Notice g2010 2g English

SORTING MACHINE
INSTRUCTIONS
INSTALLATION - USE -
OPERATING - MAINTENANCE
Translation of the original

manual
Ref : PROC – TR2G02 VERSION 05/ 2012
OPERATING AND MAINTENANCE INSTRUCTIONS
SORTING MACHINES
CONTENTS
CHAPTER TITLE CONTENTS
• Delivery
• Handling precautions
• Mechanical assembly of the equipment
ASSEMBLY
1 • Interface management
INSTRUCTIONS
• Validation of work achievement
• Interconnection of optical sorters
• Connections and machine settings
• Security
GETTING STARTED
2 • System description
• Start up
3 SOFTWARE • Description of software functions
MAINTENANCE OF • Description of all maintenance operations

4 MACHINE AND • Location of parts to be maintained and
PERIPHERALS maintenance frequency
• Description of all replacement procedures

5 PART REPLACEMENT
• Location of parts to be replaced
• Trouble-shooting
• Suggested solutions for displayed error
6 ASSISTANCE
messages
• Remote maintenance
• Machine technical characteristics

• Purity and efficiency
7 TECHNICAL DATA
• Spare parts
• Machine end of life
CERTIFICATES AND • Certificates of conformity

8
DRAWINGS • Electrical and pneumatic drawings
CUSTOMER SERVICE
9
BULLETIN
CONTENTS Version 05/2012

© This document is the property of Pellenc Selective Technologies, any reproduction, even partial, is prohibited
SORTING MACHINES
CONTACTS
Front desk:
04.90.09.47.90
04.90.79.38.19
e-mail contact@pellencst.com
Customer Support:
04.90.09.47.94
04.90.0
04.90.09.22
9.22.
22.35
e-mail sav@pellencst.com
sav@pellencst.com
PELLENC Selective Technologies

125 rue François Gernelle – BP 124
84124 PERTUIS Cedex 4
CONTACTS Version 05/2012

© This document is the property of Pellenc Selective Technologies, any reproduction, even partial, is prohibited.
ASSEMBLY INSTRUCTIONS - SORTING MACHINES
CHAPTER1
Assembly instructions
Summary
In this chapter you will find the following information:
1. Delivery and handling ............................................................................................................ 2
2. Equipment mechanical assembly ........................................................................................ 3
3. Assembling the output box ................................................................................................... 5
4. Creating power supply and network connection interfaces ....................................... 6
5. Creating the pneumatic interface........................................................................................ 7
6. Belt conveyor: Supply and Connection (in case of PST supply) .................................. 8
7. Output box motorized roller: Supply and connection ................................................... 9
8. Work achievement validation ............................................................................................... 9
9. Interconnection of optical sorters with the customer control cabinet ..................... 9

9.1 Operating modes.......................................................................................................... 9
9.2 Main cabinet inputs (terminals X11 and X9) ......................................................... 9
9.3 Wiring diagram .......................................................................................................... 11
9.4 Internal wiring diagram ........................................................................................... 11
9.5 Optical sorter controls .............................................................................................. 11
10. Connections and machine settings .................................................................................. 13

10.1 Connection of the interfaces................................................................................ 13
10.2 Tests and optimization ........................................................................................... 13
10.3 Acceptance ............................................................................................................... 13
APPENDIX 1: REMOTE MAINTENANCE INFORMATION FILE ............................................. 14

APPENDIX 2: INTERCONNECTION WORK ACHIEVEMENT.................................................. 15
CHAPTER 1: ASSEMBLY INSTRUCTIONS 1 Version 05 /2012

1. Delivery and handling
Reception and unloading of the equipment on the industrial site are at the customer's
expense.
The characteristics of the machines are laid out in the Technical Datasheet ST-FT-11-
Rev.C.
Note: for the conveyor, please refer to the conveyor manual
Lifting and crane operations must be carried out by authorised qualified personnel.
A hoisting crane will be required for machines with widths of 2400 mm and 2800 mm.
Slinging rings (mark B) are to be used for handling the optical sorter alone.
B
B

2. Equipment mechanical assembly
2.1 Removing the support frame of the optical sorter

Remove the eight retainer-screws and nuts (four on each side) (mark C) before lifting.
2.2 Positioning the optical sorter onto the conveyor

• Strap up the machine using the four lifting rings situated on top.
2.3 Aligning marks on standard and HR lines

Position marks (drilling) on the frame vertically to the axis of the conveyor driving drum.
Standard
line
Right side Left side

HR line
Right side Left side
Caution: Check that the distance between

the external part of the frame and the driving
drum axis is 314 mm on both sides of the
machine.
2.4 Fixing the optical sorter onto the conveyor
Fix the machine on the conveyor using the eight screws and nuts (four on each side)
that have been removed as indicated § 2.1 (marks D).

3. Assembling the output box
3.1 Positioning
The unit is moved into position by slinging (4 rings) according to the dimensions given
on the diagram below, symmetrically on both sides.
530
800
2064
3.2 Positioning side flaps
The side flaps (Mark F) will be positioned inward the optical sorter to allow proper
closing of the side doors (Mark H).

4. Creating power supply and network connection

interfaces
The electrical, pneumatic and network connections must be made by Pellenc ST

personnel. The customer is responsible for preparing the interfaces.
All electric interfaces must be available at the bottom of the main cabinet (Mark E) with 2
meters in length.
 Power supply cable (mark E)

The characteristics of the necessary power are laid out in the Technical Data sheet ST-FT-
11-Rev.C.
 Ground cable (mark E)

11-Rev.C.
Caution: The ground cable must be directly connected to the main grounding of the
building, not to any steel structure under any circumstances.
 Automation connecting cable (mark E)

11-Rev.C.
 Network cable and ADSL connection for remote maintenance (mark E)

The required specifications are laid out in the Technical Data sheet ST-FT-11-Rev.C.
• A network cable must be pulled from the customer’s network access point to the
Pellenc ST modem router.
• The connection of the PST router to each machine will depend on the site
configuration and the technical constraints.
• The lay-out should be validated first by Pellenc ST.

Please fill in the information form for remote maintenance (see Appendix 1 at the end of
the Chapter) and return it to Pellenc ST no later than15 days before the installation.
Note: For cables over 100 m in length, a repeater will be required every 100 m.
Note: Network cables must be at sufficient distance from the power cables (to avoid
electrical and electro-magnetic interference)
Note: The PST router must be switched on and in 24/7 operation.
Note: Network cables, RJ45 shielded connectors, connectors’ cabling and crimping are
supplied by the customer.
 MODBUS TCPIP Network cable (option) (mark E)

The required specifications are laid out in the Technical Data sheet ST-FT-11-Rev.C.
If the ADSL connection is not wired, a network cable must be pulled from the PLC to the
first machine (see diagram below).
MODBUS connection diagram
PLC
Note: Network cables, RJ45 shielded connectors, connectors’ cabling and crimping are
supplied by the customer.
Note: A data exchange table will be defined with the customer before the installation.
5. Creating the pneumatic interface
11-Rev.C.
According to the input flow on the machine (defined by Pellenc ST), your supplier will
determine the appropriate piping size.

Bring the pneumatic inlet pipe (Mark G) near the air inlet of the machine (always
alongside the main cabinet).
Note: We recommend you install a closed air network, regardless of the number of
machines.
Caution: The air system must be necessarily drained before the connection to avoid small
residues (Teflon, metal chips, etc.) being projected towards the machine. They
may cause major damage to electro-valves.
Caution: We advise you install a dew point controller which stops the compressor in case
of deteriorating dew point.
Caution: We recommend you install a quick connect air intake to plug in an airgun for
machine cleaning.
6. Belt conveyor: Supply and Connection

(in case of PST supply)
11-Rev.C.
Note: The connecting and the control of the conveyor are a customer supply. Please
refer to the conveyor manual.
Caution: For the management from your automation control cabinet and considering
the conveyor fast speed, we recommend not to integrate the stop and the restart of the
conveyor into your “Stop of Cycle” button. This avoids pushing too frequently the
mechanical components of the gear motor.
In any case, we strongly recommend you to use a soft starter for this management.

7. Output box motorized roller:

Supply and connection
The connection and management of the motor roller are supplied by the customer.
Please refer to the unit manual.
Note: According to the line, two motorized rollers may be located in the output box.
8. Work achievement validation
When the operations quoted previously are completed, you are requested to complete
and sign documents in appendix 1 and 2.
These documents must be returned to us by fax, fifteen days before the installation
intervention,
to + 33 4 90 09 79 38 19, to the attention of the account manager in charge of your
project for the planning.
9. Interconnection of optical sorters with the customer

control cabinet
9.1 Operating modes

The machine can operate under two modes.
- Manual mode
Only the states of buttons located on the main cabinet and the actions on the screen are
taken into account.
- Automatic mode
The machine is piloted via dry contacts inputs from the customer control cabinet.
9.2 Main cabinet inputs (terminals X11 and X9)

9.2.1 Belt input
In both modes, the machine requires the information "belt" with a closed contact when
the conveyor is “on”. This information comes from the PST supplied sensor located on
the conveyor.

9.2.2 Sorting On/Off
 Type « Level »
The signal is a level coming from a dry contact (two wires).
• Closed contact: “Sorting” is “On”.

