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Users manual

Unilever Brasil
C5000
Palletiser 1

Location

: Aguai

CSi order no.

: 2225

Year of manufacture : 2014


Your order no.

: DO6936357

Date of issue

: July 2010

Project manager
Version
:

A. Swikker
prelim

Telephone
Fax
E-mail
Internet

+31(0) 162 575 001


+31(0) 162 575 118
service@csiweb.nl
www.csiweb.nl

:
:
:
:

CSi industries B.V.


P.O. Box 70
4940 AB Raamsdonksveer
The Netherlands

Description
General Purpose

Owner
DJB

09-1-14

Version Date

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Titelblad.fm

C5000 Unilever Brasil

Copyright
We retain the ownership of all images, catalogues, technical details and computer programs provided by us,
unless expressly stipulated otherwise in the order confirmation. The client is responsible for ensuring that this
information is not copied and / or put at the disposal of, or submitted for inspection to, third parties without our
permission. We are not obliged to issue detailed drawings.

Terms and conditions


The details published in this user manual are based on the most recent information, and are subject to change.
CSi reserves the right to alter the construction and / or design of its products at any time, without liability to
amend previous deliveries accordingly.
All deliveries are subject to our delivery and payment conditions, filed at the Tilburg Chamber of Commerce,
which are available on request.

Original instructions
The original instructions have been written in English. Other language versions are a translation of the original
instructions. In case of doubt or small deviations in the translation, the original instructions prevail.
CSi

September 1, 2014

C5000 Unilever Brasil

Preface
This user manual contains important and useful information to enable
proper functioning and maintenance of your system / the machine(s). It
also contains important information on the prevention of accidents and
serious damage to the system / machine(s) before putting into operation,
ensuring safe and trouble-free operation.

Important instructions
Before putting the system / machine(s) into operation, please read the user
manual thoroughly.
Acquaint yourself with the operation, and strictly observe the instructions
and directions. In this context, please be referred to the safety regulations
and the importance of appropriate staff training to operate the system /
machine(s).
Store this user manual in a safe area near the system / machine(s).
K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Titelblad.fm

If you have any further queries or require additional information, please


contact CSi.

Service information card


LCSi is a dvision of CSi industries b.v., we specialise in the service and
maintenance of CSi equipment and offer you a dedicated team of service
and maintenance engineers.
This Service information card contains important information about LCSi,
and is especially useful if you wish to contact us for advice and/or technical
support.

09-1-14

This information card (included as an appendix) is intended for


maintenance and technical personnel. Therefore we suggest you hang this
card on the relevant department notice board or in the vicinity of the control
cabinet.

September 1, 2014

CSi

09-1-14

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Titelblad.fm

C5000 Unilever Brasil

CSi

September 1, 2014

C5000 Unilever Brasil

CONTENTS

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

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Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2

Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3

Safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.4

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

09-1-14

1.5

1.6

1.7

1.4.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4.2

Cautionary tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Safety features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3


1.5.1

Safety signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.5.2

Area stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.5.3

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.5.3.1

Emergency stop area . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.5.3.2

Emergency stop functionality . . . . . . . . . . . . . . . . . . 1-6

1.5.3.3

Restart after emergency stop / area stop . . . . . . . . . 1-6

1.5.4

Fencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.5.5

Door switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.5.5.1

Access to the fenced off area . . . . . . . . . . . . . . . . . . 1-7

1.5.5.2

Restarting the area . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.5.6

Safety light barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.5.7

Air supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.5.8

Main switch / local isolator switch . . . . . . . . . . . . . . . 1-9

1.5.9

Signal Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Additional safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9


1.6.1

safety during installation . . . . . . . . . . . . . . . . . . . . . . 1-9

1.6.2

Safety during operation . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.6.3

Safety during maintenance, breakdowns, repairs


and change over . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.6.4

Safety during disassembly and removal . . . . . . . . . 1-10

Additional instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11


1.7.1

September 1, 2014

Subcontractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Project/Product/machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Functional specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1


CSi

C5000 Unilever Brasil

3.3

3.4

3.5

Type RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1.2

Type RL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1.3

Type LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.1.4

Type LL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Machine construction type C5000 Si . . . . . . . . . . . . . . . . . . . . . . 3-3


3.2.1

Zero pressure conveyor. . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.2

Belt conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2.3

Infeed row-forming conveyor . . . . . . . . . . . . . . . . . . . 3-4

3.2.4

Turning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.2.4.1

Clamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.2.4.2

Turn cam (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.2.5

Package pusher (optional). . . . . . . . . . . . . . . . . . . . . 3-7

3.2.6

Row pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.2.7

Back stop and side stops. . . . . . . . . . . . . . . . . . . . . . 3-9

3.2.8

Load platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.2.9

Pallet lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.2.10

Pallet in- and outfeed. . . . . . . . . . . . . . . . . . . . . . . . 3-13

Machine construction type C5000 Ti . . . . . . . . . . . . . . . . . . . . . 3-14


3.3.1

Belt conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.3.2

Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.3.3

Zero pressure conveyor. . . . . . . . . . . . . . . . . . . . . . 3-15

Interleaving sheet module (optional) . . . . . . . . . . . . . . . . . . . . . 3-15


3.4.1

Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.4.2

Grab head for inserting interleaving sheets. . . . . . . 3-16

3.4.3

Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Control specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16


3.5.1

Optional modules. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.5.2

HMI software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.5.3

Eagle Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.5.4

Eagle edit (optional). . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.5.5

Soft PLC software . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.5.6

Hardware control platform . . . . . . . . . . . . . . . . . . . . 3-22

3.5.7

Standard E-cabinet . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.5.8

Controlling optional peripheral equipment . . . . . . . . 3-24

Operator manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1


4.1

ii

3.1.1

Introduction C5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

CSi

September 1, 2014

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3.2

Introduction C5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

09-1-14

3.1

C5000 Unilever Brasil

4.2

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4.3

4.2.1

Start button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.1.1

Indicator light (white) . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.2

Stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.3

Reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.3.1

Indicator light (blue). . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.4

Manual button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.4.1

Indicator light (yellow) . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.5

Stop Infeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.5.1

Indicator light (yellow) . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Other local panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4


4.3.1

Local panel pallet lift . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.2

Local panel destacker . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.3

Local panel safety light barrier . . . . . . . . . . . . . . . . . 4-5

4.3.4

Safety lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1

HMI panel on C5000 palletiser . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fault messages Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2

Customer Service & Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.4

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5

Gear motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.6

Chain transmission of drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

09-1-14

6.5.1

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.6.1

Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.6.2

Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.6.3

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.7

Clamping bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.8

Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.9

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.9.1

Bearing blocks with a greased lubrication nipple . . . 6-6

6.10 Pneumatic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7


6.10.1

Water separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.10.2

Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.10.3

Pressure regulator and manometer. . . . . . . . . . . . . . 6-7

6.10.4

Other pneumatic components . . . . . . . . . . . . . . . . . . 6-7

6.11 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8


6.11.1

September 1, 2014

Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.11.2

Back up electrical supply. . . . . . . . . . . . . . . . . . . . . . 6-8

6.11.3

Operating panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.11.4

Proximity switches, limit switches and door switches 6-8

6.11.5

Photo cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.11.6

Electrical cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.11.7

Cable tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8


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C5000 Unilever Brasil

6.12 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9


6.12.1

Anti-oxidant lubricant . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6.13 Maintenance diagram logistics. . . . . . . . . . . . . . . . . . . . . . . . . . 6-10


6.14 Palletising machine C5000- Si / Ti . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.14.1

Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.14.2

Machine construction. . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.14.3

Mechanical safety devices. . . . . . . . . . . . . . . . . . . . 6-13


Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.15.2

Tightening conveyor belt . . . . . . . . . . . . . . . . . . . . . 6-14

6.15.2.1

Method for tightening the belt. . . . . . . . . . . . . . . . . . 6-15

6.15.3

Replacing drive belt . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6.15.3.1

Method for replacing the belt . . . . . . . . . . . . . . . . . . 6-15

6.15.4

Method for replacing the cylinder pressure unit. . . . 6-16

6.15.5

Method for replacing the spacers / stop plate . . . . . 6-16

6.16 Row pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16


6.16.1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.16.2

Maintenance and adjustment information . . . . . . . . 6-17

6.16.2.1

Clamping bush of the axle - chain wheel


connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.17 Load platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17


6.17.1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.17.2

Checking and adjusting the timing belt tension . . . . 6-17

6.17.2.1

Tension gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6.17.2.2

Method for checking and adjusting


the timing belt tension . . . . . . . . . . . . . . . . . . . . . . . 6-19

6.17.3

Method for replacing the timing belts. . . . . . . . . . . . 6-19

6.18 Back dam and side dams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20


6.18.1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6.18.2

Maintenance and adjustment information . . . . . . . . 6-20

6.19 Pallet lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21


6.19.1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6.19.2

Maintenance and adjustment information . . . . . . . . 6-21

6.19.2.1

Pallet lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6.19.2.2

Lift wagons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6.19.2.3

Centring unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6.19.2.4

Drop lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6.20 Maintenance diagram machine C5000- Si / Ti. . . . . . . . . . . . . . 6-24

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6.15.1

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6.15 Infeed row forming conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

C5000 Unilever Brasil

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6.21 Elevator - changing chains and bearings lift shaft . . . . . . . . . . . 6-26

6.21.1

Functional description . . . . . . . . . . . . . . . . . . . . . . 6-27

6.21.2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6.21.3

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6.21.4

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6.21.4.1

Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6.21.4.2

Proximity switches, limit switches and door switches . 629

6.21.4.3

Photo cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6.21.4.4

Electrical cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6.21.4.5

Cable tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6.21.5

Replace the lift chains and/or lift shaft bearings . . . 6-30

6.21.5.1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6.21.5.2

Tools required: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6.21.5.3

Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.4

Mechanical installation of a system . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.5

7.4.1

Scope of supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.4.2

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Mechanical installation of a machine . . . . . . . . . . . . . . . . . . . . . . 7-3


7.5.1

Scope of supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.5.2

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Pneumatic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.7

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

09-1-14

7.6

7.7.1

Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.7.2

Field equipment and cabling . . . . . . . . . . . . . . . . . . . 7-5

7.7.3

Motor drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.7.4

Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.7.5

Electrical control panels and PC hardware . . . . . . . . 7-6

7.8

Testing and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.9

Operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.10 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7


7.11 After commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.12 I/O test and adjustments C5000i . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.13 General adjustments C5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.13.1

Adjustment of PAL_Type (Int) . . . . . . . . . . . . . . . . . . 7-8

7.13.2

Adjustment of Orientation (Int) . . . . . . . . . . . . . . . . . 7-9

7.14 Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

September 1, 2014

7.14.1

Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.14.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.14.2.1

Adjustment of switchover time (Int) . . . . . . . . . . . . . . 7-9

CSi

C5000 Unilever Brasil

7.15 Accumulation conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9


7.15.1

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.15.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.16 Breakfeeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10


7.16.1

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.16.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.16.2.1

Adjustment of BF1_Scale, BF2_Scale (Real) . . . . . 7-10

7.16.2.2

Adjustment of BF1_Man_Speed, BF2_Man_


Speed (int) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.17 Rotating cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10


7.17.1

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.17.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.18.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.18.2.1

Adjustment of KD1_Max_Speed, KD2_Max_Speed7-11

7.18.2.2

Adjustment of KD1_Min_Ramp, KD2_Min_Ramp. . 7-11

7.18.2.3

Adjustment of KD1_Man_Angle, KD2_Man_


Angle (Int) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.18.2.4

Adjustment of KD1_Man_Speed, KD2_Man_


Speed (Int). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.18.2.5

Adjustment of KD1_Man_Ramp, KD2_Man_


Ramp (Int) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.18.2.6

Adjustment of KD1_Home_Pos, KD2_home_


Pos (Int) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.19 Packpusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12


7.19.1

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.19.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.19.2.1

Adjustment of PP1_Max_Speed, PP2_Max_


Speed(Int) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.19.2.2

Adjustment of PP1_Min_Ramp, PP2_Min_


Ramp (int) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.19.2.3

Adjustment of PP1_Man_Stoke, PP2_Man_


Stoke (Int) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.19.2.4

Adjustment of PP1_Man_Speed, PP2_Man_


Speed (Int). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.19.2.5

Adjustment of PP1_Man_Ramp, PP2_Man_


Ramp (Int) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.19.2.6

Adjustment of PP1_Zero_Pos, PP2_Zero_Pos (Int) 7-13

7.19.2.7

Adjustment of PP1_Home_Pos, PP2_Home_


Pos (Int) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.19.2.8

Adjustment of PP1_Crank_Dia, PP2_Crank_


Dia (Int) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.20 Format area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13


7.20.1

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.20.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.20.2.1

Adjustment of FRM_Scale (Real) . . . . . . . . . . . . . . 7-13

7.20.2.2

Adjustment of FRM_Man_Speed (Int) . . . . . . . . . . . 7-14

7.21 Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14


vi

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September 1, 2014

09-1-14

7.18.1

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Handleiding-TOC.fm

7.18 Kicker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

C5000 Unilever Brasil

7.22 Rowpusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15


7.22.1

Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7.22.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7.22.2.1

Rowpusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7.22.2.2

Adjustment of RP_PC_Check_max (Int) . . . . . . . . . 7-16

7.22.2.3

Adjustment of RP_PC_Check_min (Int) . . . . . . . . . 7-16

7.22.2.4

Adjustment of RP_Between dams (Int) . . . . . . . . . . 7-17

7.22.2.5

Adjustment of RP_Input_All_Ch1 (Int) . . . . . . . . . . 7-17

7.22.2.6

Adjustment of RP_Input_All_Ch2 (Int) . . . . . . . . . . 7-17

7.22.2.7

Adjustment of RP_Safe_Max_Ch1 (Int) . . . . . . . . . 7-17

7.22.2.8

Adjustment of RP_Safe_Max_Ch2 (Int) . . . . . . . . . 7-17

7.22.2.9

Adjustment of RP_Max_Speed (Int) . . . . . . . . . . . . 7-18

7.22.2.10 Adjustment of RP_Max_Acc (Int) . . . . . . . . . . . . . . 7-18


7.22.2.11 Adjustment of RP_Man_Speed (Int) . . . . . . . . . . . . 7-18
K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Handleiding-TOC.fm

7.22.2.12 Adjustment of RP_Man_Acc (Int) . . . . . . . . . . . . . . 7-18


7.22.2.13 Adjustment of RP_Ref_Speed (Int) . . . . . . . . . . . . . 7-18
7.22.2.14 Adjustment of RP_Ref_Acc (Int) . . . . . . . . . . . . . . . 7-18
7.22.2.15 Adjustment of RP_C_Sliding_table (Int) . . . . . . . . . 7-18
7.22.2.16 Adjustment of RP_Ref_Pos (Int) . . . . . . . . . . . . . . . 7-18
7.22.2.17 Adjustment of RP_Back_Pos (Int). . . . . . . . . . . . . . 7-18
7.22.2.18 Adjustment of RP_Sweep_length (dint) . . . . . . . . . 7-19

09-1-14

7.23 Side-, backdam(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19


7.23.1

Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7.23.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7.23.2.1

Adjustment of SD1_Scale, SD2_Scale and


BD_scale (Real) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7.23.2.2

Adjustment of SD1_Max_Pos, SD2_Max_Pos and


BD_Max_Pos(Int) . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7.23.2.3

Adjustment of SD1_Max_Tol, SD2_Max_Tol and


BD_Max_Tol(Int) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7.23.2.4

Adjustment of SD1_Ref_Dis, SD2_ref_Dis and


BD_Ref_Dis (Int) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7.24 Load platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

September 1, 2014

7.24.1

Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7.24.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

CSi

vii

C5000 Unilever Brasil

7.25 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21


7.25.1

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7.25.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7.25.2.1

Adjustment of Lift_Max_Speed(Int) . . . . . . . . . . . . . 7-21

7.25.2.2

Adjustment of Lift_Max_Acc(Int) . . . . . . . . . . . . . . . 7-21

7.25.2.3

Adjustment of Lift_Man_Speed(Int) . . . . . . . . . . . . . 7-22

7.25.2.4

Adjustment of Lift_Man_Acc(Int) . . . . . . . . . . . . . . . 7-22

7.25.2.5

Adjustment of Lift_Measure_Speed(Int) . . . . . . . . . 7-22

7.25.2.6

Adjustment of L_Pos_Infeed(Int) . . . . . . . . . . . . . . . 7-22

7.25.2.7

Adjustment of L_Pos_Outfeed(Int) . . . . . . . . . . . . . 7-22

7.25.2.8

Adjustment of L_Pos_PC_Dec(Int) . . . . . . . . . . . . . 7-23

7.25.2.9

Adjustment of L_Pos_PC_Max(Int) . . . . . . . . . . . . . 7-23

7.25.2.10 Adjustment of L_Drop_Height(Int) . . . . . . . . . . . . . . 7-23

7.26 Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24


7.26.1

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7.26.2

Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7.26.2.1

Pallet conveyor 1 (Beneath the lift) . . . . . . . . . . . . . 7-24

7.26.2.2

Pallet conveyor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7.27 Movimot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25


7.27.1

Without Profibus connection . . . . . . . . . . . . . . . . . . 7-26

7.27.2

With Profibus connection. . . . . . . . . . . . . . . . . . . . . 7-26

7.27.3

Movimot LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

7.27.3.1

Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

7.28 Movidrives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30


7.28.1

Downloading and uploading of parameters . . . . . . . 7-30

7.28.2

Adjustment of the direction of motor rotation. . . . . . 7-33

7.28.3

Reading fault codes. . . . . . . . . . . . . . . . . . . . . . . . . 7-34

7.29 Bus boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34


7.29.1

Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

7.30 Valve islands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35


7.31 Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.32 Synchronising the products . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Selecting method of rotation . . . . . . . . . . . . . . . . . . 7-36

7.32.2

Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

7.32.3

Pressure zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

7.32.4

Rowpusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

7.32.5

Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Mechanical Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1


8.1

viii

7.32.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2

How to use this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.3

Ordering procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

CSi

September 1, 2014

09-1-14

7.25.2.12 L_Layerpad_Empty_pallet_Pos (mm) setting . . . . . 7-23

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Handleiding-TOC.fm

7.25.2.11 L_Max_Pos setting (mm). . . . . . . . . . . . . . . . . . . . . 7-23

C5000 Unilever Brasil

8.4

Attachments mechanical spare parts. . . . . . . . . . . . . . . . . . . . . . 8-3


8.4.1

Mechanical spare parts in pdf files . . . . . . . . . . . . . . 8-3

8.4.2

Mechanical spare parts in Excel file . . . . . . . . . . . . . 8-3

Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

10

Wiring diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

09-1-14

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September 1, 2014

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C5000 Unilever Brasil

CSi

September 1, 2014

C5000 Unilever Brasil

LIST OF FIGURES

09-1-14

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Handleiding-LOF.fm

fig. 1.1

September 1, 2014

Locations of safety devices . . . . . . . . . . . . . . . . . . . . . . . . 1-4

fig. 1.2

Locations of safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

fig. 1.3

AMLOK safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

fig. 3.1

Palletiser type RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

fig. 3.2

Palletiser type RL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

fig. 3.3

Palletiser type LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

fig. 3.4

Palletiser type LL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

fig. 3.5

Format and loading area . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

fig. 3.6

Belt conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

fig. 3.7

Infeed row-forming conveyor . . . . . . . . . . . . . . . . . . . . . . . 3-5

fig. 3.8

Clamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

fig. 3.9

turn cam (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

fig. 3.10

Package pusher (optional) . . . . . . . . . . . . . . . . . . . . . . . . 3-7

fig. 3.11

Row pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

fig. 3.12

The first row of the layer . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

fig. 3.13

The last row of the layer . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

fig. 3.14

Back- and side stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

fig. 3.15

Load platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

fig. 3.16

Pallet lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

fig. 3.17

Pallet in- and outfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

fig. 3.18

C5000Ti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

fig. 3.19

I/O: All field buses and PC interfaces . . . . . . . . . . . . . . . 3-20

fig. 3.20

Soft PLC software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

fig. 3.21

optional:
Controlling peripheral equipment:Motor modules . . . . . . 3-23

fig. 3.22

CSi machine standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

fig. 4.1

HMI panel on C5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

fig. 4.2

Safety lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

fig. 6.1

Spring tensioner row pusher . . . . . . . . . . . . . . . . . . . . . . 6-17

fig. 6.2

Load platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

fig. 6.3

Gear casing lubrication point . . . . . . . . . . . . . . . . . . . . . . 6-21

fig. 6.4

Centring unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

fig. 6.5

Drop lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

fig. 6.6

Overview Palletiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

fig. 6.7

Safety blockage lift platform . . . . . . . . . . . . . . . . . . . . . . 6-28

fig. 6.8

Safety Blockage Positions 4/5 & 29/30 . . . . . . . . . . . . . . 6-28

fig. 6.9

Position 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

fig. 6.10

Position 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33


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C5000 Unilever Brasil

Position 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

fig. 7.1

Rowpusher positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

fig. 7.2

Dam reference points . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

fig. 7.3

Infeed position of lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

fig. 7.4

Outfeed position of lift . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

fig. 7.5

Lift height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

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fig. 6.11

xii

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September 1, 2014

C5000 Unilever Brasil

LIST OF TABLES

Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

tab. 4.1

Local panel of the palet lift. . . . . . . . . . . . . . . . . . . . . . . . . 4-4

tab. 4.2

Local panel of the destacker . . . . . . . . . . . . . . . . . . . . . . . 4-5

tab. 5.1

Fault messages Eagle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

tab. 6.1

Tensioning moment clamping bushes . . . . . . . . . . . . . . . . 6-5

tab. 6.2

Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

tab. 6.3

Maintenance diagram logistics . . . . . . . . . . . . . . . . . . . . 6-11

tab. 6.4

Tension gauge settings . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

tab. 6.5

Maintenance diagram C5000- Si / Ti . . . . . . . . . . . . . . . . 6-24

tab. 7.1

Palletiser selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

tab. 7.2

Input type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

tab. 7.3

LED indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

09-1-14

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tab. 1.1

September 1, 2014

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C5000 Unilever Brasil

xiv

CSi

September 1, 2014

C5000 Unilever Brasil

Safety

SAFETY

Versie - 2.1.0 - 2011-08-23

1.1

Introduction

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These safety instructions apply to systems and machines supplied and / or


installed by CSi. These instructions must be strictly complied with to ensure
the safe operation of your system / machine(s).
CSi has endeavoured to make these instructions as comprehensive as
possible. For more information, please contact the CSis service
department.

1.2

Fundamentals

09-1-14

The user declares that:

1.3

He has read and understood the safety instructions.

He will comply with all applicable safety instructions.

He is authorised and suitably skilled to work with, operate and maintain


the system / machine(s).

He is aware of the potential hazards.

He will immediately report unsafe situations to the person internally in


charge. Appropriate actions must be taken to prevent unsafe situations
in the future.

He takes full responsibility for modifications / facilities that have not


been made and/or installed by CSi.

