.............................................................................................11
CHECKING CHAIN TENSION................................................................................................12
CHECK LIFT CHAIN TENSION..............................................................................................12
TENSION THE LIFT CHAIN....................................................................................................13
TENSION THE LIFT CHAIN....................................................................................................14
APPROVAL DRAWING...........................................................................................................15
ELECTRICAL SCHEMATIC –PAGE 1 OF 2 .........................................................................16
ELECTRICAL SCHEMATIC –PAGE 2 OF 2 .........................................................................17
WARRANTY .............................................................................................................................20

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
INTRODUCTION
This manual provides operating, maintenance and service information
regarding the Post Material Handling Portable Drum Conditioner. Keep this
manual available to management, operator and maintenance personnel who
are responsible for the equipment’s operation and maintenance.
It is essential to read, understand and follow the recommendations of this
manual before operating or servicing this equipment. Failure to do so could
result in serious injury, death and/or property damage.
This equipment should be operated only by qualified personnel. If
there are questions concerning the operation of this equipment please
contact:
POST MATERIAL HANDLING
21 Stone Castle Road
Rock Tavern, NY 12575
[phone]
[email protected]
DESCRIPTION
PRINCIPLE OF OPERATION
This equipment is designed to apply lateral forces to a drum in order to
loosen hardened material and make unloading the drum easier. A
controlled amount of force is applied to the drums by a digitally controlled
pressure regulator. The deformation of the drum is monitored by an
encoder.
The drum conditioner may be operated from selector switches on the control
panel or by the pendant. An HMI is provided to adjust drum condition
settings such as pressure and the amount to deform the drums.
GENERAL SPECIFICATIONS
Height: 83”, Width: 58”, Length: 67 1/2”
Operating voltage: 120VAC

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
DRUM CONDITIONER OPERATION
(Using Control Panel)
1. Connect power to the machine using the
120VAC watertight connector.
2. Connect air pressure to the machine.
3. Turn the electrical DISCONNECT switch to
the ON position.
4. Ensure the rear caster wheels on the
machine are locked.
5. Place the drum to be conditioned in
position in front of the machine.
6. Press the RESET button. The RESET
button will remain illuminated when the
safety relay is satisfied and the conditioner
is ready to run.
7. Press the RUN DRUM CONDITION
CYCLE button. The drum condition
sequence will proceed in the following
steps:
a. The drum conditioner will open and
zero the arm encoder.
b. The arms will carefully close as the
drum conditioner measures the
diameter of the drum at the FEEL SETPOINT in PSI. The drum should not
be compressed. If the arms do not close increase the FEEL PRESSURE
setpoint.
c. The drum conditioner opens slightly before increasing to the CRUSH
SEPOINT in PSI.
d. The drum conditioner closes the arms until the CRUSH DISTANCE is
reached, the CRUSH TIMEOUT time elapses, or the MIN ARM SPAN is
reached.
e. The arms are held stationary for the CRUSH HOLD TIME in seconds.
f. The drum conditioner opens the arms to the approximate diameter of the
drum.
g. Steps d –f are repeated for the NUMBER CYCLES setting on the DRUM
CONDITION SETTINGS SCREEN.
h. Once the cycle is complete the arms open slightly wider than the drum and
cylinder pressure is reduced to the holding pressure. The holding pressure
is linearly scaled from the maximum and minimum DRUM SIZE and DRUM
HOLDING PRESSURE settings on the HMI.
i. The arms close securely on the drum and it is ready to be lifted as
necessary to unload. “The lift is firmly holding the drum” is displayed on
the MAIN SCREEN of the HMI.
8. Rotate the LIFT selector switch to the RAISE position. The lift begins to raise the
drum.
a. When the drum is lifted above the MAX DROP DISTANCE in inches the
arms are locked. “The drum is locked – lower the lift X.X inches to release
the drum” is displayed on the MAIN SCREEN.

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
b. The drum may be manually released by pressing the UNLOCK DRUM
button on the MAINTENANCE SCREEN.
c. The lift height in inches is displayed on the MAIN SCREEN.
9. Rotate the INVERT
selector switch to
the FWD position.
The drum begins to
invert as necessary
for unloading. The
inversion angle in
degrees is
displayed on the
MAIN SCREEN.
10.When the drum is
empty rotate the
INVERT selector
switch to the REV
position. The drum
returns to the
upright position.
11.Rotate the LIFT selector switch to the LOWER position. The drum is lowered to
the ground.
12.The drum condition cycle may be aborted by pressing the RESET button.
13.If the EMERGENCY STOP button is pressed the drum condition cycle will be
paused. The RESET light will blink to indicate the cycle is paused. Press the
RUN DRUM CONDITION CYCLE button to resume the cycle.
MANUAL OPERATION (Using Control Panel)
1. To manually open the arms, rotate the DRUM ARMS selector switch to the OPEN
position. To manually close the arms, rotate the DRUM ARMS selector switch to
the CLOSED position.
2. When manually operating the drum arms, the HOLDING PRESSURE in PSI will
be set to the pressure used to handle the largest diameter drums.
3. Use the LIFT and INVERT selector switches to manually position the drum.
DRUM CONDITIONER OPERATION (Using Pendant)
1. The pendant may be used to perform all functions of the drum conditioner.
2. To start the drum condition cycle from the pendant press and hold the green
RESET button. While holding RESET press the RIGHT ARROW button to start
the drum condition cycle.
3. The UP and DOWN buttons on the pendant are equivalent to the RAISE and
LOWER positions of the LIFT selector switch.
4. The TILT RIGHT and TILT LEFT arrows on the pendant are equivalent to the
FWD and REV positions of the INVERT selector switch.
5. The green RESET button on the pendant is equivalent to the blue RESET button
on the control panel.