• Opened contact: “Sorting" is “Off”.
9.2.3 « Defect » and «machine sorting» outputs (terminal X8)

In both modes, the machine indicates two states by dry contacts.
• Closed contact: “Machine sorting” information.

• Opened contact: “Default" information.
• “Warming up”: Contact closed.
9.2.4 Safety switches (terminal X13)
The main cabinet is provided with an emergency stop button and safety door switches.
• The contacts "emergency stop" must be used in the safety circuit of the line.
• The contacts "safety doors" are available information for the global management
of the line.
• A contact for circuit loop signal is also available on X14 (Closed contact on
“emergency stop”).
Note: As an option, it is possible to connect the safety loop on X14 input to activate the
emergency stop by remote control (this input is shunted on delivery).
9.2.5 Miscellaneous information
 Machine in manual or automatic mode (terminal X9)
• Closed contact: “Automatic mode” information.

• Opened contact: “Manual mode" information.
 Machine powered on (terminal X2)
• Closed contact: “Machine under voltage” information.

9.3 Wiring diagram

Belt signal
(PST-supplied sensor)
On/Off machine Main Cabinet

Optical sorter
Control Machine sorting
Cabinet
Auto / Manual
Mistral
Power supply
Open doors Mistral Vision
Default Mistral Dual

Vision
Emergency stop
Customer PST
Emergency stop
9.4 Internal wiring diagram

The characteristics of the internal wiring are indicated in the diagram G07-D104CA02.
9.5 Optical sorter controls
Control by level (recommended by PST)
 The “On / Off” control is made through a level sent by the controller on the
input “On / Off Machine” on terminal X9.
 The signal "Machine in Sorting" sent back by the Machine on the terminal X8
indicates if the machine is operational or stopped.
To initiate the sorting process by your controller, it is necessary to verify the state
of the machine (“Machine sorting” signal on terminal X8).

- To start sorting
It is necessary to activate the controller output connected to "On / Off machine” (X9).
As soon as the machine is sorting, the signal "Machine Sorting" = 1.
Warning: There may be a delay between "Machine On/Off «and "Machine sorting" due
to a warming-up period indicated by "Machine warming up (X8)"
- To stop sorting
It is necessary to deactivate the controller output connected to " On / Off machine” (X9).
As soon as the machine is stopped, the signal "Machine Sorting" = 0.
Caution: If a default appears, it is necessary to stop sorting to be able to restart the

sorting process.
Default (X8)
Machine sorting (X8)
On/Off machine (X9)
Machine sorting (X8)
Warm-up machine (X8)
Order of sorting (X9)
Level mode control diagram

10. Connections and machine settings
10.1 Connection of the interfaces
PELLENC ST technicians are in charge of electrical and pneumatic connecting operations

brought alongside the machine and verify the respect for the measurements of
assemblies of elements (machine, conveyor and output box). The control connection
requires the presence of an automation technician to facilitate the starting.
Caution: Do not wire machines by yourself, instead of the PST team. In case of bad
connection, there is risk of loss of guarantee.
Verification that the optical sorter is operating correctly requires the presence of a
control engineer to facilitate commissioning.
10.2 Tests and optimization
To proceed to the static and dynamic trials, it is necessary to provide our team with
samples of incoming products on the machine (a hundred of items of each category),
and representative of the stream characterized on the contract.
Counting will be performed to validate correct operation.
10.3 Acceptance
When counting operations have been completed in the presence of the customer and
the Pellenc ST team, both parties will complete and sign the "Final Reception Report".
This document reports on performances attained by the installed machine(s), according

to the characteristics of the input stream.
This stage will conclude the installation intervention of the Pellenc ST team. Your
machine will be operational to ensure your production.

APPENDIX 1: REMOTE MAINTENANCE INFORMATION

FILE
TO RETURN 15 DAYS BEFORE INSTALLATION

BY FAX +33 4.90.79.38.19
OUR INTERVENTION REMAINS SUBJECT TO THE PROPER EXECUTION OF THE FOLLOWING
From: COMPANY ……………………

Sender: ……………………………
To: …………………………………… (PELLENC S.T.)
CUSTOMER NETWORK PARAMETERS TO BE COMPLETED
(For the Pellenc ST machine connection by the PST router)
Customer network parameters:

.
Static IP: . . . .
On which ports: 5900 - 5920 in input/output are open
9644 in input/output is open
IP du FAI*:
Network mask: . . . .addr. DNS Primary: . . . .
Gateway: . . . . (Secondary): . . . .
In case of VPN connexion :
Type (microsoft, cisco…..): …………………………………….
IP Address or Domain name: …………………………….……….
login: …………………………….……….
Password: …………………………….……….

APPENDIX 2: INTERCONNECTION WORK ACHIEVEMENT
TO RETURN 15 DAYS BEFORE INSTALLATION

BY FAX +33 4.90.79.38.19
OUR INTERVENTION REMAINS SUBJECT TO THE PROPER EXECUTION OF THE FOLLOWING
From: COMPANY ……………………

Sender: ……………………………
To: …………………………………… (PELLENC S.T.)
Machine : ……………. (Valid description for a machine)

Closing
MECHANICAL Reference
date
Positioning and securing of the rapid Conveyor according to the
§2
general arrangement drawing validated by both parties.
Positioning and securing of the separator according to the general
§2
arrangement drawing validated by both parties.
Positioning and securing of the Output Box, according to the general
§3
arrangement drawing validated by both parties.
ELECTRICAL
Optical sorter power supply cable presence. §4
Optical sorter ground cable presence. §4
Optical sorter automation cable presence. §4
Optical sorter network cable presence. Active ADSL connection
§4
presence.
Belt conveyor power supply cable (If PST supply). §6
Output box motorized roller power supply cable (If PST supply). §7
PNEUMATIC
Optical sorter pneumatic supply and connection presence §5
AUTOMATION
Presence of the automation technician on site during the intervention

of the Pellenc ST team of installation, to settle the communication § 10.1
between the machine and the control of the line.
MATERIAL STREAM
Presence of the contractual stream of material upon the arrival of the
§ 10.2
Pellenc ST team.
Possibility of optical sorter functioning at nominal flow with the
§ 10.2
contractual material stream.

SORTING MACHINES
CHAPTER 2 –
SAFETY AND STARTING UP
Chapter abstract
In this chapter, you will find the following information:
Subject Contents
 Safety rules
Safety  Safety instructions

 Safety symbols
 Machines concerned
System’s description
 Description of the components
 Description of system indicators and controls

 Machine start up procedure
 Automatic Shutdown procedure
Starting up  Manual shut down procedure

 Setting machine to zero pressure
 Starting up machine after shutting down with zero
pressure
CHAPTER 2 1 Version 05/2012

SORTING MACHINES
CHAPTER 2 - SAFETY
Operating Conditions – Safety Rules
 Before using the machine, make sure it is stable (check the tightening of machine
fasteners onto the conveyor and re-tighten if necessary).
 If the protective items have been removed, re-install them before operating the
machine. Failure to install these protective items may lead to serious injury.
 When the machine is sorting, make sure the operator or any person standing nearby
stay away from the ejection area. The projection of sorted objects is hazardous.
 When the conveyor is powered on or running, never work on the scraper nor on the
nozzle set (cleaning) and never lean on the nozzle bar (it may cause accidents related to
the risk of entanglement in the conveyor). For added safety we advise you to use the
available door-opening information and integrate this to the conveyor controls (refer to
the PELLENC ST installation guide for connection details).
 When the machine is powered on, make sure the operator or surrounding persons
stay away from the nozzles. Even without sorting material (sorting belt OFF), the
projection of air is hazardous for the eyes.
 When the machine is in service, if the noise level reaches 85dB (A) (continuous sound
pressure level), hearing protection for the operators (e.g. ear muffs) is required. This
protective equipment must be worn by all persons close to the machine.
 Touching reflectors while the machine is running or immediately after halogens have
been turned off is strictly prohibited due to the risk of burns.
 For safety issues relating to the conveyors, please refer to the corresponding manual.
CHAPTER 2: SAFETY 2 Version 05/2012

SORTING MACHINES
Safety instructions
 READ all the labels affixed to the machine and comply with all safety instructions prior
to operating the machine, during operation and when performing maintenance.
 Replace any labels which are damaged or illegible. These can be ordered from
PELLENC Selective Technologies.
 This machine must only be operated by qualified personnel who have received
operational training for this machine (i.e. having followed the PELLENC ST level one
training session that was given when the machine was installed).
 Any defective item which is affected by impact, distortion or wear must be replaced.
Do not operate machine without any missing part.
IMPORTANT
Before performing any work on the machine, make sure that all safety requirements
prescribed in the procedures of chapters 4 and 5 are met.

SORTING MACHINES
Safety symbols
Introduction The following table shows the safety symbol stickers on the door
of your machine.
Caution!
Failure to comply with these instructions may lead to serious injury
or damage to equipment.
Pictogram Meaning Reference

Prohibition:
Do not touch or approach during 06669
operation
Eye protection is mandatory 16983
Prior to starting :
Carefully read the Operator’s manual
before handling the machine, observe 16987
instructions and safety rules when
operating
Risk of being caught in the machine:

17201
Keep at a safe distance from the machine
Risk of projection:
17202
Keep at a safe distance from the machine
-
Ear protection is mandatory
Laser present only on Danger due to class 3A laser

MISTRAL and DUAL (red dot):
VISION machines Never look towards the source of the
laser as you may damage your eyes
Risk of burns:
Do not touch halogens immediately after
they are turned off

SORTING MACHINES
Compliance
The equipment is compliant:
- With the applicable prescriptions in directive 2006/42/CE relating to

machines, in particular those in Appendix I.
- With the prescriptions in directive 2004/108/CE concerning

electromagnetic compatibility.
- With the prescriptions in directive 2006/95/CE regarding electrical

equipment.
- With the prescriptions in directive 97/23/CE regarding equipment under

pressure.

