Introduction to Electromechanical
Systems
Instruction Manual for
Package Sorting System
Patrick Thompson, Zack Mullins, Matt Folsom
December 13, 2011
Table of Contents
I……………………………………………Theory of Operation…………………………Pg.3
II…………………………………………Description of Operation……………Pg.4-5
III………………………………………Operation Instructions…………………Pg.6
IV…………………………………………Trouble Shooting…………………………………Pg.7-10
V……………………………………………Parts List…………………………………………………Pg.11
VI…………………………………………Appendix………………………………………………………Pg.12-13
Theory of Operation
The package sorting system operates based on the size of
the package. With the system plugged into 120VAC, 60HZ, and with
switch 1 and switch 2 in the on position, the conveyer belt
rotates towards the small package sorting area and the photocell
exciter lamp activates. The conveyer belt will move a package
past two sets of photocells that control the large and medium
package sorting areas. If the package is large enough to
simultaneously cover the photocells of the large sorting area
then it will be sorted as a large package by a momentary burst
of air. If the package is large enough to simultaneously cover
only the photocells of the medium sorting section then, it will
be sorted as a medium package by a momentary burst of air. If
the package is too small to cover either set simultaneously then
it will be sorted at the end of the conveyer belt as a small
package.
Photocells
Large
Solenoid
Coil (N.O.)
Valve
Large
Conveyer
Photocell
Drive
Exciter
Motor
Lamp
Photocells
Medium
Solenoid
Coil (N.O.)
Valve
Medium
Operation Instructions
.Plug system into 120VAC, 60HZ.
.Switch S1 to the on position.
.Hold S2 in on position for 3 to 5 seconds and then release.
.Ensure conveyer belt rotates towards the small package sorting
area.
.Ensure all packages initially pass through large sorting area
.wait for all of the packages to clear off the conveyor belt
.turn S1 to the off position
Trouble Shooting
Problem
1. No power to the
system.
Cause
.Not plugged into
120V.A.C 60HZ.
.Replace S1.
.F1 is blown.
.Replace F1 that is
rated for 3A 250V.
.Not Connected to
120VAC 60HZ
.Florescent tube is
bad
.S2 is bad
3. Conveyor
Motor(M1) will
not rotate
conveyer belt
.Plug into 120V.A.C
60HZ.
.S1 is bad.
.Bad connection to
120VAC or ground
2. Exciter lamp
(L1) will not
light.
Solution
.Conveyor Motor is
not connected to
120VAC 60hz
.Check for broken
wires from 120VAC to
S1 from S1 to Ground
.Check for broken
wires from 120VAC to
Exciter Lamp,
Exciter Lamp to
ground
.Change florescent
tube
.Replace S2
.Check wires from
120VAC to M1 and
from M1 to ground
.Conveyor Motor to
Conveyor belt coupler
is disconnected or
broken
4. D.C. power
supply not
supplying
6.8VDC
.If disconnected,
properly reconnect
coupler device. If
broken replace the
coupling device
.No voltage on
.check for broken
primary of
wires from 120VAC to
transformer(T1) or no primary of T1 and
power from the
from T1 to ground.
secondary to anode
Check for broken
wire from line of
.Diode(D1)is
secondary to anode
destroyed
of D1
.Resistor(R1)has
changed its value
from 1K ohms to a
.Replace with diode
specified in parts
list and assure that
greater value or the
diode is biased
capacitor(C1)has
properly before
become permanent open power is applied
.Zener Diode(D2)has
been destroyed
.Transistor(Q1)has
been destroyed
.Replace R1 and C1
with components
specified in parts
list
.Replace D2 with
zener diode
specified in parts
list
.Replace Q1 with
transistor specified
in parts list
5. Solenoid Valve
1 (N.C.)(SV1)
activates when
one
photocell(PC1
or PC2) is
covered
6. Solenoid Valve
2 (N.C.)(SV2)
activates when
one
photocell(PC3
or PC4) is
covered
7. Solenoid Valve
1 (N.C.)(SV1)
.PC1 or PC2 is dirty
.PC1 and PC2 are in
series with each
other
.The sensitivity
adjust for the
circuit is not
adjusted correctly
.PC3 or PC4 is dirty
.PC3 and PC4 are in
series with each
other
.The sensitivity
adjust for the
circuit is not
adjusted correctly
.Broken wire from
120VAC to N.O. CR2A
.Clean the photo
cells then then make
sure SV1 operates
correctly
.Place PC1 in
parallel with PC2
then make sure SV1
works properly
.Adjust Sensitivity
adjust(R3)until SV1
works correctly
.Clean the photo
cells then then make
sure SV2 operates
correctly
.Place PC3 in
parallel with PC4
then make sure SV2
works properly
.Adjust Sensitivity
adjust(R6)until SV1
works correctly
.Find the break in
the wire with an ohm
will not
activate
or from CR2A to SV1
meter and repair the
or from SV1 to ground problematic section
.corroded contacts on .clean the contacts
N.O. CR2A
with small file
8. Solenoid Valve
2 (N.C.)(SV2)
will not
activate
.CR2 will not
energize
.see problem
shooting tip #9
.Broken wire from
120VAC to N.O. CR4A
or from CR4A to SV2
or from SV2 to ground
.Find the break in
the wire with an ohm
meter and repair the
problematic section
.corroded contacts on .clean the contacts
N.O. CR4A
with small file
9. Relay CR2 does
not energize
.CR4 will not
energize
.see problem
shooting tip #10
.Broken wire from
120VAC to N.O. CR1A
or from CR1A to CR2
or from CR2 to ground
.Find the break in
the wire with an ohm
meter and repair the
problematic section
.corroded contacts on .clean the contacts
N.O. CR1A
with small file
10.
Relay CR4
does not
energize
.CR1 will not
energize
.see problem
shooting tip #11
.Broken wire from
120VAC to N.O. CR3A
or from CR3A to CR4
or from CR4 to ground
.Find the break in
the wire with an ohm
meter and repair the
problematic section
.corroded contacts on .clean the contacts
N.O. CR3A
with small file
11.
Relay CR1
does not
energize
.CR3 will not
energize
.see problem
shooting tip #12
.Sensitivity adjust
R3 is not adjusted
correctly
.cover PC1 and PC2
then adjust R3 until
CR1 energizes
.PC1 or PC2 are
shorted
.block PC1 and PC2
from light and check
for resistance. The
.Diode D3 is not in
photocell with the
the circuit correctly lowest resistance at
this point is the
.Transistor Q2 is
shorted one. Remove
destroyed
the short from that
photocell and adjust
the circuit until
CR1 energizes
.remove Q2 from the
circuit and test. If
bad the replace with
transistor specified
in the parts list
12.
Relay CR2
does not
energize
.Sensitivity adjust
R6 is not adjusted
correctly
.make sure D3 is
reverse biased
.cover PC1 and PC2
then adjust R3 until
CR1 energizes
.PC3 or PC4 are
shorted
.block PC1 and PC2
from light and check
for resistance. The
.Diode D4 is not in
photocell with the
the circuit correctly lowest resistance at
this point is the
.Transistor Q3 is
shorted one. Remove
destroyed
the short from that
photocell and adjust
the circuit until
CR1 energizes
.remove Q2 from the
circuit and test. If
bad the replace with
transistor specified
in the parts list
.Make sure D4 is
reverse biased