Operation Manual
Lantech Wrapper Upgrade ADM
South Port, NC
Spring/2010
Packaging Systems
Account Rep: Mark Wolschlag & Steve Gibson
Project Manager: Randall Sorrells
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Table of Contents
General Wrapper Upgrade Description ............................................................................................ 3
Wrapper Area Layout ...................................................................................................................... 3
Component Description ............................................................................................................... 5
Safety .............................................................................................................................................. 8
Safety Precautions ....................................................................................................................... 8
Lockout / Tag-Out ....................................................................................................................... 8
General Operation using the Operator Interface ............................................................................. 10
Screen Navigation ..................................................................................................................... 10
HMI Overview/Automatic ......................................................................................................... 11
HMI Conveyor Jog .................................................................................................................... 12
HMI Alarms and Maintenance ................................................................................................... 14
Typical Startup .............................................................................................................................. 15
Control System ............................................................................................................................. 16
Referenced Files ........................................................................................................................ 17
Troubleshooting Guide .................................................................................................................. 18
Conveyor System ...................................................................................................................... 18
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General Wrapper Upgrade Description Loads existing the two pallitizer areas are capable of being routed to various locations. It is
possible to use both wrappers, a combination of a wrapper and manual offload with a fork truck or
no wrapper at all. On the other hand, it is possible to onload with a fork truck thus routing a load
through a wrapper. The selections are made via the input on an HMI touch screen. There are two
fork truck points which serve as both onload and offload. There are three other fork truck points
which serve as offload points only.
Pallet Dimensions: Minimum Load 48 x 40 x 50
Maximum Load 48 x 45 x 50
Rate: Sixty (60) loads per hour maximum
Weight: 2000 lbs Typical
Wrapper Area Layout
The New Wrapper System consists of seven basic components. Of which, are broken into two
sections: Lantech and xpedx. This manual will focus on the xpedx system only. Please see Lantech
documentation for information on the Lantech Top Sheet dispenser and Stretch wrapper.
Xpedx section includes:
1. Con.2 = Conveyor 2 feeds loads in from the right palletizer.
2. Con. 3= Turntable rotates clockwise and counter clockwise and can move a load from Con.
2 to Con 4, Con 2 to Con 5 or Con 5 to Con 4.
3. Con. 4 = Conveyor 4 is on the right side on the turntable closest to the older wrapper.
4. Con. 5 = Conveyor 5 is on the left side of the turntable.
5. Con. 6 = Conveyor 6 is to the left of Con. 5 with both rollers and a popup chain.
Lantech Section:
1. Con. 8 = This is the entry point into the Lantech system. Itis called the Top Sheet Dispenser.
2. Con. 9 = This is the Stretch Wrapper.
3. Con. 10 = Conveyor 10 is the outfeed and staging area for loads exiting the Lantech
Wrapper system.
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Component Description
The HMI pedestal is the point where the flow of
loads is configured and the line is
stopped/started. There is also an E-stop button
as well as a power on button.
Con.2 = Conveyor 2 feeds loads in from the
right palletizer.
The load will stop near the turntable on Con 2 if
the Turntable is not in the Home position at Con
2.
Con. 3= Turntable rotates clockwise and counter
clockwise and can move a load from Con. 2 to
Con 4, Con 2 to Con 5 or Con 5 to Con 4.
Con. 2 can be seen at the Top of this image
while Con 4 is to the Right and Con 5 is to the
Left.
***The turntable is seen here in the Home
position.
Con. 4 = Conveyor 4 is on the right side of the
turntable closest to the older wrapper. This
conveyor can pass a load on down to the old
wrapper or hold a load for offload by the fork
truck.
**You can see the red safety pull cord here as
well as the fork truck sensor underneath.
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Here is the Older Wrapper to the right of the
Turn Table.
If a load passes through Con 4 traveling into the
wrapper, the wrapper is expecting the load to
arrive at its internal turntable.
Con. 5 = Conveyor 5 is on the left side of the
turntable. A load can be passed either left or
right depending upon the flow configuration.
Con 5 can be both an offload and an on load
point for loads.
**There is a sensor to detect fork trucks
underneath at the middle. Loads will not move
if this sensor is blocked.
Con. 6 = Conveyor 6 is to the left of Con. 5 with
both rollers and a popup chains. Loads can
come out of the left palletizer and travel either
left or right based on the flow configuration.
Loads can travel from Con 5 left to the new
wrapper if the flow is set up to do so.
**If a load is at Con 5 and Con 7 at the same
time, the Load from Con 7 always gets priority.
Con. 8 = This is the entry point into the Lantech
system and is called the Top Sheet Dispenser.
Con. 9 = This is the Stretch Wrapper.
**Please see Landtech documentation for
further details.
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Con. 10 = Conveyor 10 is the outfeed and
staging area for loads exiting the Lantech
Wrapper system.