SORTING MACHINES
CHAPTER 2 –
SYSTEM’S DESCRIPTION
Machines concerned
This manual concerns the following PELLENC ST machines:
- MISTRAL (material detection)

- MISTRAL VISION (colour detection)
- MISTRAL DUAL VISION (material and colour detection)
- MISTRAL FILM (film detection)
Components
Each PELLENC Selective Technologies system consists of a feed conveyor, a

control cabinet, a detection unit, an air tank inside the unit and an output box
(depending on the machine functionality).
CHAPTER 2: SYSTEM’S DESCRIPTION 6 Version 05/2012

SORTING MACHINES
CHAPTER 2 –
STARTING UP THE SYSTEM
Controls
A column of three lights (green, orange, red) is positioned on top of the machine. The
green light comes on when the machine is ready to sort. This light is controlled by the
software. The orange light indicates a fault on the machine (air, jamming, power supply,
lighting, etc.). This light is also controlled by the software. The red light comes on for an
emergency stop. This light is not controlled by the software.
Indicator
lights:
REARM 24 V EV: M/A SORTING

Indicates presence of 24V DC power. ON (Lit when the machine is sorting)
when machine is reset (reset pushbutton
activated)
230V Machine:
Indicates that the power is
on
COND. DEFAULT:
Indicates a problem in the
air conditioning
24 V COM:
Indicates presence of
24 V DC Voltage
UPS:
Indicates that the UPS is
working
CHAPTER 2: STARTING UP 7 Version 05/2012

SORTING MACHINES
System controls:
REARM 24V EV:

Resets power following emergency stop
or machine power-up M/A SORTING:
A defect requires the machine to be Automatic sorting started or
reset stopped via pushbutton
Colour Touch screen:

Control of the machine by
the operator
LEARN/MANU/AUTO:
Selection between 3
different operating modes
(manual, automatic or
learning control)
Keyboard
USB, network,
External display
Master switch: Emergency stop button:

Machine power-on Machine power cut off

SORTING MACHINES
Recommendations
 Do not turn the cabinets off at night so as to maintain a constant temperature

and avoid warm-up when the line starts.
 On very damp sites, you must never turn off the cabinets due to the risk of water
getting inside (thermal shock) and causing short-circuits when starting up.
 If it is to be switched off for extended periods, place a humidity absorber in the

cabinet before switch off.
On power-up:
 Let the air-conditioning run for 2 to 3 hours before turning the UPS
back on and check that there is no water when you switch it on.
 When the machine stops, the UPS system is programmed to shut down after
some time. Remember to switch it back on again if it is stopped for a long time.

SORTING MACHINES
1. Machine Start up Procedure
STEPS TO DO
Make sure the doors are locked and that the emergency stop button
1 is released
Power up the control cabinet by setting the master switch to « ON »:

2  The 230V Master light comes on
 The 24V Command comes on
Press the « Reset » pushbutton to engage power:

3
 The « REARM 24 V EV » light comes on
4 Turn the UPS on
5 Wait for the software to change

- Automatic mode: Turn the control knob to the « AUTO » position
for automatic sorting
6
- Manual mode: Turn the control knob to the « MANUAL »
position for manual sorting
7 Start the conveyor line
2. Starting up machine after shutting down with zero

pressure
STEPS TO DO
1 FULLY open the air intake valve
2 Switch on the Q0 circuit breaker in the cabinet
3 Complete the « machine start up » procedure

SORTING MACHINES
3. Shutdown Procedure
STEPS TO DO
1 Stop the conveyor line
2 Switch to manual mode if in automatic mode

3
Exit the software:
Click on the red cross on the top right
side of the screen
Close the Windows 2000 interface using the “Stop PC” key: This process
4
should not take longer than 5 minutes
Switch off the UPS when the message “you can safely switch off your
5 computer” is displayed (the blue indicator under the screen
goes out)
6 Set the main switch to “Off “
4. Setting the machine to zero pressure
STEPS TO DO
1 Complete the Shutdown procedure
2 Switch off the Q0 circuit breaker in the cabinet
Close the air intake valve (any noise heard is normal, due to the purging of
3 the chamber when valve is closed).
Wait until the noise stops

SORTING MACHINES
CHAPTER 3
SOFTWARE
Chapter abstract
N° Functions
F1 Operating menu
F2 Selecting type and direction of ejected objects
F3 Start and stop sorting in manual mode
F4 Managing sorting results
F5 Consulting the event log
F6 Acknowledging defaults
Introduction
The software works for MISTRAL, MISTRAL VISION and MISTRAL DUAL VISION optical
sorters.
CHAPTER 3: SOFTWARE 1 Version 05/2012

SORTING MACHINES
F1: Operating Menu: general data

The main screen provides general information concerning the status of the machine
components:
Status of Lights Connection with

nozzle board status
Status of jam sensors Belt in operation
Air present
Power on
Status of equipment
On the main screen, the status of the machine components is as follows when light is
green:
- « Lighting »: lights switched on

- « Power»: presence of 24VDC electro-valve
- « Connection »: connection set up with nozzle control board
- « Air »: minimum pressure reached in pneumatic system (5 bars)
- « Sorting belt »: conveyor in service (constant speed: between 2 and 3 m/s).
Control buttons
Back to home
screen Nozzle Test
Ejection Language
selection selection
Statistics User level

selection
Lights Test

SORTING MACHINES
F2: Selecting type and direction of ejected objects
Proceed as follows:
- Select button:
Screen sample for the Dual Vision machine (Material + Colour sorting):
Material is ejected downward

On the example above, HDPE is ejected
downward, Yellow PET upward. The
Material is ejected upward other materials are not ejected.
Material is not ejected

- To select the direction, press the box « direction » as many times as necessary to get to
the chosen direction.
In the case of a multi-channel sorting machine, select channel.
Channel selection
Validate the changes in the ejection parameters by pressing button

SORTING MACHINES
F3: Start and stop sorting in manual mode

- To start sorting, push button « M/A SORTING » on the control cabinet.
- To stop sorting, push button « M/A SORTING » on the control cabinet.
M/A SORTING button
SORTING ON Display

SORTING MACHINES
F4: Managing sorting results
Results while sorting

The screen below is automatically displayed when you start sorting:
This screen is used for real-time monitoring of the number of sorted objects.
It provides real-time sorting results:
- The maximum number of ejected numbers since the last reset of sorting results
- the average number of objects sorted per hour
Display for each channel.

The screen disappears when the sorting process is stopped.
Results when sorting is over

To display off-SORTING statistics
Press button:
Display of the Statistics screen
Channel selection
for display
Reset counters

SORTING MACHINES
F5: Consulting the Event log

To access the Event log file, press button
The log file of the latest events is then displayed on screen:
List of the latest events
To display the whole log file, press button

SORTING MACHINES
F6: Acknowledging defaults
When a machine default occurs, the software displays the status and
the event log displays the default information in red:
Note: defaults and their solutions are listed in Chapter 6.
Acknowledge default by pressing button
When the default no longer exists, the software displays status

SORTING MACHINES
CHAPTER 4 –
MAINTENANCE
Chapter abstract
This chapter covers machine maintenance, locating and cleaning procedures as well as
a table indicating which types of maintenance should be carried out regularly on the
machine.
Some indications are also given for the maintenance of peripherals.
Preliminary steps
Maintenance frequency varies. It can be every day, each week or each month
depending on the machine component and mainly depending on the surrounding
environment (dust, airborne particles, type of stream, etc.)
The items requiring maintenance are located in the 3 following units: control cabinet,
detection unit and pneumatic system.
PRIOR TO PERFORMING MAINTENANCE, MAKE SURE THE

MACHINE IS NOT IN THE PROCESS OF SORTING AND THAT
THE CONVEYOR BELT IS TURNED OFF!!
CHAPTER 4: MAINTENANCE 1 Version 05/2012

SORTING MACHINES
How often and how much time is spent on maintenance depends on machine use and
context. The values given below concern all PELLENC Selective Technologies machines
and refer to time and frequency on specific sites. Each individual user will define the
appropriate frequency of maintenance tasks depending on use.
It is important to remember that the regular maintenance of a machine ensures it stays

in good working order.
Summary table for daily maintenance
These maintenance operations are to be carried out daily or at each change of shift.
Equipment to Safety
N° Maintenance Duration
be used CM*** CC****
« test all
Clean the nozzles using the 1 min nozzles »
D1 X
software button
- Non-greasy
D2 window type X X
Clean the jam sensors 1 min cleaner
- Soft cloth
Clean the air conditioning

D3 2 min - Blower X X
filter
- Soft cloth
Clean the glass panels of
- Window type
D4 the reflectors, the scanner X X
6 min cleaner
unit and/or the camera*
- Scraper**
* This maintenance operation should be carried out every 2-3 days

