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SYSTEM OVERVIEWTriFactor’s understanding of the expected operation of the sort center, MOB5, located in Mobile, AlabamaCONVEYOR CONTROL HARDWAREThere are four control cabinets (CCP-100, CCP-200, CCP-300 & CCP-400) hardware devices used for the conveyor system are listed here:Main Hardware DevicesREF. DEVICEABBR. SYMBOLA. Conveyor Control PanelCCPB. Conveyor DrivesR,PS,UL,SMLC. Control / Pushbutton StationPBD. PhotoeyesPEE. Emergency Stop Pull cordsPCSF. Audible HornsAHG. Proximity SensorsZSH. Pressure SwitchesPSJ. Solenoid ValvesSOLK. BeaconsLTA. Conveyor System Control Panel CCP-100 (Located Next To Primary Sort Platform)PANEL DOOR OPERATOR CONTROLSPOWER ONWhite Pilot Light Illuminates when the Main Disconnect is on, and 24VDC control power is present.E-STOPRed Illuminated Maintained Pushbutton When depressed immediately disables all powered units capable of physical movement.SYSTEM STARTGreen Illuminated Momentary Pushbutton When depressed enables all conveyors to run. SYSTEM STOPRed Momentary PushbuttonWhen depressed disables all conveyors.JAM RESETAmber Illuminated Momentary Pushbutton Illuminates when a jam condition is present. When depressed clears a jam condition.E-STOP ACTUATEDRed Pilot LightIlluminates when any e-stop is engaged.LOW AIRBlue Illuminated Momentary PushbuttonIlluminates when system has low air pressure. When depressed clears a low air conditionMOTOR FAULTRed Illuminated Momentary Pushbutton Illuminates when system has a faulted motor. When depressed clears any VFD faults that may be present. POWER MONITORGraceport 480VAC Power monitor Monitors incoming 480VAC, 3 phase power.Requirements for this cabinet are 480 Volts, 3 Phase, 60-Hertz power. Wires must be rated to carry 250 Amps of power. The main internal components of the cabinet are: 250 Amp Main Fused Disconnect (Class J Fuses)480:120 15 KVA Control Transformer1.0KVA Sola Isolation Transformer240W DC Power Supply (480VAC:24VDC)480W DC Power Supply (480VAC:24VDC)IEC Motor Starters (Non Reversing)Circuit Breakers for VFD’sAllen-Bradley Compactlogix L3 Processor and I/O modulesAllen-Bradley 15” Panelview Plus on Panel DoorSola 24 VDC UPS w/ 10 Amp BatteryB. Conveyor System Control Panel CCP-200 (Located Next To Unloader Platform)PANEL DOOR OPERATOR CONTROLS“POWER ON”White Pilot Light Illuminates when the Main Disconnect is on, and 24VDC control power is present “HEARTBEAT”Blue Pilot LightIlluminates, and flashes when the Main Disconnect is on, and communications are present with main CPU“POWER MONITOR” Graceport 480VAC Power Monitor Monitors incoming 480VAC, 3 phase powerRequirements for this cabinet are 480 Volts, 3 Phase, 60-Hertz power. Wires must be rated to carry 400 Amps of power. The main internal components of the cabinet are: 400 Amp Main Fused Disconnect (Class J Fuses)480:120 15 KVA Control Transformer240W DC Power Supply (480VAC:24VDC)480W DC Power Supply (480VAC:24VDC)IEC Motor Starters (Non Reversing)Circuit Breakers for VFD’sAllen-Bradley 1769 Remote Point I/OSola 24 VDC UPS w/ 10 Amp BatteryC. Conveyor System Control Panel CCP-300 (Located In SML1 Area)PANEL DOOR OPERATOR CONTROLS“POWER ON”White Pilot Light Illuminates when the Main Disconnect is on, and 24VDC control power is present “HEARTBEAT”Blue Pilot LightIlluminates, and flashes when the Main Disconnect is on, and communications are present with main CPURequirements for this cabinet are 480 Volts, 3 Phase, 60-Hertz power. Wires must be rated to carry 30 Amps of power, fed from CCP-200. The main internal components of the cabinet are: 30 Amp Main Circuit Breaker240W DC Power SupplyIEC Motor Starters (Non Reversing)Circuit Breakers for VFD’sAllen-Bradley 1734 Remote Point I/OD. Conveyor System Control Panel CCP-400 (Located In SML2 Area)PANEL DOOR OPERATOR CONTROLS“POWER ON”White Pilot Light Illuminates when the Main Disconnect is on, and 24VDC control power is present “HEARTBEAT”Blue Pilot LightIlluminates, and