PEPSI STARTER PALLET KIT PN: 6208500 INSTALLATION INSTRUCTIONS

PEPSISTARTER PALLET KIT

PN: 6208500

INSTALLATION INSTRUCTIONS

Components of 6208500 Starter Pallet Kit

• 1 - 6160765 Trigger Box• 2 - 6’ Serial Cables• 4 screws & nuts for mounting box to MCA cover

• 1 – 42GRU-9200 QD AB Photo Eye• 1 – 5760194-25 AB Photo Eye Cable• 1 – 9650513 AB Photo Eye Swivel Bracket• 1 – 9650512 Photo Eye Bracket (RLC)• You will also need updated software Ver. 7.0.1.P and

the new CTS-DTR Serial Trigger program Ver. 1.1Note:The Starter Pallet Kit cannot be used on a Broadway style

of line (“A” “B” “C” Labels)

Theory of Operation

• A full pallet of product is detected by the current AB photo eye.

• The new starter pallet eye is set to the height of the lowest starter pallet.

• When both of the eyes are triggered a “Full Pallet” label is printed

• When only starter pallet eye is triggered the “Starter Pallet” label is printed

• The new starter pallet software version 7.0.1.P will select the proper label based on the labels picked by the customer at time of set-up. See next slide and the “Full-Starter Pallet Instructions.doc” which is attached.

Installation Instructions• Determine which line will have the Starter Pallet kit

installed• Remove the MCA cover and locate the starter pallet

box on the cover and mark where to drill holes. On the VJ unit mount box on side cover

• Drill four clearance holes and mount the box to the MCA cover with the four (4) screws and nuts provided

VideoJet PA/6000PA/6000

• Mount the new Starter Pallet eye below the current Full Pallet eye. See Figure #1

• The height of the eye needs to be set so it will pick up a Starter Pallet but will not pick up any product on a pallet lower than a Starter Pallet. See Figure #2 and #3

• Next you want to hook up the cables to the Starter Pallet box

• Locate the old trigger cable and discard it. This cable is now replaced and superseded by the new 6160765 trigger box.

• Hook the new eye cable 5760194-25 from the Starter Pallet eye and install it on “PD1” in the trigger box.

• Hook the existing cable from the Full Pallet eye to “PD2” in the trigger box.

• Take the two 6’ serial cables and hook them to “PC” Com 1 & “Labeler” Com 5 or 6 depending on your set-up. Pre-bend the cable stand off’s to help close the cover.

Full Pallet Eye

Com 1

New Starter Pallet EyeJ3

Customer’s Conveyor

Reflector

Full Pallet Photo Eye

PHOTO EYE SET-UP

NEWStarter Pallet

Photo Eye

Beam

Beam

Figure #1


Reflector


FULL PALLET

NEWStarter Pallet

Photo Eye

Beam

Beam

Figure #2


Reflector


STARTER PALLET

NEWStarter Pallet

Photo Eye

Beam

Beam

Figure #3

When product is at this height or lower – a label is not to be applied

Installing New Starter Pallet Software Ver. 8.0.1 and CTS-DTR

Serial Trigger Program Ver. 1.3• Completely remove the old C:\Diagraph_Pepsi software.

You may have to stop the Nicewatch service to complete this.

• Install the new “Pepsi Starter Pallet” software version 8.0.1.P in the “C:\” root drive.

• Install the new “CTS-DTR Serial” trigger program in the “C:\Program Files\Diagraph. Make a short-cut of this program and install this in the “C:\Documents and Settings\All Users\Start Menu\Programs\Startup”. You may want to create a desktop shortcut also.

Make sure you delete the old trigger and the short-cut files

CTS-DTR Serial Trigger Software

• Com Port – This will Auto find the port

being used. If it does not you can select this to what Com port needed and it will stay at that setting

• Mode– Select the Mode you are

running. “1 Detector, 1 Format” is for the normal Pepsi software trigger. “2 Detectors, 2 Formats” is for the new Starter Pallet trigger

• Re-Trigger Dwell– After photo eyes are triggered

this is the dwell before another trigger can be made. This is used for bottle lines where the beam may see through the shrink wrap causing multiple triggers. You must have a number in this box to work properly.

• Trigger A + B Window– This is a delay setting for the

Full & Starter eyes to be triggered. This allows both eyes to be seen and triggered together. If you don’t set some delay, you will more than likely trigger the Starter Pallet eye before the Full Pallet eye which could cause a starter label to print instead of the Full Pallet label. You must have a number in this box to work properly.

• Trigger Polarity– If the Full and Starter pallet eyes are set to active dark, the trigger

program needs to be set to normal. It will then produce a label after the pallet leaves the eye. If the eyes are set to active light, set the program to inverted and it gives you a label as soon as the pallet

trips the eyes.

Diagraph- Pepsi Starter Pallet Tag Set-up Procedure

• From the Main Form (next slide) you can choose the following items:

– Item Number (product being run)– Full & Starter Pallet– Sequence Number– Production Line Number– Time Offset– Manual Print – Clear Starter Pallet Quantity– Palletizer “A” or “B” for the Dual Pallet configuration

Pepsi Main Form

• You need to insert the “Line Number” for production line the unit is on and any “Time Offset” if required

• Then you will choose the Full pallet Item Number of the product you are palletizing.

• Next you will push the “FULL” button and the label will populate in the “Label Preview” field and the “Full Pallet Qty” will fill in.

• If you are also running starter pallets you will choose the Starter Pallet Item Number. You can tell the case count by looking at the Case Qty field.

• Next you will push the “STARTER” button and the label will populate in the “Label Preview” field and the “Starter Pallet Qty” will fill in.

Dual Pallet Option• If you are running the Dual Pallet version of software there is

one additional step that needs to be picked and that is the “Palletizer”. You will notice the line number is the same because the filler feeds two palletizer’s. The “A” side starts with a sequence Number of 0000 and the “B” side starts with 4999.

• When you push the Full or Starter button a label preview and full or starter pallet qty are populated on the screen and the unit will print a label. You need to remove the label from the units tamp pad and verify it has the correct information.

Sequence Number(4 digits)

LTTS Label Content – 26 Characters

1341 AE 05016 1 0001 0123456 999

Production Date(mmddy)

Plant Code(2 Alpha)

Pallet Create Time(hhmm – military)

Production Line(1 Character)

LPN =

Case Qty

(3 Digits)

Item Number(7 Digits)

New 8.0.1 Label

Note:

1. Every time you push the FULL button it will clear out the Starter Pallet Qty information. This is done to eliminate the wrong starter information being printed.

2. The pictures of the New Label are not

3. You need to make sure the AB Photo Eyes being used are “Series A” and not “B”.

4. You may need to use a 8 foot of 80/20 for the Full Pallet Trigger I if at all possible. Chuck Wyke has part numbers for the 80/20 from Grainger Supply.