Safety standards
The system / machine is in conformity with the Machinery Directive 2006/
42/EC. The relevant harmonised standards are followed as far as practical.
A system may consist of a number of consecutive machines. These
machines have their own CE declaration.
In principle, a II-A declaration is supplied for the system / machines.
If the system / machine is not designed or capable of independent
operation, a IIB self-issued declaration is provided. The user is
additionally responsible for:

September 1, 2014

The final CE declaration of conformity IIA;

Safely completing and commissioning the system / machine;

CSi

1-1

C5000 Unilever Brasil

Safety

1.4
1.4.1

Comply with the additional requirements from the applicable directives.

Safety Instructions
General
The following safety instructions are based on conditions expected under
normal circumstances. Exceptions may occur. The person performing the
activities always is responsible for his own safety and the safety of others
in his immediate vicinity.
In case of doubt, CSi can always be consulted for additional advice.

1-2

The system / machine is solely intended for processing products that


match the product data as described in the specifications. Any other use
of the system / machine(s) may be dangerous.

All personnel (production, operating and maintenance personnel) must


be aware of the location and functioning of all stopping and starting
devices.

Use personal protection equipment, apparatus, tools, materials and


appliances correctly and in such a way that all safety, health and
environmental requirements are complied with.

Keep the system / machine(s) and the environment clean and free of
obstructions.

Never run, climb or stand over, on or under the system / machine(s)


except where CSi has made provisions to do so safely.

Never load the system / machine(s) in excess of permitted limits.

Never remove safety features such as guards, fencing, etc. without


taking the necessary safety precautions.

Only use safety switches, emergency stops, etc. for their intended
purpose.

Safety circuits must not be bridged, modified or altered in any way.

If an emergency stop has occurred, it is necessary to be specially alert,


as there are risks that differ from those in normal operation. Follow the
procedure as described in 1.5.4.

CSi

September 1, 2014

09-1-14

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Please read the users manual carefully and comply with all safety
instructions, for reasons of safety, health and environmental protection.

C5000 Unilever Brasil

Safety

1.4.2

Cautionary tags
In the manual these tags are used to draw your attention:

Warning
This sign is used when a situation may occur, which, when not properly
paid attention to, may lead to serious physical injury or even death.

Caution
This sign is used when a situation may occur, which when not properly
paid attention to, may lead to malfunctioning of machinery, to damage to
machinery or product, or to physical injury.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-01.fm

n
1.5

Note
This sign is used to provide additional information

Safety features
The system is fitted with safety features:

Cautionary tags

Safety signs

09-1-14

September 1, 2014

Emergency stops

Door switches

Safety light screen

Safety fencings

Air service unit

Main switch

Light beacon status indication of the palletiser

CSi

1-3

Safety

Fig. 1.1 Locations of safety devices

1.5.1

Safety signs

09-1-14

Make yourself familiar with the safety signs of your system. These signs
have been mounted on or near the system and indicate a specific warning,
instruction or prohibition.

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C5000 Unilever Brasil

Fig. 1.2 Locations of safety signs


The meaning of the safety signs is shown below.

1-4

CSi

September 1, 2014

C5000 Unilever Brasil

Safety

Safety signs can also be found in the maintenance instructions in sections


where potential hazardous and/or risky activities are described.
.

Tab. 1.1 Safety signs

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Warnings

Electrical voltage

Moving parts

Risk of Injury

Risk of getting
locked in

Danger

Risk of jam

Prohibitions

09-1-14

Access prohibited

Do not climb on
conveyor

Do not climb

Mandatory

Wear gloves

1.5.2

Wear a harnas

Area stops
The complete palletising system is split into different areas:

September 1, 2014

Palletiser including case conveyor, pallet transport and layerpad

Case conveyors

Pallet transport outside palletiser area including destacker

CSi

1-5

C5000 Unilever Brasil

Safety

1.5.3

Divider including brake feeder and zero pressure conveyors (C5000Ti


only)

Emergency stop
The emergency stop function is designed to prevent or minimise injury to
staff and/or damage to machinery and/or product.

1.5.3.1

Emergency stop area


Emergency stop areas are fitted in the system in places where people
come into contact with the system.
All control cabinets have an emergency stop.
Emergency stop functionality
When a stop is activated, the concerning safety relay switches off the
power supply to the PLC outputs, feeding outputs of motors and solenoids,
therefore causing a direct stop of the system.
Via an auxilliary contact the emergency stop relay is fed back to the PLC
as well and the outputs are switched off by software as well.

1.5.3.3

Restart after emergency stop / area stop


1 Check why, by whom and at which position the emergency stop has
been activated,
2 Solve the reason for activating the emergency stop,
3 Check for improper situations of the trays/pallets and possibly correct
these situations manually,
4 Make sure that no danger is present any more, nor can arise again and
that nobody is on/under the conveyors or behind the safety guarding
anymore,
5 Reset the emergency stop / area stop device, on the device itself,
6 Inform others that the installation will be started again,

1.5.4

09-1-14

7 Restart the system.

Fencing
The palletiser is fenced off by safety fencing. This fencing can only be
removed with the aid of tools. The fencing is meant to prevent undesired
access to the robot cell.
The palletiser system is only accessible via the safety doors in the fencing.
To allow the infeed and outfeed of pallets to and from the palletiser system
automatic doors have been fitted. These are monitored by safety
lightscreens.
The system has four acces doors. These are located at or near:

1-6

Pallet lift

Palletiser infeed

row-former

divider (C5000Ti only)

CSi

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1.5.3.2

September 1, 2014

C5000 Unilever Brasil

Safety

1.5.5

Door switch
An AMLOK safety switch is located on the door giving access to the robot
cell. The safety switch has an unique key number.

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Fig. 1.3 AMLOK safety switch


1.5.5.1

Access to the fenced off area


The acces door to the fenced off area is fitted with an AMLOK safety switch.
To access the fenced off area follow the steps below:
1 Request access to the area by turning the key to the left. The area is
brought to a stop. All current actions are finished but no new actions are
started.
2 When the area has come to a standstill the orange LED lights up.
3 Turn the handle on top and remove the handle from the lock.
4 Take the key from the lock.
5 Open the door.

09-1-14

Warning
The user must take the key into the fenced off area when entering. With
the key in the lock the area can be started with the user inside! This can
lead to serious injury or even death!
After closing the door, the doors circuit will reset itself automatically.
Turning the key in the door switch resets the system. Because the general
emergency stop circuit is interrupted as well, this circuit needs to be reset
also. It can be reset by the reset button on the operator panel.

1.5.5.2

Restarting the area


1 Make sure no one is in the fenced off area.
2 Close the door.
3 Reposition the handle into the switch.
4 Turn the handle up.
5 Insert the key into the lock.
6 Turn the key to the right. The red LED extinguishes.

September 1, 2014

CSi

1-7

C5000 Unilever Brasil

Safety

7 Turn the key to the active position, to the right, to reset the circuit. The
light in the push button now flashes slowly.
8 Push the start button.

1.5.6

Safety light barrier


A safety light barrier is an optical entry point. Entering the system through
the light barrier will result in an immediate shutdown of the system. The
barrier will trip and needs to be reset via the local reset button near the light
barrier.
Location of safety light barriers is indicated in Fig. 1.1.

c
1.5.7

RESET LIGHT SCREEN


Press button to reset light screen after it has
been tripped.
OVERRIDE
Hold button down to remove a pallet out of
the detection zone of the screen.

Caution
When running override, it is the responsibility of the operator that no one
passes the light screen and enters the dangerous zone.

Air supply unit


The installation is equipped
with an automatic air supply
unit. In case of an
emergency a valve quickly
decompresses the entire
pneumatic system. This will
also happen when the main
switch is switched off.
The air supply unit is also
fitted with a pressure guard,
which switches off as soon
as the pressure drops too low. This guard ensures that the air is at its
required pressure during automatic operation and it thus prevents
dangerous situations. It is impossible to start up the installation when the
air is not at its required pressure.
The air and pressure quality is also monitored and controlled by a water
filter, placed in front of the starting valve and a pressure regulator that
supplies the system with a constant pressure.

n
1-8

Note
The air service units pressure should be set at 6 Bar.

CSi

September 1, 2014

09-1-14

Push button (blue)

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Every safety light barrier is equipped with an operator panel with a reset/
override button. The operator panel is mouted on the safety fencing near
the light barrier.

C5000 Unilever Brasil

Safety

1.5.8

Main switch / local isolator switch


The systems main switch is located on the control cabinet. .
When working at or in the installation the main switch should be switched
off and padlocked. By doing so the entire installation is cut off from pressure
and power, thus preventing machines and machine parts being set in
motion unexpectedly.

1.5.9

Signal Beacon
To indicate the status of the installation a light beacon is fitted.

1.6
1.6.1

Additional safety instructions


safety during installation

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The installation of the system is described in Chapter 7. Please read this


chapter carefully and comply with all instructions.

1.6.2

Safety during operation


The items in the sections 1.4.1 and 1.6.1 also apply during operation.

09-1-14

In addition, also comply with the following items:

Never load the system / machine(s) in excess of permitted limits.

Ensure that clothing, hair and limbs are kept at a safe distance.

Be aware that moving parts are always dangerous, even when they are
not moving.

Never touch moving parts.

Never remove moving products and/or components.

Never try to stop moving products or parts.

Cleaning by spraying with water or a detergent is not permitted, unless


specifically mentioned otherwise.

If an emergency stop has occurred, it is necessary to be specially alert,


as there are risks that differ from those in normal operation. Follow the
procedure as described in the operating manual in the chapter
Operation.

Also take the safety items in section 1.7.1 Subcontractors into account.

1.6.3

Safety during maintenance, breakdowns, repairs


and change over
The items in the sections 1.4.1, 1.6.1 and 1.6.2 also apply during
maintenance, breakdowns, repairs and change over.
In addition, also comply with the following items:

September 1, 2014

Never work on the system / machine on your own. Make sure that an
authorised person is present in the immediate vicinity, to provide
assistance in case of need.

Never work on moving and / or rotating parts.

Remove products that may fall, turn or become dislodged.


CSi

1-9

C5000 Unilever Brasil

Safety

Prevent parts of the system / machine from moving, turning and / or


falling unintentionally by fitting a mechanical blocking or removing them.

Warning
Be particularly aware of dangers and risks when testing, checking,
adjusting and commissioning functions that require a supply of energy.

Warning
Be aware of sources of potential energy.

Before work is carried out on the system / machine(s):

c Ensure that after switching off energy supply, left-over energy is


discharged / has disappeared.
d The control cabinet may only be opened if the main switch is in the
OFF / 0 position and locked with a padlock.

Before the system / machine is restarted:


a Always re-install all safety features such as guards, fencing, etc.
and close access doors of machines (where applicable) before
switching on energy supply.
b Notify all persons present when the system / machine is to be
restarted after a particular shutdown.
c Follow the starting procedure as described in the operating
manual in the chapter Operation.

1.6.4

When replacing components, only use parts supplied by CSi. These


parts match factory specifications in terms of workmanship,
dimensional accuracy and material.

When lubricant has been spilled or leaked, the lubricant must be mixed
with sawdust, sand or absorbent granules. All used lubricants and
residual wastes must be disposed of in accordance with legal and
environmental standards.

Safety during disassembly and removal


If the system / machine is to be shut off for an extended period or
disassembled and removed, the following applies:

1-10

Prepare plan of action and a hazard analysis and take the necessary
precautionary measures.

Remove all products that may fall, turn or become dislodged before
shutting off energy supply.

CSi

September 1, 2014

09-1-14

b Close the valves and lock the relevant switches / shut-off valves
with a padlock.

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a Shut off potential electricity, compressed air, vacuum and hydraulic


fluids (where applicable) by setting the relevant main or isolator
switch(es) to the OFF / 0 position.

C5000 Unilever Brasil

Safety

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1.7
1.7.1

Shut off all supplies of electricity, compressed air, vacuum and hydraulic
fluids (where applicable).

Warning
Be aware of residual energy.

Detach and remove all power supply cables and supply lines.

Prevent components from moving, turning and/or falling unintentionally


by fitting mechanical blocking means or by removing them.

Drain all lubricants and liquids and disassemble and sort all the parts
according to type of material, and dispose of them in accordance with
legal and the environmental standards.

Grind flat uncovered fixing points on the floor and clean the floor.

Additional instructions
Subcontractors

09-1-14

Apart from these instructions, additional safety instructions apply to


deliveries by subcontractors. These can be found in the additional
dokumentation that is part of this users manual.

September 1, 2014

CSi

1-11

09-1-14

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C5000 Unilever Brasil

1-12

Safety

CSi

September 1, 2014

C5000 Unilever Brasil

Project/Product/machine data

PROJECT/PRODUCT/
MACHINE DATA

09-1-14

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See main project manual

September 1, 2014

CSi

2-1

09-1-14

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C5000 Unilever Brasil

2-2

Project/Product/machine data

CSi

September 1, 2014

C5000 Unilever Brasil

Functional specification

FUNCTIONAL SPECIFICATION

Versie 2.0.1 - 2011-08-25

3.1

Introduction C5000i
The palletiser is available in a number of standard versions.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-03.fm

3.1.1

Type RR
In this version, seen from the conveying direction, the packets are moved
to the right by the row pusher. (specification R...)

09-1-14

Seen from the direction of movement of the row pusher, the empty pallets
are fed in from the right. (specification ...R)

Fig. 3.1 Palletiser type RR

3.1.2

Type RL
In this version, seen from the conveying direction, the packets are moved
to the right by the row pusher.(specification R...)
Seen from the direction of movement of the row pusher, the empty pallets
are fed in from the left.(specification ...L)

September 1, 2014

CSi

3-1

C5000 Unilever Brasil

Functional specification

3.1.3

Type LR
In this version, seen from the conveying direction, the packets are moved
to the left by the row pusher.(specification L...)

09-1-14

Seen from the direction of movement of the row pusher, the empty pallets
are fed in from the right. (specification ...R)

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-03.fm

Fig. 3.2 Palletiser type RL

Fig. 3.3 Palletiser type LR

3.1.4

Type LL
In this version, seen from the conveying direction, the packets are moved
to the left by the row pusher. (specification L...)
Seen from the direction of movement of the row pusher, the empty pallets
are fed in from the left. (specification ...L)

3-2

CSi

September 1, 2014

C5000 Unilever Brasil

Functional specification

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-03.fm

Fig. 3.4 Palletiser type LL

3.2
3.2.1

Machine construction type C5000 Si


Zero pressure conveyor
The packets are transported to the machine by a zero pressure conveyor
at a height of approx. 3000 mm. The conveyor lines up the packets on the
basis of the data line in the machine.

09-1-14

Data line

Fig. 3.5 Format and loading area

September 1, 2014

Conveyor type

ZPC220-50V, with a "skewed" section.

Skewed section

The packets are lined up on the basis of the


data line in the machine. This is situated on
the side of the reversing unit,on the right for
type R... and on the left for type L... The
packets are lined up against a stainless steel
side guide, or against a roller side guide.
These guides are essential for correct opera-

CSi

3-3

C5000 Unilever Brasil

Functional specification

tion of the machine. They should therefore


not be altered or moved.

n
3.2.2

Note
The zero pressure conveyor is not part of the machine. Because of the
operational interface between this conveyor and the machine, the
interface needs to be incorporated in the specification.

Belt conveyor

The packets are kept apart on the braking section so that the photocell can
count them, and to create an interruption so that the packets can be turned
or put together.
The conveyor transports the packets to the feed row- forming conveyor
BC 90

Speed

The speed can be selected for each parcel


type via the IPC.
Limits:braking / metering.
Min. 150 / 300 mm/s
Max. 750 / 1500 mm/s

Drive

Frequency controlled motor reductor with


PROFIBUS connection.

09-1-14

Conveyor type

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The packets are fed into the machine by a brake-metering belt conveyor.
This conveyor blocks the packets on the zero pressure conveyor and
distributes them across the two conveyor belts using the difference in belt
speeds. A photocell is fitted at the end to count the correct number of
packets.

Fig. 3.6 Belt conveyor

3.2.3

Infeed row-forming conveyor


The conveyor feeds in the packets for one complete row. During infeed, the
packets:

3-4

can be fed straight in, without requiring any further action;

CSi

September 1, 2014

C5000 Unilever Brasil

Functional specification

can beturned, using a clamp or a turn cam;

can bedouble stacked, using a package pusher.

The packets are lined up in rows on the row forming section. The row is a
logical component of the stacking pattern. The packets can be separated
on the row forming section with a stop plate, in accordance with the
stacking pattern. The stop plates are lowered and the row is pushed from
the row forming section when the last parcel is in the defined position.
All rollers in the row forming section are pressureless when the last parcel
is ready. The pressure zones are de-activated once the row pusher has
pushed the packets from the row forming section. A timer is located above
the last parcel to detect the end of the row. The row pusher will start once
the last parcel is in the correct position. This device is known as the 'row
ready" timer.

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Photocell package pusher free:The photocell checks whether all the


packets are within the margins of the row pusher area. If this is not the
case, a feeding fault has occurred and the emergency stop will be
activated.

09-1-14

Band Conveyor

Clamp

Turn cam

Package double stacker

Fig. 3.7 Infeed row-forming conveyor

September 1, 2014

Conveyor type

Belt-powered rollers conveyorThe drive belt


is equipped on the bottom with a vulcanised
V-belt to ensure correct belt tracking.

Speed

The speed can be selected for each parcel


type via the IPC, min. 300 mm/s, max. 1500
mm/s.

Drive

Frequency controlled motor reductor with


PROFIBUS connection.

Pressure zones

The row forming section can be made pressureless in zones. These zones are able to
operate independently and are programmed
for each package type. They are operated
with a pneumatic cylinder. The operational
timing of a pressure zone is carried out via a
timer in the IPC control. This timer can be
programmed for each package type.
CSi

3-5

C5000 Unilever Brasil

Functional specification

Stop plate

3.2.4

The stop plates are positioned in accordance


with the stacking pattern. The stop plate is a
pneumatically operated plate situated vertically between the rollers.The operational timing of a stop plate is carried out via a timer in
the IPC control. This timer can be programmed for each package type.

Turning unit
Depending on the package type and machine version, a clamp and / or a
turn cam can be applied.
It is a freely programmable turning facility with servo drive.

3.2.4.1

Clamp (optional)

The arm can be adjusted for all package types and is a machine setting.
Under no circumstances should this setting be changed, as this will affect
all package types.
You can select in the IPC whether a package needs to be turned using the
clamp. The clamp operates via a timer on the basis of a photocell fitted to
the conveyor, with which the following settings can be programmed for
each package type:
speed;

angle;

acceleration;

delay time;

box delay.

09-1-14

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The axle, onto which the arm is fitted with the pusher plate, is driven by a
motor reductor.

Fig. 3.8 Clamp (optional)

3.2.4.2

Turn cam (optional)


The pawl is placed in the turning area via the servo drive. For this
component, either the package pusher or clamp can be used, depending
on the package type and the machine version.
The turn cam operates via a timer on the basis of a photocell fitted to the
conveyor. If necessary, it is possible to turn each package.
The delay time can be programmed for each package type.

3-6

CSi

September 1, 2014

C5000 Unilever Brasil

Functional specification

Fig. 3.9 turn cam (optional)

3.2.5

Package pusher (optional)


It is a freely programmable feature with servo drive for double stacking

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The drive powers a crank mechanism. Linear movement is carried out with
four linear bearings. The mechanism and servo drive ensure smooth
operation. The package pusher operates via a timer based on a photocell
fitted on the belt conveyor.
The following settings can be programmed for each package type:
start delay times;

force of impact of the package pusher;

speed;

travelling distance;

acceleration.

09-1-14

Fig. 3.10 Package pusher (optional)

3.2.6

Row pusher
When the row on the row forming section is complete, the row pusher
pushes the row in the direction of the load platform. Once the row pusher
has pushed the row from the row forming section, a new row can be
formed.
The row pusher pushes the rows in the direction of the load platform until
there are enough rows to form a pallet layer.
Three sliding bars are fitted between two parallel moving chains. When one
of the sliding bars has pushed a row to its end position, the other sliding bar
will be in the starting position to move the next row.

September 1, 2014

CSi

3-7

C5000 Unilever Brasil

Functional specification

The driving mechanism is servo controlled and the speed is fully


programmable.
This means that it is possible to program a speed profile for each package
type. The speed achieved when the bar touches the packets (producing
change of velocity) and when the row pusher touches the rows on the load
platform, can be programmed in this profile.
This ensures smooth operation: the packets can be processed carefully
without the need to adjust machine capacity. When the last row is ready,
the row pusher serves as the 4th stop and centres the layer enabling
loading. The servo control allows users to adjust the stop position to
millimetre intervals in accordance with the stacking pattern.

3-8

collision speed and maximum speed;

collision area;

the end position for centring the layer.

CSi

09-1-14

The following settings can be programmed for each package type:

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Fig. 3.11 Row pusher

September 1, 2014

Functional specification

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-03.fm

C5000 Unilever Brasil

Fig. 3.12 The first row of the layer

09-1-14

(The row pusher pushes the first row of a layer)

Fig. 3.13 The last row of the layer


(The row pusher pushes the last row of the layer and aligns the pallet load)

3.2.7

Back stop and side stops


Once all the rows making up a complete layer have been placed onto the
load platform, the stops will ensure that the pallet layers can be centred and
stacked on a pallet. The layer is pressed on all four sides so that it has
exactly the right dimensions. The row pusher pushes the front, the side
stops push the side and the rear stop pushes the back.

September 1, 2014

CSi

3-9

C5000 Unilever Brasil

Functional specification

When the last layer has been placed on the load platform, the stops are
placed in their end position in accordance with the dimensions of the
stacking pattern. This can be done to the nearest millimetre. Once the load
platform is open, the stops will return to their starting position. It is possible
to program a start delay, causing the row pusher and the rear pusher to
move forward to prevent the edges of the packets coming into contact.
Motor driven linear guided system. The driving mechanism has a double gear wheel gear rack transmission. The guide is connected to two linear guides. The stops are
driven in such a way that they will always
push against the entire layer (finger interface
on the sides). The position is adjusted with
an encoder. The motor is controlled with an
frequency inverter, while speed and acceleration are machine settings.

09-1-14

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Drive

3-10

CSi

September 1, 2014

Functional specification

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C5000 Unilever Brasil

Side stop

Side stop

09-1-14

Rear stop

Fig. 3.14 Back- and side stops

3.2.8

Load platform
Once a layer with the correct dimensions has been formed, it can be
stacked on a pallet. The pallet is placed underneath the load platform, and
the load platform ensures that a properly aligned pallet layer is formed on
the pallet.
Once a complete layer has been formed on the load platform, and the stops
have positioned the packets, the load platform will open in the centre, one
section of the load platform will slide underneath the row pusher, while the
other section slides underneath the rear stop. This will create a solid,
properly aligned pallet layer.
Once the layer has been placed on the pallet, the pallet lift will move the
layer below the level of the load platform.

September 1, 2014

CSi

3-11

C5000 Unilever Brasil

Functional specification

As soon as the layer is below the load platform, the load platform will be
closed. This process is controlled using the height detection photo cells on
the pallet lift. A special photocell has been fitted, which checks that closing
is not hindered. The start- and stop positions are controlled with proximity
switches. The driving mechanism is operated with an AC/DC converter.
Speed and acceleration are machine settings.

