Prinzen SPEEDPACK Series User manual

SERVICE MANUAL
SPEEDPACK
Prinzen B.V.
Weverij 18
7122 MS AALTEN
P.O. Box 85
7120 AB AALTEN
NEDERLAND
Phone: [phone]
Fax: [phone]
e mail: [e-mail]
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 COMPONENT ADJUSTMENTS I
4 PACKER I
5 TRAY DENESTER I
6 CURVE CONVEYOR I
7 TRAY CONVEYOR I
8 OUTFEED CONVEYOR I
9 TRAY STACKER 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? ................................................................................................................. 11
WHO SHOULD USE THIS MANUAL? ......................................................................................................... 11
MANUAL INFORMATION ......................................................................................................................... 11
SERIAL NUMBER................................................................................................................................... 11
SYMBOLS ............................................................................................................................................ 12
ADDRESS PRINZEN............................................................................................................................... 12
1. SAFETY..................................................................................................................................................13
GENERAL............................................................................................................................................. 14
SAFETY REGULATIONS.......................................................................................................................... 15
SAFETY PROVISIONS ............................................................................................................................ 17
EMERGENCY STOP BUTTON................................................................................................................................................................... 17
LOCKABLE DOOR .................................................................................................................................................................................. 17
PROTECTIVE COVER.............................................................................................................................................................................. 18
SAFETY SWITCH.................................................................................................................................................................................... 18
SAFETY INSPECTION PROCEDURE ......................................................................................................... 19
WARNING LABELS................................................................................................................................. 20
2. INSTALLATION .....................................................................................................................................23
SAFETY REGULATIONS.......................................................................................................................... 24
TRANSPORT......................................................................................................................................... 24
STORAGE ............................................................................................................................................ 24
ASSEMBLY AND INSTALLATION............................................................................................................... 24
PREPARATION...................................................................................................................................... 25
FACILITIES........................................................................................................................................... 25
INSTALLATION DATA ............................................................................................................................. 26
INSTALLATION...................................................................................................................................... 27
SAFETY REGULATIONS.......................................................................................................................... 27
PACKER ................................................................................................................................................................................................ 27
TRAY DENESTER ................................................................................................................................................................................... 28
TRAY STACKER..................................................................................................................................................................................... 30
ELECTRICAL CONNECTION TRAY STACKER TO PACKER......................................................................................................................... 31
POWER SUPPLY SPEEDPACK .................................................................................................................................................................. 34
POWER SUPPLY 3~ +N+ PE.......................................................................................................................................................................... 35
POWER SUPPLY 1~ +N+ PE.......................................................................................................................................................................... 36
CONNECTION EGG COLLECTING CONVEYOR.......................................................................................................................................... 37
TESTING SAFETY DEVICES..................................................................................................................................................................... 38
DISASSEMBLY...................................................................................................................................... 39
ENVIRONMENT CONSEQUENCES............................................................................................................ 39
3. COMPONENT ADJUSTMENTS............................................................................................................41
GENERAL ADJUSTMENTS...................................................................................................................... 42
SAFETY REGULATIONS.......................................................................................................................... 42
PROXIMITY SWITCHES........................................................................................................................................................................... 42
PHOTO SWITCHES.................................................................................................................................................................................. 43
PD30 DIFFUSE REFLECTIVE ........................................................................................................................................................................... 43
PD30 RETRO REFLECTIVE ............................................................................................................................................................................. 43
PD30 THROUGH-BEAM.................................................................................................................................................................................. 44
FREQUENCY INVERTERS........................................................................................................................................................................ 45
POWER SUPPLIES................................................................................................................................................................................... 46