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
ACCESSING MACHINE SETTINGS (HMI)
1. From the MAIN
SCREEN on the
HMI press the
SETTINGS
SCREEN button.
2. After pressing a
button on the
SETTINGS
SCREEN, login
using the
information below.
Users are
automatically
logged out and
returned to the
MAIN SCREEN
after 20 minutes of inactivity. To manually logout press the LOGOUT button on
the SETTINGS SCREEN.
Username
Password
Maint
4875
M
4875
A
4875
3. All usernames have the same password, and may access all functions of the
drum conditioner.
ADJUSTING DRUM CONDITION SETTINGS (HMI)
1. From the MAIN
SCREEN on the
HMI press the
SETTINGS
SCREEN button.
2. From the
SETTINGS
SCREEN press
the DRUM
CONDITION
SETTINGS
SCREEN button.
3. Press the
NUMBER OF
CYCLES button.
Enter the desired
number of open / close cycles while conditioning a drum.
4. Press the CRUSH DISTANCE button. Enter the desired crush distance of the
drum (below the measured diameter) in inches.
5. Press the CRUSH HOLD TIME button. Enter the crush hold time in seconds.

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
6. Press the DRUM SIZE buttons. Enter the maximum and minimum size of drums
in inches. This is used to scale the holding pressure (see PRESSURE
SETTINGS SCREEN).
7. Press the CRUSH TIMEOUT button. Enter the desired crush timeout in seconds.
When this time has elapsed, the drum conditioner will stop crushing the drum
even if it has not reached the CRUSH DISTANCE.
ADJUSTING PRESSURE SETTINGS (HMI)
1. From the MAIN
SCREEN on the
HMI press the
SETTINGS
SCREEN button.
2. From the
SETTINGS
SCREEN press
the PRESSURE
SETTINGS
SCREEN button.
3. Press the DRUM
HOLDING
PRESSURE
buttons. Enter
the maximum and
minimum drum holding pressures in PSI. The minimum holding pressure is
applied to the smallest drums. The maximum holding pressure applies to the
largest. Holding pressure is linearly scaled for intermediate sizes. The maximum
holding pressure also applies when the arms are manually jogged.
4. Press the CRUSH SETPOINT button. Enter the desired crush pressure in PSI.
This is the pressure the drum conditioner will apply during the condition cycle
while the arms are opening and closing.
5. Press the FEEL SETPOINT button. Enter the desired feel pressure in PSI. This
is the light pressure the drum conditioner will apply while measuring the diameter
of drums.
6. Press the MANIAL SETPOINT button and enter the desired pressure in PSI.
Then press ENABLE MANUAL PRESSURE SETTING to apply this pressure in
PSI to the drum conditioning arms. This setting will automatically be turned off
after 20 minutes.

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
MAINTENANCE SCREEN (HMI)
1. From the MAIN
SCREEN on the
HMI press the
SETTINGS
SCREEN button.
2. From the
SETTINGS
SCREEN press
the
MAINTENANCE
SCREEN button.
3. Press the MAX
ARM SPAN
button. Enter the
distance
between the
arms of the drum conditioner when it is completely open in inches.
4. Press the UNLOCK DRUM button to manually release a drum that has been
raised above the MAXIMUM DROP HEIGHT. Use caution when releasing heavy
drums high above the floor.
5. Press MIN / MAX LIFT HEIGHT. Enter the MIN / MAX permissible height of the
lift in inches. The lift will not move beyond these values. Lift height is displayed
on the MAIN SCREEN.
6. Press the OVERRIDE LIFT ERRORS button to override the CHAIN SLACK and
COLLISION DETECTED errors. See CHECKING LIFT CHAIN TENSION.
7. Press the MAINTENANCE REMINDER SCREEN button to clear maintenance
reminders and view usage data for the drum conditioner.
8. Press the MAX DROP HEIGHT button. Enter maximum allowable distance that a
drum may be dropped (jaws may be opened) once the conditioner detected that
it’s firmly holding a drum.
9. Press the PANEL VIEW SCREEN CONFIGURATION button to access the HMIs
configuration menu and perform functions such as screen calibration.