flashes when the Main Disconnect is on, and communications are present with main CPURequirements for this cabinet are 480 Volts, 3 Phase, 60-Hertz power. Wires must be rated to carry 30 Amps of power, fed from CCP-200. The main internal components of the cabinet are: 30 Amp Main Circuit Breaker240W DC Power SupplyIEC Motor Starters (Non Reversing)Circuit Breakers for VFD’sAllen-Bradley 1734 Remote Point I/OPower RequirementsPANELCONTROL AREAPOWER FEED SIZE (Aps)CCP-100System250 (By Amazon)CCP-200System400 (By Amazon)CCP-300System30 from CCP-200CCP-400System30 from CCP-200 E. Conveyor Drives A motor disconnect lockout switch will be placed near each conveyor motor drive unit. This will enable each motor to be locked-out individually for maintenance purposes. Each contactor has a set of auxiliary contacts so that status can be monitored. All drives are 480 Volt, 3 Phase, 60 Hertz. The following list is the motor numbers for the conveyors: CCP-100 SYSTEM RO1-1, RO1-2, RO1-3, RO1-4, RO1-5, RO1-6, RO2-1, RO2-2, RO2-3, RO2-4, RO2-5, RO2-6, RO3-1, RO3-2, RO3-3, RO3-4, RO3-5, RO3-6, RO3-7, RO4-1, RO4-2, RO4-3, RO4-4, RO4-5, and RO4-6CCP-200 SYSTEM GD-1, UL1-1, UL1-2, UL2-1, UL2-2, UL3-1, UL3-2, UL4-1, UL4-2, UL5-1, UL5-2, UL6-1, UL6-2, UL7-1, UL7-2, UL8-1, UL8-2, PS1-1, PS1-2, PS1-3 and PS1-4 CCP-300 SYSTEM SML1-1, SML1-2, SML1-3, SML1-4, and SML1-5CCP-400 SYSTEMSML2-1, SML2-2, SML2-3, SML2-4, and SML2-5Conveyors RO1-1, RO1-2, RO1-3, RO2-1, RO2-2, RO2-3, RO3-1, RO3-2, RO4-1, RO4-2, RO4-3, UL1-2, UL2-2, UL3-2, UL4-2, UL5-2, UL6-2, UL7-2, and UL8-2 are Set Speed. Conveyors PS1-1, PS1-2, PS1-3, PS1-4, SML1-1, SML1-2, SML1-3, SML1-4, SML1-5, SML2-1, SML2-2, SML2-3, SML2-4, SML2-5, RO1-4, RO1-5, RO1-6, RO2-4, RO2-5, RO2-6, RO3-3, RO3-4, RO3-5, RO3-6, RO3-7, RO4-4, RO4-5 and RO4-6 are Variable Speed. F. Photoeyes Photoelectric sensors, or photo eyes, are devices that detect the presence and/or movement of the product on the conveyor system. By sensing the interruption of an invisible beam that passes from a photo head to a reflector, the photo eye will send a signal to the PLC to indicate product status. The following list is the photo eyes used throughout the system: PE200.5119 - D1 Jam EyePE200.5122 - C1 Jam EyePE200.5123 - C2 Jam EyePE100.5225 - C3 Jam EyePE100.5226 - C4 Jam EyePE100.5228 - C5 Jam Eye #1PE100.5229 -C5 Jam Eye #2PE100.5230 - C6 Jam EyePE100.5217 - C7 Jam EyePE100.5219 - C8 Jam EyePE100.5220 - C9 Jam EyePE100.5135 - C10 Jam EyePE100.5201 - C11 Jam EyePE100.5202 - C12 Jam EyePE100.5207 - C13 Jam EyePE100.5208 - C14 Jam EyePE100.5210 - C15 Jam Eye #1PE100.5211 - C15 Jam Eye #2PE100.5512 - C16 Jam EyePE200.5120 - SML1-1 Jam EyePE200.5121 - SML2-1 Jam EyePE200.5133 -PS1-2 Jam EyePE100.4119 -Doghouse #1 50% FullPE100.4120 -Doghouse #1 75% FullPE100.4121- Doghouse #2 50% FullPE100.4122- Doghouse #2 75% Full PE100.4123- Doghouse #3 50% FullPE100.4124- Doghouse #3 75% FullPE100.4125- Doghouse #4 50% Full PE100.4126- Doghouse #4 75% FullPE100.4127- Doghouse #5 50% FullPE100.4128- Doghouse #5 75% FullPE100.4129- Doghouse #6 50% FullPE100.4130- Doghouse #6 75% FullPE100.5134- RO1-1 Jam EyePE100.5206- RO2-1 Jam EyePE100.5216- RO3-1 Jam EyePE100.5224- RO4-1 Jam EyePE100.5203- RO1-5 Jam EyePE100.5213-RO2-5 Jam EyePE100.5221- RO3-6 Jam EyePE100.5231- RO4-5 Jam EyePE100.5204- RO1-5 Full EyePE100.5205- RO1-6 Full EyePE100.5214- RO2-5 Full EyePE100.5215-RO2-6 Full EyePE100.5222- RO3-6 Full EyePE100.5223- RO3-7 Full EyePE100.5232- RO4-5 Full EyePE100.5233- RO4-6 Full EyePE100.5124- UL1 Jam EyePE100.5125- UL2 Jam EyePE100.5126- UL3 Jam EyePE100.5128- UL4 Jam EyePE100.5129- UL5 Jam EyePE100.5130- UL6 Jam EyePE100.5131- UL7 Jam EyePE100.5132- UL8 Jam EyeG. Emergency Stop Pullcords and Zones Emergency stop pullcords will be used on both sides of the conveyor system. When a cord is pulled, it will immediately disable all powered units capable of physical movement within that zone. The associated beacon will flash if the emergency