Advanced Bundle StationDocument Version 01

Doc. No.: PCE_BA_ABS_110526_001

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Contents

1 Safety 2 1.1 Safety instructions .................................................................................................................... 2 1.2 Basic safety measures ............................................................................................................. 2 1.3 Operator's duty to exercise due care.................................................................................... 3 1.4 Protection against injuries caused by electrical power .................................................... 4 1.5 Protection against injuries caused by mechanical impact ............................................... 4 1.6 Transport, installation and start-up ....................................................................................... 4 1.7 Use according to regulations.................................................................................................. 5

2 Components 6 2.1 Setting up the machine ............................................................................................................ 6 2.2 Aligning the machine frame .................................................................................................... 6 2.3 Establish the supply connections........................................................................................... 7 2.4 Compressed air.......................................................................................................................... 7 2.5 Test run ....................................................................................................................................... 8 2.6 Test the line synchronization .................................................................................................. 8

3 Hardwaredesign 9 3.1 Description ................................................................................................................................. 9 3.2 Technical Data........................................................................................................................... 9

3.2.1 User terminal.................................................................................................................... 9 3.2.2 Megapixel Camera.......................................................................................................... 9 3.2.3 Laser Line Scanner ......................................................................................................... 9

3.3 Overview of the machine ....................................................................................................... 10 3.4 Emergency Stop....................................................................................................................... 11 3.5 Configuration............................................................................................................................ 11

4 Pilot Software 12 4.1 Overview ................................................................................................................................... 12

5 Maintenance 13 5.1 Overview ................................................................................................................................... 13 5.2 Identification plates ................................................................................................................ 14 5.3 Maintenance and cleaning schedule .................................................................................. 15 5.4 Cleaning .................................................................................................................................... 16

5.4.1 General instructions on caring for high-grade steel .............................................. 16 5.4.2 Cleaning of the Touch Display .................................................................................... 16 5.4.3 Cleaning the operator console and protective covers........................................... 17 5.4.4 Cleaning the conveyor belt.......................................................................................... 17 5.4.5 Cleaning the photoelectric cells................................................................................. 17 5.4.6 Cleaning of the camera ................................................................................................ 18

5.5 Emptying the maintenance unit condensate collector..................................................... 18 5.6 Cleaning/replacing the maintenance unit filter ................................................................. 19

6 Status Displays 20 6.1 Overview ................................................................................................................................... 20

7 Settings and Adjustments 21 7.1 Settings at the pressure unit ................................................................................................. 21 7.2 Settings of the ejection .......................................................................................................... 22

Preface 1

Preface

General Information

These operating instructions shall add to the correct and safe application of the PCE components. Therefore please observe the following instructions.

I. It is necessary to read the complete operations instructions before starting up the PCE components in order to avoid false application of the machines.

II. For your own safety, please observe the safety instructions in the operations manual. Please read the instructions carefully even if you are already used to the application and operation of PC-components.

III. This symbol displays safety instructions or the danger of injury, danger of product damage and environmental damage.

< Signal >

< type of danger >

< consequences >

< measures >

IV. This symbol indicates important general instructions.

< Note>

<important references >

V. The Instructions Manual has to be always made available to the operator, in full, where the machine is installed.

VI. Please make sure that the instructions manual remains in place where the machine is installed.

VII. These operating instructions do not replace installation and service by trained personnel!

VIII. These operating instructions are to be treated as strictly confidential. The information given herein shall not be copied, misused or made available to third parties without our prior written consent.

IX. PCE continuously further develops all components. Modifications of the scope of delivery in form, technique and configuration are subject to change. We appreciate your understanding that no claims can be made from information and illustrations of this operations manual.

2 Safety

1 Safety

1.1 Safety instructions

The following symbols and notes are warning signals of possible damage to person or property or assist you as guidelines.

WARNING!

This symbol can be found in the operating instructions at all references concerning operational safety, if not adhered to there will be danger to body and live of persons.

Always observe the instructions carefully and perform with extreme attention and wariness.

Note

This symbol indicates the appropriate handling of PCE-components.

