Systec LPD User manual

Load Palletizing Device

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PRODUCT SERVICE MANUAL LOAD PALLETIZING DEVICE
2
ISSUE DATE: 1 August 2020
Table of Contents
1. INTRODUCTION ...................................................... 3
2. SAFETY .................................................................... 4
2.1 LOCKOUT/TAGOUT PROCEDURE ............................ 4
2.2 ELECTRICAL SAFETY ............................................. 4
2.3 SAFETY LABELS ................................................... 5
2.3.1 NEVER STAND OR WALK ON ANY
CONVEYORS ............................................................ 5
2.3.2 EXERCISE CAUTION WHEN WORKING ON
AUTOMATIC EQUIPMENT ....................................... 5
2.3.3 NEVER OPERATE EQUIPMENT WITHOUT
SAFETY GUARDS ...................................................... 5
2.3.4 SHOCK HAZARD ........................................ 5
2.3.5 BE SURE TO LOCKOUT BEFORE SERVICING
OR MAINTAINING EQUIPMENT .............................. 6
2.3.6 STAY CLEAR OF MOVING PARTS ............... 6
2.4 OTHER PRECAUTIONS .......................................... 6
2.5 SAFETY GUARDS ................................................. 6
2.6 WATCH FOR TRIP HAZARDS ................................. 6
3. OPERATION OVERVIEW ......................................... 6
3.1 INSTALLATION ADVICE ......................................... 7
3.2 SETTINGS & ADJUSTMENTS .................................. 7
3.2.1 Load Lifting Fork Assembly ....................... 7
3.2.2 Carriage Guide Rollers .............................. 8
3.2.3 Plow and Dampers ................................... 8
3.2.4 Backboard Assembly ................................ 8
3.3 CYCLES ............................................................. 8
3.3.1 Load Cycle No Pallet (Bypass Mode) ........ 8
3.3.2 Load Cycle with Pallet ............................... 8
3.3.3 Pusher Cycle .............................................. 8
3.4 OPERATION LEVELS ............................................. 9
3.4.1 Manual Jog Controls ................................. 9
3.4.2 Auto Pallet Selection ................................. 9
3.4.3 Bypass Mode ............................................ 9
4. COMPUTER CONTROLS .......................................... 9
4.1 HOW TO USE THE COMPUTER PANEL ..................... 9
4.2 CONTROL BASICS ............................................... 9
4.2.1 Run Manually Using Jog Controls ........... 10
4.3 HOW TO SETUP THE DEVICE AND RUN DIAGNOSTICS
10
4.3.1 Pallet Select Screen ................................. 11
4.3.2 Asi Diagnostics ........................................ 11
4.4 HOW TO CORRECT DEVICE FAULTS ...................... 11
4.4.1 View Faults with the LPD ........................ 11
4.4.2 LPD Control Faults .................................. 12
5. GENERAL MAINTENANCE ..................................... 13
5.1 CLEANING ....................................................... 14
5.2 LUBRICATION ................................................... 14
6. PREVENTIVE MAINTENANCE ............................... 15
6.1 MAINTENANCE TABLES ...................................... 15
6.1.1 Recommended Daily Preventive
Maintenance Table ............................................... 15
6.1.2 Recommended Periodic Preventive
Maintenance Table ............................................... 16
6.2 PREVENTIVE MAINTENANCE SCHEDULE ................ 17
6.3 PREVENTIVE MAINTENANCE CHECKLIST ................ 18
6.4 REPLACING COMPONENTS ................................. 19
6.4.1 Replace the Centering Device Wheels .... 19
6.4.2 Replace the Carriage Wheels ................. 19
6.4.3 Replace Fork Encoders [DWG 068D014] 19
6.4.4 Replace Lift Motor [DWG 068D001] ...... 19
6.4.5 Replace the Pallet Infeed Pusher Motor
[DWG 068D005 (3 of 3)] ....................................... 19
6.4.6 Replace the Servo Motor or Gearbox [DWG
068B013] ............................................................... 19
6.4.7 Replace the Fork Assembly ..................... 20
6.4.8 Replace the Pallet Centering Device Air
Cylinder [DWG 068D004 (1 of 4)] ........................ 20
6.5 SPARE PARTS ................................................... 21
6.6 BILL OF MATERIALS .......................................... 23
Supplemental Materials
• Maintenance Guide – PAM Lines
• HMI User Guide

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PRODUCT SERVICE MANUAL LOAD PALLETIZING DEVICE
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1. Introduction