stop is activated. The following are Rope Switches mounted throughout the system and the zones that they are in and also what conveyors are affected:E-STOP ZONE 1:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 – Panel E-stop PushbuttonPCS100.4414 - PS1-1PCS100.4415 - PS1-1PCS100.4402 - SML1PCS100.4403 - SML1PCS100.4404 - SML1PCS100.4405 - SML1PCS100.4406 - SML1PCS100.4407 - SML1PCS100.4408 - SML2PCS100.4409 - SML2PCS100.4410 - SML2PCS100.4411 - SML2PCS100.4412 - SML2PCS100.4413 - SML2Conveyors that are stopped when a rope switch is activated in Zone 1: SML1-1, SML1-2, SML1-3, SML1-4, SML1-5, SML2-1, SML2-2, SML2-3, SML2-4, SML2-5 and PS1-1 E-STOP ZONE 2:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 – Panel E-stop PushbuttonPCS200.4417 - PS1-3PCS200.4418 - PS1-3PCS200.4412 - PS1-2Conveyors that are emergency stopped when a rope switch is activated in Zone 2: PS1-2 & PS1-3.Conveyors that are controlled stopped when a rope switch is activated in Zone 2: UL1, UL2, UL3, UL4, UL5, UL6, UL7, UL8, SML1, SML2 and PS1-1 E-STOP ZONE 3:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 – Panel E-stop PushbuttonPCS100.4402- PS1-4Conveyors that are emergency stopped when a rope switch is activated in Zone 3: PS1-4.Conveyors that are controlled stopped when a rope switch is activated in Zone 3: UL1, UL2, UL3, UL4, UL5, UL6, UL7, UL8, SML1-1, SML2-1, PS1-1, PS1-2 and PS1-3E-STOP ZONE 4:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 – Panel E-stop PushbuttonPCS100.4403 - RO1-1PCS100.4404 - RO1-1Conveyors that are stopped when a rope switch is activated in Zone 5: RO1-1 and RO4-1 E-STOP ZONE 5:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonPCS100.4412 - RO2-1PCS100.4413 - RO2-1Conveyors that are stopped when a rope switch is activated in Zone 6: RO2-1 and RO3-1 E-STOP ZONE 6:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonPCS100.4405 - RO1-2PCS100.4406 - RO1-2PCS100.4407 - RO1-3/6PCS100.4409 - RO1-3/4PCS100.4408 - RO1-4/6PCS100.4410 - RO1-5PCS100.4411 - RO1-5Conveyors that are stopped when a rope switch is activated in Zone 6: RO1-1, RO1-2, RO1-3, RO1-4, RO1-5 and RO1-6 E-STOP ZONE 7:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonPCS100.4414 - RO2-2PCS100.4415 - RO2-2PCS100.4416 - RO2-4PCS100.4417 - RO2-4/6-1PCS100.4418 - RO2-4/6-2PCS100.4419 - RO2-5PCS100.4420 - RO2-5Conveyors that are stopped when a rope switch is activated in Zone 7: RO2-1, RO2-2, RO2-3, RO2-4, RO2-5 and RO2-6E-STOP ZONE 8:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonPCS100.4521 - RO3-2PCS100.4522 - RO3-2PCS100.4423 - RO3-3PCS100.4424 - RO3-3PCS100.4425 - RO3-5PCS100.4426 - RO3-5/7-1PCS100.4427 - RO3-5/7-2PCS100.4428 - RO3-6PCS100.4429 - RO3-6Conveyors that are stopped when a rope switch is activated in Zone 8: RO3-1, RO3-2, RO3-3, RO3-4, RO3-5, RO3-6 and RO3-7E-STOP ZONE 9:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonPCS100.4430 - RO4-2PCS100.4431 - RO4-2PCS100.4432 - RO4-3PCS100.4433 - RO4-3PCS100.4434 - RO4-4PCS100.4435 - RO4-4/6-1PCS100.4436 - RO4-4/6-2PCS100.4501 - RO4-5PCS100.4502 - RO4-5Conveyors that are stopped when a rope switch is activated in Zone 9: RO4-1, RO4-2, RO4-3, RO4-4, RO4-5 and RO4-6E-STOP ZONE 10:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonConveyors that are stopped when a panel E-Stop pushbutton is activated in Zone 10: UL1-1, and UL1-2E-STOP ZONE 11:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonConveyors that are stopped when a panel E-Stop pushbutton is activated in Zone 11: UL2-1, and UL2-2E-STOP ZONE 12:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonConveyors that are stopped when a panel E-Stop pushbutton is activated in Zone 12: UL3-1, and UL3-2E-STOP ZONE 13:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonConveyors that are stopped when a panel E-Stop pushbutton is activated in Zone 13: UL4-1, and UL4-2E-STOP ZONE 14:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonConveyors that are stopped when a panel E-Stop pushbutton