Fig. 3.15 Load platform

3.2.9

Pallet lift
To enable packets to be stacked at a high level, the pallet has to be brought
to just below the level of the load platform and positioned there.
The lift trolley has to be positioned in such a way that the forks are below
the level of the rollers, and the stop plate is above, so that an empty pallet
can be fed in. The pallet will be fed into the loading zone, touch the stop
plate, and be aligned.
The lift will raise the empty pallet at great speed. During lifting, the pallet
will be aligned with a centring unit. Once the photocell for high / low speeds
detects the top of the pallet, it will slow down the lift. The lift will stop in a
certain position. This is controlled from the servo drive.
If a layer is stacked on to the pallet, it will be lowered at great speed so that
the load platform can close, and the top of the pallet layer can be moved to
below the level of the load platform.
All pallet layers will be stacked using this method. When the last layer has
been stacked on to the pallet, the lift will lower the pallet in such a way that
the forks and the stop plate are below the level of the rollers. The pallet can
then be transported to the pallet conveyor, where the loaded pallet is fed
out. It is possible to feed in an empty pallet and feed out a loaded pallet
(partially) simultaneously.

3-12

CSi

September 1, 2014

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-03.fm

The back plate is driven by a motor and a


crank mechanism. The crank arm is directly
mounted onto the motor reductor with an AC/
DC converter. The positions are detected
using proximity switches. The other plate is
driven via a construction with a geared-belt
transmission, creating a reverse simultaneous movement.

09-1-14

Drive

C5000 Unilever Brasil

Functional specification

During infeed of an empty pallet and outfeed of a full pallet, the stop
position is operated using the resolver on the servo drive.

Pallet lift

The pallet lift is a counterweight lift. One of


the sides of the lift trolley is fitted with four
guide wheels.

Lift trolley

The lift trolley is raised by two chains running


along two sprocket wheels, and fitted with a
counterweight at the back. The servo drive
reductor is directly mounted to the driving
axle. The lift trolley is equipped with forks
which can be lowered between the rollers of
the pallet conveyor. When the forks are
located below the level of the rollers, the stop
plate will move above it. This allows aligning
of an empty pallet during infeed.

Centring unit

The lift trolley is equipped with a centring unit


to centre the pallets. This mechanism is
operated pneumatically with linear guides.
Chains are used to centre the pallet. One
centring guide is mounted to the top of the
chain while the other is mounted to the bottom.

Drop lock

The lift platform is fitted with a drop lock. In


the event of an emergency stop, the lift will
stop immediately and automatically block the
lift trolley.

09-1-14

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The drop lock of the lift trolley is spring operated. This spring tension can
be tightened with a pneumatic cylinder. The drop lock is activated when the
air pressure drops.

Fig. 3.16 Pallet lift

3.2.10

Pallet in- and outfeed


Empty pallets are fed in with a chain driven roller conveyor. The pallet lift
raises the empty pallet below the load platform. Full pallets are transported
to the outfeed conveyor.

September 1, 2014

CSi

3-13

C5000 Unilever Brasil

Functional specification

The lift trolley is equipped with forks which can be lowered between the
rollers of the pallet conveyor. This enables an empty pallet to be placed
onto the conveyor. When the empty pallet touches the stop plate, the lift will
raise the pallet to the load platform. The pallet is aligned during lifting. The
full pallet is lowered onto the conveyor. The forks will be lowered below the
level of the rollers.
The full pallet is then transported to the outfeed conveyor and an empty
pallet will be fed in.

The drives are controlled with an AC/DC converter. Speed and acceleration
are machine settings.
1

Fig. 3.17 Pallet in- and outfeed

n
3.3

Conveyor type

CPRC

Drive

Motors with AC/DC converter.

Note
This conveyor is not part of the machine. It is mentioned in these
specifications because its operation is closely related.

Machine construction type C5000 Ti


The double infeed machine (Ti) operates the same way as the single infeed
machine (Si), except that the packets are fed in via two infeed lines.
The packets are driven by a conveyor belt. The packets are distributed
across two transport lines by a divider.
The packets are transported in the direction of the conveyor belt by a twoline zero pressure conveyor.After the packets have reached the conveyor
belt, the machine operates the same way as the single infeed conveyor.

3-14

CSi

September 1, 2014

09-1-14

Once a full pallet is in place, it will be transported to the outfeed conveyor.


The stop plate can be raised with the lift, and an empty pallet can be
aligned, when the photocell (3) is free. The full pallet will be transported up
to the photocell (4).

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-03.fm

An empty pallet has stopped near the photocell (1). Start the infeed
conveyor (empty pallets) and the outfeed conveyor (full pallets) when the
machine gives the appropriate command. The empty pallet is transported
by the photocell (2) and aligned against the stop plate. When the pallet has
stopped and the photocell (2) is free, the pallet will be raised with the lift.

C5000 Unilever Brasil

Functional specification

Belt conveyor

Divider

Zero pressure conveyor

Fig. 3.18 C5000Ti

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3.3.1

Belt conveyor
The packets should preferably be fed by an accumulation conveyor. They
are then distributed and counted by the brake- metering belt conveyor.
Conveyor type

3.3.2

BC90

Divider
The divider distributes the packets across two lines. Distribution is based
on the number of packets needed to build up the stacking pattern for each
row.
Divider

09-1-14

3.3.3

The packets are transported on synthetic


bearing strips which move along bars. These
bars are mounted between two parallel moving chains. This enables the packets to be
guided to one of the two conveyors. Switching is carried out pneumatically.

Zero pressure conveyor


The conveyor has a "skewed" section which lines up the packets in the
direction of the infeed data line.

3.4

Interleaving sheet module (optional)


It is possible to mount a mechanism for inserting interleaving sheets onto
the machine, which enables interleaving sheets to be inserted in the
stacked layer.
The pallet lift lowers the pallet with the stacked layers and positions the top
at mechanism level. It is now possible to insert an interleaving sheet on the
stacked layer. The pallet lift will now move the pallet below the load platform
so that a new layer can be palletized. The positions of the interleaving
sheet can be freely programmed. It is also possible to place an interleaving
sheet on top of an empty pallet, though this will affect capacity.
The mechanism for inserting interleaving sheets is made up of the following
three parts.

September 1, 2014

CSi

3-15

C5000 Unilever Brasil

Functional specification

3.4.1

Container
The interleaving sheets are located in the container. To prevent the sheets
sticking to one another or being badly aligned, the sheets have to be placed
manually into the container. Depending on how the interleaving sheets are
put in the container, they are also placed onto the pallet.
The container is placed onto the container lift with a fork lift truck. This is
done via the access door. (permission needed). The container can only be
positioned one way. This is checked by the photocell. The lift raises the
container with interleaving sheets to the correct level. Once the sheet
inserter has picked up a sheet, the lift will be lowered by approx. 5 cm to
make room for the grab head to take away the sheet. Once the grab head
is in the lifting position, the lift will raise the stack again.
This process is repeated until the container is almost empty. A warning will
sound when the container is almost empty and needs filling up.

Grab head for inserting interleaving sheets


The grab head for inserting interleaving sheets sucks the sheets up from
the stack. It carefully lifts the first sheet and blows compressed air between
the stack and the interleaving sheet. Next, the stack is lowered and the
interleaving sheet is placed onto the pallet, which has been correctly
positioned with the pallet lift.

3.4.3

Lift
The lift with the container is located above the empty pallet infeed.

3.5

Control specifications

visual Basic HMI software;

IEC 61131-3 Soft PLC software;

IPC (hardware platform with 12-inch touch screen);

Standard E-cabinet;

I/O-bus control;

modular field cabling (plug and play);

the control elements are integrated in the machine.

09-1-14

Control of the machine is based on the CSi machine control system. This
is the standard system for controlling machines and optional peripheral
equipment. It is made up of the following parts:

The standard version is equipped with machine control elements and


additional peripheral equipment in accordance with the following
philosophy:

Package infeed
Empty pallet infeed

3-16

CSi

Palletiser
Machine

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-03.fm

3.4.2

Full pallet outfeed

September 1, 2014

C5000 Unilever Brasil

Functional specification

The control elements are always divided into the following four groups:
Standard

machine control elements.

optional

package infeed control elements.

optional

empty pallet infeed control elements.

optional

full pallet outfeed control elements.

Belt conveyor

Motor drive.
Controlled with frequency regulator.
The control can be programmed for each
package type via the field bus system. The
index photocell is connected to a PROFIBUS
module.

Row forming conveyor

Motor drive.
Controlled with frequency regulator.
The control can be programmed for each
package type via the field bus system.The
photocell which checks whether the push
section is empty, is connected to a PROFIBUS box.

Clamp (optional)

Servo motor drive.


Start-proximity switch connected to a PROFIBUS box. Speed, angle, acceleration and
delay can be programmed for each package
type.

Turn cam (optional)

Pneumatically controlled via a PROFIBUS


valve connecting point (bistable). The infeed
/ outfeed can be programmed for each package type (timer-based). Pneumatically
raised.

Optional package pusher

Servo motor drive.


Start-proximity switch connected to a PROFIBUS box
Speed, travel, acceleration and delay can be
programmed for each package type.

Stop plate

Pneumatically controlled via a PROFIBUS


valve connecting point (bistable).
The infeed / outfeed can be programmed for
each package type (timer-based).

Pressure zones

Pneumatically controlled via a PROFIBUS


valve connecting point (bistable).
The infeed / outfeed can be programmed for
each package type (timer-based).

Row pusher

Servo motor drive.


Start-proximity switch connected to a PROFIBUS box.
Speed, collision point, end position for the
last layer, acceleration and delay can be programmed for each package type.

Side stops (2)

Motor drive.
Controlled with frequency regulator.
The control elements are connected to a

09-1-14

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-03.fm

The standard version is configured with the following modules.

September 1, 2014

CSi

3-17

C5000 Unilever Brasil

Functional specification

Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O, and positioning can
be programmed for each layer.
Positioning is determined via an A+B
encoder connected to a PROFIBUS box..

Load platform

Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via four proximity
switches connected to a PROFIBUS box.

Pallet lift

Lift:
Servo motor drive.
Starting sensor on the lowest setting:limit
switch connected to a PROFIBUS box.
Positioning is determined with photocells and
a limit switch connected to the PROFIBUS
box, high / low speed photocell (empty pallets), photocell for scanning the top.
All other positions are detected via a
resolver-servo system.
Lift trolley with centring unit:
Pneumatically controlled centring mechanism:
Monostable valve connected to a PROFIBUS box.
Reed contacts with starting detection connected to a PROFIBUS box.
Reed contact for detecting pallet size, connected to a PROFIBUS box.
Protection against slackening/breaking of the
chain with the aid of two limit switches connected to a PROFIBUS box.
Drop lock:
The lift trolley is secured with a drop lock. In
the event of an emergency stop or safety
stop, the lift trolley will be mechanically
blocked.
The safety system is kept open with compressed air and is put in the blocking position
using spring tension.
Open detection using reed contacts on the
cylinders connected to a PROFIBUS box.
Blocking detection via limit switches connected to a PROFIBUS box.
An emergency stop or safety stop is generated via a safety relay, set at a certain time

3-18

CSi

September 1, 2014

09-1-14

Rear stop

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PROFIBUS box via I/O, and positioning can


be programmed for each layer.
Positioning is determined via an A+B
encoder connected to a PROFIBUS box.

C5000 Unilever Brasil

Functional specification

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-03.fm

interval. The blocking mechanism will be


activated after this time interval.
Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via photocells connected to a PROFIBUS box.

Safety and access

The entire machine is protected. Access to


lower levels is gained via a safety switch with
key option, as well as additional requirements. The top section is accessible via
swing doors with a safety
switch.(optional:safety switches with key
option.)
The pallet outfeed is protected with two light
screens.

Optional modules
Ti (double infeed)

Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via photocells connected to a PROFIBUS box.

Divider

Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via photocells connected to a PROFIBUS box.
Switching via a bistable pneumatically controlled valve.
Switching synchronisation via a proximity
switch connected to a PROFIBUS box.
Protection via a locked swing door.

Accumulation conveyors

Motor drive (coupled drive for two conveyors).


Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via photocells connected to a PROFIBUS box.

Interleaving sheet module

Lift:
Motor drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via photocells connected to a PROFIBUS box.

09-1-14

3.5.1

Pallet conveyors (2)

Sheet inserter:
Vacuum via an ejector:Vacuum on switch,
vacuum OKE switch, blow-off switch All are

September 1, 2014

CSi

3-19

C5000 Unilever Brasil

Functional specification

controlled and connected to a PROFIBUS


box.
Cylinder resonance:
Monostable controlled proximity switch. The
control elements are connected to a PROFIBUS box.
Drive.
Controlled with frequency regulator.
The control elements are connected to a
PROFIBUS box via I/O.
Positioning is determined via proximity
switches connected to a PROFIBUS box.

HMI software
Hardware:

12-inch touch screen colour monitor on the


platform near the package infeed.

Software:

The visualisation software is configured in


Visual Basic and connected to the PLC program via a OCX (ActiveX Control) for ADS
(Automation Device Specification) OCX;

09-1-14

3.5.2

Connection via a RS422 or PROFIBUS connection using the IPC (integrated process
control) 24 V feed.
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Barcode scanner (1 or 2)

Fig. 3.19 I/O: All field buses and PC interfaces


The visualization software package used is Eagle 2000. This software is
made up of three parts:

3-20

Eagle control;

Eagle edit (optional);

Eagle services (optional);

CSi

September 1, 2014

C5000 Unilever Brasil

Functional specification

3.5.3

Eagle Control
This component consists of a graphic real-time interface for the machine.
The actual real-time status of the different parts of the machine is displayed
on different screens. The situation displayed on the screen is always the
current real-time status of the machine, with the current packets in their
current position, as graphically shown. All counters are displayed live,
including the current task.
Errors and faults are displayed in the 'error messenger' using the following
tools:

Display location (graphic indication);

Error correction (up to component level);

Recovery procedures (step-by-step).

New tasks can be given or displayed, and tasks can be amended or


cancelled.
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Tasks contain the following information:

pallet ID;

Total number of packets or layers to be palletized for this task.

(The pallet ID contains all information needed to make one pallet.)

3.5.4

Eagle edit (optional)


Eagle edit is a tool for easily creating a palletiser program:
Define a package in the package editor and
save this package in the package library.

Step 2

Define all layers by selecting a package from


the package library. The layer is built up
using the graphic tools, and the new layer is
saved in the layer library.

Step 3

Define a new pallet by selecting a pallet type


and a layer from the layer library. It is also
possible to insert protective layers. Save the
pallet in the pallet library.
Use the task function to retrieve a pallet configuration from the pallet library.

09-1-14

Step 1

The control element calculates default values for all settings during
programming. These settings can be altered during fine adjustment and
are saved in the current program.

3.5.5

Soft PLC software


The Soft PLC software is programmed in IEC 61131-3. TwinCAT has a
programming environment (displayed in the top section of Fig. 3.19) and a
real-time output environment (displayed in the bottom section Fig. 3.19).
The program is compiled in the programming environment and
implemented in the live environment.
Program construction is based on the following:

September 1, 2014

Structured text for data and complex functions;

Function block diagrams for I/O.

CSi

3-21

C5000 Unilever Brasil

Functional specification

The program is based on a modular design. Each module collects the data
required for the current package. Once the package has been processed
in the module, the module will receive new data for the next package.This
enables the machine to work fully automatically with different packages,
and also enables package tracing.
Four Soft PLCs are active within the IPC:

1st PLC:

Palletiser

2nd PLC:

Package infeed (optional)

3rd PLC:

Empty pallet infeed

4th PLC:

Full pallet outfeed

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This process ensures that the software will always be structured and used
in modules (see figure below).

S/PLC2
Case
S/PLC2

S/PLC1
S/PLC1
Palletiser

Conv.
Case
Conv.

Palletiser

3.5.6

09-1-14

Fig. 3.20 Soft PLC software

Hardware control platform


Beckhoff industrial PC

3-22

Pentium III, 700 MHz

128 MB

SA/PCI connection for:


PROFIBUS card for one or more loops
RS 422 (optional)
3COM Ethernet card (optional)
Other
CD rom

Touch screen (12 inches)

UPS

CSi

September 1, 2014

C5000 Unilever Brasil

Functional specification

3.5.7

Standard E-cabinet
The machine has a standard control cabinet based on a modular design.
The base cabinet contains all the control elements for the basis machine.
You can choose from the following options:

Control elements of the packet pushing mechanism for channel A;

Control elements of the packet pushing mechanism for channel B;

Interleaving sheet module control elements;

Double infeed control elements;

Control elements for package infeed peripheral equipment;

Empty pallet infeed control elements;

Full pallet outfeed control elements;

Reserve control group.

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The controlling peripheral equipment option is based on a decentralised I/


O in accordance with the field equipment standards (highlighted on the
next few pages). An interface is created in the cabinet for each peripheral
option, with the following properties:

400 V feed:This is an autonomous group with its own circuit breaker,


Pilz relay (safety relay) and main relay via a 4 mm2 cable;

24 V DC via a 1.5 mm2 cable;

PROFIBUS for 32 participants.

It is possible to connect safety mechanisms for stopping certain parts of the


machine to the group safety relay.
Emergency stop buttons are connected to the main safety relay, which
switches off all group safety relays.

09-1-14

1
Pallet

2
Case

Fig. 3.21 optional:


Controlling peripheral equipment:Motor modules

September 1, 2014

CSi

3-23

C5000 Unilever Brasil

Functional specification

3.5.8

Controlling optional peripheral equipment


All drives controlled via the machine control are based on the following CSi
machine standard:

This standard offers the following:

3-24

all drives/modules are controlled with a frequency regulator and can be


programmed via the bus;

all drives/modules are operated through individual thermal overloading


with individual contact;

all drives/modules are operated with individual interruption with


individual contact;

Cable:
400 V: 4 mm2.
PROFIBUS:M12 connector cable with plug or female plug.
24 V: Flat cable with click module (Asi) and M12 connector.
All control mechanisms are connected to the connecting point with M12
connectors.

CSi

September 1, 2014

09-1-14

Fig. 3.22 CSi machine standard

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Each module has its own local control section. For complex modules such
as destackers, this could be a CSi local control mechanism.

C5000 Unilever Brasil

Operator manual

OPERATOR MANUAL

Versie 2.1 - 2012-08-25

4.1

Introduction C5000i

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The palletiser is equipped with two control panels:

A control panel located on the ground floor.


This panel is used mainly to control the lift, and for maintenance
purposes. It has a manual / automatic mode switch and push buttons to
raise and lower the lift, and is also equipped with a reset button to clear
any faults in the lower part of the system.

A control panel next to the infeed row-forming conveyor module.


This local panel is operated using a touch screen and push buttons, and
offers the full range of operator functions

The operating software, Eagle 2000 (Eagle Software), has been


specifically developed for use with this machine, and comprises of three
parts:

09-1-14

Eagle Control, for:


-

Control and status reports, counts, etc.

Manual mode operation.

Tasks (assignments).

Eagle Editor:
-

For simple programming of new stacking patterns.

Eagle services:
-

For creating machine and production specification overviews.

For a detailed description of this software, please refer to the Eagle


Software specifications.

September 1, 2014

CSi

4-1

C5000 Unilever Brasil

Operator manual

4.2

HMI panel on C5000 palletiser

4.2.1

Start button
Press the start button to start the machine. The machine will start section
wise from backwards on. The machine is ready to palletize when it has an
active palletiser assignment, and when there are no error messages. The
start mode is not available in the event of:

4.2.2

Hardware faults such as: thermal faults, profibus faults, and supply
voltage faults;

Failure to read the system files;

The emergency stop is active.

Indicator light (white)


Continuously lit

The machine is activated.

Flashing

The machine is starting up.

09-1-14

4.2.1.1

Stop button
The stop button is used to stop the machine. After the stop button is
pressed the machine will go into a controled stop. All positions will stop
when they are in a defined state. In case a section cannot stop in a defined
position because of a failure, the movement will stop after a delay time.

4.2.3

Reset button
Press this button to rest all alarms and/or warnings detected by the system.

w
4.2.3.1

Warning
Do not press the reset button casually. Always determine the reason for
an alarm/warning, and repair/remove/clear the cause before resetting the
alarm.
Indicator light (blue)
Flashing

4-2

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Fig. 4.1 HMI panel on C5000

There is an active alarm or warning.

CSi

September 1, 2014

C5000 Unilever Brasil

Operator manual

4.2.4

Manual button
When automatic mode is active
Press the manual button to change from automatic mode to manual mode.
The machine will perform a controlled stop, i.e. all parts of the machine will
finish their current action and then stop.
Manually operating the machine is only possible when the machine is also
in stand-by mode (has been started). The machine is operated manually by
selecting specific devices in Eagle.

Note
During manual mode, counters and other software parameters are not
updated. Any palletizing operation in manual mode will upset the active
program on resumption of automatic mode.
When manual mode is active

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-04.fm

Press the manual button in maual mode to return to automatic mode.


Before automatic mode is resumed, all devices will be set to the position
defined by the currently loaded and active program.
4.2.4.1

4.2.5

Indicator light (yellow)


Continuously lit

The machine is in manual mode.

Flashing

The machine is performing a controlled stop


ahead of entering manual mode.

Stop Infeed
Press this button to stop products being input through channel 1. Press this
button again to restart the infeed.

4.2.5.1

Indicator light (yellow)


The infeed from has stopped.

09-1-14

Continuously lit

September 1, 2014

CSi

4-3

C5000 Unilever Brasil

Operator manual

4.3

Other local panels

4.3.1

Local panel pallet lift


A control panel has been fitted near the lift. This panel allows manual
operation of the lift, and the resetting of alarms/warnings detected in the
lower part of the machine.
The control panel is fitted with the following controls:

Tab. 4.1 Local panel of the palet lift

The lift is in automatic mode. Manual control of the lift is not


possible through this control panel. Manual control may be
possible through the touchpanel.
The lift will ascend while this button is pressed (in manual
mode). The lift will stop moving when either a photocell
detects the pallet/products, or the maximum height limit switch
is tripped. In both situations a fault is generated
The lift will descend while this button is pressed (in manual
mode). The lift will stop moving when the lower height limit
switch is tripped.In this situation a fault is generated.
Alarms related to the lift, pallet transport, layerpad and
destacker can be reset with this button. A flashing blue light in
the button indicates an alarm is active.

4.3.2

Local panel destacker

4-4

CSi

09-1-14

The destacker has a local


controle panel which allows for
manual control of the destacker.
The control panel has three
switches.

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The lift is in manual mode. Manual control of the lift is possible.

September 1, 2014

C5000 Unilever Brasil

Operator manual

Tab. 4.2 Local panel of the destacker


Selector switch (0-1)
This selector switch puts the destacker in MANUAL or
AUTO mode.
Selector switch (1 - 0 - 2)
This returning selector operates the destacker forks
going up and down in manual mode.
Selector switch (1 - 0 - 2)
This returning selector opens and closes the destacker
forks in manual mode.

4.3.3

Local panel safety light barrier

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A safety light barrier is an optical entry point. Entering the system through
the light barrier will result in an immediate shutdown of the system. The
barrier will trip and needs to be reset via the local reset button near the light
barrier.
Location of safety light barriers is indicated in Fig. 1.1.
Every safety light barrier is equipped with an operator panel with a reset/
override button. The operator panel is mouted on the safety fencing near
the light barrier.
Push button (blue)

09-1-14

c
4.3.4

RESET LIGHT SCREEN


Press button to reset light screen after it has
been tripped.
OVERRIDE
Hold button down to remove a pallet out of
the detection zone of the screen.

