JECTOR CONTAINER EJECT SYSTEM ML0068-001-02 OWNERS REFERENCE MANUAL Enercon Industries Corp. W140 N9572 Fountain Blvd. P.O. Box (53052-0773) Menomonee Falls, WI 53051 Phone: (262) 255-6070 Fax: (262) 255-7784 E-mail: info@enerconind.com Web Site: www.enerconind.com 01/07/2003
EJECT SYSTEM TABLE OF CONTENTS SECTION 1 INTRODUCTION...1 SAFETIES AND WARNINGS...1 GENERAL...2 EJECT SYSTEM FEATURES...2 EJECT SYSTEM SPECIFICATIONS...2 SECTION 2- INSTALLATION...3 UNPACKAGING AND INSPECTION...3 EJECT SYSTEM CONTROL BOX...3 COMPRESSED AIR...3 EJECT SIGNAL...3 INPUT POWER...3 EJECT SYSTEM INSTALLATION WITH FOIL LINER DETECTOR (Figure 1)...4 EJECT SYSTEM INTALLATION WITH CAP INSPECTION SYSTEM (Figure 2)...4 SECTION 3 PRINCIPLES OF OPERATION...5 METHOD OF OPERATION...5 SECTION 4 EJECT SYSTEM MAINTENANCE...6 CLEANING...6 ADJUSTING...6 SECTION 5 TROUBLESHOOTING...7 SECTION 6 PARTS LIST...8 GENERAL...8 DESCRIPTION...8 HOW TO USE THIS PARTS LIST...8 HOW TO ORDER PARTS...8 EJECTOR PARTS BREAKDOWN (Figure 3)...9 SECTION 7 MISCELLANEOUS...10 EJECT SYSTEM PRODUCTION SETUP...10 NOTES...11
SECTION 1 INTRODUCTION WARNING Please read carefully before installing or servicing. HIGH VOLTAGE is present within the control box enclosure. Install according to local electrical codes to insure personnel safety. When SERVICING, technician must insure that external electrical power is disconnected and locked out before making contact with the equipment. As with any piece of ELECTRICAL equipment, one should become familiar with the manual and all associated drawings furnished before applying power. Proper connections and operation are required for safe use. FOLLOW INSTRUCTIONS for safety of personnel when operating or maintaining this equipment. SAFETY AND WARNING Before you install this Eject System, you should take the time to carefully read all the instructions contained in this manual. Before installing, wiring, starting, operating or making any adjustments, identify the components of the Eject System, using this manual as a guide. The operator should use common sense and good working practices while operating and maintaining this unit. Check the safety devices following the procedures contained in this manual. Qualified personnel, adequately equipped with proper tools should do maintenance. Follow the maintenance schedules as outlined in the manual to insure problem free operation after start-up. *** CAUTION *** Caution is used to indicate the presence of a hazard, which will or can cause minor personal injury or property damage if the caution is ignored. *** WARNING *** Warning is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage, if the warning is ignored. Safety instructions in this manual are bold-faced for emphasis. The signal words WARNING and CAUTION are used to indicate hazard seriousness levels as follows: 1
GENERAL The Enercon Eject System was designed to provide the packaging industry with a simple system to eject bad containers off a conveyer. The eject system can be used with any bad container detectors, such as; missing foil detectors, high cap detectors and missing cap detectors to name a few. The system accepts a contact closure from the desired bad container detector which starts a delay timer. Once timed out, the eject timer is activated, causing the plunger to eject the container off the conveyor. EJECT SYSTEM FEATURES a. Delay timer Used to set the time from when the bad container is detected to when the container reaches the eject zone. b. Eject time Used to set the time for how long the eject plunger is activated. c. Cylinder speed adjust Used to set the extension and retraction speed of the plunger. d. Air pressure regulator and gauge Used to set the force of the plunger. EJECT SYSTEM SPECIFICATIONS Electrical a. A power cord is supplied for customer connection to a local power source. The power required is either 120VAC or 240VAC ± 10%, 50/60 Hz, 1ph, 2A. Check rating plate of eject system for correct voltage. b. A 12ft. two conductor cable is also supplied for the external signal input. Air requirements a. Filtered air is required at 70-90 PSI. *** WARNING *** BE SURE ALL POWER IS DISCONNECTED AND LOCKED OUT FROM UNIT BEFORE PERFORMING ANY PREVENTATIVE MAINTENANCE PROCEDURES. 2