1.2 Basic safety measures

For safe operation of the PC components the following points must be observed:

• The components must be mounted on a stable, mechanical, permanently fixed attachment.

• During operation, the components must be protected against the influence of external light.

• The power supply of the components is provided by 12 / 24 / 36 V DC / 230 V AC-technique and supplied by an external power source. All necessary safety measures for this type of technique are to be adhered to.

• The device may only be operated by persons trained on and authorized to use the device, who are familiar with the Instruction Manual and are able to operate the device accordingly.

• In addition, these persons have to be instructed first.

WARNING!

Lightning

Lightning causes damage to the eyes.

Do not look into the lightning without adequate eye protection.

Safety 3

To ensure safe operation of the system, repeated inspections are to be carried out on all the relevant safety parts, and particularly the above-mentioned points and Instruction Manual are to be observed.

1.3 Operator's duty to exercise due care

The PCE components are developed and constructed under consideration of the harmonized norms to be adhered to, as well as further technical specifications. They meet the latest technical requirements and ensure the highest level of security during operation.

The safety of the system during everyday operation can, however, only be ensured if all the necessary, relevant measures are taken. Planning these measures and controlling their implementation is part of the system operator's responsibility for exercising due care.

The operator must ensure that:

• the system is used in accordance with the stipulations

• the system is only operated in perfect, fully functional condition

• the Instructions Manual is always in a readable condition and is available, in full, where the machine is installed

• only respectively qualified and authorized personnel operate and service the system

• this personnel is instructed on a regular basis on all the relevant aspects concerning work safety, and that they are familiar with the Instruction Manual and the safety instructions it contains

• all the system features relating to safety are carefully tested at regular intervals

• the higher the safety risks protected against by this device are, the more frequently regular inspections must be carried out.

4 Safety

1.4 Protection against injuries caused by electrical power

WARNING!

The system is operated with supply voltage! Contact with live parts can cause perilous shock currents and severe burns.

Operate system with duly mounted housing only.

The housing can be opened in dead-voltage state only by professional qualified personnel.

Unplug electric supply prior to cleaning and care.

In case of liquid has been spilled on the system, immediately switch off the system and unplug electric supply.

1.5 Protection against injuries caused by mechanical impact

WARNING!

Danger of injury by movable and rotating parts! Always adhere to the following rules:

Wear adequate personal protective equipment.

Switch off machine prior to mechanical adjustment work.

1.6 Transport, installation and start-up

During transport it must be ensured that the device is packed and transported as such that it is protected against moisture and impact.

When installing the device in an industrial environment, this should typically be done where the adverse effects of dust, moisture, temperature and vibration are at their very lowest.

Safe operation of the device can only be guaranteed if specially trained personnel have conducted the installation and start-up.

Safety 5

WARNING!

Danger of tripping and tumble accidents!

Tripping- and tumble accidents lead to severe injuries!

Install machine connections (cables) adequately in order to avoid tripping!

1.7 Use according to regulations

The Advanced Bundle Station is suited for a complete controlling of all single cartons in a bundle and printing/marking/controlling the bundle.

ATTENTION!

If the Advanced Bundle Station is not used according to regulations, safe operation of the system cannot be guaranteed. For all personal injuries and property damage resulting from operations neglecting regulations, not the manufacturer, but the operator of the PCE-system will be responsible!

6 Components

2 Components

2.1 Setting up the machine

WARNING!

Danger of personal injury and machine damage! The erection work must be carried out solely by qualified personnel who take all safety regulations into consideration!

ATTENTION!

Inspect the machine for its completeness and any possible damage. Report any incompleteness of or damage to the delivery.

2.2 Aligning the machine frame

WARNING!

A machine that tips over can lead to severe personal harm and machine damage! The machine feet must be screwed into the machine at least 50 mm. The working height specified in the order documents must not be exceeded!

Note

Erect the machine stably. Screw the machine feet (B´01) in or out to adapt the machine working-height to the up or downstream conveyance equipment.

Caution!

Interference with the printing results! The maximum permitted height tolerance of 1.5 mm must not be exceeded!

Components 7

Note

A spirit level shall be used to the machine frame to aid with level erection.