** You must not use plastic scrapers
*** CM = Stop the machine and put a safety stop on it
**** CC = Stop the conveyor and put a safety stop on it

SORTING MACHINES
Summary table for weekly maintenance

Safety
CM CC
Check the purge valve of the
W1 1 min X
compressor
W2 Check the jam alert cells 1 min
Check the pressure on the pressure

W3 0,5 min
gauges
W4 Clean the nozzle bar 3 min X X
Check the functioning of the nozzles 3 min

W5 X
using the software
W6 Perform the halogen brightness test 2 min X
W7 Maintenance and operation of the 2 min X

retractable nozzle bar
Summary table for monthly maintenance

Safety
CM CC
M1 Clean the glass panel of the 5 min* X X

reflectors
M2 Control the filter of the FRL 5 min X X
M3 Test the pressure switch 30 s X
* This time can be reduced to 2 minutes with a set of spare glass panels
Summary table for yearly maintenance
N° Maintenance
Y1 Have the air-conditioning maintenance done
Y2 Electricity check and check of pressurised equipment

SORTING MACHINES
D1: Nozzle cleaning
You are recommended to perform this test every morning before starting the machine.
Run this operation by pressing the software function « Nozzles ». (Test all nozzles)
Start a nozzle cleaning

sequence

SORTING MACHINES
D2: jam sensors

 Tools and protection required for maintenance
Non-greasy window type cleaner and soft cloth, gloves
 Location
Sight glass for jam

sensors
Important: The jam sensors detect an accumulation of objects to be sorted at the outlet
of the conveyor, which could cause our machine to malfunction and, above all, a fire
because of the intensity of the lighting. The sensors thereby eliminate the risks, by
stopping the machine (and therefore the lighting) in case jam lasts longer than 6
seconds.
The cleaning of the 2 sight glasses is therefore mandatory for guaranteeing the safety of
the site (caused, for instance, by a label stuck on the glass).
 Maintenance
- Clean the sight glass of the jam sensors located on each side of the
conveyor, using a soft cloth impregnated with degreasing window type
cleaner, or using wet wipes, to avoid scoring the glass. Wipe the glass dry.

SORTING MACHINES
D3: Air conditioning filter

Blower, glasses, gloves, anti-dust mask
 Location
Air
conditioning
unit
Filter
 Maintenance
Remove the filter

1
2 Use a blower to clean the filter

3 Reinstall the filter

SORTING MACHINES
D4: Cleaning Reflectors and Scanner Box
 Range of application
Part to clean Machines concerned
Reflector All
Scanner box All
 Location
Scanner box
Halogen
glass
covers
Glass Reflector
 Equipment required
Soft cloth, window type cleaner and scraper, gloves
 Maintenance
- Wait 5 minutes for the glass to cool down partially before beginning
maintenance.
- Clean the glasses of the scanner unit and of reflectors using a car
windshield type scraper, to remove any stuck label.

SORTING MACHINES
W1: Compressor purge valve
 Equipment to be used
Flat blade screwdriver
Retractable cover
 Location
Purge valve
2 potentiometers « TEST » Button
The purge valve can be accessed by rolling the opening cover located above the
machine.
 Maintenance
- In principle, purging occurs automatically every 15 minutes for 2 seconds,

with the emission of a relatively loud noise. The valve opening time and
the interval between 2 automatic purging operations can be adjusted but
parameters set by PELLENC ST must not be modified.
- It is important to listen to the noise made by automatic draining at least

once per week and to contact PST if the machine does not drain. A
malfunction can seriously damage the sorting machine.
- Drain it manually every week by pressing the « TEST » button.
If water comes out during emptying, check the air dryer because the electro
valves may be damaged.
CHAPTER 4: MAINTENANCE 8 Version 05 / 2012

SORTING MACHINES
W2: Checking that the jam alert cells work correctly

Gloves
 Location
Sight glass for jam alert cells
 Checking they work properly
- Choose “MANU” for the selector setting.

- Start the belt
- Place your hand in front of the jam
alert sight glass (for either the
transmitting or receiving cell)
Warning: Do not touch the belt to avoid

risk of accidental entanglement
- The cell is considered to work correctly if

the lighting turns off after 3 - 4 seconds.
- If not, change the jam alert cells
(follow procedure 8 in Chapter 5).

SORTING MACHINES
W3: Pressure gauges
 Location
Pressure gauge indicating

pressure sent to electro-
valves
Pressure gauge
indicating air chamber
pressure
 Maintenance
Check the readings of the 2 pressure gauges:

- The pressure in the air chamber must be between 8 and 10 bars (116 to 145
psi)
- The pressure sent to the electro-valves is between 6 and 6.5 bars (87 to 94 psi)
- If this is not the case, please contact your compressor supplier and have the
compressor/plant dryer pack checked.

SORTING MACHINES
W4: Maintenance of the nozzles

Gloves, glasses, anti-dust mask
 Location
Nozzle bar
Nozzle bar (upper)
Nozzle bar (lower)
 Inspection and maintenance
- Use a scraper to clean the nozzle bar. The purpose is to remove all dirt
clogging them up (scraper/electro-valves)
CAUTION
Do not use water!
You must leave air inside so as to avoid dust getting into the nozzles!
- Immediately afterwards, test the nozzles and clean them (D1) to flush out all
dirt
- Check the air exhaust on the casing. If it is blocked, clean it with an air gun.

SORTING MACHINES
W5: Nozzle control
Use the software function « Nozzles ».
Activates all nozzles one by one
Checks nozzle
board status
Tests the displayed

nozzle (see number)
CHAPTER 4: MAINTENANCE Version 05/2012

12
SORTING MACHINES
W6: Lights monitoring
Set the button to “LEARN”.
This test is performed using the

software.
This test checks whether the halogen

and scanner glass covers require
cleaning, so as to reduce preventive
maintenance time.
Prior to pressing the icon, position a reference plate

(ceramic) under the red point on the conveyor belt (in
the middle if there is one box, by a quarter of the width
if 2 boxes) Caution: Never look towards the source of
the laser as you may damage your eyes.
Ceramic
plate Red point
Run the test by pressing the icon in the red circle

as indicated below.
The displayed panel indicates whether the lights

must be replaced or not.
Note: You are strongly recommended to get

a percentage between 70 and 100% on the
final display.

SORTING MACHINES
W7: Maintenance and operation of the retractable nozzle bar
 Location
Nozzle bar
 Start-up
Remote control Bar Solutions to return to

Situation Causes
button status status/Positions normal status
Normal status of
1 the bar in closed
position
Normal status of
2 the bar in open
position
- Reset the green buttons

(machine + bar remote
During movement control)
Abnormal status of
of the bar: - Ensure that the doors are
the bar in
3 -Door opening properly closed
intermediate
- emergency stop - Press on the 2 flashing
position
- Loss of power white buttons until one of
the buttons goes off
Flashing (approximately 5 s)
- Unlock the emergency stop

Abnormal status In fixed position:
button
with bar in open or Emergency stop of
4 the bar or door
- Close the doors
Pressed in closed position - Reset the green button to
opening
One of the 2 return to situations 1 or 2
lighted
- Unlock the emergency stop
button
- Reset the green buttons
Abnormal status of
Emergency stop of (machine + bar remote
the bar in
5 the bar during bar control)
intermediate
movement - Press on the 2 flashing
position
white buttons until one of
Flashing the buttons goes off
Pressed in (approximately 5 s)

14
SORTING MACHINES
 If the bar does not move
If the situations and solutions described in the previous paragraph do not allow you to
open and close the bar, you can check the error message signalled by the "retractable
bar" box located at the rear of the machine.
"Removable bar"
box
Scrolling error
messages in the
event of
problems
2 possible messages:
1) "Default - emergency stop – door open"
Solutions:
 Close the doors
 Unlock the emergency stop
 Reset
2) "Default – Check bar - Sensor malfunction"
Solutions:
 An object may have jammed in the bar during opening / closing.
The cylinder must be unlocked. Call the Customer Service for further
information.

15
SORTING MACHINES
 Removing objects jammed in the bar
Procedure for removing objects jammed in the bar

1 Set the machine to "manual" position
Ensure that the buttons of the bar remote control are in a normal
position (situation 1)
2
If not, follow the instructions in the "start-up" paragraph to get back
to situation 1
Press on the top button

3 of the control panel to
open the bar (unlit button)
4 Remove the jammed objects with the hand
Close the bar by pressing

5 on the second button on the control
panel (unlit button)
6 Set the machine to automatic position
 Cleaning the retractable bar cylinder
Retractable bar cleaning procedure

1 Remove the flap protecting the bar
Clean the cylinders using a

blower
2
Cylinder
3 Re-scratch the flap
 Retractable nozzle bar in automatic mode
Information: At the starting up of the belt, the retractable nozzle bar moves back and
forth (opening/closing) in order to remove objects jammed in the bar.

16
SORTING MACHINES
M1: Cleaning halogen glass covers
 Protection required for maintenance

Gloves
 Location
Glass
Reflector
 Maintenance
- Wait 5 minutes for the glass to cool down partially before beginning
maintenance
- Remove the covers and clean them in a bowl of hot soapy water
- Dry them completely
- Put them back into place

SORTING MACHINES
M2: Air chamber filter

Gloves, glasses
 Location
Filter
Tank
Air shutoff valve

Drain plug Level
indicator
 Maintenance
1) Switch off the equipment air supply and close the air valve of the machine
2) Wait until draining is completely done
3) Use the level indicator to check that there is no water in the tank
If there is water in the tank:

4) Drain the system
5) Unscrew and clean the tank
Caution
Air must be dry when it enters the machine. If water is detected, call an air
specialist immediately.

