Tomra AUTOSORT User manual
USER MANUAL
A GLOBAL PIONEER IN SENSOR-BASED SORTING
English
AUTOSORT with FLYING BEAM® technology
User Manual
2UM-KO-0026-REV0.0-en
Original version
WWW.TOMRA.COM
Revision Date Responsible Description
Recycling Hub
TOMRA Sorting GmbH
Otto-Hahn-Strasse 6
56218 Mülheim-Kärlich
Germany
Phone: +49 2630 9652 0
Fax: +49 2630 9652 101
UK
TOMRA Sorting Ltd.
53-55 Queens Road
Loughborough
LE11 1HA
United Kingdom
Phone: + 44 1509 23 22 39
Fax:
Spain / Portugal
TOMRA Sorting S.L.
C. Arquitecte Gaudí, 45
17480 Roses-Girona
Spain
Phone: +34 972 154 373
Fax: +34 972 459 098
France
TOMRA Sorting SARL
VEAS Minerve
40 avenue des Gardians
Parc Régional Via Domitia Nord Lien
34160 Castries
France
Phone: +33 4 67 56 39 66
Japan
TOMRA Sorting K.K.
3-2-5 Magamoto, Minami-ku
Saitama-shi, Saitama
336-0033 Japan
Phone: +81 48 711 3135
Fax: +81 48 829 9082
Korea
TOMRA Sorting Co., Ltd.
#404-1,CentralBuilding,762-4,
412-222 Haengsin-dong
Deokyang-gu, Goyang-si, Kyeo-
nggi-do
Korea
Phone: +82 (0)31 938 7171
Fax: +82 (0)31 938 7173
Poland
TOMRA Sorting Sp. z o.o.
Ul. Ligocka 103
40-568 Katowice
Poland
Phone: +48 32 352 60 93
Fax: +48 32 352 60 94
Russia
"TOMRA Sorting" LLC
Bakhrushina str. 32 bld. 1
115054 Moscow
Russian Federation
Phone: +7 495 938 96 83
China
"TOMRA Sorting Technology
(Xiamen) Co.,Ltd
Add: 1A/E, Rihua Building,No.8,
Xinfeng 2nd Road, Huli District,
361006,Xiamen,Fujian,P.R.C.
Phone: +86 592 5720780
Fax: +86 592 5720779
Brazil
TOMRA Brasil Soluções em Segre-
gação Ltda
Rua dos Guararapes, 1.909 - andar
9 sala "F"
04.561-004 - Brooklin Novo
São Paulo, Brazil
Phone: +55 11 3476 3500
Fax: +55 11 3294 3400
United Arab Emirates
'TOMRA Sorting JLT
UnitNo.3702-21,floorNo.37,
Mayfair Executive Offices JLT,
JumeirahBusinessCenter2,
Jumeirah Lake Towers
Dubai
United Arab Emirates
User Manual
UM-KO-0026-REV0.0-en 3
1 Introduction ............................................................................................................................. 7
1.1 Liability ............................................................................................................................ 7
1.2 Information on the identification plate .............................................................................. 7
1.3 Machinery Directive .......................................................................................................... 7
1.4 Copyright ......................................................................................................................... 8
1.5 Additional documentation ................................................................................................ 8
1.6 Spare parts ....................................................................................................................... 8
1.7 List of abbreviations ......................................................................................................... 8
1.8 Layout of safety messages ................................................................................................ 9
2 Safety ...................................................................................................................................... 10
2.1 Intended use ...................................................................................................................10
2.2 Important safety messages ...............................................................................................11
2.2.1 General safety messages .............................................................................................................................11
2.2.2 Electric safety ................................................................................................................................................11
2.3 Safety precautions ........................................................................................................... 12
2.3.1 Installation of the machine ........................................................................................................................12
2.3.2 Commissioning the machine .....................................................................................................................12
2.4 Personal protective equipment ........................................................................................13
2.5 Personnel requirements ...................................................................................................14
3 Device description ................................................................................................................. 15
3.1 Functional description .....................................................................................................15
3.2 TOMRA Sorting scope of delivery .....................................................................................16
4 Technical data......................................................................................................................... 17
4.1 Ambient conditions .........................................................................................................17
4.2 Dimensions and weights .................................................................................................. 17
4.3 Power supply ..................................................................................................................18
4.4 Compressed air supply .....................................................................................................19
4.5 Different sensor configurations ....................................................................................... 20
4.6 Optional features ............................................................................................................ 22
5 Transport ................................................................................................................................ 23
5.1 Damage and claims ......................................................................................................... 24
5.2 Lifting the machine .........................................................................................................24
5.3 Storage .......................................................................................................................... 25
User Manual
4UM-KO-0026-REV0.0-en
6 Installation and commissioning......................................................................................... 26
6.1 Requirements for installation ..........................................................................................26