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PRODUCT SERVICE MANUAL LOAD PALLETIZING DEVICE
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2. Safety
You need to understand the cautions,
warnings and dangers outlined in this chapter
for your own safety, and the safety of all
employees and visitors. You also need to
consider it as part of your safety guidelines and
procedures. The SAFETY procedures supplied
below are not meant to replace your
employee’s established safety procedures.
SYSTEC urges that all personnel working
on, or around conveyor equipment and devices
receive proper training on the correct
operation, safety precautions, maintenance
and service of the equipment.
2.1 Lockout/Tagout Procedure
Most industrial accidents are caused by
the uncontrolled release of hazardous energy.
Many of these accidents can be prevented by
proper lockout/tagout procedures. In the
United States, refer to OSHA Subpart J
1910.147 for proper standards.
SYSTEC Powered Conveyors and
Machine Devices are equipped with a motor
disconnect switch at each motor location which
can be used for device lockout. See Figure 2-1
below.
After maintenance is completed,
replace all guards that were removed and
ensure that no unsafe condition exists. Make
sure all personnel are clear before removing
the lockouts and activating the controls.
For OSHA Compliance Information:
Call 800-321-OSHA (6742)
Figure 2-1 Two Motor Disconnect Switches
2.2 Electrical Safety
The conveyor system operates on 230-
575 VAC incoming electrical power and has
numerous electrical and electronic
components having the potential to shock
operators and maintenance personnel.
Failure to follow instructions and heed the
WARNINGS concerning electrical
components could result in injury or death,
and damage to the equipment. Points
where electrical shock can occur are control
panels, control consoles, transformers,
junction boxes, electrical motors, power
receptacles, the ends of the wire-ways, and
anywhere else cables and wires are
connected. For your safety and that of
others, please follow these guidelines and
warnings:
• Keep electrical components dry.
• Do not operate the equipment or system if any
wires, cables or power leads appear to be frayed or
damaged.
• Do not operate the equipment or system with any
control enclosure open, unless required for
maintenance or troubleshooting by experienced and
qualified personnel.
• Do not work on electrical components unless
authorized to do so.
• Immediately shut the equipment or system down if
sparks, smoke, fire, or extreme heat is generated at
any electrical component.
• Do not work on energized electrical components
unless there are two or more qualified people
present.
• When working on electrical components, make
certain electric power disconnect handles and
switches are in the OFF position. (Comply with OSHA
Lockout/Tagout procedures).
• Lock and attach DANGER tags to circuit breakers and
switches that have been opened to perform
maintenance. (Comply with OSHA Lockout/Tagout
procedures).
• Verify terminal connections prior to disconnecting or
connecting any wires.
• When troubleshooting electrical component
problems, verify power is OFF with a multimeter.
• If an electrical component requires electrical
isolation or removal to perform maintenance,
ensure that all miscellaneous attaching hardware

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PRODUCT SERVICE MANUAL LOAD PALLETIZING DEVICE
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(i.e., screws, nuts, washers, insulator washers,
insulator bushings and gaskets) is serviceable and
properly reinstalled after removal.
• Do not bypass or override safety switches or devices.
• Brief all personnel in the area on any electrical
hazard or abnormal conditions.
• Ensure there is adequate light for working on
electrical components.
• Keep liquids and conductive material away from
electrical receptacles.
2.3 Safety Labels
Several safety labels are placed on the
equipment to warn you of the safety concerns
of the equipment. These labels are placed for
your protection and their warnings should be
taken seriously. Please follow the instructions,
whether they are written or illustrated with a
pictogram.
2.3.1 NEVER STAND OR WALK ON ANY
CONVEYORS
NEVER STAND OR WALK on a conveyor.
The rollers can turn freely or could start turning
under power at any time. Walking across
conveyors should only be done at designated
crosswalks and only on crossover walk plates,
never on the rollers.
Figure 2-2 DO NOT Walk on Conveyors Use Cross Walks
Only label
2.3.2 EXERCISE CAUTION WHEN WORKING
ON AUTOMATIC EQUIPMENT
Be aware of the conveyors and other
areas of the system where automatic
equipment is installed. Most conveyors and
related equipment run in automatic. The
equipment may start or stop at any given time.
External devices, such as photo-eyes or
switches may remotely activate the equipment.
For this reason, caution should be taken when
working around the conveyors, devices and
controls for the overall system.
Figure 2-3 CAUTION Automatic Equipment will start At
Any Time label
2.3.3 NEVER OPERATE EQUIPMENT
WITHOUT SAFETY GUARDS
Safety guards have been installed on the
equipment to minimize injury. Never remove
them during normal operations. If you remove
or disconnect them for service or maintenance,
always replace them as they were originally
installed before resuming operation.
Figure 2-4 CAUTION Do Not Operate This Machine
Without Guards in Place label
2.3.4 SHOCK HAZARD
Shock hazards can occur at numerous
locations. These can include control panels,
operator control consoles, transformers,
junction boxes, electrical motor power

