Prinzen PSPC5 User manual

SERVICE MANUAL PSPC5
Prinzen B.V.
Weverij 18
7122 MS AALTEN
P.O. Box 85
7120 AB AALTEN
NEDERLAND
Phone: [phone]
Fax: [phone]
e mail: [email protected]
Website: www.prinzen.com

TABLE OF CONTENTS
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TABLE OF CONTENTS
CHAPTER BOOK
INTRODUCTION I
1 SAFETY I
2 INSTALLATION I
3 COMPONENTS ADJUSTMENTS I
4 DESCRIPTION PACKER I
5 DESCRIPTION OUTPUT CONVEYOR I
6 DESCRIPTION 30 CELL TRAY DENESTER I
7 DESCRIPTION HATCH TRAY DENESTER I
8 TROUBLE SHOOTING GUIDE I

TABLE OF CONTENTS
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INDEX
INTRODUCTION ................................................................................................................................................7
LIABILITY ............................................................................................................................................... 9
GENERAL ............................................................................................................................................... 9
COPYRIGHT ........................................................................................................................................... 9
GENERAL ............................................................................................................................................. 10
SAFETY REGULATIONS .......................................................................................................................... 10
LEGAL REGULATIONS ............................................................................................................................ 10
HOW TO USE THIS MANUAL ? ................................................................................................................. 10
TARGET GROUPS ................................................................................................................................. 11
SYMBOLS ............................................................................................................................................ 11
EXPLANATION OF MACHINE TAG ............................................................................................................ 12
ADDRESS PRINZEN ...............................................................................................................................13
1. SAFETY..................................................................................................................................................15
GENERAL ............................................................................................................................................. 16
SAFETY INSPECTION PROCEDURE ......................................................................................................... 16
SAFETY REGULATIONS .......................................................................................................................... 17
SAFETY PROVISIONS ............................................................................................................................ 18
DEFINITION OF SAFETY DEVICES ............................................................................................................ 18
WARNING LABELS ................................................................................................................................. 19
2. INSTALLATION .....................................................................................................................................21
SAFETY REGULATIONS .......................................................................................................................... 22
TRANSPORT ......................................................................................................................................... 22
STORAGE ............................................................................................................................................ 22
ASSEMBLY AND INSTALLATION ............................................................................................................... 22
PREPARATION ...................................................................................................................................... 23
FACILITIES ........................................................................................................................................... 23
INSTALLATION DATA ............................................................................................................................. 23
INSTALLATION ...................................................................................................................................... 24
SAFETY REGULATIONS .......................................................................................................................... 24
PACKER .......................................................................................................................................................................................................24
OUTPUT CONVEYOR ....................................................................................................................................................................................25
ELECTRICAL CONNECTION OUTPUT CONVEYOR TO PACKER ......................................................................................................................26
V ACUUM HEAD PROTECTION .....................................................................................................................................................................26
POWER AND AIR SUPPLY .............................................................................................................................................................................27
DIRECTION OF ROTATION OUTPUT CONVEYOR ..........................................................................................................................................28
TESTING ......................................................................................................................................................................................................28
FIRST EGG ...................................................................................................................................................................................................29
OUTPUT CONVEYOR POSITION ....................................................................................................................................................................29
CONNECTION EGG COLLECTING CONVEYOR ..............................................................................................................................................31
DISASSEMBLY ...................................................................................................................................... 32
3. COMPONENTS ADJUSTMENTS..........................................................................................................33
G ENERAL ADJUSTMENTS ...................................................................................................................... 34
SAFETY REGULATIONS .......................................................................................................................... 34
PHOTO SWITCHES .......................................................................................................................................................................................34
INDUCTIVE PROXIMITY SWITCHES .............................................................................................................................................................34
AIR SUPPLY .................................................................................................................................................................................................35
VALVE BLOCK .............................................................................................................................................................................................35
PLC............................................................................................................................................................................................................35
FREQUENCY INVERTERS .............................................................................................................................................................................36
POWER SUPPLIES ........................................................................................................................................................................................36
4. PACKER.................................................................................................................................................37