2.3 Establish the supply connections

DANGER!

Danger through electrical power!

Working on the machine’s electrical parts may be carried out solely by trained qualified personnel! You must comply with the domestic protective regulations when making electrical connections to the machine!

• Install the electrical cabling from the line synchronization in accordance with the circuit diagram.

• Inspect all the machine’s plug-in modules and plug-in connections for correct seating.

• Inspect all electrical lines for any possible damage. • Connect the operating voltage in accordance with the circuit diagram. • Lay the electrical cables professionally.

2.4 Compressed air

DANGER!

Danger through Explosion hazard!

Before working on pneumatically operated devices in the machine, always switch the system to a pressureless state and secure it against being reconnected!

NOTE

If the emergency stop activated, the system is pressurized!

Recommended compressed air (quality grades according to DIN ISO 8573-1):

• Residual oil: Class 1 • Residual water: Class 4 • Residual particles: Class 1

8 Components

2.5 Test run

If the machine is being put into operation for the first time after in-plant transportation or after a long downtime, a machine test run in the available operating modes must be carried out.

Perform a test run in automatic mode with products, to check the functioning of all options with products.

• e.g., were the products verificated correctly? • Were the bad packagings sorted out? • etc.

2.6 Test the line synchronization

Check communications with the up- and downstream system parts in the line by checking the I/O signals.

NOTE

If you cannot remedy the malfunctions, please call the manufacturer’s service department.

Hardwaredesign 9

3 Hardwaredesign

3.1 Description

The Advanced Bundle Station is suited for controlling all single cartons in a bundle and marking/controlling the bundle.

3.2 Technical Data

3.2.1 User terminal

Touch display (15") Resolution 1024 x 768 Monitor input voltage, current

+12VDC +/- 5% at 2.5A maximum

3.2.2 Megapixel Camera

Camera housing Stainless steel (HxWxD) 1003 x 153 x 290 mm Voltage 24 V DC/approx. 300mA Image processing Digital signal processor for image evaluation Inputs / outputs Outputs 24 V DC, max. 400mA per output, overload protected,

short-circuit-proof, 4 inputs 24 V DC, optical isolated, protection against ext. voltage up to 30V

Data Interface USB Illumination Led’s in flash operation Lens 50 mm focal length Distance between object - frame

f = 10 mm ... 20 mm

Angle of inclination of head Up to approx. 20 degrees as opposed to vertical light incidence

Resolution 11 MP Field of view 300 x 100 (multiple) mm

3.2.3 Laser Line Scanner

Focus f = 250mm (170-300mm possible, according to barcode size)

Scan Rate up to 1200 Scans per sec.

Accepted Codes Pharmaceutical Binarycode, Barcodes (EAN, Code128, Code39, UPC, Interleaved)

Optical Scan Area Scanlength 150mm

Power 24V, via VGL7 24V +/- 20%

Temperature 0 - 50°C (IP 65)

10 Hardwaredesign

3.3 Overview of the machine

1 Door locks

2 Touchscreen

3 Laser line scanner

4 Main control cabinet

5 Counter check sensor

6 Belt drive

7 Air pressure unit

8 Two sensors „end position eject mechanism“

9 Sensor “Eject jam”

10 Eject bin

11 Emergency stop button

12 „Power On“ light

13 USB Port 2

14 USB Port 1

15 Confirm button

16 Start/Stop button

17 Key switch

18 Control cabinet for PC and UPS

19 Sensor Product

1

2

4

3

5

6

7

9

8

10

18

20

19

17 16 15 14 13 12 11 20 Megapixel camera

Hardwaredesign 11

3.4 Emergency Stop

In case of emergency or malfunction, press the emergency stop button. The emergency stop button allows the user to stop the machine. The program directly stops.

CAUTION!

When the emergency stop button is pressed, the operator has to completely empty the conveyer belt.

3.5 Configuration

Any change of the configuration shall be executed only by a trained administrator or a PCE-employee. Configuration changes can lead to erroneous functions of the camera system.

DANGER!

Alterations of the original configuration can lead to erroneous functions.

