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Installation and Tote
Indexing system setup
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 Connect
the main power 16amp plug 3ph 400v to the supply socket.
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Connect the 32 pin Hartin plug to the
process machine socket and this will interface with the machine
emergency stop circuit and mold cycle count.
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Connect compressed air to the tote handler
air filter regulator and set it at 3 bar. Please note that some of the
infeed swan neck conveyors have static de-ioniser bars fitted and these
require compressed to the air filter regulators and set at 0.5 – 1 bar.
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Turn the Tote control mains power on and
press the green CONTROL ON button, which will illuminate.
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Once the PLC test sequence has finished the
Tote indexing system can setup.
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 On
the control screen the operator can set how many mold cycles are
required in each tote by setting the SP (Set Point) value. To do
this press ENTER and then use the UP or DOWN arrows to change the value
and the press ENTER again to finish the set up.
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The PV value can not be changed
manually as it is the actual mold cycle count from the process machine.
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The “Swan neck conveyor” that conveys
components into the tote has a delay timer that can be set by pressing
either the UP/DOWN arrows, then press ENTER to adjust the value. The
delay time value is the time in seconds it takes for the final mold
cycle to drop components and elevate them into the totes.
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The operator can now load empty totes onto
the right hand conveyor lane and the control will automatically start up
in the incline conveyor and start counting mold cycles once the set up
sequence is complete.
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NOTE: To stop the Incline conveyor and
index a part full Tote press the F1 button once. There is a delay of 10
seconds and then the tote will index over.
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During normal operation the swan neck
conveyor will feed parts into the totes and once the SP (Set Point)
target is reached the full tote will move across onto the out feed
conveyor and a new empty tote will move in to position below the infeed
chute and the cycle will restart. The operator can move a full tote out
by pressing the green button located on the left hand frame.
Tote Indexing system alarm
screens
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 Actuator
Fault! Perform a visual check on the pneumatic linear actuator; this
is the arm that moves the totes from the right hand conveyor lane to
the left hand side. If the linear actuator is not working correctly
check the pneumatic air pressure is ok. If the linear actuator has
moved out of sequence the operator needs to isolate the mains power
supply turn off the pneumatic air and remove the tote. Reset the mains
power and pneumatic air, press the control on button and the system
will restart with the linear actuator in the correct position.
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To manually enter the alarm screens press
the ESC button on the control, SETUP press the enter
button, DISPLAY ALARM press the enter button, ALARM PAGE
press the enter button to view a list of current alarms. The
OPERATOR AND DIAGNOSTIC MENU is for UPM technicians to use during
setup.
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Empty
Box required alarm! Indicates that the operator needs to place new
empty totes onto the right hand conveyor lane and once completed the
alarm will stop. The control will continue to count the mold cycles
from the process machine.
Discharge
Conveyor Full! Indicates that the operator needs to remove the full
totes from the left hand conveyor lane place new empty totes onto the
right hand conveyor lane and once completed the alarm will stop. The
control will continue to count the mold cycles from the process
machine.
A
Conveyor Circuit Breaker Has Tripped! Indicates that an engineer needs
to isolate the mains power and open the control panel front door to
perform a visual check on the circuit breakers, identify the problem
and once completed the alarm will stop.