SORTING MACHINES
M3: Testing the pressure switch

 Location
Pressure switch
Air tank
 Check
1) Close the air vent

2) Air pressure will begin to drop. When it reaches 4.5 Bars (65 psi), the following message should
be displayed:
3) If not, call our Customer service

4) If the message is displayed, you can open the air vent again

SORTING MACHINES
Y1: Air-conditioning Maintenance
All air-conditioning systems must undergo an annual inspection before the summer
season. Inspection is notably intended to check the coolant gas load status. The inside of
the air-conditioning system must also be thoroughly cleaned.
The purpose of this examination is to avoid machine breakdown when the surrounding
temperature increases.
This inspection must be carried out by an approved professional. You may, if you wish,
contact a local refrigerating engineer.
Y2: Electricity check and check of pressurised equipment
We remind you that an electricity check and a check on pressurised equipment must be
carried out according to the regulations currently in force.

SORTING MACHINES
CHAPTER 4
MAINTENANCE OF
PERIPHERALS AND METAL
SENSOR
These operations are carried out after machine shutdown.
Note: For better maintenance of peripherals, refer to the corresponding manuals.
Maintenance of output boxes
 Cleaning the side panes

You should clean the side panes when you can no longer see inside the box.
Use a soft wet cloth to do this.
 Cleaning the separator bars

For better machine efficiency, you must regularly remove any waste that remains stuck
to the separator bars.
Maintenance of rollers
 Cleaning the rollers

Remove any objects that may impede or block the rollers once every shift.

SORTING MACHINES
Maintenance of the conveyor
For conveyor maintenance, please refer to the corresponding manual supplied with the
conveyor.
"Guard iron" maintenance
The guard is only located on the lower nozzle bar (item 2). Its purpose is to prevent objects
from falling between the nozzle bar and the conveyor belt. If residual products were to
remain in this position, there is a risk of damaging the belt.
Perform a visual and mechanical check of this system DAILY.
Adjusting the scraper
The scraper must not rest too heavily on the belt as this could constrain or prematurely
wear out the belt, or cause damage to the scraper itself. Adjustment is performed using
two threaded rods inserted through "half-clamp assemblies" on the control head drums.
When the machine is started, loosen the scraper, then; with the conveyor running,
progressively retighten the springs using the two threaded rods, until the scraper is in
continuous contact with the belt.
Metal sensor maintenance
Once the metal sensor is installed and adjusted, no maintenance is required for it to
operate correctly.

SORTING MACHINES
CHAPTER 5 – PART
REPLACEMENT PROCEDURES
N° Procedures Machines Duration**
1 Nozzle board replacement All 5 min
2 Halogen replacement All 2 min
3 Electro-valve replacement All 30 min
4 PC replacement All 20 min
5 Air conditioning replacement All 30 min
6 Encoder replacement All 10 min
7 UPS replacement All 10 min
8 Jam cell replacement All 15 min
9 Halogen socket replacement All 30 min
** These times are given for informational use only and must not be used as a reference.
In fact, the duration of each procedure can vary according to the machine environment
and the person performing this task.
Safety
 Procedures 1, 2, 3, 6, 8, and 9 are carried out with the conveyor locked out and made
safe.
 Electrical lockout is required for procedures 1, 2, 3, 4, 5, 6, 7, 8 and 9.
 Pneumatic lockout is obligatory when changing electro-valves.
CHAPTER 5: PART REPLACEMENT 1 Version 05/2012

NOTICE UTILISATION – ENTRETIEN - MAINTENANCE
MACHINES DE TRI
Procedure 1: REPLACEMENT OF A NOZZLE BOARD
This procedure applies to all machines.
 Location
Nozzle board
Locks
 Access to the nozzle boards
Operations
The “setting machine to zero pressure” and “automatic shutdown”
procedures, explained in Chapter 2, are necessary for machine electrical and
pneumatic lockout.
Caution: The conveyor is not controlled by the machine and must therefore
be made safe. Please follow the conveyor shutdown procedure to ensure it
does not start up.
1 Turn the locks on the yellow box to get access to the nozzle board.

© Ce document est la propriété de Pellenc Selective Technologies, toute reproduction, même partielle, est interdite
MACHINES DE TRI
Perform a nozzle test to identify the defective

nozzle board.
Nozzle board
3 Once the nozzle board has been identified, the operator must precisely follow
the procedure for replacing the nozzle board described below.
4 When the procedure is completed, the machine can be returned to its initial
configuration by performing the above operations in the reverse order.
 Replacement of a nozzle board
1 Selector 1
3 0
4 Strap
Selector 2
5 1 6 7 2

MACHINES DE TRI
Preliminary steps
The machine is now completely switched off. Check that there is no power
1
and that the nozzle boards are no longer powered on (all lights are OFF)
Identify the position of the various wires, as well as the position of the 2
2
selectors and of the strap before disconnecting them!
Disconnection
Cut the 24V power supply and active power (2 red wires, 2 black wires) –
3 Marks 1,2 3 and 4
Note: the 24V control wire has the smallest diameter
Disconnect the (white) power pins from the nozzle unit and the associated
4
ground wires - Marks 5,6,7 and 8
5 Disconnect the communication cable from the PC – Mark 9
6 Disconnect the pressure switch cable - Mark 10
Installing the new board
7 Remove the 4 screws securing the board
8 Remove the board to be replaced
Install the new board and select its number using the two encoder disks
9 (the number is the same as the one on the out of order board).
Reposition the strap.
Reconnections
10 Connect the communication cable to the PC – Mark 9
11 Connect the pressure switch cable– Mark 10
Connect the 24V power supply and active power (2 red wires, 2 black
12
wires) - Marks 1,2 3 and 4
Connect the (white) pins of the nozzle unit (and the associated ground
13
wires) - Marks 5,6,7 and 8

MACHINES DE TRI
Restoring the initial situation
Switch the machine back on: all the lights of the nozzle boards are ON
14
15 Clear the defect on screen after pressing the green “REARM 24V EV” button
Check for correct operation (perform a nozzle test and make sure each
16
nozzle is active)
17 Close the yellow box

SORTING MACHINES
Procedure 2: HALOGEN REPLACEMENT

 Protections required for maintenance
Gloves

Warning: You must never touch the reflective metal sheets with either your fingers or a
soft cloth.
 Location
Locate the reflector where the halogen needs replacement by testing the lights (H6).
Reflector

SORTING MACHINES
Reflector description
Screw
Socket
Halogen
Reflecting glass
Opening the glass cover
 Remove the 6 screws
 Open the glass cover with care by pulling it downwards (step 1) and
swinging it down gently (step 2)
Caution: hold the glass while it is moving vertically
Step 1
Step 2

SORTING MACHINES
Replacing the halogen
Remove the halogen by pushing it against one of the sockets (as you would
1
do with domestic halogen lamps)
Position the new halogen in the same manner, using a soft cloth or gloves
so as not to touch it with your fingers
Correct
Incorrect
3 Check that you can spin the lamp
4 Close the glass cover by swinging it back up and pushing closed
5 Tighten the 6 screws

SORTING MACHINES
Procedure 3: ELECTRO-VALVE REPLACEMENT

Gloves
Location
Nozzle bars
Nozzle bar (upper)
Nozzle bar (lower)
Preliminary steps
Shut off the air supply located near the air-conditioning by

closing the air valve (horizontal position)
Wait until end of draining process (no more air in the tank)

SORTING MACHINES
Opening the protective cover
Unscrew screws of the protective cover without removing them
Upper nozzle bar Lower nozzle bar
Lift the protective cover
Inserting a new electro-valve
3 Using a blower, blow the hexagon socket recess of each screw to be

removed, as well as the unit so as to avoid dirt getting in after the electro-
valve is removed
Using an Allen/BTR 2.5mm wrench, unscrew the 2 screws securing the

faulty electro-valve

bas

SORTING MACHINES
Remove the electro-valve by pulling it perpendicularly to its seat.