is activated in Zone 14: UL5-1, and UL5-2E-STOP ZONE 15:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonConveyors that are stopped when a panel E-Stop pushbutton is activated in Zone 15: UL6-1, and UL6-2E-STOP ZONE 16:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonConveyors that are stopped when a panel E-Stop pushbutton is activated in Zone 16: UL7-1, and UL7-2E-STOP ZONE 17:PBLT100.4401 - Panel E-Stop PushbuttonPBLT200.4401 - Panel E-Stop PushbuttonConveyors that are stopped when a panel E-Stop pushbutton is activated in Zone 17: UL8-1, and UL8-2H. Audible Horn: An audible horn is used to alert personnel that the conveyor system is about to start. A five second delay will be used once the warning horn starts to sound. The following list is the warning horns used throughout the system:AH100.3103 - CCP100AH200. - CCP200AH100.3104 - RO1AH100.3105 - RO2AH100.3106 - RO3AH100.3107 - RO4I. Proximity Sensors: Proximity sensors will be used at the divert arms on the sorter. These sensors are used to detect when the arm is in the retracted position. The following list is the limit switches used throughout the system:PRS100.5110 – Divert Arm Chute #1 is retracted PRS100.5111 – Divert Arm Chute #2 is retracted PRS100.5112 – Divert Arm Chute #3 is retracted PRS100.5113 – Divert Arm Chute #4 is retracted PRS100.5114 – Divert Arm Chute #5 is retracted PRS100.5115 – Divert Arm Chute #6 is retractedJ. Pressure Switches: A pressure switch will be used to detect system air pressure.PS100.5117 - Air Pressure is Present – 80psiK. Solenoid Valves: Solenoid valves are located at the sorter PS1-6 for the extending of the divert arms, spring returning. The following list is the solenoid valves used throughout the system: SOL100.4110 – Energize to extend divert arm at Chute #1 SOL100.4111 – Energize to extend divert arm at Chute #2 SOL100.4112 – Energize to extend divert arm at Chute #3 SOL100.4113 – Energize to extend divert arm at Chute #4 SOL100.4114 – Energize to extend divert arm at Chute #5 SOL100.4115 – Energize to extend divert arm at Chute #6 L. Beacons: Beacons are used to give the Operator Status condition of the system. Blue Beacons: Indicates a lane full condition.LT100.5802 - RO1-5LT100.5803 - RO1-6LT100.5804 - RO2-5LT100.5805 - RO2-6LT100.5806 - RO3-6LT100.5807 - RO3-7LT100.5808 - RO4-5LT100.5809 - RO4-6Amber Beacons: Indicates a jam condition.LT200.5502 -D1LT200.5505 -C1LT200.5506 -C2LT100.5722 - C3LT100.5723 - C4LT100.5724 - C5-1LT100.5725 -C5-2LT100.5726 - C6LT100.5716 - C7LT100.5717 - C8LT100.5718 - C9LT100.5703 - C10LT100.5704 - C11LT100.5705 - C12LT100.5708 -C13LT100.5709 -C14LT100.5711 -C15-1LT100.5712 -C15-2LT100.5713 -C16LT200.5503 -SML1-1LT200.5504 -SML2-1LT200.5434 -PS1-2LT100.5702 -RO1-1LT100.5707 -RO2-1LT100.5715 -RO3-1LT100.5721 -RO4-1LT100.5706 -RO1-5LT100.5714 -RO2-5LT100.5720 -RO3-6LT100.5727 -RO4-5LT200.5507 - UL1LT200.5508 - UL2LT200.5509 - UL3LT200.5511 - UL4LT200.5512 - UL5LT200.5513 - UL6LT200.5514 - UL7LT200.5515 - UL8Red Beacons: Indicates an e-stop condition.LT100.5729 -RO1-5LT100.5730 -RO1-6LT100.5731 -RO2-5LT100.5732 -RO2-6LT100.5733 -RO3-6LT100.5734 -RO3-7LT100.5735 - RO4-5LT100.5736 - RO4-6LT100.5827 - PS1-4Lane Status Beacons: Located on the high, outside edge of the sort platform for sort platform associates to see while they are sorting within the platform sort stations. Indicates each line’s status, specifically “run”, “jam”, “full lane”, and “emergency stop” conditions.LT100.5902 -RO1LT100.5903 -RO2LT100.5904 -RO3LT100.5905 -RO4M. CONTROL STATIONS (START/STOP): Control Stations are used to give the Operator the ability to start and stop the individual zones without having to go back to the main Control Panel CCP-100.PBLT200.5320, PBLT200.5321, PB200.5322, & PB200.5322A - SML1 (Start/Stops SML1-2, SML1-3, SML1-4 & SML1-5)PBLT200.5323, PBLT200.5324, PB200.5325, & PB200.5325A - SML2 (Start/Stops SML2-2, SML2-3, SML2-4 & SML2-5PBLT200.5201, & PB200.5202 - PS1-1 (Start/Stops