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
MAINTENANCE REMINDER SCREEN (HMI)
1. From the MAIN
SCREEN on the
HMI press the
SETTINGS
SCREEN button.
2. From the
SETTINGS
SCREEN press the
MAINTENANCE
SCREEN button.
3. From the
SETTINGS
SCREEN press the
MAINTENANCE
REMINDER
SCREEN button.
4. Press ARM CHAIN MAINT. INSTRUCTIONS to view maintenance tasks
necessary for the drum conditioning chain.
5. Press LIFT CHAIN MAINT. INSTRUCTIONS to view maintenance tasks
necessary for the main lift chain.
6. Press and hold CLEAR MAINT. REMINDERS for 3 seconds to clear any active
maintenance reminders. They will remain off until the next maintenance interval
occurs.
7. The distance moved by each axis is displayed, along with the number of drum
condition cycles performed.
ADVANCED SETTINGS SCREEN (HMI)
1. From the MAIN
SCREEN on the
HMI press the
SETTINGS
SCREEN button.
2. From the
SETTINGS
SCREEN press
the ADVANCED
SETTINGS
SCREEN button.
3. The amount the
arms open during
the drum
condition cycle
may be adjusted
using the CLEARNANCE DISTANCES DURING CYCLE section. The arms open
by the amounts shown after different steps in the cycle. MEASURING WIDTH is
the amount the arms open before measuring drum diameter. This should be

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
larger than the largest drum. GENERAL CLEARANCE applies after the
measurement step. POST CRUSH CLEARANCE applies when the arms are
crushing the drum for the specified number of crushes. Enter a negative number
to keep the arms very tight on the drum.
4. When LIMIT HEIGH WHEN DRUM IS LOOSE is displayed the lift will not go
above the MAX LOOSE HEIGHT unless the drum is firmly held. The drum will be
firmly held after a drum condition cycle. The drum conditioner will also detect
when the user has jogged the arms into a firm hold on the drum (the arm encoder
remains motionless while the arms are closed).
5. Press the COLLISION HEIGHT button. Enter the minimum height at which the
drum conditioning attachment will collide with the base of the machine. Height is
displayed in inches on the main screen.
EMERGENCY STOP
Pressing the “Emergency Stop” button will stop the drum conditioner immediately at
any time. To recover from an Emergency stop condition (when in a safe operating
condition), pull to release the emergency stop button, then press the RESET button on
the face of the panel. Twist to release the emergency stop button on the pendant.
SAFETY
Do not operate the Drum Conditioner if the maintenance schedule has not been
followed.
Do not defeat any interlocks on the equipment.
This equipment is not designed to operate with any materials than originally specified
and should not be used for purposes other than which it has been designed.
The equipment should only be operated by qualified personnel that have thoroughly
read and understood the information in this manual.
Do not operate this equipment if any unusual noise or vibration is observed.
MAINTENANCE
Inspect the slot covers for wear and replace if necessary.
Inspect the pneumatic cylinders and hoses for wear.
Check chain of the lift and arm chains within the first two weeks of operation.
Lubricate the chains every six months. Remove the slot cover as described below to
gain access to the chains. Inspect chain tension and adjust if necessary. Maintenance
reminders will appear on the screen when the chains need to be serviced.
The pneumatic components are pre-lubricated and do not require oiled air. If an oiler
is used at any point, the pre-lubrication will be washed out and the machine must use
oiled air from that point on.

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
REMOVING THE SLOT COVER –DRUM CONDITIONER
1. Remove the 8 bolts holding each compressor arm on and remove arm.
2. Loosen the slot cover tensioner bolts on each side of the compressor.
3. Remove the 4 screws on each end cap.
4. Feed the slot cover through the compressor carriage.

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
CHECKING CHAIN TENSION
1. If the compression arms are able to be moved any amount side to side by hand the
chain needs to be tensioned.
2. Check the chain tension by removing the slot cover. If there is any play in the chain
tighten the nut on the chain terminal bolt. After the chain is tensioned tighten the lock
nut.
3. Install the slot cover.
CHECK LIFT CHAIN TENSION
Remove the slot cover as described earlier. Check the chain tension on the underside
of the carriage. The chain tension sensor has a light that should be illuminated when
the chain is properly tensioned.

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
TENSION THE LIFT CHAIN
Remove the slot cover as described above to gain access to the chain tensioning
nuts. Check the lower portion of the chain, below the lift carriage, for tension. If the
chain is loose, tighten the chain tensioning double nuts. Do not over tighten.
If the chain cannot be tensioned any more, replace the chain.

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
TENSION THE LIFT CHAIN
Remove the slot cover as described above to gain access to the chain tensioning nuts.
Check the lower portion of the chain, below the lift carriage, for tension. If the chain is
loose, tighten the chain tensioning double nuts. Do not over tighten.
If the chain cannot be tensioned any more, replace the chain.

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
APPROVAL DRAWING

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
ELECTRICAL SCHEMATIC –PAGE 1 OF 5

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
ELECTRICAL SCHEMATIC –PAGE 2 OF 5

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
ELECTRICAL SCHEMATIC –PAGE 3 OF 5

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
ELECTRICAL SCHEMATIC –PAGE 4 OF 5

POST MATERIAL HANDLING
21 Stone Castle Road, Rock Tavern, NY 12575 [phone] www.posthoist.com
ELECTRICAL SCHEMATIC –PAGE 5 OF 5