5 (CAUTION: the electrical connector is fragile
Using a cloth, clean the seat of the electro-valve (residual grease)

6
CAUTION : prevent contamination from entering the feeder openings
7 Position the seal in the hollow section on the new electro-valve
Re-position the new electro-valve by placing it perpendicular to the seat

8
(CAUTION: the electrical connector is fragile)
9 Tighten the 2 screws
Restoring initial situation
10 Open the air shut-off valve
11 Make sure there are no leaks when pressure is applied again
12 Perform a nozzle test
Tighten the screws on the covers and check that the casket is placed
correctly
Casket
13
Lower nozzle bar

SORTING MACHINES
Procedure 4: PC REPLACEMENT
 Location
Open doors:
PC
 PC Replacement
PRECAUTIONS
Some cables are identical, so clearly identify the cables and
their position
STEPS OPERATIONS
1 Turn off power to the machine (electrical lockout)
2 Check there is no power
3 Switch off the UPS
Open the cabinet and disconnect the cables connected to the PC (7
4
minimum)
5 Remove the screws securing the PC (2 screws)
Unpack the replacement PC and turn over the assembly rails
6
(inverted during shipment)
7 Position and secure the PC using the PC fastening screws (2 screws)
Reconnect all cables (7 at the minimum) according to the indications
8
below (See wiring)
Power up the cabinet then the PC, and make sure all the
9
components are operational (inverter, nozzle board…)
CHAPTER 5: PART REPLACEMENT Version 05/2012
12
SORTING MACHINES
 Wiring: PC Mistral and Mistral Vision (width: 800, 1200 and 1600
single-head)
5 10
7 9 6
Connect the various peripheral devices to the connectors in accordance with the
different configurations. Tighten the connector screws moderately.
1 5 9
USB connected to
switch
2 6 10
3 7
4 8

13
SORTING MACHINES
 Wiring: PC Dual Vision (width: 800, 1200 and 1600 single head)
PC Mistral and Mistral Vision (width: 2000, 2400 and 2800)
3
4
7 9 6 5 10
configurations below. Tighten the connector screws moderately.
1 5 9
USB connected to
switch
2 6 10
3 7
4 8

14
SORTING MACHINES
 Wiring: PC Dual Vision (width: 2000, 2400 and 2800)
7 9 6 5 10
configurations below. Tighten the connector screws moderately.
1 5 9
USB connected to
switch
2 6 10
3 7
4 8

SORTING MACHINES
Metal option
Nozzle board
bundle
Metal sensor
bundle

MACHINES DE TRI
Procedure 5: REPLACING THE AIR CONDITIONING UNIT

Gloves
Caution:
The air conditioning system must remain vertical for 24 hours before starting up.
 Location
 Replacing the air conditioning unit
Removing the air conditioning unit

1 Switch off the machine
2 Open the control cabinet and disconnect the quick-disconnect cable
3 Unscrew screws from the air conditioning unit
4 Remove the air conditioning unit

Installing the air conditioning unit
Correctly position the air conditioning unit and then tighten the screws.
5 CAUTION: place the cover attachment fittings between the control cabinet
and the air conditioning unit
Check that the air conditioning unit is correctly attached and that it is secured
6
against the control cabinet
7 Connect the quick-disconnect cable
Wait for an hour before switching on the air-conditioning unit to allow the
8
liquid in the cooling circuit to stabilize
Switch on the machine and check that the air-conditioning unit is running
9
correctly

SORTING MACHINES
Procedure 6: REPLACING THE ENCODER

Switch the conveyor off and set it to lockout.
Location
The encoder is located on the side of the conveyor. Detection screw
M5 screw
Encoder
Disc Rotation sensor

Removing the encoder
1 Disconnect the encoder cable
2 Unscrew the encoder nut near the wheel
3 Remove the encoder by its back end
Installing the new encoder
Insert the new encoder into the original position

Caution: When remounting, make sure there is a 3 mm gap between the disc
and the encoder sensor.
Checking it works properly

5 Start the conveyor
A LED should flash to indicate that the belt is running. If not, move the sensor
6
closer to the wheel

18
SORTING MACHINES
Procedure 7: REPLACING THE UPS SYSTEM
Location
UPS Open doors
Removing the UPS

1 Remove the screws
2 Unplug the cables from the back
3 Remove the damaged UPS (in black)
Installing the new UPS
4 Put a new UPS into place
5 Reconnect the cables as shown:
6 Tighten the screws

19
SORTING MACHINES
Procedure 8: REPLACING A JAM ALERT CELL
Location
Jam alert cells
Identifying the jam alert cells
Jam alert cells are made of 2 components:
- A transmitter: on the left hand side of the machine and without controls
- A receiver: on the right hand side of the machine composed of several controls

SORTING MACHINES
Replacing the cells

1 Remove the two screws on both cells
2
Disconnect the connectors
3 Replace both cells (transmitter and receiver)

4 Tighten the screws
5 Reconnect the connector
Sensor controls
INDICATORS LEARNING
BUTTON
PROGRAMMING
TIME SWITCH
SETTING
1 Switch the machine on:

The green indicator lights up
2 Press button TEACH for 5 seconds
When the orange indicator

3 comes on, release the button
4 Set the potentionmeter to 5 seconds
Checking it works properly
Follow procedure H2 to check it works properly

SORTING MACHINES
Procedure 9: REPLACING A HALOGEN SOCKET

Gloves
Caution: Never touch the reflecting plates with fingers nor soft cloth.
 Location
Locate the halogen where the socket is to be replaced.
 Replacing the socket
Opening the glass

1 Follow steps 1 and 2 of Procedure 2
Replacing the socket
1 Remove the halogen lamp
2 Unplug the connector situated at

the back of the reflector
Unscrew the connector to

3 remove the contact block
Contact block
Mark the position of the wire from the socket to be replaced (position 1 or
2) then get the specific tool provided with the machine.
4
Specific tool
Possible locations of the wire
(identify before removing)

22
SORTING MACHINES
Drive the tool into the contact slot and pull the wire out.
6 Unscrew the connector steel sheath.
Unclip the socket and pull the wire. If the wire proves difficult to remove,
7
refer to paragraph ”Socket wire and ground wire” further down.
Clip the new socket into place

with the slot facing upwards
(so the wire can be easily inserted)
8
Note: There is a movable part and a
stationary part, make sure to put them in their
right place.
Insert the wire fitted with its red

thermal protection into the sheath,
9 holding it straight to avoid radius of
curvature and to make it easier to
thread it through.
10 Fasten the steel sheath to the connector.
Put the wire back into the place that you noted in the contact block. Push it
11
into place until you hear a click.

23
SORTING MACHINES
12 Replace the contact block in the connector and tighten the screws
13 Plug the connector back in
14 Put the halogen back into place
15 Swing the glass cover back up and push into place
16 Insert and tighten the 6 screws
Socket wire and ground wire
If you have trouble inserting the wire (step 7) due to the ground wire,
unscrew the threaded cover located on the side of the reflector
16
The wire should pass through more easily

If it still cannot be done, unscrew the steel duct on the side of the reflector
Insert the new wire and the ground wire into the red high voltage duct and
17
then insert the whole set into the steel sheath
18 Screw the steel sheath back on again
19 Position and tighten the threaded cover on the side of the reflector
20 Follow the previous procedure from step 11 onwards

24
SORTING MACHINES
CHAPTER 6 – HELP
This chapter gives help on trouble shooting and remote maintenance.
Subject Cause of the problems

 Lights
 Software
Diagnostic aid  Ejection
 Sorting
1 – I/O drive boards

2 – Power validation
3 – No lights
4 – Connection with nozzle control unit
Error messages and 5 – Low air pressure
solutions
6 – Problem with nozzle board
7 – Nozzle control board diagnostic in nozzle control
board unit
8 – Acquisition
Remote maintenance
CHAPTER 6: HELP 1 Version 05/2012

SORTING MACHINES
CHAPTER 6 - Diagnostic aids

and fault-tracing
Lights
What should I do if the lights don’t come on?

 Make sure the doors are locked.
 Check the halogens (cleanliness and operation)
 Should you see the message “Mistral on standby: belt stopped” while the
conveyor is working, check the encoder
Software
What should I do if the error message "acquisition card missing" is displayed

when the software starts up?
 Switch off the machine, wait several seconds, then switch it on again (PC is
stopped)
 If the problem persists, call Pellenc Selective Technologies Customer Service
What should I do if the error message "No Power" is displayed?

 Make sure the emergency stop button is not applied.
 Press the "REARM 24V EV" button
 Check the status of the circuit breakers
 Confirm on screen
Ejection
What should I do if the objects are incorrectly ejected?
 Check the service air and that the nozzles are working correctly
 Try and identify the trajectory of the object when it is blown out by passing it
through the belt several times. (Check for twisting)
 Make sure the nozzles are not directing the air stream next to the object.
 Check the operation of the nozzle board
CHAPTER 6: DIAGNOSTIC AIDS 2 Version 05/2012

SORTING MACHINES
How do I check the synchronization (this requires 2 persons):
 Check the lateral synchronization (perform a mirror centring – Restricted

access to customers with Level 2 training)
 Perform a blowing timing test:
 Pick a PE bottle
 Select the material to be blown: PE if possible
 Check for correct detection (some caps are made of PP)
 Run sorting mode
 Position the bottle on the belt cross-wise supporting it with your hand to
prevent it from moving when released
The object must be clearly ejected and must not swirl around itself.
Nozzles start blowing too early: contact Pellenc ST

Customer Service and report the default
Nozzles start blowing too late: contact Pellenc ST

Customer Service and report the default
What should I do in the event of nozzle failure?
 Check for the presence of air

 Check the connection between the PC and the nozzle boards (nozzle test)
 Check that the nozzles are not clogged (“clean nozzles”)
 Check that there is not a wire crushed in the 16-pin connector on the nozzle
ramp
 Check the nozzle board safety fuses

SORTING MACHINES
Sorting
What should I do if the machine does not sort?
 Make sure the belt is in operation

 Should you see the message “Mistral on standby: belt stopped” while the
conveyor is working, check the encoder.
 Check the connection with the nozzle board
What should I do in the event of a drop in sorting purity or efficiency?
 Check the lights : all the reflectors must be ON

 Check that the reflectors are clean (test)
 If the test fails, check the detection unit: the windows and the inside must be
clean
 Check the machine pressure. If it is too low, the problem may stem from the
compressor.
 Check for correct operation of each nozzle
 Check the position of the separating plate in the output box
 Check the quality of the flow: too much commingled material during ejection.
Similarly, a wet stream can cause detection to be faulty.