PS1-1, PS1-2, PS1-3, PS1-4, SML1-1, & SML2-1)PBLT200.5203, & PB200.5204 - PS1-2 (Start/Stops PS1-1, PS1-2, PS1-3, PS1-4, SML1-1, & SML2-1)PBLT200.5205, & PB200.5206 - PS1-2 (Start/Stops PS1-1, PS1-2, PS1-3, PS1-4, SML1-1, & SML2-1)PBLT100.5316, & PB100.5317 - PS1-4 (Start/Stops PS1-1, PS1-2, PS1-3, PS1-4, SML1-1, & SML2-1)PBLT100.5301, & PBLT100.5302 - Sort #1 (Sort Lane Active/Sort Lane Inactive/ E-Stop Zone 3)PBLT100.5303, & PBLT100.5304 - Sort #2 (Sort Lane Active/Sort Lane Inactive/ E-Stop Zone 3)PBLT100.5305, & PBLT100.5306 - Sort #3 (Sort Lane Active/Sort Lane Inactive/ E-Stop Zone 3)PBLT100.5307, & PBLT100.5308 - Sort #4 (Sort Lane Active/Sort Lane Inactive/ E-Stop Zone 3)PBLT100.5310, & PBLT100.5311 - Sort #5 (Sort Lane Active/Sort Lane Inactive/ E-Stop Zone 3)PBLT100.5312, & PBLT100.5313 - Sort #6 (Sort Lane Active/Sort Lane Inactive/ E-Stop Zone 3)PBLT100.5314, & PBLT100.5315 - Sort #7 (Sort Lane Active/Sort Lane Inactive/ E-Stop Zone 3)PBLT100.4201, PBLT100.4202, PB100.4203, & PB100.4203A - RO1-5 (Start/Stops RO1-1, RO1-2, RO1-3, RO1-4 and RO1-5)PBLT100.4204, PBLT100.4205, PB100.4206, & PB100.4206A - RO1-6 (Start/Stops RO1-6)PBLT100.4207, PBLT100.4208, PB100.4209, & PB100.4209A - RO2-5 (Start/Stops RO2-1, RO2-2, RO2-3, RO2-4 and RO2-5)PBLT100.4210, PBLT100.4211, PB100.4212, & PB100.4212A - RO2-6 (Start/Stops RO2-6)PBLT100.4213, PBLT100.4214, PB100.4215, & PB100.4215A - RO3-6 (Start/Stops RO3-1, RO3-2, RO3-3, RO3-4, RO3-5 and RO3-6)PBLT100.4216, PBLT100.4217, PB100.4218, & PB100.4218A - RO3-7 (Start/Stops RO3-7)PBLT100.4219, PBLT100.4220, PB100.4221, & PB100.4221A - RO4-5 (Start/Stops RO4-1, RO4-2, RO4-3, RO4-4 and RO4-5)PBLT100.4222, PBLT100.4223, PB100.4224, & PB100.4224A - RO4-6 (Start/Stops RO4-6)N. CONTROL STATIONS (JAM RESET): Control Stations are used to give the Operator the ability to RESET jams at the jam point.PB200.5028 - D1(Reset Ability for D1 to Dump onto PS1-1)PB200.5031 - C1(Restarts PS1-1, PS1-2, SML1-1 & SML1-2)PB200.5032 - C2 (Restarts PS1-1, PS1-2, PS1-3, SML1-1 & SML1-2)PB100.5521 - C3 (Restarts RO4-1)PB100.5522 - C4 (Restarts RO4-1 & RO4-2)PB100.5523 - C5-1 (Restarts RO4-1, RO4-2 & RO4-3)PB100.5524 - C5-2 (Restarts RO4-1, RO4-2 & RO4-3)PB100.5525- C6 (Restarts RO4-1, RO4-2, RO4-3 & RO4-4)PB100.5515 - C7 (Restarts RO3-1)PB100.5516 - C8 (Restarts RO3-2 & RO3-2)PB100.5517 - C9 (Restarts RO3-1, RO3-2, RO3-3, RO3-4 & RO3-5)PB100.5502 - C10 (Restarts RO1-1)PB100.5503 - C11 (Restarts RO1-1 & RO1-2)PB100.5504 - C12 (Restarts RO1-1, RO1-2, RO1-3 & RO1-4)PB100.5507 - C13 (Restarts RO2-1)PB100.5508 - C14 (Restarts RO2-1 & RO2-2)PB100.5510 - C15-1 (Restarts RO2-1, RO2-2 & RO2-3)PB100.5511 - C15-2 (Restarts RO2-1, RO2-2 & RO2-3)PB100.5512 - C16 (Restarts RO2-1, RO2-2, RO2-3 & RO2-4)PB100.5501 - RO1-1 (Restarts RO1-1)PB100.5506 - RO2-1 (Restarts RO2-1)PB100.5514 - RO3-1 (Restarts RO3-1)PB100.5520 - RO4-1 (Restarts RO4-1)PB100.5505 - RO1-5 (Restarts RO1-1, RO1-2, RO1-3, RO1-4 & RO1-5)PB100.5513 - RO2-5 (Restarts RO2-1, RO2-2, RO2-3, RO2-4 & RO2-5)PB100.5519 - RO3-6 (Restarts RO3-1, RO3-2, RO3-3, RO3-4, RO3-5 & RO3-6)PB100.5526 - RO4-5 (Restarts RO4-1, RO4-2, RO4-3, RO4-4 & RO4-5)PB200.5029 - SML1-1 (Restarts SML1-1 & PS1-1)PB200.5030 - SML2-1 (Restarts SML2-1 & PS1-1)PB200.5035 - PS1-2 (Restarts UL1-1 & 1-2 or UL2-1 & 2-2 or UL3-1 & 3-2 or UL4-1 & 4-2 or UL5-1 & 5-2 or UL6-1 & 6-2 or UL7-1 & 7-2 or UL8-1 & 8-2)DESCRIPTION OF OPERATIONAfter turning on the Main Disconnect of Control Panel CCP-100, CCP-200, CCP-300, and CCP-400 the following conditions must be met prior to starting the system: “POWER ON” pilot light on CCP-100, CCP-200, CCP-300, and CCP-400 must be illuminated “EMERGENCY STOP devices RESET. System Air Pressure Present With these conditions met, the system can be globally started by depressing the “SYSTEM START” illuminated green Pushbutton, located on CCP-100. Each individual zone can be locally started or stopped, once the global system is running, by depressing the “LOCAL