Caution
When running override, it is the responsibility of the operator that no one
passes the light screen and enters the dangerous zone.

Safety lock
The access door to the lift is fitted with a safety lock.

September 1, 2014

CSi

4-5

C5000 Unilever Brasil

Operator manual

To close the door, reinsert the bolt


back into the lock. Put the key
back into the override key switch,
and turn it to the right. Reset the
emergency stop and restart the
machine
Fig. 4.2 Safety lock
Warning
Take the override key with you when entering the cell. Thus the machine
cannot be restarted with you still inside the lift area.

09-1-14

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Access to the lift area is initiated


by turning the override key to the
left and removing it. This action
sends a request for a controlled
stop to the machine. Once the
machine has stopped, it will
switch to emergency stop mode.
A solenoid is then activated that
releases the bolt that locks the
door. A yellow light indicates that
the lock is free and the door can
be opened (using the bolt).

4-6

CSi

September 1, 2014

C5000 Unilever Brasil

Fault-finding

FAULT-FINDING

Versie 2.0.1 - 2011-08-25

5.1

Fault messages Eagle

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-05.fm

Eagle can generate the following fault messages.

Tab. 5.1 Fault messages Eagle (Sheet 1 of 7)


CAUSE / SOLUTION

Msg52=Access failure;Wrong access


level. (Must be level '%s'.) Change
access level ?

Your login level is not high enough to


carry out the action you require. You must
log in at a higher level.

Msg24=Assignment Failure;Packs
allready divided

The number of boxes entered for the


command changes is too low. The boxes
have already been processed by the
machine.

Msg26=Assignment Failure;Amount
packs or layer = 0

A command has been given in which the


number of layers is 0. This is not
possible; enter the number of layers or
boxes.

Msg22=Assignment Failure;Fifo Full

A command is already active or the


command buffer is full. Delete the
command by clicking on the Empty Run
button or wait until the command buffer is
less full.

Msg25=Assignment Failure;Pallet or
LayerID not found

An unrecognised command has been


given to the palletiser. The Pallet ID
cannot be found. Check the command
that was entered.

Msg23=Assignment Failure;Sequention
number not found

With the command changes, the


command change has not been found by
the machine.

Msg21=Assignment
Message;Assignment Accepted

A new command has been accepted by


the machine.

09-1-14

FAULT MESSAGE

September 1, 2014

CSi

5-1

C5000 Unilever Brasil

Fault-finding

5-2

CAUSE / SOLUTION

Msg39=Communication Failure;%s to
PLC.

There is no communication with the PLC.


Check if the PLC is working.

Msg201=Communication timeout reader

A communication time-out has occurred


with the barcode reader.

Msg104=Confirm update other


layer(s);Update all other layer(s) (in this
pallet) with same layer dimensions ?

With the adjustment of the layer


dimensions for a layer on a pallet, the
layer dimensions for the other layers on
the same pallet can be adjusted
automatically.

Msg2147217887=Database
failure;DbMessage = %s

Database error.

Msg56=Error in Pattern;Pack number not


correct. Goto 'Pack-editor' and correct
Pack assignment.

The box numbers entered in the Box


Editor in the Layer Editor are not followed
up within a row or do not start with a 1.

Msg55=Error in Pattern;Row number not


correct. No row given for row sweep.
Goto 'Pack-editor' and correct row
assignment.

The number of rows in the pattern is


incorrect. Go to the Row Editor in the
Layer Editor and generate the rows again
(default data).

Msg1040=Error; Compacting database


file %s not posible

A copy of the database is automatically


made every week, and it is then
compressed and cleared. This operation
has not been successful.

Msg54=Error;DataBase cannot be
opened....

The database cannot be opened or is


missing. Restore an old working
database.

Msg1003=Error; Database file is greater


than diskspace on A:

The database is too big for making a


backup on floppy disk. If possible, make
a backup via a network or other such
system.

Msg1002=Error; Disk in A: not empty

The disk in drive A is not empty. It is not


possible to make a backup.

Msg1021=Error; No database file found


on A: (Pattern.mdb)

No database can be found on the


diskette. A pattern.mdb file must be in the
root.

Msg1030=Error; No disk in A: Or Read /


Write Error

There is no disk in drive A or a fault has


occurred in reading the disk. Try another
backup.

CSi

September 1, 2014

09-1-14

FAULT MESSAGE

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Tab. 5.1 Fault messages Eagle (Sheet 2 of 7)

C5000 Unilever Brasil

Fault-finding

09-1-14

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-05.fm

Tab. 5.1 Fault messages Eagle (Sheet 3 of 7)

September 1, 2014

FAULT MESSAGE

CAUSE / SOLUTION

Msg1010=Error; No disk in A: Or Write


Error

There is no disk in drive A or a fault has


occurred in writing to disk. Try another
diskette.

Msg1=Failure;ID number changed


without update by pressing OK. Press
OK first

You have changed the ID number without


first clicking on the OK button.

Msg29=Failure;No record present. Press


'New' first.

There are no patterns available in the


system. Create the patterns first.

Msg32=Failure;Pack definition already


exist.

The ID number entered already exists;


select another one.

Msg31=Failure;PackLength, width or
height too smal. (<10mm)

The box dimensions are too small; select


bigger ones.

Msg49=Failure;Spacer output number


must be between 0 and 16

An invalid spacer number has been input.


Enter a spacer number between 0 and 16
(0 is not a spacer).

Msg50=Failure;Spacer output number


not unique

A spacer number has been entered


which is not unique. Enter a unique
spacer number.

Msg51=Failure;Wrong Password.

An invalid password has been typed in;


try typing the password in again.

Msg2=ID Number;Layer ID number not


found.

The Layer ID number was not found in


the database. Invalid Layer ID entered.

Msg38=Input failure;Input contains


wrong character '%s'. Character replaced
with '_'.

Invalid characters have been entered.


These characters are replaced by _ (for
example, spaces in an ID).

Msg10=Input Failure;Layer ID number


not known.

The Layer ID that is input is not


recognised. Check the Layer ID that was
entered.

Msg33=Input failure;Layer number to big


(Max = '%s')

You try to place more layers on a pallet


than is permissible. If it is necessary to
place more layers on a pallet, you should
contact CSi.

Msg16=Input failure;No Layer number


given

The layer number has not been entered.

Msg5=Input Failure;One of the input


fields no or wrong data.

You have typed in no data or invalid data


in a text field.

CSi

5-3

C5000 Unilever Brasil

Fault-finding

5-4

CAUSE / SOLUTION

Msg15=Input Failure;Pack ID number not


uniek or unknown.

To create a new or to change an existing


pack definition, a Pack ID has been
entered which already exists. Change the
Pack ID.

Msg20=Input failure;Packs, layers or


total packs not given.

With the giving of a command, the


number of layers or boxes on a pallet to
be entered should be a minimum.

Msg8=Input Failure;Pallet ID number not


known.

The Pallet ID that is input is not


recognised. Check the Pallet ID that was
entered.

Msg2147217900=Input failure;Record
cannot changed because of field-input
failure. ***** DbaseMessage = %s

Database error.

Msg6=Input Failure;Row-, Pack-number


not given, or not unique.

Every box must have a unique box and


row number. When this is not the case,
adapt the row and/or box number.

Msg9=Layer Nummer;Layer number not


unique.

The layer number that is input is not


unique. Check the layer number that was
input.

Msg40=Mode failure
Palletiser in manual mode.

The palletiser is in manual mode.

Msg200=No Message from Barcode


reader

No message has been received from the


barcode reader.

Msg204=No Read

No barcode has been read on the box.

Msg18=Number failure;Pack and/or rownumber incorrect, or already used.

Every box must have a unique box and


row number. When this is not the case,
adapt the row and/or box number.

Msg19=Number failure;SpacerNr and/or


Presure-number incorrect.

There is a space number or pressure


zone in the pattern which does not exist.
This is deleted and the pattern is
checked. This can occur after a change
has been made in the spacer
configuration.

Msg203=Reader Error

General barcode reader error message.

Msg4=Record used;Record can not be


deleted because it is used by other
record.

You are trying, for example, to delete a


box definition or layer in the editor while it
is still being used in a pallet.

CSi

September 1, 2014

09-1-14

FAULT MESSAGE

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Tab. 5.1 Fault messages Eagle (Sheet 4 of 7)

C5000 Unilever Brasil

Fault-finding

09-1-14

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-05.fm

Tab. 5.1 Fault messages Eagle (Sheet 5 of 7)

September 1, 2014

FAULT MESSAGE

CAUSE / SOLUTION

Msg1020=Restore Database; Insert


database disk in A:

Insert the backup diskette into drive A of


the IPC (floppy drive) for restoring a
backup of the database.

Msg7=Row Nummer;Row number not


unique.

Every box must have a unique box and


row number. When this is not the case,
adapt the row and/or box number.

Msg1001=Save Database; Erase old


database file on A:

There is still a database file on the floppy.


This must be deleted.

Msg1000=Save Database; Insert empty


disk in A:

Insert an empty diskette into drive A of


the IPC (floppy drive) to make a backup
of the database.

Msg100=Warning Overwrite
dimensions;Old values = LayerWidth
'%s' , LayerLength '%s' Accept new
values?

Confirmation is requested for overwriting


the existing layer dimensions with the
new set dimensions.

Msg44=Warning;Are you sure to change


spacer configuration ?

Confirmation is requested for changes to


the spacer configuration.

Msg101=Warning;Are you sure to delete


: '%s' ?

Confirmation is requested for deletion.

Msg102=Warning;Are you sure to delete


layer number: '%s' ?

Confirmation is requested for deletion of


a layer.

Msg28=Warning;Data changed. Accept


or cancel data first.

You try to quit a screen without first


saving the changes. Click on the OK or
Cancel button first.

Msg47=Warning;Data changed. Cancel


changes?

Confirmation is requested after clicking


on the Cancel button.

Msg103=Warning;Generate Default data


with formatArea motor speed '%s' mm/s
and PackLenght '%s' mm ?

Confirmation is requested for the


generation of default settings and the
overwriting of existing settings.

Msg17=Warning;No assignment active


for this device. Therefor no finetune
possible.

Fine-tuning can only be carried out when


a command is active. When this is not the
case, values can be adjusted in the Pack
Definition Editor.

Msg14=Warning;No Device data given


for this Layer, or write failure, therefor
Binairy file incomplete

In creating a layer, no Pack ID has been


entered. It is now no longer possible to
rotate it on the palletiser. Select a Pack ID
in the Layer Editor.

CSi

5-5

C5000 Unilever Brasil

Fault-finding

5-6

CAUSE / SOLUTION

Msg53=Warning;No help availabe in this


selected language.

No help file is available in the selected


language.

Msg30=Warning;No help available

No help text is available.

Msg11=Warning;No Layers selected for


this pallet, or write failure, therefor Binairy
file incomplete

A pallet has been made without any


layers. It is now no longer possible to
rotate it on the palletiser. First add layers
in the Pallet Editor.

Msg13=Warning;No Pack data given for


this Layer, or write failure, therefor
Binairy file incomplete

In creating a layer, no pattern has been


made in the Pack Editor. It is now no
longer possible to rotate it on the
palletiser. First make a pattern in the
Pattern Editor in the Layer Editor.

Msg12=Warning;No Row data given for


this Layer, or write failure, therefor
Binairy file incomplete

A layer has been made without having


created any row information. It is now no
longer possible to rotate it on the
palletiser. First create the row information
in the Row Editor.

Msg48=Warning;Password not right. Try


again.

An invalid password has been typed in;


try typing the password in again.

Msg42=Warning;Record cannot be
deleted because it is used by Palletizer.

The pattern cannot be deleted because it


is still active. The product is rotated.

Msg41=Warning;Record name cannot


be changed because it is used by
Palletizer.

The ID cannot be changed because it is


being used by the machine. The product
is rotated.

Msg27=Warning;Select Pack first. Click


on requested pack.

No box has been selected. Select a box


first.

Msg45=Warning;Spacer used in layer


'%s'.

After changing a spacer configuration,


Eagle checks all patterns and generates
a message if there is a layer in it with a
spacer that no longer exists. Check the
relevant layer.

Msg46=Warning;Spacer used in layer(s).


Do you still want to delete the spacer?

Eagle requests confirmation to delete a


spacer. The spacer is already being used
in a pattern.

Msg34=Warning;String too long. String


cut off at 20 characters

The text that is entered is too long. The


text is automatically truncated after 20
characters.

CSi

September 1, 2014

09-1-14

FAULT MESSAGE

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Tab. 5.1 Fault messages Eagle (Sheet 6 of 7)

C5000 Unilever Brasil

Fault-finding

FAULT MESSAGE

CAUSE / SOLUTION

Msg57=Warning;This function will end


assignment and reject pallet. Continue?

Warning after the giving of an Empty Run


command.

Msg43=Warning;This function will


overwrite old value's... Do you want to
continue?

While generating default settings, Eagle


requests if you are certain that you want
to overwrite the old values.

Msg58=Warning;This function will reject


pallet. Continue?

Warning after the giving of a Pallet Delete


command.

Msg36=Warning;Value not numeric.


Therefor value changed in '0'

You have typed in letters instead of


numbers. The letters are automatically
converted to zeros.

Msg35=Warning;Value too big or too


small. Value changed to limit '%s'

You have entered a number that is too


large or too small. This number is
automatically adjusted to the limits.

Msg37=Write Failure;File '%s' cannot be


opened. File still opened by palletizer.

File conflict between the machine and


Eagle. If this occurs, disconnect the
machine and reconnect it again.

Msg202=Wrong message from reader

An invalid message was received from


the barcode reader.

09-1-14

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Tab. 5.1 Fault messages Eagle (Sheet 7 of 7)

September 1, 2014

CSi

5-7

09-1-14

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C5000 Unilever Brasil

5-8

Fault-finding

CSi

September 1, 2014

C5000 Unilever Brasil

Maintenance

MAINTENANCE

Versie 2.1.0 - 2011-08-23

6.1

Introduction

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

These instructions apply to the maintenance of systems and machines


designed and manufactured by CSi.
The first section of the maintenance instructions deals with general
maintenance, while the second part covers specific maintenance for each
of the conveyors and machines.

Note
We suggest you only consult those sections of the general instructions
that apply to the conveyors and machines supplied to you.
The maintenance instructions of equipment supplied by subcontractors
can be found in Chapter 9.
Keep the conveyors and machines in tip-top condition by carrying out the
prescribed maintenance. This is necessary to keep the machine
functioning correctly and safely.
Maintenance work may be carried out by authorised personnel only.

09-1-14

6.2

Customer Service & Support


Should you require advice or technical assistance, please contact the
Customer Service & Support department of CSi and refer to the information
located on the identification plate of the relevant conveyor / machine.
CSi industries B.V.
Lissenveld 41 4941 VL Raamsdonksveer
P.O. Box 70 4940 AB Raamsdonksveer, Netherlands
Tel: +31 162 575 000 Fax: +31 162 575 111
E-mail: info@csiportal.com Internet: www.csiportal.com
Customer Service & Support
CSi Lifecycle Services el: +31 162 575 001 Fax: +31 162 575 118
E-mail: frontoffice@csiportal.com Internet: www.csiportal.com
We advise you to have a technical inspection carried out at least once a
year by service specialists of CSi Lifecycle Services.
We would advise you to pursue an effective and efficient policy, and in
particular to adopt a planned approach to the entire maintenance trajectory,
based on a maintenance contract. Such a contract outlines the service
agreed upon, tuned to your specific preferences and demands.

September 1, 2014

CSi

6-1

C5000 Unilever Brasil

Maintenance

To ensure the best possible maintenance and to minimize loss of time


when carrying out repairs, it is important that spare parts are available on
site.
Original parts match manufacturing specifications in terms of manufacture,
accuracy of measurement and materials. As such, only original
components issued by CSi may be used.
For information on ordering spare parts, please see Chapter 8. When
ordering spare parts, please adhere to the ordering procedure, as this is the
only way in which assignments can be carried out quickly and correctly.

Warning
Safety devices should be operated with utmost vigilance and alertness as
they ensure the safety of staff.

Warning
Improper use, faulty installation or operation, improper removal or
switching-off of safety devices and opening of protective covers without
taking safety precautions can result in serious injury or death as well as
major material damage.
Work, of whatever nature, should be carried out by qualified and authorized
personnel only. The safety instructions as mentioned in Chapter 1 "Safety"
should have been read first and all necessary safety precautions should
have been taken prior to the start of work.
Familiarize yourself properly with safety instructions before carrying out
maintenance work or repairs.
Safety instructions must be strictly observed, in particular those described
in Chapter 1 ("Safety") under paragraph "Safety in the event of
maintenance, faults, repairs and adjustments".
Please also read and adhere to the applicable safety instructions described
in this chapter.
Before carrying out any work, please ensure that electric power supply and
compressed air supply are switched and closed off at all times, and that the
switch / valve is padlocked.
These maintenance instructions include pictograms (see alongside) that
warn you about hazards, and draw your attention to necessary
precautions.
Safety devices have been fitted. This chapter outlines the mechanical
safety devices. Information on electric safety devices can be found in the
chapter "Safety".
When carrying out inspection and/or maintenance work, please ensure
that:

6-2

All safety devices are present, in working order and functioning properly.

Components that could affect safety are undamaged and functioning


properly.

CSi

September 1, 2014

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Safety

09-1-14

6.3

C5000 Unilever Brasil

Maintenance

Any defect, fault or flaw in any safety device should be put right before the
installation is put into operation.

6.4

Cleaning
Warning
External cleaning by spraying with water or a cleaning liquid is not
permitted, unless specifically mentioned otherwise.
Never use petrol or solvents to clean the machine.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Cleaning work is only permitted if the electric power supply and


compressed air supply have been switched and closed off. Cleaning must
be carried out with all due care.
Daily:

Remove bulky rubbish like sticky tape, packaging and product remnants, glass fragments, wood splinters etc. immediately to
avoid damage, wear and tear and faults.

Every 3 months:

Check chains, bearings, rollers, conveyor


belts and driving belts, frames, wheels, chain
guides, photo cells etc. for dirt. Clean if necessary.

The frequency of cleaning depends on environmental influences such as


dust, dirt, damp etc. You might therefore need to clean more often than
instructed.

Note
After cleaning, some components may need to be re-lubricated. Check
and lubricate the relevant components in accordance with instructions.

09-1-14

Driving belts and conveyor belts may need to be cleaned to prevent e.g.
steering problems. Do this sparingly, using water and a neutral soap. Never
use corrosive cleaning agents.

6.5

Gear motors
Carry out maintenance work in accordance with the manufacturers
instructions (see chapter 9).
The type plate indicates the type of lubricant used to fill the gearbox and
the amount of lubricant in litres.
The lubricant used and the filling quantity depends on the type of gear
motor, its shape and operating conditions.
Never mix different types of lubricants.

6.5.1

Replacing
Read the manufacturers instructions carefully before replacing a gear
motor. Make sure that the new motors specification match the old ones
exactly, i.e. that you install the same motor.
A new gear motor can come with a screwed-in vent, fitted with a transport
seal. Remove the seal to put the gear motor into working order.

September 1, 2014

CSi

6-3

C5000 Unilever Brasil

Maintenance

When replacing the gear motor, please check the alignment of the drive
and the oil level in the gearbox.

6.6
6.6.1

Chain transmission of drive


Lubricating
Lubricants / method:

6.6.2

See paragraph 6.12

Tensioning
The chain is correctly tensioned if there is play in the unloaded part on the
half centre distance of the sprockets. This can be determined as follows:

Centre-to-centre distance of the sprockets is e.g. 300 mm.


This means that the play of the chain is 300 / 20 = 15 mm.
Depending on construction, it is possible to compensate for chain
stretching as follows:

by loosening the fastening bolts of the gear motor or the motor


foundation plate and moving these using theadjustment bolts. If
regionalising the chain in this way, please check the alignment of the
chain transmission. The sprockets need to be parallel to one another
and aligned. This can be checked by keeping a ruler along the
sprockets;

by adjusting a permanent chain tensioner;

by using a spring load chain tensioner. The chain automatically


maintains a constant tension.

When the full tensioning capacity of the chain has been used up, the
tensioning device should be returned to the starting position and the chain
either shortened or replaced.
It is not possible to re-tension the short roller drive chains.

6.6.3

Replacing
The resulting friction in the hinge points of the transmission chain causes
wear and tear, resulting in chain lengthening. The maximum permissible
length increase is 3%.
Do not replace transmission chain and sprockets separately; always
replace both.
Transmission chains come in standard length and must be brought to
correct length on-site, using disassembly tools.
When re-assembling the transmission chains and sprockets, please retain
the original running direction.
sprockets should be fitted and disassembled using special tools. Use the
special screw thread in the end of the shaft.

6-4

CSi

September 1, 2014

09-1-14

Example of how to determine play:

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Play (mm) is the centre-to-centre distance of the sprockets (mm) divided by


20.

C5000 Unilever Brasil

Maintenance

When replacing and adjusting, please check the alignment of the chain
transmission. The sprockets need to be parallel to one another and aligned
This can be checked by keeping a ruler along the sprockets of the
sprockets;
Take care! Loosen the socket screw of the sprocket when disassembling
and fasten when assembling.
For installment of the sprocket that must be installed via a key way
connection to a shaft, use an appropriate anti-oxidant lubricant, see
paragraph 6.12.1.

6.7

Clamping bushes

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Upon assembly, clamping bolts for clamping bushes must be locked


equally using a torque spanner in accordance with the table below.

MAKE
Bikon

ETP Classic

Ringfeder

09-1-14

Taper-lock

TYPE NO.
Bikon 1006 / 020 - 047
Bikon 1006 / 055 - 085
Bikon 1006 / 065 - 095
Bikon 8000 / 060 - 077
ETP 20 / 028 - 022
ETP 25 / 034 - 027
ETP 70 / 090 - 072
RfN 7012 / 025 - 050
RfN 7013.1 / 035 - 060
RfN 7013.1 / 045 - 075
1008 / 1108
1210 / 1610 / 1615
2012
2517
3020 / 3030

TENSIONING

BOLTS
(NO. / DIM.)