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PRODUCT SERVICE MANUAL LOAD PALLETIZING DEVICE
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receptacles, the ends of wire-ways and
anywhere else cables and wires are connected.
Please exercise extreme caution when
operating in the vicinity of electrical
components.
Service should be performed only by
qualified and trained personnel.
2.3.5 BE SURE TO LOCKOUT BEFORE
SERVICING OR MAINTAINING EQUIPMENT
This label is placed near the motor
disconnect switch.
Figure 2-5 CAUTION Before Proceeding with Repair
Work, All Sources of Power to the Machine Must be
Tagged-Out and/or Secured with a Locking Device
label
2.3.6 STAY CLEAR OF MOVING PARTS
Generally, moving parts within the
conveyors or mobile conveyors can create, or
are direct pinch points. Material handling
systems, such as SYSTEC conveyors and devices,
must have some moving parts exposed, such as
rollers, to do the job for which it is intended.
Although SYSTEC safeguards against
injury as much as possible, some "pinch points"
inherently exist. Extreme caution should be
used to avoid these potentially hazardous
areas.
2.4 Other Precautions
• Wear the proper safety equipment,
such as earplugs, safety glasses, hard
hats, safety shoes and safety harnesses.
• Always use proper equipment for lifting
and pulling and make sure it is rigged
safely. Use machine dollies to move
heavy machinery.
• When starting or testing any motor,
make sure of proper direction of
rotation. Improper rotation can cause
damage to equipment and/or personal
injury.
• Do not crawl under any conveyors that
are not supported properly.
2.5 Safety Guards
Safety guards should be checked for
proper mounting. Guards that are damaged to
the extent that they no longer function should
be replaced. If you must remove or disconnect
guards for service or maintenance, always
replace them as they were originally installed.
2.6 Watch for Trip Hazards
Some areas of equipment or conveyors
require guarding that extends outside the
parameters of the conveyor itself. This guarding
is in place to keep personnel from entering a
potential hazardous situation yet must remain
below the rollers' surface to avoid interference
with the loads on the conveyors. The extended
guarding can itself become a potential trip
hazard. Extra caution should be extended for
potential trip hazards in the work area.
3. Operation Overview
A load entering the Load Palletizing
Device is measured by a photoeye. The
measurement is used to center the load along
the length of the heads. As the load is centered
and stopped inside the device, the heads
advance toward the load and force the load to
the center of the conveyor, squaring the load at
the same time. Once the load is centered and
squared, it is lifted by the head and load lifting
forks.
The forklifting drive is located on the
top of the carriage frame. The drive is designed
to lift up to 5000 lb (2270 kg) in 1.5 seconds

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PRODUCT SERVICE MANUAL LOAD PALLETIZING DEVICE
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and fault out in 1.7 seconds. Hard urethane
dampers are installed to absorb the lifting
shock and two lock pin holes are provided to
support the raised head during maintenance.
Two proximity switches, mounted on a slide
hanging from the carriage frame, control the up
and down movement of the forks.
Meanwhile, a pallet is delivered to the
device at the pallet infeed point. The pallet
centering device is actuated by an air cylinder
connected to slides by cables. The factory air
pressure setting is 40 PSI. The centering heads
engage to center and square the pallet, which
puts the pallet in direct line with the centered
and squared load. Next, the pusher head
engages and delivers the pallet to the center of
the conveyor. The pallet infeed pusher is driven
by a chain and sprocket drive. An encoder
mounted on the drive shaft controls the pusher
displacement and a panel drive controls
acceleration and torque delivered to the pallet.
The load lift forks retract to deliver the
load onto the pallet and the palletized load
advances downstream. The next load to be
palletized is released simultaneously for the
same operation.
3.1 Installation Advice
All of the pallet insertion equipment will
center on the thru conveyor: a standard 126”
(3200mm) or optional 180” (4572mm) length
conveyor. The distance from the center of the
main line to the front edge of the delivered
pallet is 144” (3657.6mm). This dimension must
be maintained in order to accommodate the
full range of pallet sizes (from 24” x 24” to 48” x
84”). This will also allow adequate room for the
pallet delivery device to miss the pallet pusher
and pallet centering device.
The V-track of the carriage drive
assembly should be located 9 3/8” (238mm) off
the center line of the thru conveyor (approx. 1
3/8” or 35mm from the tension frame). These
V-tracks need to be leveled to the thru
conveyor. During installation, the carriage drive
assembly can help align the V-tracks. There are
2 alignment bolts on each end of these
assemblies, these bolts match holes in the V-
track plate and have been numbered during
set-up and testing at the SYSTEC plant. Do not
use them as jack screws.
Verify the V-tracks and carriage drives
are square and aligned with the opposing drive
set. Remove the servo drive chain and roll the
carriage assembly over the V-tracks and
lowered drive shaft. Roll the carriage from front
to back a few times to seat the V-tracks under
the carriage. Lag the V-tracks in place through
the slotted holes.
Using the eight jack screws, raise the
drive assembly so the pitch lines of the pinion
gears and gear racks align. Shim around the lag
bolt holes that are adjacent to the jack screws
on the drive assembly and lag the drives. Verify
gear-rack tooth engagement and shaft
straightness. Again, roll the carriage back and
forth over the free drive shaft to check the
location and square of the carriage to V-track
and gear engagement. One or more of the
racks have slots in them for adjustment. During
assembly at the SYSTEC plant, these gear racks
were pinned after alignment and testing and
should not need re-mounting.
The mechanical switches for the
carriage maximum travel and home positions
can be positioned while the carriage is free.
3.2 Settings & Adjustments
3.2.1 Load Lifting Fork Assembly
Figure 3-1 Forks Lifting Load