START” illuminated Green Pushbuttons, located in control stations listed in paragraph M above. The audible horns will sound for 5 seconds to indicate the system is starting, when the 5 seconds expire the Horn will silence, and the system will start running. If a rope switch or e-stop pushbutton is activated, the zone in which the device is located will shut down all conveyors in that zone. Zones are listed above. Once the rope switch or e-stop pushbutton is reset then any Start/Stop Control station located in that zone will restart the conveyors. Once the system has been started the following conveyor systems will start as follows: Zone 1 -3 Sortation conveyor PS1-4 will start. Once PS1-4 has become up to speed PS1-3 will start. Once PS1-3 has become up to speed PS1-2 will start. Once PS1-2 is up to speed PS1-1 will start. When PS1-1 is up to speed SML1, and SML2 will start.Zone 10 – 17 Incline conveyors UL1-2, UL2-2, UL3-2, UL4-2, UL5-2, UL6-2, UL7-2, and UL8-2 will start once PS1-2 has become up to speed and there is not a jam. These conveyors are permitted to run as long as PS1-2 is up to speed.Zone 6 Conveyors will start as follows: RO1-5 and RO1-6 will run as long as the gravity downstream is not full and there is not a jam. Once RO1-5 is running, RO1-4 will start. After RO1-4 is running, RO1-3 will start. After RO1-3 is running, RO1-2 will start. After RO1-2 is running, RO1-1 will start.Zone 7 Conveyors will start as follows: RO2-5 and RO2-6 will run as long as the gravity downstream is not full and there is not a jam. Once RO2-5 is running, RO2-4 will start. After RO2-4 is running, RO2-3 will start. After RO2-3 is running, RO2-2 will start. After RO2-2 is running, RO2-1 will start.Zone 8 Conveyors will start as follows: RO3-6 and RO3-7 will run as long as the gravity downstream is not full and there is not a jam. Once RO3-6 is running, RO3-5 will start. Once RO3-5 is running, RO3-4 will start. After RO3-4 is running, RO3-3 will start. After RO3-3 is running, RO3-2 will start. After RO3-2 is running, RO3-1 will start.Zone 9 Conveyors will start as follows: RO4-5 and RO4-6 will run as long as the gravity downstream is not full and there is not a jam. Once RO4-5 is running, RO4-4 will start. After RO4-4 is running, RO4-3 will start. After RO4-3 is running, RO4-2 will start. After RO4-2 is running, RO4-1 will start.Conveyors RO1-5, RO1-6, RO2-5, RO2-6, RO3-6, RO3-7, RO4-5 and RO4-6 gravity full line timers are set for 10 seconds blocked to represent a full line and 10 seconds clear to represent full line clear. When the clear timer equals 5 remaining seconds the audible horn will sound to represent conveyor re-start. In the event that a full lane condition exists, all powered run-out conveyors upstream of the associated full lane photoeye will turn off until after the 10 second clear time is met. DESCRIPTION OF OPERATION con’tJam photocell at each chute is set for 45 seconds blocked to represent a jam. Once the jam is detected the Amber Warning Beacon located at the respective jam point will illuminate, the conveyor and all powered upstream conveyors will stop running. To reset the jam the PE must be clear and the “JAM RESET” pushbutton located at the jam point must be depressed. With these conditions met the system will sound the horn for 5 seconds, the Amber beacon will go off and the conveyor will start. Divert arm Extend/Retract jam timers are set for 10 seconds. If the divert arm is told to extend and it does not see the limit switch go off in 10 seconds then a divert jam is detected. This same logic is for the retract condition as well. Once the limit switch is made the jam condition can be reset at the panel door of CCP-100 by depressing the “JAM RESET” illuminated pushbutton on the door. With these conditions met the system will sound the horn for 5 seconds, the Amber beacon will go off and the conveyor will start. The telescopic belted unloaders are interlocked with each of their respective incline