MOMENT

5 / M6
8 / M8
9 / M8
9 / M8
3 / M5
4 / M5
6 / M8
9 / M6
9 / M6
9 / M8
2 / 1/4" BSW
2 / 3/8" BSW
2 / 7/16" BSW
2 / 1/2" BSW
2 / 5/8" BSW

17
41
41
41
8
8
32
14
17
41
6
20
31
48
90

TA (NM)

Tab. 6.1 Tensioning moment clamping bushes

September 1, 2014

CSi

6-5

C5000 Unilever Brasil

Maintenance

TollokClampex

TLK 130 / 040 - 065


TLK 131 / 035 - 060
TLK 131 / 050 - 080
TLK 132 / 025 - 050
TLK 132 / 040 - 065
TLK 132 / 045 - 075
TLK 132 / 050 - 080
TLK 132 / 055 - 085
TLK 132 / 065 - 095
TLK 132 / 080 - 120
TLK 133 / 020 - 047
TLK 133 / 022 - 047
TLK 133 / 030 - 055
TLK 133 / 032 - 060
TLK 133 / 045 - 075
TLK 133 / 050 - 080
TLK 133 / 055 - 085
TLK 133 / 070 - 110

BOLTS
(NO. / DIM.)
8 / M6
8 / M6
8 / M8
6 / M6
8 / M6
8 / M8
8 / M8
8 / M8
8 / M8
8 / M10
6 / M6
6 / M6
6 / M6
8 / M6
8 / M8
8 / M8
8 / M8
8 / M10

TENSIONING
MOMENT

TA (NM)
17
17
41
14
14
35
35
35
35
70
17
17
17
17
41
41
41
83

Tab. 6.1 Tensioning moment clamping bushes

6.8

Rollers
Please replace the entire roller if there is too much radial and / or axial play,
if it produces noises, is damaged, or runs with difficulty.
As a rule, roller bearings are not adjustable and not removable.

6.9

Bearings
Please replace a bearing if there is too much radial and / or axial play, if it
produces noises, is damaged, or runs with difficulty.
In certain instances, it is difficult or impossible to replace bearings, and the
component will have to be replaced in its entirety. This applies to e.g. rollers
and wheels.
When replacing bearing blocks, please use an appropriate anti-oxidant
lubricant during installment, see paragraph 6.12.1.

6.9.1

Bearing blocks with a greased lubrication nipple


The bearing blocks of e.g. shafts and drums, for the most part, standardly
come with a lubrication nipple.
Circumstances when bearing blocks should be lubricated:

6-6

In an environment with an increased risk of contamination of dust, dirt


and moisture.
Lubrication frequency: every 3 months

CSi

September 1, 2014

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TYPE NO.

09-1-14

MAKE

C5000 Unilever Brasil

Maintenance

Applications when bearing blocks operate under heavy load. Bearing


blocks that should be lubricated then, are mentioned in the
maintenance scheme.

In case of a high/low ambient temperature, specific lubrication


instructions apply, depending on the particular circumstances.

For safety purposes, bearing blocks fitted to the outside of the frame may
come with a detachable guard. If such a bearing block should be lubricated,
first remove the protective guard to let excess lubricant run off and once the
bearing block has been lubricated, re-attach the protective guard.

6.10

Pneumatic installation
Make sure that dirt can not enter the pneumatic system.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

The compressed air that enters at the connecting point of the pneumatic
installation, should be dry, clean and pre-filtered.
The connecting point of the compressed air supply line must have an "air
service unit" installed to remove dirt particles from the pipe system and to
set the air pressure. This is a combination of water separator, air filter,
pressure regulator and manometer.

6.10.1

Water separator
The water separator comes equipped with a condensate drain. The
frequency of draining depends on the condition of the compressed air and
on operating conditions.
If there is too much moisture in the supply line, please check whether the
supplied air meets requirements.

6.10.2

Air filter
The filter element should be cleaned or replaced when dirty.

09-1-14

6.10.3

Pressure regulator and manometer


This device sets the compressed air supplied to the set at a specific
working pressure and compensates for fluctuations in pressure.
The basic setting of the working pressure is carried out by CSi during
testing and commissioning and may not be alterated by the user.

6.10.4

Other pneumatic components


Important when inspecting and carrying out maintenance:

September 1, 2014

Please ensure that the piston rod(s) of the pneumatic cylinder(s) is/are
clean; this will prevent wear and tear and leakage.

Please check that the pneumatic valves are in proper working order.

Check the pneumatic hose and connections for leaks and damage.
Please ensure that the hosing isnt twisted or jammed.

CSi

6-7

C5000 Unilever Brasil

Maintenance

6.11

w
6.11.1

Electrical installation
Warning
Work, of any nature, on the installation should be carried out by qualified
and authorised personnel only. Please read Chapter 1 ("Safety") and
take all necessary precautions.

Control cabinet
Please close the cabinet door properly always so that dust and moisture
cannot enter.
If the control cabinet is equipped with a ventilator, please check the filter
element for dirt and clean or replace when necessary. The air inlets and
outlets must remain easily accessible i.e. kept free of obstacles.

Please take particular care to check security switches and other switches
that are used now and again only.

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Back up electrical supply

Photo cells

09-1-14

6.11.2

The PLC is fitted with batteries and the IPC is fitted with a UPS
(Uninterrupted Power Supply)
Every 6 months:

Check UPS

Every 3 years:

Replace the batteries in the PLC

Please ensure that all activities are carried out in accordance with
manufacturers instructions.

6.11.3

Operating panels
Keep the operating panel clean and check functioning of control elements
and indicator lamps on a regular basis.

6.11.4

6.11.5

Proximity switches, limit switches and door switches

Clean the lenses of photo cells and reflectors with a soft cloth.
The frequency of cleaning depends on environmental influences such as
dust, dirt, damp etc. You might therefore need to clean more often than
instructed.

6.11.6

Electrical cabling
Please ensure that cable ducts dont become damaged. Please keep
cable work of the control current separate from cable work of the main
current. Loops in cables must be avoided.

6.11.7

Cable tracks
Depending on the application, cable tracks are used free-bearing or in
combination with cable ductings.
Important when inspecting and carrying out maintenance work:

6-8

CSi

September 1, 2014

C5000 Unilever Brasil

Maintenance

6.12

Cable ductings may not be damaged or dirty. Bulky rubbish such as


sticky tape, packaging and product remnants, glass fragments, wood
splinters etc. must be removed immediately .

Please shut cable tracks correctly and insure that connections and
internal sections are not damaged or loose.

Cables and pneumatic hosings (if applicable) must not become twisted
or jammed. Please also ensure that there is enough play for lengthwise
movement in the cable track.

Cables and hosings must be secured with a pull relief on outer ends of
cable tracks.

Lubricants

09-1-14

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

The table below provides an overview of the lubricants for general use.
For components requiring specific re-lubrication, please read the relevant
maintenance paragraph.

Note
The frequency of re-lubricating is highlighted in the maintenance
diagram.
Different lubricants and regulations apply if the conveyors / machines are
connected to a central lubricating system, are set up in a dirty or corrosive
environment or in areas with high or low temperatures.
Different types of lubricant should not be mixed.

APPLICATION
Bearing blocks with a greased
lubrication nipple.
(see paragraph 6.9.1)
Transmission chains
(see paragraph 6.6)

LUBRICANT

METHOD

Grease:

With a grease gun via lubrication nipple.

- Shell Alvania Grease EP(LF) 2


- Shell Grease FG 2 1)
Oil:

With an oil gun and a brush.

- Shell Vitrea Oil M 100

- Shell Cassida Chain Oil 150 1)


Spray with a sprayer and let seep in for
Chain spray:
Shell Cassida Chain Oil 1000 1) approx. 10 minutes before putting the
chain under load.
Reduction gearbox of the motor
Quantity and type of lubricant: Via air release / overpressure vent.
reductor
See type plate on the motor
reductor.
Grease:
Clean both contact surfaces and apply
For the installment of parts
the lubricant evenly with a cloth or a
to facilitate installment and prevent SKF grease LGMT 2
brush.
oxidation.
Paste:
(see paragraph 6.12.1)

NOCO -Fluid
(see SEW Eurodrive
manufacturer's instructions)
Tab. 6.2 Lubricant table

September 1, 2014

CSi

6-9

C5000 Unilever Brasil

Maintenance

1) Registered by NSF (Class H1) and meet USDA H1 guidelines (1998) for
lubricants for use where there is a potential for incidental contact with food.
Made only from substances permitted under the US FDA Title 21 CFR 178.3570,
178.3620 and 182 for use in food grade lubricants.

6.12.1

Anti-oxidant lubricant
Use an appropriate lubricant when replacing e.g. a slip-on motor reductor,
bearing blocks or when replacing transmission components that are
installed via a key way connection to a shaft, see lubricant table Tab. 6.2.
Lubrication facilitates installment and prevents oxidation.

6.13

Maintenance diagram logistics

09-1-14

Keep the conveyors and machines in tip-top condition by carrying out the
prescribed maintenance. This is necessary to keep the machine
functioning correctly and safely. The maintenance frequency indicated is
based on 24 hours/day and 7 days/week operation.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Warning
If you wish to use another equivalent lubricant, please make sure it
doesnt contain lead or copper. These additives are not compatible with
parts that have received a chemically blackened surface treatment.
These additives can corrode the chemically blackened layer which
complicates future disassembly.

6-10

CSi

September 1, 2014

C5000 Unilever Brasil

Maintenance

Energy powered moving parts can cause hazardous situations and may
lead to serious injury or even death. Make sure to always switch off power
supply, shut down air supply and secure the particular switch / valve with
a padlock, before carrying out any work on the machine.
Inspection and maintenance work highlighted in the columns need to be
carried out while the conveyor is in operation. You must therefor be extra
vigilant and aware about the risks and the consequences.

Cleaning

Every week Safety devices

Every 3
months

General inspection

I
I

Cleaning
Gear motors

Chain transmission

Rollers

Bearings

ICL
ICL
ICL
ICL
ICL
ICL
ICL
ICL

RUNNING WARM

SEE PAR.

PLAY
TRACKING
TENSION

WEAR AND TEAR


LUBRICATION

DIRT

OPERATION
DAMAGE
FASTENING
NOISES
POSITIONING
FUNCTIONAL OPERATION
LEAK
OIL LEVEL
Every day

General maintenance

09-1-14

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

MODULE FREQUENCY COMPONENT

INSPECTION & MAINTENANCE


A= ADJUST R= REFILL I= INSPECT
CL= CLEANING L= LUBRICATION CH= CHANGE
DW= DRAIN OFF WATER

6.4
6.3
I

I
6.4

I 6.5

I I-L

I-A

6.6

6.8

I 6.9

Tab. 6.3 Maintenance diagram logistics (Sheet 1 of 2)

September 1, 2014

CSi

6-11

C5000 Unilever Brasil

Maintenance

I
I

General inspection

Control cabinet

Back up electrical supply


Operating panels
I

I
6.11.1

Cable tracks

6.11.2
6.11.3

ICL
ICL

ICL
ICL

RUNNING WARM

PLAY
TRACKING
TENSION

6.11.5

Proximity switches, limit


switches and door
switches
Electrical cabling

Back up electrical supply


(replace batteries)
Water separator
General inspection

ICL
ICL
ICL

6.11.4

6.11.6

6.11.7
6.11.2

DW
I- I
CL

6.10.1
I

Tab. 6.3 Maintenance diagram logistics (Sheet 2 of 2)

Versie 2.0.1 - 2011-08-25

6.14
6.14.1

Palletising machine C5000- Si / Ti


Function
Used to automatically load products onto pallets.

6.14.2

Machine construction
The machine consists of the following main groups:

6-12

Conveyors for product input

CSi

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Every 3
years
Every week
Every 3
months

Photo cells

SEE PAR.

09-1-14

Installation

Pneumatic Electrical installation

Every 3
months
Every 6
months

WEAR AND TEAR


LUBRICATION

OPERATION
DAMAGE
FASTENING
NOISES
POSITIONING
FUNCTIONAL OPERATION
LEAK
OIL LEVEL

MODULE FREQUENCY COMPONENT

DIRT

INSPECTION & MAINTENANCE


A= ADJUST R= REFILL I= INSPECT
CL= CLEANING L= LUBRICATION CH= CHANGE
DW= DRAIN OFF WATER

September 1, 2014

C5000 Unilever Brasil

Maintenance

The modules:
-

Infeed row forming conveyor

Rotating unit

Row pusher

Load platform

Back- and side dams

Pallet lift

(Optional)

Pusher
Interleaving sheet module
Glue module

Conveyors for empty pallet infeed and full pallet removal.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

The machine can be extended with one or more optional extras and have
customer specific alterations. The optional extra is part of the machine if the
control of the optional extra is integrated in the control of the machine.

09-1-14

6.14.3

September 1, 2014

Mechanical safety devices

Fixed guards that can only be removed with the aid of tools for
maintenance purposes.

Guards which can be opened and closed using a tool or a key.

Lockable main/operating switches.

Lockable stopcock for the pressured air supply.

Product infeed row forming conveyor zone:


-

Located at a height of approximately 3,000 mm and is accessible via


a ladder and a gangplank. The gangplank has a hand railing.

Is equipped locally with a touch screen control panel with an


emergency stop button.

One entrance door for the product infeed zone and one door for the
row forming zone. Both have a lock in accordance with CE safety
class 3.
To gain access, the STOP button on the local control panel must be
pressed.

CSi

6-13

C5000 Unilever Brasil

Maintenance

6.15
6.15.1

6.15.2

Equipped locally with a control panel with an emergency stop button.

Fixed guard by means of fencing.

Empty pallet infeed via a narrow passage.

Full pallet removal equipped with a light screen as an entrance


safety device in accordance with CE safety class 3.

Accessible via a lockable door which can be opened and closed with
a safety key.
The entrance is cleared and the lock can be unlocked when the
machine has been turned off correctly. After closing the door, it must
be locked again using a key and the machine must be restarted via
the local control panel beside the entrance door.

The pallet lifts lift wagon is equipped with a mechanical drop lock.

Warning
Safety devices which are not assembled and/or not closed, or which are
not in working order or which do not function correctly, will cause
dangerous situations which may result in serious physical injury or death.

Infeed row forming conveyor


Description
Drive

The drive pulley is driven by a gear motor.

Drive belt

Continuously welded with a V-belt on the bottom. The belt can be tensioned using a
moveable tensioning pulley.

Rollers

The drive side of the rollers is pushed onto


the drive belt by draw springs. A couple of
rollers are driven by round belts.

Pressure unit

Is located under the rollers on the drive side,


each consists of a brake block and a pneumatic cylinder .

Spacers en stop plate

A plate fitted between plastic guides which is


moved using a pneumatically operated cylinder.

Tightening conveyor belt


For a full load, check whether the belt slips over the drive pulley when the
conveyor is started. If the belt is slipping and / or producing noises, the
prestress has been set too low and the belt will need to be re-tightened.
Pre-stressing the belt:

6-14

CSi

September 1, 2014

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Pallet loading zone:

09-1-14

C5000 Unilever Brasil

Maintenance

6.15.2.1

Method for tightening the belt.


1 Take the necessary precautions (see "Safety" chapter <section?>) to
ensure that you are working safely.
2 Make sure there are no products on the conveyor and that the push bars
of the row pusher are in such a position that the rollers are free to be
disassembled and assembled.
3 Rotate the main switch to the OFF/0 position and lock the switch using
a padlock.
4 Disassemble the belts bottom guard.
5 Over a length of approximately 1,500 mm, disassemble the draw
springs that push the rollers downwards and remove the rollers from the
fame.
6 On both sides, unscrew the bolt which secures the tensioning pulley in
the frame.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

7 Remove the tension in the belt by rotating both tensioning bolts the
same number of turns in the correct direction.
8 Draw a linear measurement of 1,000 mm on the top of the belt.
9 Tension the belt by turning both tensioning bolts an equal number of
turns in the correct direction until there is an 2 mm increase in the length
of the line. This is equal to the required pre-tensioning of 0.2%. When
tensioning, check whether the drive belt is correctly positioned with
respect to the pulleys
10 Measure to see whether the tensioning pulley is positioned at right
angles in the frame.
11 Fit the rollers and tension springs.
12 Assemble the drive belts bottom guard.
13 Unlock the main switch and turn it to ON / 1 position.
14 Start the machine and test whether it functions correctly

09-1-14

6.15.3

Replacing drive belt


If the belt needs replacing, please ensure that it is fitted endless.
Before disassembling and assembling, please check whether the belt has
become worn out as a result of normal wear or whether it has been
damaged by something else.

6.15.3.1

Method for replacing the belt


1 Carry out the work as described in points 1 to 4 of paragraph 6.15.2.1
2 Dismantle the springs that push the rollers down and remove the rollers
from the frame.
3 On both sides, unscrew the bolt which is used to secure the tensioning
pulley in the frame.
4 Remove the tension in the belt and disassemble the belt tensioner
together with the shaft.
5 On the inside, disassemble the short axle ends of the guide pulleys.

September 1, 2014

CSi

6-15

C5000 Unilever Brasil

Maintenance

6 Remove the drive belt via the underside.

Note
It is recommended to inspect the pulleys for dirt and wear before
beginning the assembly.
7 Assemble the continuous belt.
8 Tighten the belt and assemble in the correct order, see points 8 to 12 of
paragraph 6.15.2.1.
9 Unlock the main switch and turn it to ON / 1 position.
10 Bring into operation and test the functional operation.

6.15.4

Method for replacing the cylinder pressure unit

3 Remove the two bolts used to secure the pressure unit to the ruler and
remove the pressure unit from the ruler via the bottom of the ruler.
4 Replace the cylinder.
5 Fit the pressure unit into the ruler and fix the air connections.
6 Assemble the bottom guard.
7 Unlock the main switch and turn it to ON / 1 position.
8 Bring into operation and test the functional operation.

6.15.5

Method for replacing the spacers / stop plate


Disassemble and assemble via the top. To do so, five rollers must be
disassembled from the left and the right of the spacer/stop plate concerned
as described in points 1 to 5 of paragraph 6.15.2.1.
Take care! First, mark the position of the spacer/stop plate so that it can be
reassembled in the correct position.

6.16
6.16.1

6-16

Row pusher
Description
Drive

The chains are driven by a gear motor via a


central drive shaft and two chain transmissions.

Row pusher bars

Are secured to the chains on both sides


using a locking link.

Chain guide

The chains are guided using plastic guide


profiles.

Chain tensioners

The chains which are connected to the pusher bars are automatically kept at the correct
tension by a spring tensioner. The drive
chains are tensioned by adjusting a tensioning wheel.

CSi

September 1, 2014

09-1-14

2 Loosen the air connections to the cylinder.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

1 Carry out the work as described in points 1 to 4 of paragraph 6.15.2.1.

C5000 Unilever Brasil

Maintenance

6.16.2

Maintenance and adjustment information


The compression spring of the chain tensioner is pre-tensioned by 10%.
This corresponds to a tensioned length of 230 mm. (see Fig. 6.1) The
compression springs must be re-tensioned when they are no longer placed
under sufficient tension.
If the chains must be replaced, assemble the new chains with the same
number of chain links as the disassembled chains.

6.16.2.1

Clamping bush of the axle - chain wheel


connection

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

The tensioning bolts of the clamping bush should be tightened diagonally


and evenly to the specified torque when being assembled and
disassembled.
Clamping bush

TLK131 / 035 - 060

Tensioning bolts

9 pcs. M6

Tightening torque (Ta)

17 Nm

09-1-14

230

Fig. 6.1 Spring tensioner row pusher

6.17
6.17.1

6.17.2

Load platform
Description
Drive

The back plate is driven via a slide crank


drive mechanism by a gear motor. The plates
move in synchronization and in the opposite
direction to each other by means of a timing
belt drive.

Guide

The plates are guided by running wheels.

Checking and adjusting the timing belt tension


Pre-tension of the timing belt: 400 N.

September 1, 2014

CSi

6-17

C5000 Unilever Brasil

Maintenance

6.17.2.1

Tension gauge
In order to check and adjust the pre-tension, you must have a Gates Sonic
Tension Meter, model type 507C.
Read the tension gauges instruction manual and follow the instructions.
The tension gauge only has to be calibrated once by inputting the weight,
width and span length and saving the data in the memory of the tension
gauge. (see table Tab. 6.4)

WEIGHT
(M=G/M/MM)

WIDTH
(W=MM/#R)

SPAN
(S=MM)

004,5

025,0

0771 (fully
closed)

004,5

025,0

0660 (fully
closed)

004,5

025,0

0682 (fully
closed)

004,5

025,0

1011 (fully
closed)

004,5

025,0

1341 (fully open)

004,5

025,0

1580 (fully open)

In the SPAN column, the span length between two fixed points is indicated
(see Fig. 6.2) over which the timing belt can freely move up and down and
where the pre-tension must be measured.
The load platform must be fully closed for measurements 1 to 4. The load
platform must be fully open for measurements 5 and 6.

1750,5
771(1341 full open)

682

660

1011 (1580 full open)

Fig. 6.2 Load platform

6-18

CSi

September 1, 2014

09-1-14

SELECT

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Tab. 6.4 Tension gauge settings

C5000 Unilever Brasil

Maintenance

6.17.2.2

Method for checking and adjusting


the timing belt tension
1 Take the necessary precautions (see "Safety" chapter <section?>) to
ensure that you are working safely.
2 Make sure that there are no products standing on the load platform.
3 Turn the main switch to the OFF / 0 position and secure with a padlock.
4 Take the tension gauge. Connect the sensor and press POWER.
5 Press SELECT and press 1 for the first measurement.
Take care! Make sure the load platform is fully closed.
6 Press MEASURE. The green LED will start to flash.
7 Gently tap the timing belt at the length indicated in the SPAN column
(see Tab. 6.4) so that the timing belt starts to vibrate and hold the sensor
a distance of approximately 1 cm from the surface of the belt.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

8 Read the measured tension when the green LED goes out.
9 If the tension is higher or lower, correct the tension to a value of 400 N.
10 Check and tension the other timing belt as described in points 5 to 9.
11 Carry out measurement 2, followed by measurements 3 and 4 (see
table Tab. 6.4) as described in points 5 to 10.
12 Turn the motors fan by hand until the load platform is fully open.
13 Carry out measurement 5 followed by measurement 6 as described in
points 5 to 10..
14 Repeat the measurements, see points 5 to 13.
The tension values obtained must not differ greatly.
15 Unlock the gear motors brake by unscrewing the handbrake releaser
and assemble the motors fan cover.
16 Unlock the main switch and turn it to ON / 1 position.
17 Switch the machine on and test the whether it is working properly.

09-1-14

6.17.3

Method for replacing the timing belts


Warning
The load platforms timing belts must not be replaced separately. They
must only be replaced together.
1 Take the necessary precautions (see "Safety" chapter <section?>) to
ensure that you are working safely.
2 Make sure that there are no products standing on the load platform.
3 Turn the main switch to the OFF / 0 position and secure with a padlock.
4 Slacken and dismantle the two timing belts.

Note
It is recommended to inspect the pulleys for dirt and wear before starting
the assembly.
5 Adjust both tensioners to the start position.

September 1, 2014

CSi

6-19

C5000 Unilever Brasil

Maintenance

6 Release the gear motors brake and secure it in position by screwing in


the handbrake releaser and removing the fan cover from the motor.
7 Rotate the motors fan by hand until the driven plate is fully open.
8 Fit both timing belts over the drive pulley and the rotating pulley and
clamp the ends between the clamping plates and the belt tensioner.
Take care! Make sure the ends of the timing belt are in line with the
tensioner and the bolts are not tightened too much.
9 Rotate the motors fan by hand until the driven plate is fully closed.
10 Move the other half of the load platform to a distance of 10 cm from the
driven plate and measure to see whether this is in line with the driven
plate.
11 Secure both timing belts to the driven plate.
12 Tension the timing belt, see points 4 to 14 of paragraph 6.17.2.2.
13 Unlock the main switch and turn it to ON / 1 position.

