Palletizer start up manual
Date : 26/9/2017
De-stacker control panel
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Control On Selector – control panel supply switch
De stacker Man / Auto - section 2 De stacker hydraulic lifting system Man / Auto Selection
Operate / bypass selector – select section 3 in operation or bypass
Chain pusher selector – section 2 enable to chain pusher inching forward and reverse manually
Chain pusher Man / Auto selector – section 2 chain pusher man / auto selection
Bag 3 wait selector – pallet will be stayed after cycle for checking purpose
Motor ON – Conveyor motor run forward
Bag 2 wait – pallet will be stayed after cycle for checking purpose
Manual hydraulic de stack up – manual push button to inch lifter up
Manual hydraulic de stack down – manual push button to inch lifter down
Chain pusher forward inching button – manually inching chain pusher forward
Bag 3 down – manual bag 3 down
Bag 2 down – manual bag 2 down
Chain pusher raise – Chain pusher pull bar up
Chain pusher low – Chain pusher pull bar down
Chain pusher reverse inching button – manually inching chain pusher reverse
Bag 1 down – manually bag 1 down
Reset button – reset chain broken safety limit switch to energise conveyor motor
Stacker control panel
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Control On Selector – control panel supply switch
De stacker Man / Auto - section 2 stacker hydraulic lifting system Man / Auto Selection
Hydraulic motor – turn on hydraulic motor
Cylinder pusher selector – cylinder pusher off / on selector ( turn on to enable )
Cylinder pusher Man / Auto – section 5 cylinder pusher Man / Auto selection
Operation / bypass selector – select section 5 in operation or bypass
Bag 4 wait – pallet will stay at section 4 after finish cycle
Bag 5 wait – pallet will stay at section 5 after finish cycle
Bag 6 wait - pallet will stay at section 6 after finish cycle
Manual hydraulic stacker up – manually push button to inch lifter up
Manual hydraulic stacker down – manually push button to inch lifter down
Man bag 6 – manually bag 6 down
Man bag 5 – manually bag 5 down
Man bag 4 – manually bag 4 down
Cylinder pusher raise – manually bring up section 5 pull bar
Cylinder pusher low – manually bring down section 5 pull bar down
Reset counter – reset counter at the conveyor
X54 and x55 – spare
Method of adjusting Limit switch
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adjust the trigger angle - Unscrew or loosen the plunger or finger
remove the cap and put in the angle that you need
tighten the screw at the plunger or finger
check the plunger or finger still have at least 10% tolerant to move ,this is to avoid it is over
tension and may break the limit switch
Method of resetting motor over load
1. once the motor is tripped , come forward to office control panel to reset conveyor or
hydraulic motor overload manually
2. once the motor conveyor chain is broken , turn off motor on selector and reset at the
de -stacker reset button , check and rectify the fault before running the machine
Office control panel touch screen unit
1. touch screen provide the limit switch on/off data
2. touch screen provide PLC valve output data
3. motor chain broken alarm fault
General trouble shooting on machine fault
Section 1
1. air bag 1 must be up all time without pallet
2. pallet in position section 1 ,air bag 1 will be down by manual button or auto mode ,check
hydraulic hooks up position , hydraulic lifter left/right down position if the pallet doesn’t
move in.
3. once pallet is transferred to section 2 , the section air bag will go up after 10 seconds.
Section 2
1. pallet in position section 2 , pallet stop and stay if in manual mode
2. in auto mode , pallet will be de-stack the top stack
3. hydraulic lifter will travel up to middle position (M325) , and 4 nos. hooks will be engaged to
lift the upper stack.
4. Operator must monitor the lifter is hooked correctly when continue to upper position,
otherwise it may lift and tilt to dangerous position, same situation when it is travel down
while carry any stack load.
5. Operator must check the limit switch M350 for 2 or 3 stacks detection
6. One stack will standby at the air bag 2 , once air bag 3 is clear , it will be transfer to section 3
Section 3
1. Pallet stop and stay at section 3 in manual mode
2. Can release this by manual air bag 3 down
3. Auto mode , the mechanical clamp will bring the pallet bar up ( check M348 High position
and N345 Low position )
4. Once the pallet bar is up , alignment pusher will start pushing , if it is not check the M348
high limit )
5. Next step , the chain pusher start pushing cylinders out from pallet , if it is failed , check the
alignment pusher home position M341 )
6. When all cylinders are cleared , the chain pusher will return to home ( back position ) , if it is
failed , check the M338 limit switch and M339 limit ,may be its out of position due to
mechanical vibration.
7. Pallet 3 will be transfer to section 4 , once section 4 is cleared
8. If pallet cannot transfer to section 4 in auto. The reason is unclamp pallet bar is not smooth
,operator need to aware this situation.
Section 4
Section 4 pallet will be transfer forward once section 5 is cleared
Section 5
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Pallet stop and stay at section 5 in manual mode
In auto mode , pallet bar will be brought up by mechanical clamp
Conveyor pusher will push in every 5 cylinders in line
If the counting is faulty , check the M912 and M913 limit switch
Once 7 rows are lined up inside pallet , M902 will be triggered acknowledge the pallet is
ready .
6. The conveyor stopper will stop cylinders come in to the counting position
7. Pallet will be transferred forward once section 6 is clear , section 6 bottom without pallet or
upper pallet is ready stack on top .hydraulic cylinder must be either upper with hooks
engaged or lowest position with all 4 hooks are clear up position.
Section 6
1. Pallet will be stop and stay in position in manual mode , operator can bring it forward to
section 7 in manual or switch it to auto mode for carrying the next task
2. In Auto mode , pallet will be brought up to upper position with all hooks engaged to lift the
pallet, operator must aware the lifting process in order to avoid any accident happen
3. When 2 pallets are stacked ready , this will be transferred forward once section 7 is cleared
Section 7
1. When pallet is removed by fortlift , the section 7 air bag will go down after 15 seconds
Precaution to be taken
1. Either in de-stack or stack process , operator must aware of the lifting up and down process,
it may happen accident due to the following reasons : Pallet is not in good shape
 Gas cylinders are not arranged properly inside pallet
 Hydraulic cylinder Left and right side are moving simultaneously , causing hooking at
wrong position when moving upward or downward
2. Section 3 chain pusher M338 , it may miss trigger when the chain pusher move to front end
because of mechanical vibration
Solution is to check the M338 limit switch every day ( tightness and plunger shape )
3. Section 5 counting sensor , operator check the limit switch rod ( tightness and rod shape )
In order to avoid wrong counting of cylinders
Air bag operation
1. Every section consists of two limit switches at the bottom , when pallet come forward ,1st
limit switch is triggered to acknowledge the exist of pallet
2. The second limit switch is to confirm the pallet in position ,energise the air bag up and hook
up
3. Once the pallet is needed to transfer forward , the air bag and hook will be down , to allow
pallet rest on conveyor while running