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PRODUCT SERVICE MANUAL LOAD PALLETIZING DEVICE
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The fork assembly is powered in and
out by a rack and pinion drive and is guided by
cam followers. The side to side movement of
the fork assembly should be limited to 1/8”
(3mm) max. The cams can be adjusted in and
out. Verify the fork assembly is set square on
the rack. The encoder responsible for
controlling the forks’ position is located on this
drive shaft.
The load lifting forks should lie at least
½” (13 mm) below and parallel to the top of the
thru conveyor rolls when the fork assembly is
lowered and resting on the rubber pads. This
allows the plow teeth to be lower than the top
of the conveyor rollers as the plow rolls on the
forks.
Forks can extend 24 inches (609.6mm)
beyond front plate to 1 inch (25.4mm) behind
front plate. Individual fork adjustments can also
be made. By using the fork clamping
assemblies, the individual forks can be moved
right and left, and the fork tips can be moved
up and down.
3.2.2 Carriage Guide Rollers
In order for the forks to be parallel to
the rolls, the carriage V-tracks and Thru
Conveyor must be level. This should be taken
care of during installation, using the supplied
shims if necessary. Also, the yoke roll total
clearance around the vertical carriage columns
should be 1/16” (1.5mm). If the clearance
exceeds 1/8” (3mm), larger 2-1/4” (57mm)
outer diameter yoke rolls can be installed.
3.2.3 Plow and Dampers
Plow pressure against the product
waster sheet (or product) is accomplished using
the weight of the plow itself and either (or
both) a hydraulic damper or spring assembly.
The damper produces a constant force against
the product and supports the plow as it
retracts. The hydraulic damper can be adjusted
by detaching the top end from the backboard.
Then the force can be increased or decreased
by pulling the rod out as far as possible and
turning counterclockwise or clockwise.
CAUTION: The dampers must close to
stop the machine as the backboard contacts
the product. Both dampers on the plow should
be adjusted the same, as should both plows.
The spring assembly provides extra plow force
at the end of the stroke. Different combinations
of springs and chain links will change the
amount and timing of that force.
The angle of the plow blade can be
adjusted by the height of the rubber pads in the
vertical cam follower slot. A ½” (13 mm) rubber
pad was installed at the SYSTEC plant
3.2.4 Backboard Assembly
Located on the backboard assembly is a
set of proximity switches which control the load
centering stroke of the machine. These
switches read the location of the cam follower
on the plow. Also attached to the backboard is
the proximity flag for the up and down machine
motion. These proximity switches are located
on an adjusting slide attached to the carriage
frame.
3.3 Cycles
The operation of the Load Palletizing
Device is divided into three separate cycles:
Load Cycle No Pallet or Bypass Mode, Load
Cycle with Pallet, and Pusher Cycle.
3.3.1 Load Cycle No Pallet (Bypass Mode)
The load moves straight through the
Load Palletizing Device without a pallet being
placed under it.
3.3.2 Load Cycle with Pallet
The load is centered and raised inside
the device to allow the placing of a pallet
underneath the load. Once a pallet has been
positioned, the load is lowered onto the pallet
and the palletized load exits the device.
3.3.3 Pusher Cycle
The pusher positions the pallet under a
raised load inside the device.