**There is a sensor to detect fork trucks. Loads
will not move if this sensor is blocked.
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Safety
Safety Precautions
Before working on the xpedx and Lantech systems disconnect all incoming power.
Turn off all electrical and air connections to the equipment and all Interfaced Equipment before
repairing or cleaning.
Do not put hands or tools in the equipment or any Interfaced Equipment while in operation.
Do not wear neckties, jewelry, loose clothing, or other items that can become caught in moving
parts or mechanisms in the vicinity of equipment or Interfaced Equipment.
Do not operate, troubleshoot, or maintain the equipment or Interfaced Equipment while under the
influence of any type of drugs or alcohol.
Do not operate the equipment or any of the Interfaced Equipment without all guards and safety
mechanisms in place.
Always observe all safety warnings and notices on all equipment and in this manual and all
Interfaced Equipment manuals.
Do not use flammable or toxic cleaning fluids such as gasoline, benzene, or ether when cleaning
and maintaining the equipment or any other Interfaced Equipment.
Wear all company-specified protective equipment while operating the equipment or any Interfaced
Equipment.
Lockout / Tag-Out
Follow ADM safety procedures and follow the Lockout / Tag-Out procedures as defined by
OSHA, before servicing the machines.
The xpedx system has a single control panel with a lockable disconnect beside the door as well as
an upstream safety switch mounted to the HMI pedestal and another upstream safety disconnect
mounted near the control cabinet on the column. Any of the three disconnects will de-energize the
following devices:
� All conveyor motors on Con. 2, 3, 4, 5, 6
� All solenoid valves on Con 6
� All sensors on Con. 2, 3, 4, 5, 6
The potential for stored energy on this line exists because of the use of pneumatic controls. Follow
ADM safety procedures and follow the Lockout / Tag-Out procedures as defined by OSHA. Be sure
to bleed off air pressures before servicing the Con 6. Always bring up the air pressure slowly to
avoid fast movement of devices as the air pressure increases.
The xpedx equipment has been equipped with several devices to help enhance the overall safety of
Please read all manufacturers Manuals and Training Guides of equipment
interfaced with the Transfer Table. Please read all manufacturers Manuals and Training Guides of equipment
interfaced with the xpedx equipment.
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the system. The control system was designed with a Category I safety control circuitry.
The HMI panel is equipped with a xpedx system
Only E-stop Button. Once all E-stops are
cleared this is also the only point the control
circuitry can be reset.
Three safety pull cords were also provided to
surround the perimeter of the xpedx conveyors
giving the operators the ability to stop the
equipment in the event a controlled stop from
the HMI is not possible.
** Pull cords are Red and run along the outside
of the conveyors.
Large yellow barriers were provided by ADM to
prevent entry into areas of moving parts.
Please Note: The equipment is designed to hold pallets up to 40”x48” at near 2000 lbs. Anything
outside of this could exceed the weight and size capacity causing the conveyor to collapse and/or
jam.
Warning: The conveying equipment is not made to sit, stand or place anything other than loaded
pallets onto.
Failure to comply can cause personnel and equipment damage.
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General Operation using the Operator Interface
Screen Navigation
Screen
Navigation
Start Screen Flow
Configuration
Jog Select
Screen
Alarm Screen Maintenance
Screen
Flow Status
Screen
Jog 2 and 3 Jog 5 and 6 Jog 3 and 4 Jog 3 and 5
PLC Inputs &
Outputs
HMI Shutdown
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\
HMI Overview/Automatic
When the system is first powered up, this
will be the screen displayed. Each screen
area can be selected here. Choosing “Flow
Config” will open the screen necessary to
select load directions.
While the system is in Stop, select the
direction you want the loads to flow. You
can also select if you want loads to be held
on Con 5 or Con 4 instead of allowing them
to flow to the next area. Pass/Hold can be
changed at any time.
Selecting the “Return” button will send you
back to the “Screen Navigation” screen.
The line can be operated with any
component in Auto or Manual. Any
component can be changed from
Auto/Manual in both the stopped or
Running mode.
Starting the line activates a warning buzzer
and lights the amber light on the main
control cabinet. 20 seconds will pass
before fully in the Run Mode. Bothe the
Green and Amber light will be lit.
**Note a conveyor cannot operate manually
if in auto on this screen.
**Cycling from Auto/Manual is a good way
to reset a conveyor
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This is just a verbal representation of the
setup configuration for load flow.
HMI Conveyor Jog
To manually Jog any of the conveyors,
select the conveyor you wish to jog.
**Note a conveyor cannot operate
manually if in auto on the “Start Screen”.
**In Manual Jog there are little oversight
by the system to allow for safe movement
of loads. Take extra precaution.
To manually operate a conveyor make sure
the corresponding button is “Selected” and
is Green.
The Turntable can rotate clockwise and
counter clockwise.
The Turntable must be directed toward one
of the three positions to allow bed rollers to
activate.