TABLE OF CONTENTS
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4. PACKER.................................................................................................................................................47
DESCRIPTION PACKER.......................................................................................................................... 48
ADJUSTMENTS PACKER ........................................................................................................................ 53
STOP POSITION EGG CHAIN.................................................................................................................................................................... 53
SYNCHRONIZING GRIPPER TRANSPORT TO ROLLER TRACK.................................................................................................................... 54
DOUBLE EGG IN GRIPPER SENSOR.......................................................................................................................................................... 55
START TRAY CONVEYOR SENSOR.......................................................................................................................................................... 55
MAIN DRIVE CHAIN TENSION................................................................................................................................................................. 56
INFEED CONVEYOR DRIVE CHAIN TENSION ........................................................................................................................................... 56
INFEED BELT TENSION .......................................................................................................................................................................... 57
GRIPPER TRANSPORT CHAIN TENSION ................................................................................................................................................... 58
5. TRAY DENESTER .................................................................................................................................59
DESCRIPTION TRAY DENESTER.............................................................................................................. 60
ADJUSTMENTS TRAY DENESTER............................................................................................................ 65
BUNKER ADJUSTMENT .......................................................................................................................................................................... 65
TRAY GUIDE ADJUSTMENT.................................................................................................................................................................... 65
TRAY LIFT ADJUSTMENT ....................................................................................................................................................................... 66
DENESTER SEQUENCE ........................................................................................................................................................................... 67
GRIPPER ADJUSTMENT .......................................................................................................................................................................... 68
LOWER GRIPPER ADJUSTMENT........................................................................................................................................................................ 69
UPPER GRIPPER ADJUSTMENT ........................................................................................................................................................................ 69
6. CURVE CONVEYOR .............................................................................................................................71
DESCRIPTION CURVE CONVEYOR .......................................................................................................... 72
ADJUSTMENTS CURVE CONVEYOR......................................................................................................... 73
BELT TENSION....................................................................................................................................................................................... 73
7. TRAY CONVEYOR ................................................................................................................................75
DESCRIPTION TRAY CONVEYOR............................................................................................................. 76
ADJUSTMENTS TRAY CONVEYOR........................................................................................................... 78
STOP POSITION TRAY CONVEYOR.......................................................................................................................................................... 78
TRAY DETECTION.................................................................................................................................................................................. 79
TRAY CONVEYOR TENSION ................................................................................................................................................................... 80
8. OUTFEED CONVEYOR.........................................................................................................................81
DESCRIPTION OUTFEED CONVEYOR....................................................................................................... 82
ADJUSTMENTS OUTFEED CONVEYOR..................................................................................................... 84
BELT TENSION....................................................................................................................................................................................... 84
9. TRAY STRACKER.................................................................................................................................85
DESCRIPTION TRAY STACKER................................................................................................................ 86
ADJUSTMENTS TRAY STACKER.............................................................................................................. 90
SAFETY SLIPPING CLUTCH..................................................................................................................................................................... 90
LEVEL GRIPPERS ................................................................................................................................................................................... 91

INTRODUCTION
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INTRODUCTION

INTRODUCTION
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CAUTION:
This manual must be read by each person, before that person adjusts the machine.
Using this service manual is at your own risk.
Prinzen cannot be held responsible for any consequential damages to the system
caused after using this service manual.
ATTENCION:
Cualquier persona que ajusta esta máquina, debe leer este manual de manejo antes
de ajustar.
El uso de este manual de manejo es por su propio riesgo.
Prinzen no puede ser responsible por daños al sistema a causa del uso de este
manual de manejo.
ATTENTION:
Chacun qui règle cette machine doit lire le manuel en avant.
L‟usage de ce manuel est à ses propres risques et périls .
Prinzen n‟est pas responsable pour dommages sur le système à cause d‟user de
manuel.
VORSICHT:
Jeder, der diese Maschine einstellen soll, muß vorher diese Hinweise lesen.
Benutzung dieser Hinweise ist auf eigene Rechnung und Gefahr.
Prinzen ist nicht verantwortlich für Folgschaden ans System nach Benutzung dieser
Hinweise.
ATTENTIE:
Een ieder, die deze machine afstelt dient vooraf deze handleiding te lezen.
Gebruik van deze service handleiding is voor uw eigen risico.
Prinzen kan niet verantwoordelijk worden gesteld voor enige schade aan het
systeem veroorzaakt door het gebruiken van deze service handleiding.

INTRODUCTION
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LIABILITY
Prinzen BV cannot be held responsible for any costs, damage or personal injury if its system is not
used in accordance with the instructions as described in this manual.
The information provided in this manual is valid for the standard design of the system. Parts of your
system may differ from this standard design.
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 or the owner of the system.
-Warranty becomes invalid when consequential damages to the system, caused by technical
changes, unprofessional maintenance and repairs, were executed by the dealer or the owner
of the system.
DANGER!
Failure to obey legal regulations may result in permanent personal injury or death.
ATTENTION!
Failure to obey legal regulations may result in damage to the system.