6.18.1

Lubricant

Shell Alvania Grease EP (LF) 2 or


Shell Grease FG 2

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6.18

Lubrication method

Via lubrication nipple with the aid of the grease gun

09-1-14

14 Bring into operation and test the functional operation.

Frequency

See maintenance diagram Tab. 6.5.

Back dam and side dams


Description
Drive

6.18.2

Each drive is driven by a gear motor via a


central axle and a double geared wheel gear rack transmission.

Maintenance and adjustment information


The cogwheel - gear rack transmissions should be lubricated.
Position of lubrication points See Fig. 6.3.

6-20

CSi

September 1, 2014

C5000 Unilever Brasil

Maintenance

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Fig. 6.3 Gear casing lubrication point

6.19

09-1-14

6.19.1

6.19.2

Pallet lift
Description
Pallet lift

The drive shaft is driven by a gear motor.


Two chain wheels, over which the lift chains
run, are mounted on the drive axle. The lifting chains are connected on one side to a lift
wagon and on the other to a counterweight.

Lift wagon

Is guided vertically by guide wheels and


plastic guide blocks and is equipped with a
centring unit and a drop lock.

Centring unit

The centring guides are connected to each


other by a chain transmission and are moved
using a pneumatic cylinder.

Drop lock

Two locking pins automatically block the lift


wagon by means of spring pressure if the air
pressure in the pneumatic cylinders suddenly drops.

Maintenance and adjustment information


Warning
It is not permitted to use the pallet lift to lift people or to stand under or in
the pallet lift without taking the necessary safety measures.
BE AWARE OF DANGER WHILST CARRYING OUT WORK!
Before entering the pallet loading zone, first check whether the lift wagons
drop lock is turned on. (see Fig. 6.5)

September 1, 2014

CSi

6-21

C5000 Unilever Brasil

Maintenance

6.19.2.1

Pallet lift
The lift chains and the bearing blocks of the drive axle should be relubricated, see paragraph 6.12.
Position of the lubrication points
The lubrication nipples for the bearing blocks
are connected to the bearing block via a
lubrication line and are located on the outside of the frame.
Frequency

See maintenance diagram Tab. 6.5.

Replacing the lifting chains


The lifting chains and the chain wheels must not be replaced separately.
They must always be replaced together. It is best to have this carried out
by the CSi service specialists.

The bearings of the vertical guide wheels must be re-lubricated.


Position of the lubrication points
There are four lubrication points on the front
of the machine. These are indicated with a
red mark.

6.19.2.3

Lubricant

Shell Alvania Grease EP (LF) 2 or


Shell Grease FG 2

Method

Via lubrication nipple with the aid of the grease gun

Frequency

See maintenance diagram Tab. 6.5

Centring unit
The chains should be re-lubricated, see paragraph 6.12.
Frequency

See maintenance programme

The chains are correctly tensioned if the chains do not make much noise
when rolling onto and off of the chain wheels, have almost no free
movement and if it is not possible for the chains to touch the top of the
pneumatic cylinder (see Fig. 6.4).

Fig. 6.4 Centring unit


6.19.2.4

Drop lock
Always first support the counterweight and the lift wagon if you must carry
out work on the drop lock

6-22

CSi

September 1, 2014

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Lift wagons

09-1-14

6.19.2.2

09-1-14

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C5000 Unilever Brasil

September 1, 2014

Maintenance

Fig. 6.5 Drop lock

CSi

6-23

C5000 Unilever Brasil

Maintenance

6.20

Maintenance diagram machine C5000- Si / Ti


Keep the conveyors and machines in tip-top condition by carrying out the
prescribed maintenance. This is necessary to keep the machine
functioning correctly and safely. The maintenance frequency indicated is
based on 24 operating per day for 7 days a week.
Standing and moving parts that are live i.e. still supplied with electricity,
cause hazardous situations to occur and may lead to serious injury or even
death. Make sure you always switch off the electrical supply, close down
the air supply and secure the switch/valve concerned with a padlock,
before you carry out any work on the machine.
The inspection and maintenance work highlighted in the columns need to
be carried out while the conveyor is in operation. You must thereby be extra
vigilant about the risks and the consequences.

Every three months.

conveyor

Infeed row-forming
6-24

RUNNING WARM

TENSION

TRACKING

PLAY

LUBRICATION

WEAR AND TEAR

DIRT

OIL LEVEL

LEAK

FUNCTIONAL OPERATION

POSITIONING

NOISES

FASTENING

DAMAGE

See maintenance programme Logistics


I

I
C

I
C

6.15.
4

6.8

Pressure unit

Rollers

I
C

Spacers / stop
plate

I
C

CSi

I
A

09-1-14

OPERATION
General maintenance
Electrical installation
Pneumatic installation

Drive belt

SEE
PAR.

A= ADJUST R= REFILL I= INSPECT


C= CLEANING L= LUBRICATION C= CHANGE
DA= DRAIN OFF WATER

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

INSPECTION & MAINTENANCE

COMPONENT

FREQUENCY

MODULE

Tab. 6.5 Maintenance diagram C5000- Si / Ti

6.15.
2
6.15.
3

6.15.
5

September 1, 2014

C5000 Unilever Brasil

Maintenance

INSPECTION & MAINTENANCE

COMPONENT

I
C

I
C

I
C

I
C

Plates

Running wheels

I
C

Slide crank
mechanism

I
C

Geared wheel gear rack


transmission

I
C

CSi

I
L

I
L

RUNNING WARM

TENSION

TRACKING

PLAY

LUBRICATION

WEAR AND TEAR

timing belts

DIRT

OIL LEVEL

Chain guides

LEAK

FUNCTIONAL OPERATION

POSITIONING

FASTENING

Chain
transmission

NOISES

DAMAGE

Every 3 months
Every 3 months
Every 3 months

Row

Pusher

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm


09-1-14

Load platform
Back- and

side dams

September 1, 2014

SEE
PAR.

A= ADJUST R= REFILL I= INSPECT


C= CLEANING L= LUBRICATION C= CHANGE
DA= DRAIN OFF WATER

OPERATION

FREQUENCY

MODULE

Tab. 6.5 Maintenance diagram C5000- Si / Ti

I
A

6.16.
2

I
A

6.17.
2
6.17.
3

6.18.
2

6-25

C5000 Unilever Brasil

Maintenance

INSPECTION & MAINTENANCE

6.19.
2.1

Lift wagon

I
C

I
L

6.19.
2.2

Centring unit

I
C

I
L

Drop lock

I
C

TENSION

I
L

TRACKING

PLAY

I
C

DIRT

OIL LEVEL

LEAK

I
A

6.19.
2.3
6.19.
2.4

Versie 1.0.0 - 2011-08-25 rev VV 2012-01-12

6.21

Elevator - changing chains and bearings lift shaft


See also drawing 0T.67.71A-2 (click to open)

6-26

CSi

September 1, 2014

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

RUNNING WARM

LUBRICATION

WEAR AND TEAR

FUNCTIONAL OPERATION

POSITIONING

FASTENING

Pallet lift

NOISES

DAMAGE

OPERATION
Every 3 months

Pallet lift

SEE
PAR.

A= ADJUST R= REFILL I= INSPECT


C= CLEANING L= LUBRICATION C= CHANGE
DA= DRAIN OFF WATER

09-1-14

COMPONENT

FREQUENCY

MODULE

Tab. 6.5 Maintenance diagram C5000- Si / Ti

C5000 Unilever Brasil

Maintenance

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Elevator or lift platform

09-1-14

Fig. 6.6 Overview Palletiser

6.21.1

Functional description
The lifting elevator function is integrated in the palletising function.
The lift function drive is designed for a specific maximum pallet weight of
1500 kg.
A pallet is positioned on a pallet roller conveyor.
This pallet roller conveyor is integrated on a lifting platform.
For optimal handling / energizing the unit is equipped with a guided
counterweight.
The pallet is lifted to a position under the loading platform (stripper table),
depending on the actual height of the pallet.
The loading platform opens and a layer is dropped on top of the pallet (or
pallet load).
Now the pallet(load) is lowered in high speed until the top of the pallet(load)
is under the loading platform.

September 1, 2014

CSi

6-27

C5000 Unilever Brasil

Maintenance

Then it will raise the pallet(load) in slow speed back towards the platform
for the next layer to be accepted.

6.21.2

Description
Lift construction

See drawing drawing OT.67.71A-0

The lift construction consists of:


15 Geared motor with torque support.
16 Main shaft.
17 Two bearings for shaft support.
18 Two Sprockets on the main shaft for chain 1 duplex.
19 Two chains 1D.
20 Lift platform.

Fig. 6.7 Safety blockage lift platform


23 Safety blockage counter weight See Fig. 6.8 Safety Blockage Positions
4/5 & 29/30 .

Blocking pin

Fig. 6.8 Safety Blockage Positions 4/5 & 29/30

6-28

CSi

September 1, 2014

09-1-14

22 Safety blockage lift platform See 2.1 or 7.1 or Fig 2 below

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

21 Counter weight.

C5000 Unilever Brasil

Maintenance

6.21.3

w
6.21.4

w
K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

6.21.4.1

Safety
Warning
Improper use, faulty installation or operation, improper removal or
switching-off of safety devices and opening of protective covers without
taking safety precautions can result in serious injury or death as well as
major material damage.

Electrical installation
Warning
Work, of any nature, on the installation should be carried out by qualified
and authorised personnel only. Please read Chapter 1 ("Safety") and
take all necessary precautions.
Control cabinet
Please close the cabinet door properly always so that dust and moisture
cannot enter.
If the control cabinet is equipped with a ventilator, please check the filter
element for dirt and clean or replace when necessary. The air inlets and
outlets must remain easily accessible i.e. kept free of obstacles.

6.21.4.2

Proximity switches, limit switches and door switches


Please take particular care to check security switches and other switches
that are used now and again only.

6.21.4.3

Photo cells
Clean the lenses of photo cells and reflectors with a soft cloth.

09-1-14

The frequency of cleaning depends on environmental influences such as


dust, dirt, damp etc. You might therefore need to clean more often than
instructed.
6.21.4.4

Electrical cabling
Please ensure that cable duct do not become damaged. Please keep
cable work of the control current separate from cable work of the main
current. Loops in cables must be avoided.

6.21.4.5

Cable tracks
Depending on the application, cable tracks are used free-bearing or in
combination with cable ducts

September 1, 2014

CSi

6-29

C5000 Unilever Brasil

Maintenance

Important when inspecting and carrying out maintenance work:

6.21.5

Cable ducts may not be damaged or dirty. Bulky rubbish such as


sticky tape, packaging and product remnants, glass fragments,
wood splinters etc. must be removed immediately .

Please shut cable tracks correctly and insure that connections and
internal sections are not damaged or loose.

Cables and pneumatic hoses (if applicable) must not become


twisted or jammed. Please also ensure that there is enough play for
lengthwise movement in the cable track.

Cables and hoses must be secured with a pull relief on outer ends
of cable tracks.

Replace the lift chains and/or lift shaft bearings

Warning
The counterweight must be blocked mechanically.
For that reason a blocking provision (See Fig. 6.8 Safety Blockage
Positions 4/5 & 29/30) has been fitted on each side of the frame.
Each blocking provision has two blocking pins. ( See Fig. 6.7 Safety
blockage lift platform positions 3) In total four counterweight blocking pins
have been fitted.
Check prior to works
1 Check that the platform is empty.
(No load allowed on the conveyor.)
2 Bring the lift platform up and the counter weight down (Using the manual
control on the main operator panel)
Required:

w
6.21.5.2

6-30

Operation

09-1-14

6.21.5.1

lift platform on high level for easier access.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

General

Warning
The work must always be carried out by two persons.
Tools required:
-

Two padlocks.

Access to the lift drive motor.

Scaffolding and or a ladder.

Pulley wrench for motor drive removal.

CSi

September 1, 2014

C5000 Unilever Brasil

Maintenance

6.21.5.3

Chain
Lift chain needs to be exchanged if the elongation is more than 3 %
1 Open the door
The safety cylinders will go out (on spring actuation) and at least one of the
cylinders will be captured in the safety profile. (See Fig. 6.7 Safety
blockage lift platform)
On each side of the elevator frame a blocking provision is mounted on the
outside (see Fig. 6.8 Safety Blockage Positions 4/5 & 29/30).
2 Remove the two dummy bolts M20 positioned in the provisions (one
each) side and approx 700 mm height. holes in the elevator frame will
occur.
3 The locking pin (See Fig. 6.9 Position 2 ) can now be taken from the
blockage provision. (see Fig. 6.8 Safety Blockage Positions 4/5 & 29/
30).

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Keep the pins with you for further handling.


1 Place the dummy M20 into the (now) free slot (position) of the blocking
provision.

09-1-14

2 Remove the four (4) protection plates (See Fig. 6.9 Position 2) on the
lifting mechanism inside the palletiser.

Fig. 6.9 Position 2

w
September 1, 2014

Warning
The counterbalance weight must be secured!

CSi

6-31

C5000 Unilever Brasil

Maintenance

Chains must be set slack on both sides


1 Switch to manual mode (using the manual control on the main operator
panel)
-

One person to Lower the lift platform and raise the counterweight in
manual operating of the elevator.

One person on the outside of the fencing to visually check when the
bolt slot(s) become free. The counter weight must be above the bolt
slots.

2 The operator can now stop moving the elevator.


3 Mount the locking pins in the blocking provision for the counterweight
from the outside.
(See Fig. 6.8 Safety Blockage Positions 4/5 & 29/30)
4 When all four pins are installed, the operator must raise the platform
shortly and lower the counterweight onto the pins. (using the manual
control on the main operator panel)
The chains to the counterweight now become slack.
5 Open the door.
The safety cylinders will go out (on spring) and at least one of the cylinders
will be captured in the safety profile.( See Fig. 6.6 Overview Palletiser
position 7.1)

Warning
Normally we will be needing some kind of slack of the chain
In order to work safely the strong hold of the lifting platform on the lifting
chain should be eliminated!
Create slack on the chains to the lifting platform.

09-1-14

Note
See Fig. 6.6 Overview Palletiser positions 7.1 and 7.2
1 Lift by hand the brakes of the elevator drive so that the platform will drop
downwards until the lift blockage system will stop the movement.
One of the safety cylinders is now against the bottom of the hole in the
safety catching profile.

Note
The chain is to be slack on both sides!
2 Switch off the air supply.
a Make sure surplus air is let off.
b Padlock the main air valve in order to work safely.
3 Switch off the entire system electrically.
a Padlock the main switch on the related panel.
4 Secure access around the drives on higher level.

6-32

CSi

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

The pin to enter into the profile of the moving area of the counterweight.

September 1, 2014

C5000 Unilever Brasil

Maintenance

Scaffolding or ladders are needed for access.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Relevant safety ropes See Fig below position 22

Fig. 6.10 Position 22


5 Lift motor disconnect.
a Disconnect all cabling from the lift motor.

09-1-14

Note
The C5000 has one elevator drive.
6 Liftmotor removal/weight
a Expected weight 85 kg . Always check the actual indicated weight
on the available drive.
b Use sufficient lifting gear (hoist or crane) for safe handling of the
drive.
c Use sufficient and lifting rope(s) in combination with lifting gear .
d Only use equipment rated for the load required.

Note
Use tested and validated lifting equipment.
7 Lift rope(s)

September 1, 2014

CSi

6-33

C5000 Unilever Brasil

Maintenance

For removal of the drive the lift a rope must be tightened in such a way that
it can be shifted to one side.

Note
Make sure the drive does not drop down when it comes off the shaft!
Torque arm
After the drive is secured we can now safely remove the torque arm
support.

Note
The shaft will not start turning because the blocking mechanism prevents
the chains to move the shaft.
If you only want to exchange the drive it is not required to use the
counterweight mechanical blockage system.
1 Lift drive motor and lift chains
a Lift drive motor is to be removed from the shaft before the lift
chains can be accessed.
b Pull the drive from the shaft (Use pulley wrench if necessary).

Note
See item 8 and make sure the drive is held properly by the lifting
equipment and rope(s)!
c Replace lift chain on the drive motor side.
2 Remove the bracket (16) from the top frame on the drive motor side.
This is one of the connections between the lift frame and top part.
Now the lifting chain on the drive motor side of the elevator is free.

Warning
Mind the weight of the chain!
3 Visually check the chain for wear and tear.
If necessary exchange the chain.

Note
If chains and or bearings need to be replaced always exchange both
bearings and or chains during the stop.
a Check the status of the chain sprockets.
When chain sprockets are worn (and or if there is play between the
key connections and the chain sprocket and drive shaft) and they
need to be replaced continue with item 18.

6-34

CSi

September 1, 2014

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

Note
The drive still remains on the shaft.

09-1-14

n
n

C5000 Unilever Brasil

Maintenance

b Check the following for damages;


- The drive shaft ends.
- Drive shaft fixation key and the shaft key into the connection slot.
If so continue with item 18.
-

Bearing lift shaft drive side.

To access and remove the bearings the drive shaft must be supported.
4 Support the shaft from the top frame ( See Fig. 6.10 Position 22 using
ropes and ratchet belts.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

n
n

Note
Only use equipment rated for the load required.
Note
Use tested and validated lifting equipment.
Bearing on drive side.
1 Untighten bearing and slide bearing sideways of the shaft.
2 Slide new bearing in position.
3 Tighten.
4 Loosen and remove ropes (etc) on this side.
5 On the driven side all checks are executed.
a Lift chain on the non-driven side.
Note
On the drive side the bracket is still not connected.

09-1-14

September 1, 2014

CSi

6-35

C5000 Unilever Brasil

Maintenance

This bracket (24) is the second of the connections between the lift frame
and top part.
Now the lifting chain at the non-driven side is free.

Note
Mind the weight of the chain!
a Check the chain on visual damage and on the actual elongation.
If necessary exchange the chain.

Note
Reminder if to be exchanged always exchange the pair.
b Check the status of the chain sprocket.
- When chain sprocket is worn and needs to be replaced go to item
18.
c Bearing on non-driven side.
7 Untighten and slide sideways of the shaft.
8 Slide new bearing in position.
9 Tighten.
10 Loosen and remove ropes (etc) on this side.
11 Reassemble.

6-36

CSi

September 1, 2014

09-1-14

Fig. 6.11 Position 24

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

6 Remove the bracket ( See Fig. 6.11 Position 24) from the top frame at
the non- driven side.

C5000 Unilever Brasil

Maintenance

a Install bracket 24.


b Install bracket 16.
12 In case of damage to the elevator shaft or chain wheels as under 10 or
1: call CSi service (LCSI) for exchanging the shaft.
In case of damage, stop this instruction from here.
13 Re-install the lift drive.
The shaft and bushings must be greased with correct lube prior to
assembly.
(For specification see drive. Normally to be expected is that the grease is
packed separately with the drive. If drive is re-installed check and apply
grease. )
a Carefully position the drive in front of the shaft and pay attention to
the key!
K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-06.fm

b Now slide over the shaft.


c If necessary lift the brake of the motor and turn the drive to its
position.
d Fix drive.
14 Re-install torque arm support .
a Loosen ropes etc from drive.
b Remove ropes etc from machine.
15 Connect drive.
a Connect cabling etc to the drive.
16 Power up.
17 Air up.
18 Check on safety.
19 Manual operation.

09-1-14

a Check that the installation is still in manual.


b Run lift platform down. The counterweight will now come off the
bolts.
c In this situation with all doors closed the lift platform blockage
system is now given free!
20 Stop the palletiser.
21 Remove blocking pins.
a From aside (you do not need to enter into the palletiser area)
remove the blocking pins (all 4).
b Exchange the 4 blocking pins with the 4 dummies.
c Seal the four dummies into position.
22 Back into manual.
a Run lift platform to highest position.
23 Re-install the protection plates.
a Stop palletiser. Open door (now the lift platform is automatically
blocked).
September 1, 2014

CSi

6-37

C5000 Unilever Brasil

Maintenance

b Re-install protection plates items 2 to the lifting mechanism inside


the palletiser.

09-1-14

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24 Reset and restart .

6-38

CSi

September 1, 2014

C5000 Unilever Brasil

Installation

INSTALLATION

Versie 2.1.0 - 2011-08-23

7.1

Introduction

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These instructions apply to the installation and commissioning of systems


and machines designed and manufactured by CSi.
If you still have queries, please contact the CSi Project Manager in charge.

7.2

Safety
The system / machine has been designed and manufactured in such a way
that it can be installed and commissioned safely. Ensure that installation is
carried out solely and exclusively by authorised and qualified personnel.
Please read the Safety chapter carefully. Safety regulations must be
adhered to strictly.

7.3

General
It is advisable to have, at the very least, a CSi supervisor present during
installation. He can carry out installation work, instruct and assist others,
and coordinate during start-up and commissioning.

09-1-14

Tools and other resources required:

September 1, 2014

Mechanical, electric and pneumatic hand tools, such as a set of ring and
open-end spanners, socket wrenches and Allen keys, tape measures,
screwdrivers, spirit level, drills, rotary grinder, etc., in the number
required by the installation team.

Instrument level and/or laser level.

Jack and hoisting gear.

Personal protection equipment such as safety shoes, safety spectacles,


welding goggles, gloves, ear protectors, appropriate work clothing, in
the number required by the installation team.

Welding blankets and fire extinguishers.

Telescopic platform and mobile scaffold.

Fork lift truck or side loader, matched to the required lifting height and
lifting capacity.

Sufficient test products, helpers and other resources as required for


testing and commissioning the system / machine.

CSi

7-1

C5000 Unilever Brasil

Installation

Connection points for electric power and air and adequate lighting at the
installation site.

Layout drawing, functional specification, electrical and pneumatic


diagrams, suppliers documentation, subcontractors documentation,
etc.

Packing lists for checking for complete delivery.

Product data such as dimensions, weights, conveying direction and


capacities.

Drawings of platforms, support structures, staircases, etc.

Store the system and machine parts in a dry, clean place.


The installation site should be readily accessible in order to bring
components to the installation site.

7.4
7.4.1

Check the materials delivery against the packing list. Report any
damage and / or shortage to CSi immediately.

Check measurements of the system / machine in relation to the building


and structures according to the layout drawing.

Check the electrical and pneumatic supply points in the building.

Mechanical installation of a system


Scope of supply
A system generally consists of conveyors that are constructed from one or
more section lengths of max. 3 metres.
The conveyors come with a data plate bearing the CSi project number, and
an item number that corresponds with the item number on the layout
drawing.

7.4.2

Procedure
Depending on the design, complexity and operating conditions, minor
differences may occur; hence this procedure should be regarded as a
guideline.
1 Bring the materials to the place of use with a forklift truck and / or a side
loader.
2 Define the fixed coordination points according to the layout drawing and
on the basis of these points, erect the conveyors with the aid of a laser
measuring instrument.
3 Raise the conveyors to the correct belt height with a forklift truck or a
hoist and fit the supports and / or hangers. The correct belt height can
be found on the layout drawing.

7-2

CSi

September 1, 2014

09-1-14

The following checks should be made before commencing installation:

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Welding, cutting and grinding work must be permitted provided that


appropriate safety measures are taken.