Erroneous function of the camera system

Configuration changes only by trained personnel

12 Pilot Software

4 Pilot Software

4.1 Overview

You can find the description for the Pilot software in a separate manual.

Maintenance 13

5 Maintenance

5.1 Overview

CAUTION!

The machine may be serviced only by authorized and instructed qualified personnel.

General instructions on maintenance

The prerequisite for flawless machine operation is that the maintenance work is carried out carefully and with respect to the corresponding intervals. Carry out a functional test including a safety check after all maintenance work. If parts of the machine were dismantled for maintenance work, you must ensure all parts have been replaced after finishing the repair work.

WARNING!

Danger of injury through electrical tension and unintentionally triggered machine functions! If not otherwise indicated, the machine is to be electrically and pneumatically disconnected from the mains and secured against reconnection before carrying out any maintenance and service!

CAUTION!

Use only genuine spare parts and accessories approved by the manufacturer! The use of non-approved parts can negatively influence the specified constructive attributes of the machine and lead to a loss of performance or damage or injury. The manufacturer is not liable for any damage or harm arising from use of non-approved parts.

14 Maintenance

5.2 Identification plates

Machine identification plates

The machine can be unambiguously identified using the identification plate on the Advanced Bundle Station.

The information relevant for spare parts ordering is:

• Device type • SN

In order to correctly order the spare parts, make sure you include the above-mentioned information on the order.

Maintenance 15

5.3 Maintenance and cleaning schedule

Interval Job Make a visual inspection of the mechanics (e.g. conveyor belt) Check/set the parameters according to the product. Check the precision of the print using a test product.

Daily before starting production

Check the sorting devices. Clean conveyor belt if necessary. Clean machine frame if necessary. Clean operator console if necessary.

Daily after the end of production

Clean Camera if necessary. Check the conveyor belt for damage. Monitor/adjust the belt run.

Monthly

Check the conveyor system (belt, rollers, bearings, motors and timing belts) for unusual noises (rattling and scraping). Check the Camera and record this Check the Printer and record this

½ yearly

Check the maintenance unit pressure setting and document this.

Annually Replace the timing belts on the conveyors. Every 1¾ years Replace the drive and guide rollers on the conveyor system. Every 3 years Replace the motor on the conveyor.

Replace the pneumatic cylinder on the pusher. Clean the maintenance unit filter. Empty the maintenance-unit condensate collector. Clean the operating console. Replace the backup battery.

As needed

Clean the photoelectric sensors.

NOTE

The repair and cleaning schedule is based on an average machine runtime during one-shift operation. For multiple shift operation and correspondingly higher machine operating times, the intervals need to be correspondingly shortened.

16 Maintenance

5.4 Cleaning

The components have been developed specifically for industrial requirements. Therefore reliable operation is guaranteed under the usual conditions on the production facilities, if the components have been built in by trained personnel.

Switch off the master switch before cleaning the machine. Properly close existing covers and protective hoods before cleaning the machine. Use only a moist cloth or a soft brush to clean the machine. Never use a metal brush or aggressive cleansing agents. Do not clean with steam or a high-pressure water blaster under any circumstances.

Immediately repair any possible damage detected during machine cleaning.

ATTENTION!

The substances in the cleansing agent can cause damage, destruction, poisoning, etc. of the product to be monitored under certain circumstances. Use only suitable cleansing agents and observe the manufacturer’s product notifications!

Prevent static discharges! Never use chemicals to clean! Always observe the cleansing-agent manufacturer’s specifications concerning this!

5.4.1 General instructions on caring for high-grade steel

In comparison to steel or aluminium, high-grade steel provides much better protection from corrosion. Still, high-grade steel is not completely rust-free under all circumstances. Depending on the use and ambient conditions, even high-grade steel can become partially soiled or rusty. The most common causes for this are flash rust (fine iron particles in the air), active gasses, collection of grime deposits and clinging salts. These surface impairments can be easily removed with daily care using stainless steel spray or a mild soap detergent. After cleaning with soapsuds, make sure the remnants of the suds are washed off with plenty of water.

5.4.2 Cleaning of the Touch Display

The display surface consists of glass and the housing is made of stainless steel.