belts. In order for the telescopic belted unloaders to start or continue to run, the collector belt, PS1-2 must be running. Each incline belt runs when the respective telescopic unloader belt is running. The gaylord dumper, D1, is interlocked with the PS1-1 conveyor such that D1 can only dump if PS1-1 is running. The four lane status beacons located on the high end of the primary sort platform in full view of all associates working in the platform indicate the status of each run out line.Green indicates that the line is powered and running with no emergency stops, jams or full lane conditionsAmber indicates that there is a jam on the line that needs to be cleared and resetBlue indicates a full lane on the line that needs to be clearedRed indicates an emergency stop condition on the line that needs to be reset in order to restartSort Slide Description of Operation152399126365213450021345Background and PurposeThe purpose of the Sort Slide is to evenly distribute work among a possibly continually-varying number of operators. The slide also acts as a buffer, allowing the upstream (unload) and downstream (pallet build lines) sections of the building to ebb and flow without directly affecting the other. The logic of the sortslide diverters should be written to be as flexible as possible to varying input and output thruput. The logic should also require minimal operator interaction.Operator StationsEach operator station should be numbered, and be able to be independently enabled and disabled. Each station should also have a user-configurable divert time. The system should prevent the user from inputting a divert time that will either cause equipment damage (too short), or input a time that will cause an arithmetic error (a negative value time). This includes the slide’s “Default Divert,” which may have a fixed diverter, or no divert at all. In the figure above, position #5 is the default divert. Each position should also have a sensor (e.g. photoeye) to determine when the station is full or available.Divert SequenceTo best protect product, diverting should start with the most upstream available station and proceed downstream. Diverters should be fully engaged before product comes in contact with it. This sequence minimizes instances of diverters sweeping across product, which minimized opportunity for product damage.TerminologyFor the sake of this document, terminology is defined as follows:Each section of accumulation on the sort slide is termed a “Station.” This includes the default position.A “Diverter” refers to the physical mechanism by which packages are routed to individual stations. These typically take the form of swing-arm diverters, but can take other forms.A diverter is “Closed” when it is out on the belt, diverting product and “Open” when it is back home, enabling product to pass. A station is “Enabled” when it is turned on by the operator station and “Disabled” when it is not. The station is “Full” when the sensor is blocked continually. It is “Not full” otherwise. A station is “Available” when it is both enabled and not full and “Not Available” otherwise. “Upstream” and “downstream” stations or diverts are in reference to the sort slide feed conveyor.“Current divert” refers to the station that is currently receiving product.“Next Divert” refers to the next available divert, downstream from the Current Divert“First Divert” refers to the most upstream available divert.“Last Divert” refers to the most downstream available divert.