SECTION 2- INSTALLATION UNPACKAGING AND INSPECTION Carefully open all shipping containers and remove the contents. Each item should be thoroughly inspected for damage. NOTE: Be extra careful if using a sharp instrument when removing the protective wrapping from the equipment. File a claim with the freight carrier for any damage incurred. Enercon Industries should also be contacted as soon as possible to expedite the shipment of replacements parts. CONTACT: Enercon Customer Service Department Phone Number: (262) 255-6070 Fax Number: (262) 255-2462 E-Mail Address: info@enerconind.com Website: www.enerconind.com 24hr Customer Service is available. IMPORTANT: If concealed loss or damage is discovered after delivery, notify your carrier at once and request an inspection. This is absolutely necessary for the carrier to consider your claim. If damage is detected, be sure to note it on freight bill before signing it to acknowledge receipt. The carrier agent should make an inspection and issue a loss or damage report. If you give the carrier a clear receipt for goods that have been damaged or lost in transit, you do so at your own risk and expense. EJECT SYSTEM CONTROL BOX The eject system control box should be mounted near the bad container detection system that is being used. If the eject system is being used with an Enercon supplied Foil Liner Detector it should be mounted downstream of the detector (See Figure 1). If the eject system is being used with an Enercon supplied Cap Inspection System it should be mounted between the high cap sensor and the power supply (See Figure 2). The eject system must be mounted no further than 9.99 seconds down stream due to the maximum range of the delay timer. To calculate the maximum distance the ejector can be mounted from the bad container detector simply multiply the conveyer speed in feet/second times 9.99 seconds. The ejector should 3 then be mounted somewhere within this window. The ejector can then be mounted on the side of the conveyor using the angle brackets and hardware supplied. COMPRESSED AIR Once the eject system control box has been installed, filtered compressed air (70-90 PSI) will need to be supplied to the control box (see the installation diagram for the location). For ease of installation, a one touch fitting for 3/8 outside diameter plastic tubing is supplied. EJECT SIGNAL The eject control box requires a normally open contact signal that momentarily closes from the bad container detector for activation. A 12ft twoconductor cable for this signal is supplied. If you have purchased this for an Enercon cap sealer this cord will have a plug on the end which is to be connected to the back of the power supply. INPUT POWER A power cord is supplied with the eject system and can be plugged into a standard 120V receptacle to power the system. (240V power is optional. Observe the rating plate for the correct voltage)
EJECT SYSTEM INSTALLATION WITH FOIL LINER DETECTOR Figure 1 EJECT SYSTEM INTALLATION WITH CAP INSPECTION SYSTEM Figure 2 4
METHOD OF OPERATION Once the eject system has been installed, adjust the air pressure regulator to 70 PSI. Apply power to the eject system by using the power on switch on the right side of the box to turn the unit on. (Insure the timer displays energize with power applied.) The system is now ready for testing and calibrating. The eject system is designed to use an external eject signal from a bad container detector. Upon receiving an eject signal, the delay timer is activated. As the bad container approaches the eject box, the delay timer will time out. Once timed out the plunger will be activated for a set time and consequently push the container off the conveyor. If the plunger activates prior to the container reaching the plunger increase the delay time by using the up arrow and repeat the test. Continue this process until the plunger makes contact with the center of the container as it passes in front of the plunger. If the plunger activates after the container reaches the plunger decrease the delay time by using the down arrow and repeat the test. Continue this process until the plunger makes contact with the center of the container as it passes in front of the plunger. The amount of time the plunger is in the extended position is also adjustable and can be increased or decreased by using the up/down arrows. (It is recommended to adjust this time to approximately 0.08 seconds as a starting point when setting up the system) This timer should not be operated with a timer setting longer then the delay timer setting To ensure the proper ejection on the container you may need to adjust the speed of the cylinder plunger by adjusting the speed control valves located on the front of the eject box. NOTE: The ejector was designed with a built in cache of 29 containers, which means a total of 29 bad containers can occur between when a bad container is sensed and when the first bad container is ejected. This should be more than adequate for the spacing between the detection device and the eject system. (If more than 29 containers are detected before the first bottle is ejected the timing function of the ejector will be out of synchronization.) SECTION 3 PRINCIPLES OF OPERATION 5