C5000 Unilever Brasil

Installation

4 Join individual sections together by means of connecting plates and / or


supports. Depending on the type of conveyor, when joining the frame
sections together the fitting of endless driving and conveying belts
should be taken into account. The supports are marked with a number
that corresponds to the number on the layout drawing. The supports are
usually fixed to the frame with clamping sets. Spacing of the supports
depends on the type of conveyor.
5 Align the conveyors, adjust to the correct height and level them. Height
adjustment of the supports is accomplished with sliding legs or threaded
adjusting legs. Take care that an adequate length of sliding leg / thread
remains in the frame and that fixing bolts and locking nuts are secured.
6 Check junctions and test with the products to be conveyed.

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7 Fix supports to the floor, platform, roof or structure.


Fixing holes are provided in the baseplates of the adjusting legs and
anchor bolts are included in the supply. Anchors are usually fixed in
concrete by adhesive bonding. The packaging contains installation
instructions.
8 Fit the lateral guides and adjust them in height and lateral direction,
according to the products to be processed.
9 Make all necessary adjustments (if applicable) of driving and conveying
belts and conveying chains according to the instructions in the operating
manual.
10 Fit collision prevention features, guards and fencing (if any).
11 Affix safety pictograms at potentially dangerous locations.

09-1-14

7.5
7.5.1

Note
Certain adjustment work cannot be done until the system is ready for trial
operation. Additional adjustment of belt height may be necessary to
ensure trouble-free operation at junctions between conveyors.
Adjustment of lateral guides may also be necessary.

Mechanical installation of a machine


Scope of supply
The machine has undergone trial operation in our factory and usually has
been tested with your products. The machine is transported in the largest
sections possible. Certain parts may be supplied separately for practical
reasons and to prevent damage and loss in transit.

Warning
Avoid severe jolts, vibrations and shaking during transport in order to
prevent damage to the machine.
The machine is equipped with hoisting and lifting points. Use only these
points for loading, unloading and erecting the machine.

September 1, 2014

CSi

7-3

C5000 Unilever Brasil

Installation

7.5.2

Procedure
Depending on design, complexity and operating conditions, minor
differences may occur; hence this procedure should be regarded as a
guideline.
1 Transport machine parts to the place of use with a forklift truck and / or
a side loader.
2 Position machine parts in relation to each other and assemble.
3 Set machine to correct height and level, using a level and a jack. Height
adjustment of supports is accomplished with threaded adjusting legs.
Take care that an adequate length of thread remains in the frame and
that all locking nuts are secured.

6 Make adjustments (if applicable) of driving and conveying belts and


conveying chains according to the instructions in the operating manual.
7 Fit all guards and fencings.
8 Affix safety pictograms at locations with potential danger.

n
7.6

Note
Certain adjustment work cannot be done until the machine is ready for
trial operation.

Pneumatic installation
Our systems and machines are generally designed for a compressed air
pressure of 6 bar.
The connection points for air are shown in the layout drawing.
An air service unit should be installed as close as possible to the air
equipment as to ensure that the quality of the compressed air meets the
defined requirements.
Install and connect cylinders, valves, air service units and piping in
accordance with the pneumatic diagram.

7.7

w
7-4

Electrical installation
Warning
Ensure that installation of the electrical equipment is carried out solely
and exclusively by authorised and qualified personnel.

CSi

September 1, 2014

09-1-14

5 Fit lateral guides and adjust them in height and lateral direction,
according to the products to be processed.

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4 Fix supports to the floor. Fixing holes are provided in the baseplates of
the adjusting legs and anchor bolts are included in the supply. The
anchors are usually fixed in concrete by adhesive bonding. The
packaging contains installation instructions.

C5000 Unilever Brasil

Installation

7.7.1

Study
Before commencing installation of the electrical equipment, the functional
specification and the electrical documentation should be studied.
The electrical documentation comprises:

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7.7.2

Front sheets

Main current sheets

Control current sheets

I/O sheets

Cable connection diagrams

Electrical equipment layout drawings

Material and nameplate sheets

Field equipment and cabling


Machines are generally fitted with cables and field equipment at our factory.
Install field equipment and electrical safety provisions and connect the
cables in accordance with the electrical layout drawings, diagrams and
connection instructions.
Prevent cables from rubbing against moving parts.
Cables of moving parts must be fitted with flexible protection.
Codes of field equipment and cables as shown in the diagram.
Take care that all photocells, proximity switches, etc. are installed and set
as accurately as possible.

7.7.3

Motor drives
The rated voltage and frequency of the motors (see the rating plate on the
gear motor) must correspond to those of the supply system.

09-1-14

Consult the electrical diagram and the manufacturers connection


instructions for how to connect the drives correctly. When connecting, note
the correct rotational direction of the drive.
The gear motor may be supplied with a screwed-in breather sealed with a
transport seal. Remove the seal.
Check the oil level in the gear motor using the oil level screw. The lubricant
used to fill the geared motor and the quantity of lubricant in litres are shown
on the rating plate.

7.7.4

Control cabinet
The following components are installed in the control cabinet:

September 1, 2014

Main switch

Fuses

Power supply

Operating equipment

Motor contactors

Thermal relays
CSi

7-5

C5000 Unilever Brasil

Installation

Terminals

Interface relay

PLC/IPC

Install the control cabinet and make all necessary connections in


accordance with the diagrams.

7.7.5

Electrical control panels and PC hardware


Install the electrical control panels and the PC hardware.

7.8

Testing and commissioning


Use the following procedure for testing and commissioning.

3 Set the thermal relays.


4 Check that all switches, valves, etc. are in the OFF / 0 position in order
to ensure that the system and / or machine cannot come into operation
unintentionally.
5 Admit compressed air to the pneumatic system, check the entire system
for leaks and manually test valves and cylinders.
6 Set the pressure gauges of the air service units to the required working
pressure.
7 Upload all necessary software into the PLC/IPC.
8 Test all input and output.
9 Test the software application.
10 Test the emergency stop protection and other safety features in
accordance with the CE standardisation.
11 Test without product and make all necessary electrical and mechanical
adjustments, such as fine adjustment of photocells, proximity switches,
etc.
12 Test with product under non-production conditions and make all
necessary adjustments, such as fine adjustment of lateral guides, etc.

Warning
When testing, checking and adjusting certain functions that require a
supply of energy, please be particularly aware of dangers and risks.
13 Test manual operation.
14 Download the PC software.
15 Test the communication between the PLCs and IPCs and between the
IPCs.
16 Test the error messages.
17 Test the whole system with product under production conditions.
18 Test all control panels, manual operation and the reports print out.

7-6

CSi

September 1, 2014

09-1-14

2 Check the control cabinet against the diagrams.

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1 Check the mechanical, pneumatic and electrical installation work for


deficiencies, particularly in the area of safety.

C5000 Unilever Brasil

Installation

19 Make an EPROM.
20 Test the system / machine with regard to capacity and functionality.

7.9

Operating manual
Once the system / machine is fully operational, the operating manual
should reflect the as built state.

7.10

Training
Put together a training programme and give training to operating,
production and maintenance personnel.

09-1-14

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Important items for theoretical training:

Explanation of how to use the operating manual.

Explanation of layout via the product routing and by pass facilities (if
any).

Explanation of functional operation.

Location of all control panels.

Explanation of electrical equipment, signal exchanges between the


various components, location of terminal boxes and of special
components such as frequency controllers, etc.

Measures and instructions for working safely with the system / machine
(emergency stop protection, pull-cord switches, door switches, access
barriers, pneumatic switches, etc).

Explanation of alarm messages in the event of malfunctions (display,


alarm lights, bells, etc.).

Maintenance instructions and fault analysis.

Reset and start-up procedures.

Procedure for putting on and removing products by hand.

Important items to be demonstrated in practice:

7.11

Measures and instructions for safe working with the system / machine,
such as emergency stop, pull-cord and access barriers, door switches,
pneumatic switches, shut-off valves, light curtains, etc.

Reset and start-up procedures.

Control panels and field components.

Operation.

Maintenance and fault analysis.

After commissioning
Continue to comply with all instructions as described in the operating
manual for reliable, safe operation of your system / machine(s).
Versie 2.0.1 - 2011-08-25

September 1, 2014

CSi

7-7

C5000 Unilever Brasil

Installation

7.12

I/O test and adjustments C5000i


This chapter contains descriptions of the mechanical, electrical and
software adjustments required to be made to the machine. The software
adjustments can be carried out through Eagle. These adjustments are as
follows:

n
7.13
7.13.1

Note
The system parameters can only be changed by qualified employees.
Therefore you logged in on level 3 maintenance.

General adjustments C5000i


Adjustment of PAL_Type (Int)
Input possibilities:
Value

Description

5000Si

1 palletiser channel

5000Ti

2 palletiser channels
Tab. 7.1 Palletiser selection

7-8

CSi

September 1, 2014

09-1-14

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Using the mouse, click on START, Service and System Parameters.

C5000 Unilever Brasil

Installation

If there is another value assigned, the software is not functioning correctly


and the task should not be continued.

7.13.2

Adjustment of Orientation (Int)


Input possibilities:

Value

Description

Input right Pallet output right

Input left Pallet output left

Input right Pallet output left

Input left Pallet output right


Tab. 7.2 Input type

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

If there is another value assigned, the software is not functioning correctly.


The orientation of the machine determines the direction of rotation, break
feeders and layer pad. The centring of the side dams is also determined by
the orientation.

7.14
7.14.1

Divider
Hardware
Switching moment control
The switching moment control prox is set in such a way that the prox fire
can be switched.
Air pressure

09-1-14

The air pressure is set to bar. The air pressure control switch is set to
bar.

7.14.2

Eagle

7.14.2.1

Adjustment of switchover time (Int)


This time determines the switching moment of the divider. The time is set
in such a way that the divider switches just after the box.
Default: 700 msec.

7.15
7.15.1

Accumulation conveyors
Hardware
The photocells are positioned so that there is still sufficient space between
the divider and the photocells to enable the divider to rotate when empty as
it rotates when full. The photocells are always positioned at an angle.

September 1, 2014

CSi

7-9

C5000 Unilever Brasil

Installation

The belt guides are set so that the boxes run level alongside the machine
kicker
1 Set the guides on the breakfeeder(s) wide.
2 Adjust the accumulation belt guides so that the products run level
alongside the kicker.
3 Adjust the breakfeeder guides so that the products are just not touching.

7.15.2

Eagle
Not applicable. In the future, both the full and empty reporting times of the
photocells will be able to be set up.

Hardware
The photocell is positioned about 10-15cm before the end of the
breakfeeder. If products stop at the breakfeeder, the photocell causes it to
come to a stop a few cm before the end of the belt. The photocell should
not be set to high (consider tray edges, transparent bottles, holes in
products etc.).
If the direction of breakfeeder rotation is not correct, the machine
orientation has probably not been set up properly.

7.16.2

Eagle

7.16.2.1

Adjustment of BF1_Scale, BF2_Scale (Real)


Convert breakfeeder(s) scale factor for the palletiser.
BF1_Scale = 50 / Belt speed (mm/s at 50Hz)
DEFAULT: 0.0359 mm-1
Always control the speed evenly using the belt speed meter and, if
necessary, adjust the scale factor.

7.16.2.2

Adjustment of BF1_Man_Speed, BF2_Man_


Speed (int)
Manual speed of the breakfeeder.
DEFAULT: 800 mm/s

7.17
7.17.1

Rotating cam
Hardware
Set the cylinder to as fast as possible. Set the microswitch to the cylinder
home position.

7.17.2

Eagle
Not applicable.

7-10

CSi

September 1, 2014

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7.16.1

Breakfeeders

09-1-14

7.16

C5000 Unilever Brasil

Installation

7.18
7.18.1

Kicker
Hardware
Set the arm length to no longer than the longest box. Set the home prox so
that it just burns in the minimum position of the kicker (the kicker is then
against the frame). When the direction of kicker rotation is not correct,
adjust it with the controller.

7.18.2

Eagle
The kicker only takes control of the changes when the machine is in the
Stop position.

7.18.2.1

Adjustment of KD1_Max_Speed, KD2_Max_Speed

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The maximum speed of the kicker. This is the speed that the kicker goes
back to its home position. For forward movement, the assigned speed (in
%) increases with this speed. When this speed is adjusted, the kicker goes
slower or faster.
DEFAULT: 100%
7.18.2.2

Adjustment of KD1_Min_Ramp, KD2_Min_Ramp


The time in which the kicker accelerates to its maximum from 0 to 3000
revs/min.
DEFAULT: 30 ms

7.18.2.3

Adjustment of KD1_Man_Angle, KD2_Man_


Angle (Int)
The rotation in degrees which the kicker makes during manual operation.
DEFAULT: 30o

7.18.2.4

Adjustment of KD1_Man_Speed, KD2_Man_


Speed (Int)

09-1-14

The speed with which the kicker kicks during manual operation (0 - 100%)

Note
If 0% is input, it takes a long time for the rotation to be ready. Therefore
please avoid doing this.
DEFAULT: 60%

7.18.2.5

Adjustment of KD1_Man_Ramp, KD2_Man_


Ramp (Int)
The acceleration by which the speed of the kicker builds up and runs down
in the forward direction with kicks.
Adjustable from 0 - 100%. 0% is slow acceleration, 100% is fast
acceleration.
DEFAULT: 50%

September 1, 2014

CSi

7-11

C5000 Unilever Brasil

Installation

7.18.2.6

Adjustment of KD1_Home_Pos, KD2_home_


Pos (Int)
Home position of the kicker. After changing the home position, the kicker
takes over just when the installation is set to the Stop position and
thereafter is kicked manually. Set the home position so that the package
runs as near as possible alongside the kicker.
DEFAULT: 2 o

7.19
7.19.1

Packpusher
Hardware

7.19.2

Eagle

7.19.2.1

Adjustment of PP1_Max_Speed, PP2_Max_


Speed(Int)
The maximum speed of the packpusher. This is the speed with which the
packpusher goes back to its home position. For forward movement, this
means that the assigned speed (in %) is increased with this speed. When
this speed is adjusted, the packpusher goes slower or faster.
DEFAULT: 80%

7.19.2.2

Adjustment of PP1_Min_Ramp, PP2_Min_


Ramp (int)
The time in which the packpusher accelerates to its maximum from 0 to
3000 revs/min.
DEFAULT: 100ms
Adjustment of PP1_Man_Stoke, PP2_Man_
Stoke (Int)

09-1-14

7.19.2.3

The stroke in mm which the packpusher makes during manual operation.


The stroke which is made is calculated from the 0 position, not from the
home position!! When the stroke is greater or equal to the crank diameter,
the packpusher will make a complete stroke. Where this is not the case, the
stroke will be advanced or retarded.
DEFAULT: 300 mm
7.19.2.4

Adjustment of PP1_Man_Speed, PP2_Man_


Speed (Int)
The speed which the packpusher kicks during manual operation (0 100%).

Note
If 0% is input, it takes a long time for the rotation to be ready. Therefore
please avoid doing this.
DEFAULT: 30 %

7-12

CSi

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

Select the stroke size of the packpusher equal to the greatest width of the
rotating products. The position of the reference prox is not important and
can be set up in Eagle. The direction of rotation is also not important.

September 1, 2014

C5000 Unilever Brasil

Installation

7.19.2.5

Adjustment of PP1_Man_Ramp, PP2_Man_


Ramp (Int)
The acceleration by which the packpusher builds up and runs down in the
forward direction with kicks.
Adjustable from 0-100%. 0% is slow acceleration, 100% is fast
acceleration.
DEFAULT: 30 %

7.19.2.6

Adjustment of PP1_Zero_Pos, PP2_Zero_Pos (Int)


The zero position of the packpusher. After changing the zero position, this
is just taken over by the packpusher when the installation is set to Stop,
and thereafter is pushed manually. First set the home position to 0 before
the zero position is synchronised. Set the zero position so that the
packpusher is in the dead center position and the plate is roughly in its
home position.

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DEFAULT: 85 o, 175 o, 265 o or 355 o (Dependent on the stroke selected)


7.19.2.7

Adjustment of PP1_Home_Pos, PP2_Home_


Pos (Int)
The home position of the packpusher. After changing the home position,
this is just taken over by the packpusher when the installation is set to
Stop, and thereafter is pushed manually. Adjust the home position so that
the package runs as near as possible alongside the packpusher. First set
the zero position before the home position is synchronised (The home
position is offset with respect to the zero point).
DEFAULT: 0 o

7.19.2.8

Adjustment of PP1_Crank_Dia, PP2_Crank_


Dia (Int)
Total length of the stroke that the packpusher can make.
Mechanical standards for the following stroke lengths:

09-1-14

150, 200, 250 and 300 mm


DEFAULT: 300 mm
Software suitable for all possible stroke lengths.

7.20
7.20.1

Format area
Hardware
Direction of motor rotation is determined manually for the assigned
orientation.

7.20.2

Eagle

7.20.2.1

Adjustment of FRM_Scale (Real)


Conversion scale factor for Format area.
FRM_Scale = 50 / Belt speed (mm/s)
DEFAULT: 0.03435 mm

September 1, 2014

CSi

(Belt speed at 50Hz)

-1

7-13

C5000 Unilever Brasil

Installation

Always control the speed evenly using the belt speed meter.
7.20.2.2

Adjustment of FRM_Man_Speed (Int)


Manual speed of the forming table.
DEFAULT: 800 mm/s

7.21

Spacers

09-1-14

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The position of the spacers can be configured in the spacer configuration


table in Eagle. In this table, you can first come through to the spacer editor
to go to the layer editor.

Select Add/Rem from this screen. After you have selected the channel
number to see, you then get the following screen:

7-14

CSi

September 1, 2014

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C5000 Unilever Brasil

Installation

The spacers are configured by typing in the valve number for each spacer.
When there is no spacer at the position, a 0 should be input. A maximum
of 16 spacers can be configured for each channel. Where there are more
than 8 spacers in a channel, a second valve island should be set up. The
changes in the Eagle plates are changed just after Eagle restarts.

09-1-14

7.22
7.22.1

Rowpusher
Hardware
The position of the reference prox is not so important and can be set up in
Eagle. The row length monitoring photocell is set up so that it is not
positioned too high (consider tray edges, transparent bottles etc.). The
direction of motor rotation is adjusted by the controller.

7.22.2

Eagle

7.22.2.1

Rowpusher
Fig. 7.1 shows all of the adjustment positions. All positions can be
measured with respect to the 0 point. The 0 point is the position where the
rowpusher beam is just before the format area.

September 1, 2014

CSi

7-15

C5000 Unilever Brasil

Installation

RP_C_Sliding_Table
Reference prox
RP_Ref_Pos

RP_Between_Dams
RP_Safe_Max
RP_PC_Check

Channel 2
RP_Input_All_Ch1
RP_Input_All_Ch2
0 position

Rowpusher beam
in 0 position

7.22.2.2

09-1-14

Fig. 7.1 Rowpusher positions

Adjustment of RP_PC_Check_max (Int)


The rowpusher stroke is controlled when the pusher is free. Control is
maintained until the RP_PC_Check_max position is attained. Normally, the
value of RP_PC_Check_max position, in mm, is where the rowpusher is
just in front of the sliding cover plate.
The position is measured from the 0 point.
DEFAULT:

7.22.2.3

C5000Si

950 mm

C5000Ti

1550 mm

Adjustment of RP_PC_Check_min (Int)


The rowpusher stroke is controlled when the pusher is free. Control is
effected from the RP_PC_Check_min position. Normally, the value of
RP_PC_Check_min in (mm) is where the rowpusher is just in front of the
sliding cover plate.
The position is measured from the 0 point.

7-16

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Channel 1

September 1, 2014

C5000 Unilever Brasil

Installation

DEFAULT:

7.22.2.4

C5000Si

0 mm

C5000Ti

0 mm

Adjustment of RP_Between dams (Int)


After the overthrust of the last stroke of a layer, the side strokes go inwards
when the rowpusher is at this position.
The position is measured from the 0 point.
DEFAULT:

7.22.2.5

C5000Si

1510 mm

C5000Ti

2350 mm

Adjustment of RP_Input_All_Ch1 (Int)

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

When the rowpusher has passed this position, the input of channel 1
indicates free. This is valid for the maximum rowpusher speed. When the
rowpusher speed is lower, this position is moved automatically.
The position is measured from the 0 point.
DEFAULT:

7.22.2.6

C5000Si

400 mm

C5000Ti

900 mm

Adjustment of RP_Input_All_Ch2 (Int)


When the rowpusher has passed this position, the input of channel 2
indicates free. This is valid for the maximum rowpusher speed. When the
rowpusher speed is lower, this position is moved automatically.
The position is measured from the 0 point.

09-1-14

DEFAULT:

7.22.2.7

C5000Si

200 mm

C5000Ti

250 mm

Adjustment of RP_Safe_Max_Ch1 (Int)


After the rowpusher has reached this position, the pressure zones are
driven again.
The position is measured from the 0 point.
DEFAULT:

7.22.2.8

C5000Si

1010 mm

C5000Ti

1600 mm

Adjustment of RP_Safe_Max_Ch2 (Int)


After the rowpusher has reached this position, the pressure zones are
driven again.
The position is measured from the 0 point.
DEFAULT:

September 1, 2014

C5000Si

1010 mm

C5000Ti

850 mm

CSi

7-17

C5000 Unilever Brasil

Installation

7.22.2.9

Adjustment of RP_Max_Speed (Int)


Maximum rowpusher speed in mm/s.
DEFAULT: 1000 mm/s

7.22.2.10

Adjustment of RP_Max_Acc (Int)


Maximum rowpusher acceleration in mm/s2
DEFAULT: 1000 mm/s2

7.22.2.11

Adjustment of RP_Man_Speed (Int)


Manual rowpusher speed in mm/s.
DEFAULT: 150 mm/s

7.22.2.12

Adjustment of RP_Man_Acc (Int)


DEFAULT: 1000 mm/s2

7.22.2.13

Adjustment of RP_Ref_Speed (Int)


Rowpusher speed during referral in mm/s.
DEFAULT: 150 mm/s

7.22.2.14

Adjustment of RP_Ref_Acc (Int)


Rowpusher acceleration during referral mm/s2
DEFAULT: 1000 mm/s2

7.22.2.15

Adjustment of RP_C_Sliding_table (Int)


Centre of sliding table measured with respect to the 0 point in mm. This
measurement is necessary to enable calculation of the forming position.

7.22.2.16

C5000Si

2070 mm

C5000Ti

2735 mm

09-1-14

DEFAULT:

Adjustment of RP_Ref_Pos (Int)


Reference position measured from the 0 point in mm. The reference point
is the position of the beam with respect to the ascending side of the
reference prox as the beam is moved forward.
DEFAULT:

7.22.2.17

C5000Si

1515 mm

C5000Ti

2175 mm

Adjustment of RP_Back_Pos (Int)


This is the manual control for the All Dams open for the rowpusher, and is
moved backwards the assigned measurement (in mm) with respect to the
forming position.
DEFAULT: 100 mm

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Manual rowpusher acceleration in mm/s2

September 1, 2014

C5000 Unilever Brasil

Installation

7.22.2.18

Adjustment of RP_Sweep_length (dint)


Total length of 1 rowpusher stroke in encoder pulses.
DEFAULT:

7.23
7.23.1

C5000Si

280622 pulses/stroke

C5000Ti

638887 pulses/stroke

Side-, backdam(s)
Hardware
First check the directions of motor rotation. If these are incorrect, change
the motor rotation direction around (The 24VDC signals in the movimot).