6.2 Installation .....................................................................................................................27
6.3 Commissioning ...............................................................................................................27
6.3.1 Installation ...................................................................................................................................................28
6.3.2 Commissioning ...........................................................................................................................................28
6.3.3 Optimization during production .............................................................................................................. 29
7 Electrical connections.......................................................................................................... 30
7.1 Electrical welding ............................................................................................................ 31
7.2 Power connection ...........................................................................................................32
7.3 Signal interface and operating conditions ........................................................................33
7.3.1 Terminal list .................................................................................................................................................34
7.3.2 Flex signals .................................................................................................................................................. 35
7.3.3 Optional VBPS signals ............................................................................................................................... 35
7.3.4 Sequence diagram ..................................................................................................................................... 36
8 Operation ............................................................................................................................... 37
8.1 Before commencing operation ........................................................................................38
8.2 Operating and display elements ......................................................................................39
8.2.1 Main control unit ......................................................................................................................................... 39
8.2.2 Operating software ....................................................................................................................................40
8.3 VBPS .............................................................................................................................. 41
8.3.1 Setup .............................................................................................................................................................41
8.3.2 Valve block movement ..............................................................................................................................42
8.4 Start-up sequence ...........................................................................................................43
8.4.1 Local or remote sorter control .................................................................................................................43
8.4.2 Local start up ...............................................................................................................................................44
8.4.3 Remote start up ..........................................................................................................................................45
8.4.4 Central control room functions ................................................................................................................46
8.5 Stop/emergency stop .....................................................................................................46
8.5.1 Stop ...............................................................................................................................................................46
8.5.2 Start-up after stop .....................................................................................................................................46
8.5.3 Start-up after emergency stop ................................................................................................................46
8.5.4 Emergency stop for VBPS ......................................................................................................................... 47
8.6 Operating pressure for different applications ...................................................................48
9 Cleaning.................................................................................................................................. 49
9.1 Cleaning equipment ........................................................................................................50
9.2 Cleaning intervals ...........................................................................................................50
9.3 Cleaning scanner glass window .......................................................................................50
9.4 Cleaning heat exchanger ................................................................................................. 51
User Manual
UM-KO-0026-REV0.0-en 5
9.5 Cleaning valve block cover for nozzles .............................................................................51
9.6 Cleaning valves .............................................................................................................. 52
9.7 Cleaning VBPS ................................................................................................................ 52
9.8 Cleaning the gap between valve block and conveyor ....................................................... 52
9.9 Cleaning touchscreen ..................................................................................................... 52
9.10 Cleaning heat exchanger ................................................................................................. 53
10 Troubleshooting.................................................................................................................... 54
10.1 Operational fault conditions ............................................................................................ 56
10.2 Messages ........................................................................................................................ 59