SORTING MACHINES
CHAPTER 6 – ERROR
MESSAGES AND SOLUTIONS
Diagnosis of displayed messages common to all machines
The machine status indicator turns red to indicate a blocking error.
Example:
Error messages are displayed in red

Acknowledgement icon when
error has been identified
CHAPTER 6: ERROR MESSAGES 5 Version 05/2012

SORTING MACHINES
Problem 1: No I/O board
Error message I/O card unavailable

Cause:
The I/O Drive Board is not detected by the software.
Solutions:
Acknowledge the error.
The I/O board is faulty or is not detected, the machine cannot be used:
- Terminate the application
- Switch off the control cabinet (PC included)
- Wait several seconds
- Start the machine again.
If the problem persists, please contact PELLENC Selective Technologies Customer

Service.

SORTING MACHINES
Problem 2: Power
Error message No power 24V
Cause:
The software does not detect any power.
Solutions:
The “REARM 24V EV” button of the control cabinet is also OFF:
- Release the emergency stop button
- Engage power by pressing the reset pushbutton
- Acknowledge the error message.
In addition, check that all the circuit breakers are ON. If this is not the case, switch any
circuit breakers to ON, then reset and confirm.

SORTING MACHINES
Problem 3: No lights
Error message Lighting default
Cause:
The software starts up without lights.
Solutions:
- Check circuit breaker Q4, it must be closed

- Check if lights are powered on
- Acknowledge the error message
- Check the halogen tubes
- Check that the jam cells are not clogged

SORTING MACHINES
Problem 4: Jam
Error message Belt jamming detected

Cause:
An object blocks the jam cells located in the light beam.
Solutions:
- Check for objects blocking cells and remove if any


SORTING MACHINES
Problem 5: Low air pressure
Error message Pressure default

Cause:
The air tank pressure is lower than the nozzle operating pressure.
Solutions:
- Check the compressed air supply: it must be above 4 bars (58 psi)
- Check the supply system
- Make sure the pressure regulator is set to 4 bars (58 psi)

SORTING MACHINES
Problem 6: Nozzle board default
Error message Ejection: system busy

Cause:
An output stage is faulty.
Solutions:
- Find the faulty output for which the control diode is off (see next page)
- Switch off the control cabinet (master switch)
- Check the connections between the output and the nozzle wire bundle
- re-start the machine
If the problem persists, replace the nozzle control PCB.

Please return the defective PCB to the PELLENC ST Customer Service along with the
number you were given for the return of goods Authorization.

SORTING MACHINES
Problem 7: Nozzle control board diagnosis in nozzle control unit
F1
24 V Control Ld33
24 V
Ld34 Ld39 Ld38 Ld37
Ld36
Ld1 Ld32
24 V
Puissance
Power
Ld i: Lights welded on the board
Power indicators
Ld33: Presence 24 V Control (check fuse F1)

Ld34: Presence 5 V Control
Electrodistributors control indicators
With the presence of « 24V Power », Leds Ld1 to Ld32 must be ON.
If one of the Leds (Ld1 to Ld32) is OFF, this indicates a problem with the electrical
connection between the board and the coil:
- open circuit (cable cut, faulty connector crimping or coil unserviceable)

- short-circuit (cable crushed or coil unserviceable)
Ld39 ON: indicates a program error or microprocessor defect. Switch off and then
switch on the machine. If fault persists, replace the board
Ld36 flashing: indicates board is OK
Ld37 flashing: indicates normal communication between board and computer

SORTING MACHINES
Diagnosis of displayed messages specific to the MISTRAL

software
Problem 8: NIR Acquisition
Error Message The NIR sensor is unavailable

Cause:
The acquisition board is not detected by the software.
Solutions:
The acquisition card is faulty or has not been detected, it is impossible to use the
machine:
- quit the application
- switch off the control cabinet (PC included)
- wait several seconds
- re-start the machine
If the problem persists, please contact the PELLENC Selective Technologies Customer
Service.

SORTING MACHINES
Diagnosis of displayed messages specific to the VISION

software
Problem 9: VISION Acquisition
Error message The VISION sensor is unavailable

Cause:
The vision board is not detected by the software.
Solutions:
The vision board is defective or is not detected, it is impossible to use the machine:
- Exit the software
- Wait a few seconds
- Re-start the machine
Service.

SORTING MACHINES
Diagnosis of displayed messages specific to the METAL

software
Problem 10: METAL Acquisition
Error message The metal sensor is unavailable
Cause:
The metal board is not detected by the software.
Solutions:
The vision board is defective or is not detected, it is impossible to use the machine:
- Exit the software
- Wait a few seconds
- Re-start the machine
Service.

SORTING MACHINES
CHAPTER 6
REMOTE MAINTENANCE
After consulting the previous chapters, if you still cannot resolve your problem, you can
call the After Sales Technician for remote maintenance.
BEFOR REMOTE MAINTENANCE:

 Identify the remote maintenance mode of your machine, either MODEM or ADSL
(when purchased)
 Make sure the telephone line is connected to the machine
 Collect samples that may be used for tests if necessary
Call Pellenc ST
Customer service
DURING THE REMOTE MAINTENANCE:
 Make sure the machine is not sorting

 Set the machine to mode “LEARN”
 Follow the instructions given by our technician
 During the remote maintenance operation, our technician may request you to
position an object under the light beam, on the measuring section. If so, position
the object under the red point on the belt (Caution: Never look directly into the
laser source as you may damage your eyes).
Try to choose a rather large object with no label
AFTER THE REMOTE MAINTENANCE:
 Return to automatic mode (switch turning button Control to “AUTO”

Return to the sorting mode (press M/A Sorting)
CHAPTER 6: REMOTE MAINTENANCE 16 Version 05/2012

SORTING MACHINES
CHAPTER 7
TECHNICAL
CHARACTERISTICS
Technical characteristics for
MISTRAL, Mistral Vision and Dual Vision
machines
Machine width
800 1200 1600 2000 2400 2800
Technical data
Width of working passage (in mm) 730 1130 1530 1930 2330 2730
Air tank capacity (in litres) 50 50 50 50 50 50
Lighting power (in kW) 2 3 3 4,5 4,5 6
Total electrical power of the machine
3,5 3,5 5 5,5 6 8
(in kW)
Mass of optical separator alone (in Kg) 710 840 970 1100 1230 1360
Power supply Single phase 230 Volts ± 10% - 50/60 Hz
Relative humidity < 80 %
Working temperature From - 15°C to + 43°C (+5°F to +110°F)
Distance between detection and ejection 100 -150 mm
Standard noise level* Between 85 dB and 90 dB
* Measurement of the noise level of the whole machine running at the conveyor belt
design output, measured with a sound meter at a distance of one meter all around
the machine
CHAPTER 7: TECHNICAL DATA Version 05/2012

1
SORTING MACHINES
Technical characteristics for

MISTRAL, MISTRAL VISION and DUAL
VISION machines
“MATERIAL” SORTING NIR system
Minimum size of objects detected 10 mm
Minimum size of objects ejected 30 mm
Analysis resolution 1 cm2
Nozzle spacing 25 mm
Machine width
800 1200 1600 2000 2400 2800
Technical data
Binary Configuration (1 lower nozzle bar) Yes Yes Yes Yes Yes Yes
Binary Configuration (1 upper nozzle bar) Yes Yes Yes Yes Yes Yes
Ternary Configuration (2 nozzle bars) Yes Yes Yes Yes Yes Yes
Metal detector option Yes Yes Yes Yes Yes Yes
Multichannel option (modifiable channel

No Yes Yes Yes Yes Yes
width, minimum width = 600 mm)
Pneumatic system
Pressure 8 bars
Unlubricated dehumidified air
Air filtration at 5µ
Air quality at tank inlet Oil filtration at 0.1 mgr/m3 maximum
Dew point between –40° and -20°C at tank
inlet depending on climate

2
SORTING MACHINES
CHAPTER 7
Sorting Efficiency and Purity
Definitions
Once the machine has sorted the various materials, its performance can be measured
by means of two indicators: efficiency and purity.
Sorting efficiency refers to the sorting output or yield.
Sorting purity refers to the quantity of objects sorted without error.
In the examples below, we will consider numbers but performance can also be
measured in volume.
Material Efficiency/Purity-Positive Sorting
Example: 100 objects made from PET and 50 objects made from another material are
present at the input stream of the machine.
 Efficiency: Out of 100 bottles made from PET, 93 are ejected into the PET
outlet and the 7 other PET bottles into another outlet. PET sorting efficiency is
93%.
 Purity: 97 objects are counted in the PET outlet. Of these 97 objects, 93 are
objects made from PET. PET sorting purity is 93/97, i.e. 95.8%.
MATERIAL PURITY / EFFICIENCY – Positive sorting
100 PET objects

50 other objects
+
-
Diagram 1
7 PET 93 PET
46 Other
4 Other
Other output PET output
Total=53 objects Total= 97 objects
PET sorting efficiency: 93% As 93 Purity of clear objects: 95,8%

