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control stations and panel boards, together with obsolete diagrams, indicators,
control labels, and other material which serve to confuse the operator.
SAfETY dEVICES
A)
All safety devices, including wiring of electrical safety devices, shall be
arranged to operate in a "fail-Safe" manner, that is, if power failure or failure of the
device itself would occur, a hazardous condition must not result.
B)
Emergency Stops and Restarts. Conveyor controls shall be so arranged
that, in case of emergency stop, manual reset or start at the location where the
emergency stop was initiated, shall be required of the conveyor(s) and associated
equipment to resume operation.
C) Before restarting a conveyor which has been stopped because of an
emergency, an inspection of the conveyor shall be made and the cause of the
stoppage determined. The starting device shall be locked out before any attempt
is made to remove the cause of stoppage, unless operation is necessary to
determine the cause or to safely remove the stoppage.
Refer to ANSI z244.1-1982, American National Standard for Personnel Protection
– Lockout/Tagout of Energy Sources – minimum Safety Requirements and OSHA
Standard Number 29 CfR 1910.147 "The Control of Hazardous Energy (Lockout/
Tagout)."
OPERATION
• Conveyor Start-Up
Before conveyor is turned on, check for foreign objects that may have been left
inside conveyor during installation. These objects could cause serious damage
during start-up.
After conveyor has been turned on and is operating, check all moving parts to
make sure they are working freely.
CAUTION! Because of the many moving parts on the conveyor, all personnel in the
area of the conveyor need to be warned that the conveyor is about to be started.
MAINTENANCE
• Lubrication
BEARINGS
A) NO GREASE fITTING - Prelubricated - No lubrication required.
B) WITH GREASE fITTING - Relubricate approximately every 10 to 12 weeks with
lithium base grease suitable for ball bearing service.
RECOMMENDED CHAIN LUBRICANT
A good grade of clean non-
detergent petroleum or synthetic
oil is recommended. See chart
for proper viscosity.
REDUCERS
See recommendations by manufacturer.
• Controlling the ProSort
A good software package is essential for the proper operation of the ProSort
sorter. With proper controls, the sorter will provide accurate, efficient, reliable
sorting for many years.
Inadequate controls, however, may result in poor
sorter performance and other mechanical failures of the sorter itself, including
"crashes". Hytrol recommends using the Hytrol ProLogix software package.
Every sortation system is different, which means that the controls for the system
are custom and unique to that system. These custom controls are provided
either by Hytrol, the Hytrol Integration Partner or a third party.
Hytrol has built into the sorter some of the controls necessary to operate the
divert switches, eliminating the need to control this function externally. Other
electrical control components are provided with the sorter to allow the external
controls
to monitor critical items and to provide an interface between the
electrical controls and the mechanical sorter. Still other control components must
be provided by the supplier of the custom controls package to insure proper
sorter operation.
This section of the manual includes the following information for the custom
controls provider:
1. A description of the divert switch control components supplied, their function,
and how to interface with them.
2. A description of the other control components provided with the sorter and
their intended function.
3. A description of control components that are not included with the sorter that
must be provided by the controls supplier.
4. Some control do's and dont's to assist in the design and installation of the
controls package.
Please read this section thoroughly and share this information with the controls
provider.
Ambient Temperature
SAE
degrees f
20-40
20
40-100
30
DIVERT SWITCH CONTROL
Proper control of the divert switch is critical to the safe and reliable operation of
the sorter. failure to properly control the divert switch is one of the most common
causes of switch damage and can cause "crashes."
The divert switch functions similar to a switch on a train track to cause the divert
shoes to travel either in a straight-through, "non-divert" track or diagonally across
the sorter along a "divert track" to push product off of the sorter. When the switch is
in the "home" position, the divert shoes travel through the switch along the straight-
through track. When the switch is in the "divert" position, the shoes are caused to
move along the divert track.
The transition of the switch between the "home" and "divert" positions must be
accurately timed to prevent sorter crashes. Just as a train track switch cannot
be safely operated while a train is passing through the switch, the divert switch
cannot be safely operated while a divert shoe is passing through the switch. If the
movement of the switch mechanism is not timed to occur only when no shoe is
present in the switch, the guide pin of the shoe may collide with the point of the
divert block, resulting in damage to the switch and potentially costly downtime.
The ProSort has two control components at each divert switch that work together
to accurately time the divert switch movement or operation, eliminating the need
for the controls provider to do so. These components are the smart prox and the
high-speed solenoid air valve.
SMART PROX
The "smart prox" is a special inductive proximity sensor developed exclusively for
Hytrol that has the "intelligence" needed to control the switch timing built-in. The
prox plugs to the y-cable. See figure 6A.
Y Cable
The y-cable is used to connect the smart prox, solenoid air valve and the system
controls. The male micro cord set from the smart prox connects to the terminal
#1 of the y-cable. The pico pigtail, of the y-cable, connects to the male plug on
the solenoid air valve at divert switch. The micro cord set with female end, plugs
to terminal #2 of the y-cable. The leads from the terminal #2 cord set have the
following functions (fig. 6A). NOTE: Y-cable not used on dual divert sections.
Brown—+24VdC power input to the prox.
Blue—Ground (-) lead for the prox.
Gray—divert enable input lead for the prox. When a 24VdC (high) signal is given
to this lead by the system controls, the prox waits for the next time it detects a
divert shoe, at which time it provides a 24VdC output through the y-cable to the
high speed solenoid air valve. The solenoid air valve then causes the switch to
move to "divert" position. All shoes traveling through the switch will then follow the
divert track as long as the enable signal is active (held high). When the divert signal
is removed (taken low) the prox waits for the next time it detects a divert shoe, at
which time it will turn off the output to the solenoid air valve. The switch then returns
to the "home" position, and subsequent shoes will follow the "non-divert" track. The
enable signal to this lead is the only signal that the system controls must
provide to control divert switching.
ISO
46 or 68
FIGURE 6A
100
SmART PROX
SmART
PROX
6
SmART PROX
ANd VALVE
CONNECTION
fOR
SINGLE-SIdEd
SORTERS
ONLY
(smart prOX Y
COneXIOn a
ValVUla sOlO para
sOrtes de ladO
senCIllO)
1
2
BROWN/CAfÉ
BLUE/AzUL
GRAY/GRIS
(NOT USEd/SIN USAR)
WHITE/BLANCO
BLACK/NEGRO
SOLENOID
VALVE
(ValVUla
sOlenOIde)
SmART PROX
TO SOLENOId
"Y" CONNECTOR
032.21124
(smart prOX Y
a sOlenOIde
Cable Y)
SmART PROX
CORd SET
+24 VOLTS dC
dC COmmON
SmART PROX ENABLE
SmART PROX STATE
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