TABLE OF CONTENTS
Page 6 of 73 SERVICE MANUAL PSPC5 SM-PSPC5-01-E/12-2007
DESCRIPTION PACKER
.......................................................................................................................... 38
ADJUSTMENTS PACKER ........................................................................................................................ 42
INFEED BELT TENSION ................................................................................................................................................................................42
GATE BLOCKERS .........................................................................................................................................................................................42
GATE EGG DETECTION ................................................................................................................................................................................42
ROLLER TRACK STOP POSITION ..................................................................................................................................................................43
FLAP SHAFT STOP POSITION ........................................................................................................................................................................43
CUP CONVEYOR STOP POSITION ..................................................................................................................................................................44
MAIN DRIVE STOP SENSOR ..........................................................................................................................................................................44
MAIN DRIVE CHAIN TENSION ......................................................................................................................................................................45
LOOSEN UP TAPER LOCKS ...........................................................................................................................................................................45
T IGHTEN UP TAPER LOCKS .........................................................................................................................................................................45
EGG LIFTER POSITION .................................................................................................................................................................................46
VACUUM HEAD HORIZONTAL POSITION .....................................................................................................................................................47
VACUUM LIFTER CHAIN TENSION ...............................................................................................................................................................47
VACUUM HEAD FRONT REAR ......................................................................................................................................................................47
VACUUM HEAD LEFT RIGHT ........................................................................................................................................................................47
VACUUM HEAD PICK UP POSITION ..............................................................................................................................................................48
VACUUM HEAD TRAY SET POSITION ...........................................................................................................................................................48
SPEED LEFT RIGHT ......................................................................................................................................................................................49
VACUUM HEAD ZERO POSITION ..................................................................................................................................................................49
VACUUM VALVE PARTS REPLACEMENT .....................................................................................................................................................50
5. OUTPUT CONVEYOR...........................................................................................................................53
DESCRIPTION OUTPUT CONVEYOR ......................................................................................................... 54
ADJUSTMENTS OUTPUT CONVEYOR ....................................................................................................... 56
TRANSPORT BELT TENSION .........................................................................................................................................................................56
30 CELL TRAY GUIDE ..................................................................................................................................................................................56
HATCH TRAY GUIDE ...................................................................................................................................................................................56
HATCH TRAY DETECTION ...........................................................................................................................................................................56
HATCH T RAY STOP POSITION .....................................................................................................................................................................57
6. 30 CELL TRAY DENESTER..................................................................................................................59
DESCRIPTION 30 CELL TRAY DENESTER ................................................................................................ 60
ADJUSTMENTS 30 CELL TRAY DENESTER ............................................................................................... 62
BUNKER ADJUSTMENT ................................................................................................................................................................................62
TRAY GUIDE ................................................................................................................................................................................................62
LOWER GRIPPERS ........................................................................................................................................................................................62
TOP GRIPPERS .............................................................................................................................................................................................62
DENESTER STOP POSITION ..........................................................................................................................................................................63
TIE ROD ADJUSTMENT ................................................................................................................................................................................63
7. HATCH TRAY DENESTER....................................................................................................................65
DESCRIPTION HATCH TRAY DENESTER ................................................................................................... 66
ADJUSTMENTS HATCH TRAY DENESTER ................................................................................................. 68
BUNKER ADJUSTMENT ................................................................................................................................................................................68
TOP GRIPPER ...............................................................................................................................................................................................68
DENESTER STOP POSITION ..........................................................................................................................................................................69
TIE ROD ADJUSTMENT ................................................................................................................................................................................69
8. TROUBLE SHOOTING GUIDE .............................................................................................................71

INTRODUCTION
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INTRODUCTION

INTRODUCTION
Page 8 of 73 SERVICE MANUAL PSPC5 SM-PSPC5-01-E/12-2007
CAUTION:
This manual must be read by each person, before that person adjusts
the machine.
ATTENCION:
Cualquier persona que ajusta esta máquina, debe leer este manual de
manejo antes de ajustar.
ATTENTION:
Chacun qui régle cette machine doit lire le manuel en avant.
VORSICHT:
Jeder, der diese Maschine einstellen soll, muß vorher diese Hinweise
lesen.
ATTENTIE:
Een ieder, die deze machine afstelt dient vooraf deze handleiding te
lezen.