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PRODUCT SERVICE MANUAL LOAD PALLETIZING DEVICE
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3.4 Operation Levels
The Load Palletizing Device can operate
in either Manual Jog Controls mode or with
Auto Pallet Selection enabled. The different
cycles allow correcting a problem in one area
without affecting the operation in other areas.
3.4.1 Manual Jog Controls
The operator uses push buttons and
switches on the panel to manually run the
device. The operator has full control minus
some safeguards to protect the machine. The
operator is given more control when on the
Service Screen. These controls are generally
only used to correct problems that occurred
while in automatic. The controls for the device
allow opening and closing the heads, raising
and lowering the heads, running the forks in
and out, running the pallet pusher forward and
reverse, and closing and opening the pallet
centering device.
Once a cycle has started, use the
Manual Jog Controls to completely cancel a
cycle. The manual jog controls can produce the
actions that would normally indicate that the
cycle has finished.
3.4.2 Auto Pallet Selection
The pallet type may be either manually
chosen or transferred to the Load Palletizing
Device automatically. The only information the
device needs for each load is the type of pallet
to be used. If the Pallet Selection is in manual,
the operator needs to enter the pallet type for
each load once it is in position upstream of the
Load Palletizing Device. In automatic, the pallet
type is selected at the stripper console, either
by the operator or by the Bar Code Scanner.
When the load moves to the Load Palletizing
Device, the pallet type is automatically sent to
the device controls.
3.4.3 Bypass Mode
In addition to the above modes, the
device also has a Bypass Mode. When the
Bypass mode is selected, loads will move
straight through the device and all of the
other cycles are disabled. This mode would
generally only be used when there is a problem
with the device that cannot be immediately
repaired or corrected.
4. Computer Controls
The operator controls equipment using
a high-performance computer panel, which
incorporates the latest technology to provide
an easy-to-use touch screen.
4.1 How to Use the Computer
Panel
The computer panel is made up of three
areas: Display/Touch Screen, Numeric
Membrane Keypad and Function Keys. The
Display/Touch Screen allows the operator to
touch the screen to carry out commands.
Function keys allow the operator to go to
different screens. When a pallet type needs to
be changed, use the keypad to enter the
number desired. Then use the ENTER key when
the desired number has been completed.
4.2 Control Basics
Figure 4-1 Title Screen
After turning on the control power, the
TITLE SCREEN appears (See Figure 4-1).
When the Title Screen appears, press F1
to enable all drives. Press F7 to home plow
heads before continuing to other operations.
Function Keys on Title Screen:
F1 = Drive Power On/Off

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PRODUCT SERVICE MANUAL LOAD PALLETIZING DEVICE
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F2 = Status Screen
F3 = Service Screen (Authorized Personnel Only)
F4 = Pallet Select
F5 = ASi Diagnostics
F6 = Faults
F7 = Home Heads
Figure 4-2 Status Screen
4.2.1 Run Manually Using Jog Controls
When problems occur in automatic, the
operator may choose to use the manual jog
controls on the panel (see Figure 4-3).
Figure 4-3 Full Control Panel including jog controls
Use as follows:
• To stop the device immediately, use the
EMERGENCY STOP button in the upper left
corner.
• When the switch is set to Bypass, loads will
move straight through the device and all of
the other cycles are disabled. This mode
could be used when there is a problem with
the device, and it cannot be immediately
repaired.
• Control power to the device by using the
PULL ON/PUSH OFF button.
• To open or close the heads of the device,
use the PLOW switch.
• To lower or raise the heads, use the LIFT
PULL UP/PUSH DOWN button.
• To jog the thru conveyor forward or
reverse, use the CONVEYOR switch.
• To release the conveyor, use the other thru
conveyor MANUAL RELEASE switch.
• To jog a pallet forward or reverse use the
PALLET PUSHER switch located on the
status screen.(See Figure 4-2)
• To open or close the pallet pusher device,
use the CENTERING DEVICE CYCLE switch
located on the status screen.(See Figure 4-
2)
4.3 How to Setup the Device and
Run Diagnostics
The Service Screen is used to setup the
device or to diagnose problems with the
equipment.
Figure 4-4 Service Screen
NOTE: The Service Screen is reserved for
authorized service personnel use only. Using it
may cause unwarranted damage to the system.
To Setup the Device:
1. Access the SERVICE Screen (F3) (See Figure
4-4)
2. Press button next to Enter Access Code (the
system is password protected)
3. Enter the Access Code using the keypad.
4. Press ENTER
5. When finished with this screen, select F8 to
return to the MAIN SCREEN.