PET objects out of 100 present at As at clear PET output, there are 93 clear
input are found at PET output, PET objects out of 97 objects in total, i.e.
i.e. 93 :100 =93% 93 :97 =95.8%

3
SORTING MACHINES
Colour Efficiency/Purity-Positive Sorting

Example: 100 objects made from clear PET and 50 objects made from coloured PET
are present at the input stream of the machine.
 Efficiency: Of the 100 clear PET bottles, 93 are ejected in the Clear PET outlet
and the 7 other clear PET bottles are ejected into the Coloured outlet. PET
sorting efficiency is 93%.
 Purity: 97 objects are counted in the clear PET outlet. Of these 97 objects, 93
are clear PET objects. Clear PET sorting purity is 93/97, i.e. 95.8%.
Efficiency of clear PET: 93%

As at clear PET output, there are 93 clear PET
100 Clear PET objects objects out of 100 clear PET in total i.e
50 Coloured PET objects 93:100=93%
+
-
Purity of clear PET: 95.8%
As at clear PET output, there are 93 clear PET
objects out of 97 objects in total, i.e.
93 : 97 = 95.8%
93 PET
7 Clear PET
Clear
46 PET
Colour
Diagram 2 4 Colour
Colour output Clear output
Material Efficiency/Purity-Negative Sorting

Example: 1000 objects made from PET and 100 objects made from another material
are present at the input stream of the machine.
 Efficiency: Of the 100 impurities present at the input, 95 are ejected. PET
classification efficiency is 95%.
 Purity: In the PET outlet there are 990 bottles made from PET out of 995
objects in total. PET output purity is 99.5%.
Efficiency of impurity fraction: 95%

1000 PET objects
As at Impurity output, there are 95 impurities
100 Other material out of 100, i.e. 95:100= 95%
objects
-
+
Purity of PET fraction: 99.5 %
As at PET output, there are 990 PET objects
out of 995 objects in total, i.e.
10 PET 990 :995=99.5%
990 PET
95 Other
Diagram 3 5 Other
Impurity output PET Output

4
SORTING MACHINES
CHAPTER 7
SPARE PARTS
In this chapter is a list of the important spare parts that you are most likely need to
order someday.
The parts are given by area and are numbered in the photos.
Area C
Area A
Area L
Area D
Area N
Area G
Area B
Area M
Area K
Area F
Area J
Area E
Area H
Area I
CHAPTER 7: SPARE PARTS 5 Version 05/2012

SORTING MACHINES
Area - Number Description

A1 Screen on/off
A2 Main on/off switch
A3 Emergency shutdown button
A4 Sorting on/off button
A5 Keyboard
A6 Touch screen
A9 Auto/Manu/Learning switch
A4
A6
A1
A9
A5 A2
A3

SORTING MACHINES
Area - Number Description *

B1 SIROCCO PC
B2 MISTRAL PC
B3 UPS
B4 Spectrometer/Biplexer
B5 PELTIER effect module * (According to the option)
B6 PELTIER pilot board (According to the option)
B7 Diode ampli board * (According to the option)
B8 Screen power supply
B9 Biplexer pilot board*
B10 Switch or router (depending on the configuration)
* This part can only be changed by PST.
B8
B2
B3
B10
B4
B9
B7
B5
B6

SORTING MACHINES

C1 I/O board
C2 2 way VISION board
C3 Modem card
C4 CAN module
C5 National Instrument board
C6 Metal board
C7 Hard drive
VISION
PC
C2
C1
34 C3
36 C4
37
C7
C5
MISTRAL
C6
PC

SORTING MACHINES

D1 20 A Power supply
D2 40 A Power supply
D3 Fusadee cartridge
D4 Intensity control relay
D5 Fuses
D9 I/O Power card
D1 D3
D4
D9 D2
D5
33
D5

SORTING MACHINES

E1 Halogen tube
E2 Lampholder bundle unit
E3 Reflector glass cover
E4 Reflector unit
E2
E4
E3
E1

SORTING MACHINES

F1 Mirror set *
F2 Camera box*
* This part can only be changed by PST.
F1
45
F2

SORTING MACHINES

G1 Encoder
G2 Belt rotation sensor
G3 Belt
G4 Rolling bearing 1
G5 Rolling bearing 2
G6 Return rolling bearing
G7 Gear motor
G1 G2
G3
G5
42
G6
43 G4
41
G7

SORTING MACHINES

H1 Jam alert cells (pair)
H2 Protective cover
H3 Magnetic door switch
H1
H2
H3

SORTING MACHINES

I1 Scraper
I2 Electro-valve unit joint
I3 Electro-valve unit
I4 Electro-valve
I5 Joint + electro-valve filter
I6 Electro-valve unit air supply
I7 Electro-valve unit holder
I8 Nozzle ramp fitting holder
I9 EV protective cover
I3
I8
I5
I4
I2 I9
I1
I7 I6

SORTING MACHINES

J1 FRL unit
J2 FRL filter
J3 Harting connector
J4 Harting socket
J5 Continuous output pressure regulator
J6 Oil trap filter
J3 J4
J5
J6
J1 46
J2

SORTING MACHINES

K2 Air valve
K3 Flowmeter
K4 Pressure switch
K5 Safety valve
K6 Air tank
K7 Automatic drain valve
K4 K5
K3
K6 K7
K2

SORTING MACHINES

M1 Air-conditioning
M2 Air-conditioner filter
L1 Nozzle board
M
1
L1
M
2

SORTING MACHINES
CHAPTER 7
Future of the machine at the
end of life
Actions
PELLENC ST machines must be dismantled at the end of their life and the different
types of waste must be collected and processed by the appropriate approved
channels.
Specialised channels
Here are a few channels which are able to process the waste from our machines:
Industrial Waste market

 Steel and construction metal
 Wiring
 Plastics
 Glass
WEEE (Electric and electronic waste) channel (PAM- small electrical goods)
 Computer
 Electronic material
WEEE market (F- large electrical goods)

 Air conditioning
WEEE market (screen)

 Computer screen
CHAPTER 7: TECHNICAL DATA 18 Version 05/2012


Notice g2010 2g English

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Notice g2010 2g English

Hochgeladen von

Copyright:

Verfügbare Formate

SORTING MACHINE

Translation of the original

3 SOFTWARE • Description of software functions

MAINTENANCE OF • Description of all maintenance operations

• Description of all replacement procedures

• Machine technical characteristics

CERTIFICATES AND • Certificates of conformity

CONTENTS Version 05/2012

PELLENC Selective Technologies

CONTACTS Version 05/2012

In this chapter you will find the following information:

1. Delivery and handling ............................................................................................................ 2

2. Equipment mechanical assembly ........................................................................................ 3

3. Assembling the output box ................................................................................................... 5

4. Creating power supply and network connection interfaces ....................................... 6

5. Creating the pneumatic interface........................................................................................ 7

7. Output box motorized roller: Supply and connection ................................................... 9

8. Work achievement validation ............................................................................................... 9

9. Interconnection of optical sorters with the customer control cabinet ..................... 9

10. Connections and machine settings .................................................................................. 13

APPENDIX 1: REMOTE MAINTENANCE INFORMATION FILE ............................................. 14

CHAPTER 1: ASSEMBLY INSTRUCTIONS 1 Version 05 /2012

1. Delivery and handling

Note: for the conveyor, please refer to the conveyor manual

CHAPTER 1: ASSEMBLY INSTRUCTIONS 2 Version 05 /2012

2. Equipment mechanical assembly

2.1 Removing the support frame of the optical sorter

2.2 Positioning the optical sorter onto the conveyor

2.3 Aligning marks on standard and HR lines

Right side Left side

Right side Left side

Caution: Check that the distance between

2.4 Fixing the optical sorter onto the conveyor

CHAPTER 1: ASSEMBLY INSTRUCTIONS 4 Version 05 /2012

3. Assembling the output box

3.2 Positioning side flaps

CHAPTER 1: ASSEMBLY INSTRUCTIONS 5 Version 05 /2012

4. Creating power supply and network connection

The electrical, pneumatic and network connections must be made by Pellenc ST

 Power supply cable (mark E)

 Ground cable (mark E)

 Automation connecting cable (mark E)

 Network cable and ADSL connection for remote maintenance (mark E)

CHAPTER 1: ASSEMBLY INSTRUCTIONS 6 Version 05 /2012

Note: The PST router must be switched on and in 24/7 operation.

 MODBUS TCPIP Network cable (option) (mark E)

MODBUS connection diagram

5. Creating the pneumatic interface

CHAPTER 1: ASSEMBLY INSTRUCTIONS 7 Version 05 /2012

6. Belt conveyor: Supply and Connection

CHAPTER 1: ASSEMBLY INSTRUCTIONS 8 Version 05 /2012

7. Output box motorized roller:

8. Work achievement validation

9. Interconnection of optical sorters with the customer

9.1 Operating modes

9.2 Main cabinet inputs (terminals X11 and X9)

CHAPTER 1: ASSEMBLY INSTRUCTIONS 9 Version 05 /2012

9.2.2 Sorting On/Off

• Closed contact: “Sorting” is “On”.

9.2.3 « Defect » and «machine sorting» outputs (terminal X8)

• Closed contact: “Machine sorting” information.

9.2.4 Safety switches (terminal X13)

9.2.5 Miscellaneous information

 Machine in manual or automatic mode (terminal X9)