INTRODUCTION
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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.
Since Prinzen BV is constantly improving its systems it may be possible that there are small
differences between your system and this manual.
Though this manual has been put together with the utmost care, Prinzen BV cannot accept any
responsibility for costs, damage or personal injury arising from any fault and/or incompleteness in the
content of this document.
GENERAL
This manual is intended to be used by service engineers of Prinzen and its official dealers. It contains
important information concerning safety and adjustment of the Prinzen BV system. For uncomplicated
functioning of the system, read this manual carefully and adjust according to the directions in this
manual.
Beside the design and the used materials also the correct adjustment of the system has great impact
on the functioning, the life span and the operational costs of the system.
This manual will help you to gain knowledge for correct adjustment of the system.
A Prinzen BV system meets the demands, mentioned in the European machine guideline (CE).
COPYRIGHT
Prinzen BV ©
This document contains confidential information and information protected by
copyright of Prinzen BV. Reproduction or transmission of any part of this
document to third parties, or the use thereof is only permitted after express
written permission of Prinzen BV.
All rights rest with Prinzen BV, Aalten, The Netherlands.
Written by Visser Machine Services.

INTRODUCTION
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GENERAL
This manual contains important information concerning:
- Safety
- Installation
- Adjustments
Read and understand this total service manual before starting to adjust the system. Beside this
manual also knowledge about the operating, maintaining and cleaning of the system is necessary for a
safe and correct adjustment of the system. Also read and understand the complete user manual of the
system before starting to adjust it.
Never change the sequence of procedures as described in this manual.
SAFETY REGULATIONS
Before starting to adjust the system first read this chapter and chapter Safety.
LEGAL REGULATIONS
All safety directions stated in this manual must be observed.
Along with the safety regulations in this chapter the instructions of the qualified trade organization of
your country must be observed to avoid accidents.
Before starting to adjust the machine always consult the safety manager of the company to discuss if
a work permit is required for this job.
All safety devices, installed in the machine by the manufacturer and the indications mentioned in the
manuals are conditions to control the machine safely.
Technical changes, which influence the safety working of the machine, may only be executed by the
service department of Prinzen.
Do not change controls, and/or PLC programs, without written permission from Prinzen because this
may affect the safety of the machine.
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.
Warranty becomes invalid when consequential damages to the system, caused by technical changes,
unprofessional maintenance and repairs, were executed by the dealer.
HOW TO USE THIS MANUAL?
The manual is constructed to provide a maximum amount of information with a minimum amount of
searching. The key to easy reference is the Table of contents. Familiarize yourself with it and you
won’t have any trouble locating information from any area of machine.

INTRODUCTION
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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.
Service engineer:
The service engineer is a professional employed by Prinzen or its official dealers. The service
engineer must read the total manual.
SYMBOLS
Symbols are used in the manual when special attention/caution is required while working on the
system. The special symbols and their meaning are depicted in the below table.
Symbol: Meaning:
DANGER!
This symbol is used when instructions should be followed to the letter. If not they may result in permanent personal
injury or death.
CAUTION!
This symbol is used when instructions should be followed to the letter. If not they may result in permanent personal
injury.
ATTENTION!
This symbol is used when instructions should be followed to the letter. If not they may cause damage to the
system.
TIP!
This symbol is used as a helpful hint to simplify the execution of certain tasks.

INTRODUCTION
Page 12 of 73 SERVICE MANUAL PSPC5 SM-PSPC5-01-E/12-2007
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.
Wires 3~N = 3 phase + N + PE
Wires 3~ = 3 phase + PE
Wires 1~ N = 1 phase + N + PE
Frequency = 50 Hz
Power 400/230V = 400 V phase voltage, 230 line voltage.
Power 230V = 230 V phase voltage or 230 V line voltage.
Maximum primary fuse:
This is the necessary external fuse.
Serial number:
This is the unique serial number of this system.
Date:
This is the construction month and year of the system.

