TROUBLE SHOOTING TRAINING MANUAL This manual may not b

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TROUBLE SHOOTING TRAINING MANUAL

• This manual may not be reproduced with out the
  written permission of AS/R Systems

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122 BOARD

• 122 Board (motor control board)
• The motor control board is just what it says. It
  controls the motor speed at start and at ramp
  down. The High, and Low potentiometers on this
  board controls the speed to a finer degree.
• DO NOT TOUCH THE SLOW POD
• J2 from this board feeds J10 on the 124 board.
• Current limit (P4) and IR Comp (P3)
• Is controlled from this board also.
• TP1 to ground will give you the current limit in
  DCV

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122 BOARD

• 122 Board (motor control board)
• The motor control board is just what it says. It
  controls the motor speed at start and at ramp
  down. The High, and Low potentiometers on this
  board controls the speed to a finer degree.
• DO NOT TOUCH THE SLOW POD
• J2 from this board feeds J10 on the 124 board.
• Current limit (P4) and IR Comp (P3)
• Is controlled from this board also.
• TP1 to ground will give you the current limit in
  DCV

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122 BOARD

• The 122 (motor control board) controls the input
  power to the various accessories in the 680 box
  i.e. SCR bridge, Field Bridge, Contactors etc.
  More importantly, the 124 board
• Jumpers 1 2 are dependent on input voltage.
• 230vac jumper 2 is removed
• 460vac both removed

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124 BOARD

• The RMI 124 board (computer interface board) Is
  the brains of the 680 Motor Control Box. There
  is a series of small led lights on this board.
  They act as a conduit of information depending on
  which lights are on/off
• J2 J3Foot switch
• J4, J12 E Stop Jumpers
• J7 Reference Sensor
• J9 Count Direction Sensor
• J11 Controls left/right direction
• and Dynamic brake

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124 BOARD

• The LI (D Brake) must be on for the carousel to
  work. If this light is out the e stop circuit is
  open. Depending on the safeties, something is
  tripped.
• L2 is the low speed light
• L3 Left direction
• L4 Right Direction
• L5 This in conjunction with L3 or L4
• L6 This works in conjunction with L3,4, and 5
• Voltage at J6 14 should be240vac
• If carousel is not stopping at the proper bin,
  and check lights L5 and 6
• They should flutter as the carousels slows to a
  stop using the foot switch
• If they stay solid, replace C/D sensor
• Transformers on top convert 230vac to 12vdc

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IPC CONTROL BOARD

• The IPC is the termination point for all
  safeties, lite trees, Sort Bars, e stops,
• Reset button and computer cable
• One IPC can control 4 Carousels
• Each tower represents a carousel
• The green lights tells the operator what is
  on/off when something is not working. In this
  scenario, everything is a go

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SCR BRIDGE

• The SCR bridge acts as a buffer between the input
  current from TS 12/14 on the main terminal strip
  (11/12 on older 680s)
• A bad SCR bridge will cause the main fuse to blow
  immediately and, in most cases, blow the 122
  board.

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Contactors

• There are two contactors, left and right. They
  have a set of points that over time, tend to
  stick. A small file or emory board can be a
  temporary fix in an emergency.
• On occasions, you may hear the tell tale click
  of the contactor working but nothing happens.
  The carousel works in one direction but not the
  other. Determine which one is not working, cut
  power, file the points, then try again.
• Replace ASAP

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Contact Coil

• The Contact Coil works in conjunction with the
  L/R Contactors. If you watch closely, you can
  see and hear the Latch release at the same time
  the contactor opens.

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Field Bridge

• The Field Bridge is fed from TS 5 and 6
• On the Power Terminal Strip. TS 5 and 6
  represent the F2 and F4 field windings in the
  motor.

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C/D Sensor

• The Count Direction Sensor is represented on the
  124 board by LED
• 5 for direction and 6 for count. If your
  carousel is being run by computer or a 530 box,
  this item controls where your carousel stops. If
  using a computer and your machine goes in one
  direction and does not stop. Chances are the
  count sensor is bad. If it starts and then stops
  after a few seconds, chances are its the
  direction sensor.
• Have some one rotate the carousel a few bins.
  Look at the bottom two led lights on the 124
  board. As the carousel slows down they will
  begin to flicker on and off until the machine
  stops. If one did not flicker and remained on
  all the time it is bad.

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Disk Blade, C/D sensor

• The Disk Blade or, Chopper Blade Is what the
  C/D Sensor uses to count.
• Each Blade is a pulse. Depending on the type
  of Carousel, pulse counts range from 245 to 315
  with a 530 box or 945 to 1260 with a IPC. This
  is a 7 lobe 245 pulse count disk.

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Reference Sensor

• The reference sensor starts the Homing
  process. Once the pendulum is hit by the clapper
  (next slide) The C/D se nsor (slide 12) starts
  counting the pluses generated by the chopper
  blade (slide 13). The pulses are counted by the
  IPC/CIB and determines the bin to stop at.

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Clapper

• The Clapper is mounted on top of a bin,
  (usually bin 1). When the clapper hits the
  pendulum on the reference sensor, the IPC/CIB
  starts counting the pulses generated by the
  chopper blade as it passes thru the C/D sensor.
  (The lack of metal on the chopper blade
  generates the pulse)

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Carousel Homing

• All carousels using either IPCs or CIBs, use
  the same procedure and hardware to find home.
  The only difference being the pulse count which
  is determined by the type of carousel. WH, the
  most popular, uses 980 in an IPC and 245 in a
  CIB.
• There are Four separate pieces of hardware
  required for either IPC or CIBs
• 1. Reference center- usually mounted on
  the first joint channel on the top of the
  carousel. The joint channel is where the first
  section is joined to the second section. The
  sensor is generally put on the right side as you
  face the carousel. The ref sensor has a
  pendulum that starts the count
• 2.Clapper The clapper is simply an L
  bracket mounted on top of a bin, usually bin 1.
• 3.The Disk or Chopper Blade is mounted
  on the side of the gear reducer.
• The absence of metal creates the
  pulse used by the C/D sensor
• 4.The last part is the C/D sensor for
  count and direction. This is mounted on the
  side of the gear reducer at the front of the
  carousel.

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Homing

• This can be on the rear reducer but very rare.
• Placement is dependent on where the control boxes
  are placed usually to save on cabling.
• When an IPC/CIB is first turned on, its lost.
  When a go command is given to turn to a certain
  bin, the carousel does not know where it is, ET
  must go Home.
• The carousel will start to spin, depending on its
  present location, it could go 360 degrees or just
  a couple of bins, and it depends on where the
  clapper is.
• Lets say the present position is bin 45 on a 50
  bin carousel. The carousel has not been Homed
  and you send it to bin 47. The carousel will
  rotate clockwise until the clapper (lets say its
  on bin one) hits the ref sensor, it will travel
  about a bin past the ref sensor, It now knows
  where it is. It knows where it is suppose to go,
  so, at this point the carousel will stop, and
  then go backwards to bin 47 as this is the
  shortest distance of travel. Once Homed, the
  carousel will always take the shortest route to
  its next location

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SUMMARY

• The 122 board is called the _____________________
  _____
• Which board controls the motor speed
  _________________
• Minimum voltage to run a carousel is
  __________________
• My carousel wont stop at the proper bin. Whats
  Wrong ____________
• The fuse blows at power up. Probable cause
  _______________________
• My carousel only works in one direction.
  Probable cause is ____________
• each IPC controls up to ______________ carousels
• The reference sensor starts the ___________ count
• The current limit is found at ____________________
  _
• Pulse count for your machine is
  ___________________