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

Check the direction of encoder rotation. When the dams run to the middle
of the pallet, the encoder value in Eagle will be greater. If this is not the
case, then change round the encoder connection cables. The home prox
is adjusted so that the dam is in the home position, is far enough inwards,
and to ensure that no products can get caught behind.

7.23.2

Eagle

7.23.2.1

Adjustment of SD1_Scale, SD2_Scale and


BD_scale (Real)
Conversion scale factor for encoders.
SD1_Scale = Distance covered (mm) / encoder pulses.
The encoder pulses are measured in quadrature. This means that every A
and B pulse on both the ascending and descending side is counted. This
gives an encoder of 25 pulses per rotation, and 4*25=100 encoder pulses
per rotation.
DEFAULT: 2.8274 mm/inc

09-1-14

7.23.2.2

Adjustment of SD1_Max_Pos, SD2_Max_Pos and


BD_Max_Pos(Int)
The maximum out-position of the dam in mm. This position is measured
with respect to the descending side of the reference prox.
DEFAULT:
SD1 205 mm
SD2 205 mm
BD

7.23.2.3

310 mm

Adjustment of SD1_Max_Tol, SD2_Max_Tol and


BD_Max_Tol(Int)
The maximum position tolerance in which there is no correction made for
the position. Do not set this too low as it can cause oscillations.
DEFAULT: 20 mm

September 1, 2014

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7-19

C5000 Unilever Brasil

Installation

7.23.2.4

Adjustment of SD1_Ref_Dis, SD2_ref_Dis and


BD_Ref_Dis (Int)

Lift

Uitslag:
Sidedam 1 = Ref_distance - 1/2 Pallet_Length + 1/2 Load_Length - Length_Offset
Sidedam 2 = Ref_distance - 1/2 Pallet_Length - 1/2 Load_Length + Length_Offset
Backdam = Ref_distance - 1/2 Load_width + Width_Offset

Fig. 7.2 Dam reference points


The side dam reference points are measured with respect to the pallet stop
position. Side dam 1 is always the side dam on the pallet stop side.
The back dam reference point is measured with respect to the centre of the
sliding table, which is also the centre of the pallet.
DEFAULT:
SD1

50 mm

SD2 1258 mm
BD

7.24
7.24.1

616 mm

Load platform
Hardware
The proxes are controlled when they are first used with the load platform.
This is effected as follows:
1 Adjust the semicircular plates so that they have maximum slide with
respect to each other.
2 Close the load platform (only 1 prox now burns).

7-20

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Ref
distan
ce

09-1-14

Ref distance

Sidedam in homepos

Ref distance

Sidedam in homepos

Backdam in homepos

C5000 Unilever Brasil

Installation

3 Check that the load platform is also closed in Eagle. If this is not the
case, then turn the proxes around.
4 Now set the load platform to the middle position (this can possibly be
done using the hand control and emergency stop).
5 Now close the load platform using the hand control in Eagle. The load
platform now closes immediately. If this is not the case, turn around the
direction of rotation in the movimot and try again.
6 Now adjust the two semicircular plates so that the load platform stops
with a right crank. Only move the plate for which the prox does not burn
nearer to (to rotate further) or farther from (to stop earlier) the prox.

7.24.2

Eagle
Not applicable.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

7.25
7.25.1

Lift
Hardware
1 First check the direction of rotation of the lift motor. Operate the lift using
the hand control in Eagle. If the direction of rotation is incorrect, change
it using the control.
2 Now check the direction of rotation using the control panel by the lift. If
the direction of rotation is incorrect, change the switch connections in
the control panel.
3 Check the lift limit switches and set them to the correct height (when the
lift runs in the limit switches, this can only be obtained through a reset).
Centring unit:
1 Set the home microswitches to the farthest position of the centring unit.

09-1-14

2 Set both of the pallet width detection microswitches so that they


illuminate when the width is about 900 mm between the centring unit
clips.
3 Set the speed so that the centring unit opens and closes in about 1
second.

7.25.2

c
7.25.2.1

Eagle
Caution
Incorrect adjustment of the lift parameters can cause serious damage to
the sliding table.
Adjustment of Lift_Max_Speed(Int)
Maximum speed of the lift in mm/s. This is also the speed with which the lift
ascends with an empty pallet.
DEFAULT: 975 mm/s

7.25.2.2

Adjustment of Lift_Max_Acc(Int)
Maximum acceleration of the lift in mm/s. This is also the acceleration with
which the lift ascends with an empty pallet.

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C5000 Unilever Brasil

Installation

DEFAULT: 1200 mm/s2


7.25.2.3

Adjustment of Lift_Man_Speed(Int)
Manual speed of the lift in mm/s.
DEFAULT: 150 mm/s

7.25.2.4

Adjustment of Lift_Man_Acc(Int)
Manual acceleration of the Lift in mm/s2.
DEFAULT: 500 mm/s2

7.25.2.5

Adjustment of Lift_Measure_Speed(Int)
Speed of the lift in mm/s with the measurement of pallet height.
DEFAULT: 100 mm/s
Adjustment of L_Pos_Infeed(Int)

Fig. 7.3 Infeed position of lift

This is the position of the lift, in mm, when it is in the infeed position. The
infeed position is shown in Figure 1-3. In this position, the pallet comes to
a stop above the pallet belt. The lift forks are just beneath the pallet belt.
DEFAULT: 250 mm
Adjustment of L_Pos_Outfeed(Int)

09-1-14

7.25.2.7

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

7.25.2.6

Fig. 7.4 Outfeed position of lift

This is the position of the lift, in mm, when it is in the outfeed position. The
outfeed position is shown in Figure 1-4. In this position, the pallet stop and
the pallet forks are beneath the pallet belt. Ensure that this position is not
set too low by which the lift comes up against the limit switch.
DEFAULT: 210 mm

7-22

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September 1, 2014

C5000 Unilever Brasil

Installation

Adjustment of L_Pos_PC_Dec(Int)

Lift height

7.25.2.8

Fig. 7.5 Lift height

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

This adjustment is used to set the height of the deceleration photocell. The
deceleration photocell is the lowest photocell of the lift. The set height is the
distance, in mm, measured between the lowest limit switch and the
photocell with the lift height subtracted from it (see Figure 1-5). This
distance can also be determined with the lift empty by using manual
upward movements (the lift serving as a reference). The position in which
the lift photocell is just covered is the L_Pos_PC_Dec position. This
position can be read off from the operator panel (subtract the pallet height
from it).
DEFAULT: 1500 mm
7.25.2.9

Adjustment of L_Pos_PC_Max(Int)
This adjustment is used to set the height of the maximum photocell. The
maximum photocell is the highest photocell of the lift. The set height is the
distance, in mm, measured between the lowest limit switch and the
photocell with the lift height subtracted from it (see Figure 1-5). This
distance can also be determined by the empty lift by using manual upward
movements (the lift serving as a reference). The position by which the lift
photocell is just covered is the L_Pos_PC_Max position. This position can
be read off from the operator panel (subtract the pallet height from it).
DEFAULT: 2000 mm

09-1-14

7.25.2.10

Adjustment of L_Drop_Height(Int)
This is the distance, in mm, that the lift goes higher than the maximum
photocell.
DEFAULT: 30 mm

w
7.25.2.11

Warning
If this value is set too high, damage can be caused to the sliding table.
L_Max_Pos setting (mm)
This is the distance (in mm), where the lift slows down when carrying no
pallets, or when carrying too low a pallet. The Max-Pos distance is
determined by taking the distance between the top and bottom limit switch
and deducting the length of the skate on the lift ( 100 mm ).

7.25.2.12

L_Layerpad_Empty_pallet_Pos (mm) setting


This is the distance (in mm) of the lift relative to the bottom limit switch,
when the layer pad trolley has to place an interleaving sheet onto the pallet.

September 1, 2014

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7-23

C5000 Unilever Brasil

Installation

Default: 2250 mm.

w
7.26
7.26.1

Warning
Setting the value too high can damage the layer pad trolley.

Conveyors
Hardware

7.26.2

Eagle

7.26.2.1

Pallet conveyor 1 (Beneath the lift)


Adjustment of C1_Time_Out(Int)
Time-out time of the pallet belt beneath the lift for the output of the pallet.
Time is set in seconds.
DEFAULT: 100 sec
Adjustment of C1_Time_Inf(Int)
Minimum time that the pallet belt remains running at the input of a pallet.
Just after this time has elapsed and both photocells are free, the lift
ascends.
DEFAULT: 6 sec
Adjustment of C1_Time_Outf(Int)
Minimum time that the pallet belt remains running at the output of a pallet.
Just after this time has elapsed and the output photocell is free, the lift
ascends to the input position.

7.26.2.2

09-1-14

DEFAULT: 4 sec
Pallet conveyor 2
Adjustment of C2_Time_Out(Int)
Time-out time of the pallet belt at the output of the pallet. Time is set in
seconds.
DEFAULT: 100 sec
Adjustment of C2_Time_Outf(Int)
Minimum time that the pallet belt remains running at the output of a pallet.
Just after this time has elapsed and the photocell is free, the belt is made
free and the data is copied.
DEFAULT: 6 sec

7-24

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Check the direction of rotation of the conveyor belts. If they are incorrect,
turn them around in the movimot.

CSi

September 1, 2014

C5000 Unilever Brasil

Installation

Movimot

09-1-14

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

7.27

1 Identification of the circuit type


2 Terminal box
3 Connection plug between connection unit and inverter
4 Connection box cover with inverter and heat sink
5 Connection unit with terminals
6 Electronics terminal strip X2
7 Connection of brake coil (X3); in motors without brake: Connection of
internal braking resistor BW.
(standard)
8 Mains connection L1, L2, L3 (X3) (suitable for 2 x 4 mm 2 )
9 Screws for PE connection y
10 Cable screw fittings
11 Electronics nameplate
12 Safety hood for inverter electronics
September 1, 2014

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7-25

C5000 Unilever Brasil

Installation

13 Set point potentiometer f1 (not visible), accessible through a screw


fitting on the top of the connection box cover
14 Set point switch f2 (green)
15 Switch t1 for generator ramp (white)
16 DIP switch S1 for setting the bus address, motor protection, DC braking,
PWM frequency
17 Status LED (visible from the top of the connection box cover)

7.27.1

Without Profibus connection


When the movimot is used without profibus connection, the jumpers are set
as follows:
off
off
off
off
off
on
off
By using the adjusting knob in the movimot cover, it is possible to set up
the speed of the motor which is normally always set to 5 (it is only set
differently if it is specified otherwise in the signal package). The ramp can
be set up using the adjusting knob t1 in the movimot, and is always set to
0. With the pallet belts, this can be set higher so that the belts start up
slowly and run in.
In principle, adjusting knob f2 is not used. When this knob is connected, it
is possible to set up a second speed.

With Profibus connection

09-1-14

7.27.2

The jumpers in the movimot are set as follows:


on
off
off
off
off
off
on
off
Adjusting knob f1 in the cover should be set to 10 and adjusting knob t1 in
the movimot should be set to 0. It is not possible to change the speed with
adjusting knobs f1 and t1 as this action is carried out in the plc.
The movimot only works via the profibus when the R and L terminals are
connected to the 24VDC supply.

7-26

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off

September 1, 2014

C5000 Unilever Brasil

Installation

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

Connection example:

n
7.27.3

Note
Use the correct type of EMC swivels.

Movimot LEDs

09-1-14

The following table applies to the LEDs on the movimot, not to those on the
field or profibus cabinets.

September 1, 2014

CSi

7-27

C5000 Unilever Brasil

Installation

When the movimot malfunctions, as it is connected to the profibus it can be


reset by using the reset knob on the control panel. If the movimot is not
directly connected to the profibus, it can only be reset by disconnecting the
24VDC supply in the cabinet.
The LEDs on the profibus cabinet of the movimot have the following
statuses:

7-28

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Fault codes

09-1-14

7.27.3.1

09-1-14

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C5000 Unilever Brasil

September 1, 2014

Installation

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7-29

C5000 Unilever Brasil

Installation

n
7.28
7.28.1

Note
The sys fault LED illuminates when the operating switch is off.

Movidrives
Downloading and uploading of parameters
The uploading and downloading of parameters is effected through
movitoolsThe downloading of parameters is only possible when the
machine is in emergency shutdown.

09-1-14

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

First start up the MT Manager. Set the radio button under the Connect to:
part of the screen to Single Inverter (Peer-to-Peer).

Connect the controller to your PC and press the update button. When this
has been accepted, a controller will be visible in the Connected Inverters
table. If this is not the case, check the cable and COM port number (this
must usually be set to COM 1).
Now click on the Shell button. The Movitools Shell now starts up.
Select Copy data from the Movitools Shell File menu (see also the
illustration).

7-30

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C5000 Unilever Brasil

Installation

09-1-14

You will now see the following screen:

Set the radio buttons as shown in the above screen to enable the
downloading of parameters to the controller. Use the Browse button to
search for the file to be downloaded.
When you want to upload parameters from the controller to a file, you must
set things up as follows:

September 1, 2014

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7-31

Installation

Click the Start button to begin downloading or uploading parameters.

09-1-14

When you want to download parameters you will see the following screen:

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

C5000 Unilever Brasil

In this screen, check the All inverter data and Run IPOS Program
options. Now click the OK button. The downloading of parameters will now
begin.
If you had selected uploading of parameters, you would see the following
screen:

7-32

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C5000 Unilever Brasil

Installation

It is possible to insert some comments such as the date, client name,


controller etc. If you now click the OK button, the parameters will be
uploaded from the controller.

7.28.2

Adjustment of the direction of motor rotation


The adjustment of the direction of motor rotation can also be effected
through the Movitools Shell screen as follows:

09-1-14

In the Parameters menu, select the Main Menu option. You will then see
the Main Menu (left-hand part of the following screen printout). In the Main
Menu, select the Motor parameters option. Now double-click on the 35.
Motor sense of rotation option (you will now also see the right-hand part of
the following screen printout). Set parameters 350 and 351 to ON when
they are set to OFF, otherwise turn them around. The changes to these
parameters are only possible when the machine is in emergency
shutdown. After the changes have been made, upload the parameters.

September 1, 2014

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7-33

7.28.3

Reading fault codes


It is possible to read off the controller status and the fault codes by selecting the Status program in the MT Manager. When you select this program, you will see the following screen:

If there is a fault present, the red bar will illuminate and you may be able to
read what the fault message means. It is possible to reset the fault by
clicking the reset button.

7.29

Bus boxes
LEDs:
LED Indications
Bus

Normal Operation: Green,


No Communication: Red
OK: Green, Error: Red
ON: 8 x Green
Sensor Inputs Shorted: 1 x Red
ON: 8 x Green

Module Status
Inputs
Short-circuit
Outputs

Tab. 7.3 LED indication

7-34

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Installation

09-1-14

C5000 Unilever Brasil

C5000 Unilever Brasil

Installation

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

7.29.1

7.30

Connections

Valve islands
The green LED is constantly illuminated. If this is not the case, then one of
the two supply voltages has failed.

7.31

Profibus

09-1-14

Building up the profibus network:


The profibus network is a linear network which means that no branches can
be made. The cables must always be unloaded from one participant to
another. Both the first and last participants must be provided with a terminal
resistor. All other participants cannot have terminating resistors. The
master (PC or PLC) can sit anywhere within the network, and does not
necessarily have to sit at the end or beginning of the network. The order of
participants is also not important.
Always check whether the terminal resistors correspond (also check if the
network appears to be working). This can be checked by measuring the
terminal resistance between the A and B wires. This resistance must be
about 110 ohms. The A or B line is measured with respect to earth and
must also be about 110 ohms.
The bus boxes are not provided with terminal resistors and, if necessary,
make use of loose terminal resistors. With the movimot and movidrive, the
terminal resistor can be connected or disconnected by using jumpers.
Plugs for the valve islands are provided with terminal resistors in the plugs
(two yellow bolts). Some 9-pole plugs are provided with a terminal resistor.
This is usually in the form of a little switch on the exterior of the plug.

September 1, 2014

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C5000 Unilever Brasil

Installation

7.32
7.32.1

Synchronising the products


Selecting method of rotation
Depending on the type of product, the method can be selected from several
rotational principles, namely:
1 Kicker
2 Rotating cam

Advantages of using the rotating cam method compared to the kicker


method:

7.32.2

There is no movement of the zero line.

The products are always rotated 90 degrees.

Easy to synchronise.

Stable.

Disadvantages of using the rotating cam method compared to the kicker


method:

The rotations are made slowly which can cause the following products
to run inwards too early (this can possibly be resolved by utilising the
kicker as a rotational aid).

Spacer / pressure zone timing is adversely affected by the slow


rotations. This can possibly be rectified by setting a Delay offset.

Spacers
Ensure that the spacer times are adjusted such that the spacer in the
middle between the boxes always goes upwards (the boxes must then
stand up against each other on the breakfeeder).
In the first instance, adjust the spacers on unrotated boxes. When the
spacers are correctly adjusted for unrotated boxes but are still not correctly
adjusted for rotated boxes, an offset time can be set for the kicker or
rotating cam (depending on whether it is used). This offset time is counted
up for all spacer times when the box is rotated. Through this offset, possible
rotational decelerations can be controlled.

7.32.3

Pressure zones
Regarding adjustment of the pressure zone times, two principles can be
adopted, namely:
1 Preset stroke
2 Extra long rotation

7-36

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September 1, 2014

09-1-14

As a rule, it is accepted that wide products (i.e. products with a length to


width ratio less than 1.5) are rotated using the rotating cam method, and
long narrow products are rotated using the kicker method. Preference is
always given to the rotating cam method. If the rotating cam produces too
much deceleration (where boxes are sometimes almost at a standstill), the
kicker method can be employed as a rotational aid. Allow the kicker to
make a small contact to the back of the product.

K:\Projects\22--\222500 Unilever Aguai\Manual\C5000-EN\2225_Hoofdstuk-07.fm

3 Rotating cam with kicker as a rotational aid

C5000 Unilever Brasil

Installation

With heavy and/or breakable products, preset strokes are the best option.
Using preset strokes, set the pressure zones so that they go upwards
before the product runs against a spacer or against the preceding product.
With normal products it is usually better for the pressure zones to just
disconnect after the product has run against a spacer or against another
product. To prevent the product from rebounding, it is prudent to allow the
pressure zones to run a bit longer.

7.32.4

Rowpusher
Adjust the rowpusher spees so that the product is not damaged or breaks
loose during the pushover operation.

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For each row, it is possible to set a RowReady time in the layer editor. The
default for this time is usually 3000 msec. The rowpusher starts after this
time as the last box in the row is run inwards. Try to make this time as low
as possible as the capacity is strongly dependent on such time. If this time
is set too high, products wait around needlessly. If this time is set too low,
the last product will not connect in time. It is also possible that the
rowpusher free check photocell will give a fault message.

7.32.5

Forming

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Always check that the layer is not formed too tightly on the pallet. If this is
the case, drop the layer just on the lift when the dams open. It is also
possible to not get any holes in the pattern. Adjust the dimensions of the
dams so that all products still have a bit of leeway on the pallet.

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Installation

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Mechanical Spare parts

MECHANICAL SPARE PARTS

Versie 2.1.1 - 201-08-13

8.1

Introduction

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This chapter has been compiled in order to identify and order spare parts
for the by CSi designed and manufactured conveyors and machines.
The mechanical and general electrical spare parts mounted on the
machine(s) are listed in this chapter 8. The remainder of electrical parts is
specified and listed in chapter 10. Refer to chapter 9 if you need to order
parts that originate from a subcontractor.
Before ordering any parts, please read this chapter carefully.

8.2

How to use this chapter


You can use this chapter to identify spare parts, localise them in the
concerned spare parts list and order those spare parts.

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When ordering the component you need the following data:

8.3

CSi order number

Position number

Article number of the spare part

The amount of parts

Ordering procedure
The CSi installations and machines are subdivided into modules. These
modules all have a corresponding position number. These position
numbers are printed on the type plate or sticker mounted on the system or
machine.
In the index of spare part lists the position number refers to the list of spare
parts that are used in that particular position number. The spare part list is
ranged by position numbers. Under each position number all spare parts
used at that position number are listed.

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Mechanical Spare parts

Example of how to identify and localise a spare part in the printed


users manual:
First check where this part has come off from. Find the type plate or
sticker on the module concerned. On this type plate you will find the
CSI order number and the position number.

Look up this position number in the index of the spare part lists. The
position number refers to a page with a list of all spare parts used in
this particular position number, the so-called position numbers spare
part list.

In the list of spare parts on this page you will find the spare part you
seek.

Listed under that spare part you will find a description of the part and
an article number. Listed also, is the amount of parts of that particular
part used in the entire position number.

The information you have found is needed to order the particular part at
CSis: the CSi order number, the position number and the article number.
Example of how to identify and localise a spare part in the digital
users manual:
On the floor you notice a broken part.
-

First check where this part has come off from. Find the type plate or
sticker on the module concerned. On this type plate you will find the
CSI order number and the position number.

Keep the position number in mind and double click on this chapter 8.
This will lead you to the index of the spare part lists.

In the index, you double click on the position number you found on
the module. This position number is listed in the first column. This
will lead you to the position numbers spare part list.

In this postion numbers spare part list you will find the part you seek.

Listed under that spare part, you will find a description of the part and
an article number. Listed also is the amount of parts of that particular
part that is used in the entire position number.

The information you have found is needed to order the particular part at
CSis: the CSi order number, the position number and the article number.
The same information can also be obtained through the lay-out:
-

On the lay-out drawing (which is a synopsis of the installation) and


all section drawings, all modules have been given a position number.

With this position number in mind, check the index of the spare parts
lists. In this list your position number refers to a page with a list of all
spare parts used in that particular position number.

On this page you will find the spare part you want to order.

Listed under that spare part you will find a description of the part and
an article number. Listed also is the number of parts of that particular
part used in the entire position number.

The information you have found is needed to order the particular part at
CSis: the CSi order number, the position number and the article number.

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On the floor you notice a broken part.

C5000 Unilever Brasil

Mechanical Spare parts

The information can be sent either by fax or by e-mail, to:


CSi Lifecycle Services
P.O. Box 70
4940 AB Raamsdonksveer, The Netherlands
Tel: +31 (0) 162 575 400
Fax: +31 (0) 162 575 118
E-mail: parts@csiportal.com

8.4

Attachments mechanical spare parts

8.4.1

Mechanical spare parts in pdf files

8.4.2

Mechanical spare parts in Excel file

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In the mechanical spare parts list in Excel format it is quite easy to identify
and locate spare parts.
1 Open the spare parts list in Excel.
2 Go to the tab-page transport. In this page click in the left upper corner
(above 1 and left from the A). The list turns blue.
3 Click Data, Filter and Autofilter to activate this Autofilter.
4 Click CSi order no and select a level at will.
5 Before closing the file, de-activate the Autofilter. Excel has trouble
opening the file with the Autofilter on.
Another method is using the Find function (Control + F) to search for part
numbers.
1 Use Control + F.
2 Enter the part number you are looking for.

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3 Confirm with Enter. The line with the wanted spare part number
appears.

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Attachments

ATTACHMENTS

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Attachments

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10

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Wiring diagrams

WIRING DIAGRAMS

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Wiring diagrams

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