INTRODUCTION
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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.
WHO SHOULD USE THIS MANUAL?
Dealer:
The dealer is the person (concern) that represents Prinzen BV. The dealer must take care that its
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.
Owner:
The owner (contractor, concern) is the person that owns or hires the machine and puts this machine
into production. The owner must be aware that this service manual is intended to be used by service
engineers from Prinzen and its official dealers. Since this manual contains valuable information for
communication with the Prinzen service department or dealer it is delivered as a part of the system.
Be aware that using this service manual for adjusting your system is at your own risk.
Prinzen cannot be held responsible for any consequential damages to the system caused after using
this service manual.
MANUAL INFORMATION
Machine type: Speedpack
Manual revision: 01 (April 2011)
SERIAL NUMBER
Each machine has a unique serial number printed on the machine tag, which can be found in the
electrical cabinet. Note down this serial number to have it available when contacting the Prinzen
service department.
ABCDE
3~N 50Hz 400/230V
3 x 995A
AB1234
08-2010

INTRODUCTION
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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.
NOTE!
This symbol advises to use edible products and to work in a hygienically way. Disregarding this advice may cause
illness.
TIP!
This symbol is used as a helpful hint to simplify the execution of certain tasks.
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 stop 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.
DANGER!
Keep children and incompetent persons away from the system!
The system is designed for packing eggs into specific packaging. Any other use of the system is not
permitted.

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 bodybecause they maycause
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 nearest emergency stop 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 oil, grease or 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 first be switched off and secured
against accidental switching on.
Work inside the electrical cabinet may only be undertaken by skilled personnel like Prinzen service
engineers or its dealer‟s service engineers.
Always switch off the main switch before opening electrical cabinets.
After switching off the main switch, parts inside the electrical cabinet remain live for approximately 1
minute. The frequency inverters may hold a high voltage charge during this time. Do not touch parts
inside the electrical cabinet as long as displays of frequency inverters are on.

SAFETY
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Several parts inside the electrical cabinet maintain voltage even when the main switch is turned off
(main switch, main power supply, terminals for egg collecting belts, etcetera).
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
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SAFETY PROVISIONS
Before operating the machine the safety
devices must be checked for correct
functioning.
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.
Safety devices are:
2. Emergency stop buttons
3. Lockable doors
4. Protective covers
5. Safety switches
EMERGENCY STOP BUTTON
To stop the machine in case of an emergency,
the system has one or more emergency stop
buttons (2).
Only use the emergency stop button in case of
an emergency. When the emergency stop
button is pressed, the system stops
immediately. The button stays mechanically
locked so the machine cannot start until it is
considered safe to do so. Release the
emergency stop button by turning it clockwise.
Do not release the emergency stop button
when it is not certain why and by whom it was
pressed.
Personnel working with the system must know
the positions of the emergency stop buttons.
LOCKABLE DOOR
Lockable doors are doors that can only be
opened with a key (3). 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
3
3
1
2
2

SAFETY
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PROTECTIVE COVER
Protective covers (4) shield off dangerous
moving parts. These covers cannot be
removed without tools and should be attached
to the system before starting to use it.
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!
SAFETY SWITCH
Safety switches (5) are provided on safety
doors or safety covers to prevent the operation
of the machine or to stop the machine
immediately when this door or cover is opened.
DANGER!
Make sure the safety door or safety cover
remains open and make sure the system is not
able to start when you are inside the system.
4
55

SAFETY
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SAFETY INSPECTION PROCEDURE
Before starting the machine all protective covers must be in place and doors should be locked. The
emergency stop buttons and safety switches should be operating. Trained personnel must check
safety devices on a daily basis to assure proper operation.
Check emergency stop buttons (2):
1. Start and stop the system.
2. Wait until the system has completely stopped and push an emergency stop button.
3. Push the start button, the machine should not start.
4. Release the emergency stop button and reset the emergency circuit.
5. Repeat the above steps 2, 3 and 4 for all emergency stop buttons.
6. Make sure that the machine does not start when any emergency stop button is pressed.
Check safety switches (5):
1. Start and stop the system.
2. Wait until the system has completely stopped and open a safety door or safety cover.
3. Push the start button, the machine should not start.
4. Close the door or cover and reset the emergency circuit.
5. Repeat the above steps 2, 3 and 4 for all doors and covers.
6. Make sure that the machine does not start when a door or a cover is opened.
If the machine operates when an emergency stop button is pressed, a door is opened, a safety screen
is interrupted or a trolley is removed, this machine is not safe to operate. Immediately call a qualified
technician to repair this defective safety device.
2
5

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.
DANGER!
Keep the warning labels clean. When labels become
unclear, replace them.
The flashlight label 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.
These signs are 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.