**There are hard stops which will prevent
rotation passed 180 degrees. Damage can
occurred if manually jogged into the hard
stops
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To manually operate a conveyor make sure
the corresponding button is “Selected” and
is Green.
The Turntable can rotate clockwise and
counter clockwise.
The Turntable must be directed toward one
of the three positions to allow bed rollers to
activate.
**There are hard stops which will prevent
rotation passed 180 degrees. Damage can
occurred if manually jogged into the hard
stops
To manually operate a conveyor make sure
the corresponding button is “Selected” and
is Green.
The Turntable can rotate clockwise and
counter clockwise.
The Turntable must be directed toward one
of the three positions to allow bed rollers to
activate.
**There are hard stops which will prevent
rotation passed 180 degrees. Damage can
occurred if manually jogged into the hard
stops
To manually operate a conveyor make sure
the corresponding button is “Selected” and
is Green.
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HMI Alarms and Maintenance
The alarm screen displays in red the active
alarm. The buzzer on the main control
cabinet will also be active. The buzzer can
be silenced by the button in the middle of the
screen.
Alarms will disappear once the condition is
corrected.
The “Maintenance Screen” displays the
current system configuration. From here the
HMI can be shut down into its own operating
system.
Advancing to the next series of maintenance
screens allows for the viewing of all of the
system Inputs and Outputs.
**Shutdown of HMI should be done only by
qualified technicians.
Advancing to the next series of maintenance
screens allows for the viewing of all of the
system Inputs and Outputs.
Active I/O will be noted by the yellow
indicators
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Typical Startup Power the main control panel using the main disconnect and/or upstream safety switches.
Give the HMI and PLC as much as 5 minutes to properly boot up into the run mode. Attempt to
reset the control power by pushing the control power reset button on the HMI pedestal. If no pull
cord conditions are active the green button will light up. If it does not, then check the listed alarms
on the HMI screen to see which pull cord and/or E-stop is active.
Once the E-stop and pull cord conditions are corrected, push the control power reset button
to turn on the control power for the xpedx system. Select the “Flow Config Screen”. Select the
direction you would like the loads to flow and whether or not you want the loads to be offloaded on
Conveyors 4 and/or 5.
Please note: it may be necessary to us a stylus to make selections on the HMI screen.
Navigate to the Start screen. Set the necessary conveyors in the Auto mode.
Select start.
It is best to empty the system of any loads and place Con 3 Turntable in the Home position.
However if that is not possible, make sure the load is sitting in a known position blocking a photo
eye. Make sure the Con 3 Turntable is at one of the three known positions.
Manual Jog While in the Run Mode, any conveyor can be placed into manual from the Start screen. Navigate to
the appropriate Jog screen. Select the appropriate conveyor and jog as needed.
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Control System
The control system is housed in the Main
Control panel. This panel is located on the back
side of Con 5.
The HMI pedestal is located just to the left of
Con 3 Turntable. It is equipped with a touch
screen, E-stop Push button and a Power rest
push button. The safety switch mounted to the
back of the pedestal should be locked out before
crossing and or servicing associated conveyors.
The HMI is a AB Panel view Plus 600 which
talks to the PLC via RS-232.
The system is controlled by a AB Micro Logix
1500 PLC with two serial ports for connectivity.
The variable frequency drive is a AB general
purpose Power flex drive.
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Referenced Files
Cad layout with Control Notes = ADM Layout 041510 with c notes.dwg
Electrical Cad Drawings = ADM Master Elect 041510.dwg
PLC File = ADM NEW7.RSS
HMI file = ADM TRANSITION CONVEYORS2.apa
HMI compressed file = ADM TRANSITION CONVEYORS.mer
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Troubleshooting Guide
Conveyor System
Control power will not come on
Main Conveyor System will not
start
Any single conveyor will not start
Turntable will not move in Auto
Conveyor 5 is on and will not turn
off in Auto
Conveyor 5 will not start in Auto
Conveyor 4 will not start in Auto
� Push Control Power Reset on HMI panel
� Confirm Main Control Panel disconnects are on.
� Check all system E-stop push buttons/pull cords.
(Reset)
� Check circuit breakers
� System Control Power must be on.
� Push Control Power Reset on HMI panel
� Select Start button from the HMI Start Screen
� Ensure green light flashing on stack light. If not
clear faults
� Check Alarms page for active alarms and rectify
� Ensure system is configured correctly
� Check to see if it is in Auto on Start Screen
� Check for motor faults
� Check Circuit Breakers
� Cycle from Auto to Manual and back to Auto
� Not at a know position, put it in manual and jog
to Home (Con 2) make sure display says “Home”
� Cycle from Auto-Manual-Auto; It thinks a load is
still on it
� The load is not being seen by Photo Eye
� The fork truck sensor is blocked
� The load is not being seen by Photo Eye
� The fork truck sensor is blocked