For accurate functioning it is necessary to clean the windowpane of the touch display in regular intervals. For the cleaning only special cleaning cloths and detergents may be used:

• commercial detergents for PCs • disinfectants with alcohol

Maintenance 17

ATTENTION!

Never use thinner, benzol, abrasives or other strong dilutions as these can cause damage to the display!

5.4.3 Cleaning the operator console and protective covers

The operator console and protective covers on the operator console and machine frame are to be cleaned as needed.

• Switch off the master switch. • Clean the operator console with compressed air or wipe with a moist cloth

depending on how soiled it is. • Clean the touch screen with a lint-free, moist cloth. In case of heavy soiling, a

commercially available glass cleaner (without scouring agents) can be used for cleaning after being diluted with water.

• Clean the protective covers and the machine frame and, if necessary, additional optionally existing protective covers with a commercially available glass cleaner (without scouring agents).

5.4.4 Cleaning the conveyor belt

• Clean the conveyor belt daily. • Switch off the master switch. • Clean the conveyor belt with compressed air or wipe with a moist cloth depending on

how soiled they are.

5.4.5 Cleaning the photoelectric cells

Clean sensor and reflector in the photoelectric cell as needed.

• Switch off the master switch. • Clean the sensor and reflector with compressed air or wipe with a moist cloth

depending on how soiled they are. In case of heavy soiling, a commercially available glass cleaner (without scouring agents) can be used for cleaning after being diluted with water.

18 Maintenance

5.4.6 Cleaning of the camera

The camera is not accessible to the normal user. You can only clean the glass to the conveyor belt. The following agents can be used:

• eyeglasses cleaning cloth • moist, fluff-free cloth

ATTENTION!

The cleaning of the camera and the objective in particular shall be executed by PCE service technicians or by their certified partners only. If the housing has been opened by unauthorized personnel, guarantee claims expire!

5.5 Emptying the maintenance unit condensate collector

1 2

Empty the condensate collector (1) in the maintenance unit as needed.

• If the condensate collector (1) is full, place a suitable vessel underneath and open the drain screw (2).

• After draining the condensate, retighten the drain screw (2).

Maintenance 19

5.6 Cleaning/replacing the maintenance unit filter

1

Clean or replace the maintenance unit filter when heavily soiled.

• Disconnect the compressed air supply. • Remove the condensate collector by

moving down the lock (1) and turning the collector.

• Turn the support spring to the left and remove the filter element.

• Clean the filter element with naphtha or water (max. 60°C).

• Simply reassemble by using the reverse sequence.

20 Status Displays

6 Status Displays

6.1 Overview

There are three LED’s on the top of the Advanced Bundle Station that display the status.

Status displays Meaning Green LED is constantly lit.

• System is ready. • System is active, production is running.

Green LED flashes. • Accumulation on external conveyor. • Automatic re-start after accumulation clearance.

Yellow LED flashes. • Warning.

Red LED is constantly lit.

• Production not running. • Error.

Red LED flashes. • Teach-in is active.

Settings and Adjustments 21

7 Settings and Adjustments

7.1 Settings at the pressure unit

1 Pressure switch (on/off)

2 Pressure adjustment

3 Drain screw condensate collector

4 Sensor “Air pressure control”

1

2

3

4

1. Make sure that the pressure switch (1) is turned on. 2. Turn the pressure adjustment (2) until the display shows 3.8 bar. 3. Turn the setscrew at the sensor “Air pressure control” (4) (placed at bottom) until the

LEDs at the sensor changes from green to yellow or vice versa. 4. Turn the pressure adjustment (2) to 6 bar.

22 Settings and Adjustments

7.2 Settings of the ejection

You can set the speed of the ejection and the speed of the return of the ejection with the following hand wheels. They are located on the left side in the control cabinet.

1 Speed of ejection

2 Speed return of the ejection 1 2

Clockwise: lowering speed Counter clockwise: advance

speed

Author: Pharmacontrol Electronic GmbH

This documentation has been provided for the registered client. No part of this documentation shall be re-produced, transmitted, assigned, recorded in a data processing system or translated into another language in any form without prior written consent.