INTRODUCTION
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ADDRESS PRINZEN
Prinzen BV
Weverij 18, 7122 MS AALTEN
P.O. Box 85, 7120 AB AALTEN
The Netherlands
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Website: www.prinzen.com

SAFETY
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1. SAFETY

SAFETY
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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.
- Familiar with the national and regional regulations regarding safety.
These persons should have reached the minimum legal age required to perform this work.
These persons are NOT under influence of any drug, medicine or alcoholic drink.
The system is designed for packing eggs into specific packaging. Any other use of the system is not
permitted.
SAFETY INSPECTION PROCEDURE
Before starting any adjustments and after finishing an adjustment job, make sure that all protective
covers are in place, all lockable doors are closed and locked, all covers are closed and the emergency
button operates correct. Check the emergency button to assure proper operation.
1. Push the emergency button.
2. Push the start button, the machine should not start.
3. Turn emergency button clockwise to release it.
4. Make sure that the machine does not start when the emergency button is pressed.
If the machine operates when the emergency button is pressed, this machine is not safe to operate.
Immediately repair the defective emergency button.
Make sure all warning labels are legible and are not damaged or removed. Replace them immediately
when necessary.

SAFETY
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SAFETY REGULATIONS
Do not use the system when safety devices have been removed. This system may contain sharp
edged parts, moving parts and rotating parts.
When protective covers are removed, sharp edges and pinch points may be exposed. Use extreme
caution and avoid touching or striking these areas with your hands or body because they may cause
injuries.
Do not enter parts of your body or objects into openings in the system. This may lead to serious
physical injury or damage to the system. It is dangerous to be in, on or under the system while it is
operational.
Loosely hanging clothing, wide sleeved clothing, ties, chains or rings are prohibited. Long hair should
be worn tied back.
Make sure that there is sufficient light around the machine.
Do not touch or come near moving or rotating parts. Physical contact with these parts is dangerous.
Do not stand or walk on any of the system parts.
Do not work alone on the system. At least one other person should be present
Before starting to adjust the machine follow the steps mentioned below:
- Switch off the machine and secure it against accidental switching on.
- Post “Do not switch on” warning sign on the main switch:
- Operate the emergency button.
- Make sure that no components are moving.
Before switching on the machine, you must check the following:
- All safety devices are in place and are functioning.
- No other persons are in, underneath or above the system.
- No tools or objects are in the system.
- No other persons are at risk.
Do not use water to clean electricity cabinets and other electronic components.
For save and easy adjustment keep the machine and the area and floor around the machine clean,
free of production materials, oil, grease and obstacles.
When an extension cable is used for power supply, make sure that the cable diameter in relation to
the length of the cable is correct. Make sure the cable is completely unrolled
When the safety devices are put out of operation, the machine must be switched off and secured
against accidental switching on.
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.

SAFETY
Page 18 of 73 SERVICE MANUAL PSPC5 SM-PSPC5-01-E/12-2007
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. Always
switch off the system and lock up the power
source (1) before working on the machine.
DANGER!
Protective covers safeguard dangerous
machine areas. These covers are of utmost
importance to operate the machine safely.
Never operate the machine when protective
covers are removed because serious injury or
death may occur!
DEFINITION OF SAFETY
DEVICES
Safety devices are: lockable doors (2),
emergency buttons (3), and protective covers.
The emergency button prevents the machine
from operating and should stop the machine
immediately when it is pressed. Protective
covers shield off dangerous moving parts.
These covers cannot be removed without
tools.
Lockable doors are doors that can only be
opened with a key. The key should only be in
possession of a supervisor.
DANGER!
Lockable doors safeguard dangerous
machine areas. These doors are of utmost
importance to operate the machine safely.
Never operate the machine when doors are
open or not locked because serious injury or
death may occur!
1
2
3

SAFETY
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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. Contacting parts
inside this cabinet may result in permanent
personal injury or death.
This sign is used to warn for dangerous
movements. Keep a safe distance to those
parts. Disregarding this warning may result in
permanent personal injury.
This sign is used to warn for the danger of
limbs being pulled in. Keep a safe distance to
those parts. Disregarding this warning may
result in permanent personal injury.
This sign is used to warn for crushing danger.
Keep a safe distance to those parts.
Disregarding this warning may result in
permanent personal injury.