11 Maintenance.......................................................................................................................... 60
11.1 Safety equipment ...........................................................................................................63
11.2 Scanner .......................................................................................................................... 63
11.2.1 Calibrating the sensors ..............................................................................................................................63
11.2.2 Replacing halogen lamp unit ....................................................................................................................64
11.3 Valve block ..................................................................................................................... 68
11.3.1 Replacing valve block cover for nozzles .................................................................................................68
11.3.2 Replacing nozzles .......................................................................................................................................69
11.3.3 Replacing valve block cover of housing .................................................................................................70
11.3.4 Replacing valves ..........................................................................................................................................71
11.3.5 Valve test .....................................................................................................................................................72
11.4 VBPS .............................................................................................................................. 72
11.4.1 Lubrication ...................................................................................................................................................72
11.4.2 Pressure setting ..........................................................................................................................................73
11.5 Pressure equipment ........................................................................................................ 74
11.5.1 Replacing pressure regulator ...................................................................................................................74
11.5.2 Exchanging pressure regulator filter .......................................................................................................75
11.5.3 Replacing manometers ..............................................................................................................................76
11.6 Belt speed measurement ................................................................................................ 77
11.7 After maintenance ..........................................................................................................77
11.8 Electrical Safety .............................................................................................................. 77
12 Maintenance plan.................................................................................................................. 78
13 Decommissioning and disassembly .................................................................................. 79
14 Signs ........................................................................................................................................ 81
14.1 Sign “Do not operate” .....................................................................................................81
14.2 Warning sign - Operating instructions ............................................................................. 82
15 Declaration of Incorporation .............................................................................................. 83
User Manual
6UM-KO-0026-REV0.0-en
User Manual
Introduction 1
UM-KO-0026-REV0.0-en 7
1 Introduction
1.1 Liability
1.2 Information on the identification plate
1.3 Machinery Directive
User Manual
Introduction
8
1
1.4 Copyright
1.5 Additional documentation
1.6 Spare parts
1.7 List of abbreviations
Abbreviation Description
Tab. 1: List of abbreviations
User Manual
Introduction 1
UM-KO-0026-REV0.0-en 9
1.8 Layout of safety messages
example
CAUTION
–
Symbol Signal word Risk Consequence
if disregarded
DANGER
WARNING
CAUTION
NOTICE
Tab. 2: Hierarchy of safety messages
Abbreviation Description
Tab. 1: List of abbreviations
User Manual
Safety
10
2
2 Safety
2.1 Intended use
WARNING
–
–
User Manual
Safety 2
UM-KO-0026-REV0.0-en 11
2.2 Important safety messages
2.2.1 General safety messages
DANGER
–
2.2.2 Electric safety
WARNING
–
–
–
–
Fig. 1: Padlock at main switch
WARNING
–
–
–
–
User Manual
Safety
12
2
2.3 Safety precautions
2.3.1 Installation of the machine
2.3.2 Commissioning the machine
User Manual
Safety 2
UM-KO-0026-REV0.0-en 13
2.4 Personal protective equipment
User Manual
Safety
14
2
2.5 Personnel requirements
Instruction level Requirements
Tab. 3: Personnel requirements
Operating phase Requirements Explanation
Tab. 4: Assignment of roles during various operating phases
User Manual
Device description 3
UM-KO-0026-REV0.0-en 15
3 Device description
3.1 Functional description
Fig. 2: Functional principle
12
3
User Manual
Device description
16
3
3.2 TOMRA Sorting scope of delivery
Fig. 3: Exploded view of the AUTOSORT
1
2
3
4
5
6
7
8
9
10
11 12
User Manual
Technical data 4
UM-KO-0026-REV0.0-en 17
4 Technical data
4.1 Ambient conditions
4.2 Dimensions and weights
Characteristic Value Reference
Tab. 5: Ambient conditions
Component Type - Assembly
height
Weight
Kg (lbs)
Length
mm (inch)
Width
mm (inch)
Height
mm (inch)
Tab. 6: AUTOSORT part specification
User Manual
Technical data
18
4
4.3 Power supply
Item Control Unit
Tab. 7: Technical specification control unit
Component Type - Assembly
height
Weight
Kg (lbs)
Length
mm (inch)
Width
mm (inch)
Height
mm (inch)
Tab. 6: AUTOSORT part specification
User Manual
Technical data 4
UM-KO-0026-REV0.0-en 19
4.4 Compressed air supply
Fig. 4: Air connections to AUTOSORT to be supplied by the customer
Valve type Particles Water Oil
Tab. 8: Compressed air purity according to ISO 8573-1
Valve type Temperature range Pressure
Tab. 9: Valve parameters
AB
1 2 34 53
User Manual
Technical data
20
4
4.5 Different sensor configurations
Sensor
Configuration
Performance Mounting
High
Low
Valve
block
Recomm.
min. particle
size [mm]
Working width [mm]
Tab. 10: Sensor configuration
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