“Accumulated Product” refers to the time of product between the Last Divert and the First Divert. Detailed Description of OperationCode is to be written assuming a continuous, steady state of flow into the sort area. At all times, the Last Divert is to be closed continually. In the case of a default slide, there is no divert, but the physics of the design achieve the same result.If, during the course of the cycle, the default slide becomes unavailable, the next upstream available diverter should close until such time as a more downstream station becomes available, when that station’s corresponding diverter should be constantly closed. Each divert’s cycle time, or TCycle should be calculated as follows:TCycle=TDivert+TClose+TOffsetWhere: TDivert= Configured Divert Time (minimum 6-15 seconds)TClose= Amount of time for Diverter to go from home position to closed position on belt.TOffset= Time to compensate for empty space on belt between Previous Divert and Current Divert. In order to account for the “bubble” of air that exists between two diverts between opening an upstream diverter and packages hitting the downstream diverter, a Toffset is calculated as is shown below. The figure below illustrates this concept. 53975662940001900555-593725Bubble created by space between diverts00Bubble created by space between diverts1899920-11874600189357020345400013620751661795001831975170116500167957515487650015271751396365001374775124396500315023511150600029584659944100027501858750300031635708350250027571701185545003152775132461000282829013557250029197301552575003153410160147000267843018135600031991301831340003199130204343000271399020605750013385801212850013271503282950010172702806700010198109398000713740400685007359651308100035877528130500349253276600035623513970001500505136525004243070135890002134521345TOffset= Distance Between Current and Next DivertsVBeltIn sort slides with equally-spaced diverts, this can be calculated as follows:TOffset= DNext-DCurrentpVBeltWhere:DNext = Divert Number of Next DivertDCurrent = Divert Number of Current Divertp= Divert pitchVBelt = Belt SpeedThe cycle is to start with the First Divert closing for its calculated divert time. Just before the divert cycle time is complete, the Next Divert will close. This time advance should be sufficient so that the Next Diverter is completely closed before the Current Divert Opens. At the end of the First Divert’s TCycle, the first divert will open and the cycle will continue as such. At all times, the system should calculate the remaining product that exists between the current divert and the last. By doing this, and restarting the cycle accordingly, the last divert does not get flooded with product that would be leftover on the belt between the First and Last Divert. Accumulated product (TAccum) is calculated as is shown below. This equation assumes diverters are spaced evenly. TAccum= DLast-DCurrentpVBeltWhen TAccum is greater than TRemaining, the First Divert should close, and the whole cycle restart. TRemaining is simply the sum of all cycle times between the Current Divert and the Last Divet.TRemaining=D=CurrentLastTCycleDWhen there are no Available Diverts, the feed belt should stop, to be restarted when a divert becomes available. Diverts 3 and 5 will close for 4 seconds on startup of feed belt and then return to Open position.It is important that all calculations are dynamic, and recalculated as stations become Full or Disabled, or come out of those states. It is also critical that units of measure are worked out in the above calculations that involve speeds, distances, etcAPPROVAL ACKNOWLEDGEMENT The undersigned acknowledges receipt, review, and approval, either as submitted, or as noted, of all sections and details specified and contained within the contents of this document. A failure to review and either note agreed upon changes or sign this document assumes this document is approved as-is and as such, is the basis for final design and implementation.Any future changes or deviations required from the contents of the document, whether signed and approved, or not, constitutes the basis for a Change Order, which may or may not result in additional project costs and a possible extension to the project timeline.TRIFACTOR SOLUTIONS, LLCAuthorizing Name – please printAuthorizing Name – please printTitleTitleAuthorizing SignatureAuthorizing SignatureDateDate ................
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