SECTION 4 EJECT SYSTEM MAINTENANCE Due to the nature of this system the amount of maintenance required will be minimal. The main priority for maintenance will be keeping the unit and air supply clean and properly adjusted. CLEANING As long as clean air is supplied to the ejector minimal cleaning is required for proper operation. ADJUSTING If the line speed or product type does not change there should be no reason to make any adjustments to the system, however you may want to periodically check the mounting hardware, if this loosens the timing of the system may be thrown off. NOTE: For each new product that is run you may have to adjust the eject delay, eject time and plunger speed to ensure proper ejects. 6
SECTION 5 TROUBLESHOOTING SYMPTON CHECK No power to the control box. (Seven segment LED s do not light) 1. Check the input power 2. Is the power switch on at the power entry module 3. Check the fuse inside the power entry module 4. Remove power and open the box and ensure the ribbon cable is properly connected between the display board and the ejector control board 5. Contact Enercon service department for assistance Eject plunger does not function 1. Check the eject signal 2. Check for proper inlet air pressure 3. Remove power and open the box and inspect the hose connections, looking for an open hose or a kink in a hose. 4. Check solenoid wiring 5. Possible bad solenoid 6. Contact Enercon service department for assistance Ejector timing seems to change 1. Are the containers sliding on the conveyor? 2. Is the conveyor speed changing? 3. Check the bad container detector for proper adjustment. Delay time or eject time are not adjustable 1. Remove input power and open the box and ensure the ribbon cable is properly connected between the display board and the eject control board 2. Bad display board 3. Bad eject control board 4. Contact Enercon service department for assistance *** WARNING *** BE SURE ALL POWER IS DISCONNECTED AND LOCKED OUT FROM UNIT BEFORE PERFORMING CHECK. 7
SECTION 6 PARTS LIST GENERAL This manual, which contains an illustrated parts breakdown, has been prepared as an aid in identifying and ordering parts in the ejector. All of the parts listed in the parts breakdown are manufactured with the same precision as the original equipment. DESCRIPTION The illustrated parts breakdown illustrates the various assemblies, sub-assemblies and detailed parts that make up the ejector. The following illustration shows each part clearly and in its correct location relative to the other parts in the illustration. To order, contact: Enercon Customer Service Department Phone Number: (262) 255-6070 Fax Number: (262) 255-2462 E-Mail Address: info@enerconind.com Website: www.enerconind.com 24hr Customer Service is available. The description and quantity required per station is listed in numerical order on the following pages. HOW TO USE THIS PARTS LIST 1. Turn to the Parts Section to locate the desired illustrations. 2. Locate the part on the illustration by visual identification and the Index Number. 3. Find the Index Number on the tabulated page, along with the description. HOW TO ORDER PARTS In order that all avoidable errors are eliminated when ordering parts, please specify the following: 1. The Model Number of the unit as shown on the Ejector Rating Plate. 2. The Serial Number of the unit as shown on the Ejector Rating Plate. 3. The Form Number of this manual located on cover. 4. The Part Number, description and quantity needed exactly as listed on parts breakdown drawings. 8
EJECTOR PARTS BREAKDOWN INDEX NO. PART NO. DESCRIPTION QTY. 1 PN0093 Pressure Gauge, Panel Mount 1 2 PN0092 Regulator, Panel Mount 1 3 PN0091 Flow Control, Panel Mount 2 4 HW0101 Bumper 1 5 CN0059 Power Entry Module 1 6 LM4439-01 Eject Display Board 1 7A LM4440-01 Eject Control Board (120 VAC) 1 7B LM4440-02 Eject Control Board (240 VAC) 1 8 PN0090 Body Ported Valve, Dual Solenoid 1 9 PN0094 Air Cylinder 1 10 CA1085 20 Pin Ribbon Cable 1 Figure 3 9
SECTION 7 MISCELLANEOUS EJECT SYSTEM PRODUCTION SET-UP Product Delay Time Eject Time Plunger Speed Air Pressure Line Speed High Cap Ejects (Y/N) Missing Foil Ejects (Y/N) 10
11 NOTES