The A-B-C Conveyor Book No. 2 Electrical Controls For .
The A-B-C Conveyor BookNo. 2Electrical Controls for ConveyorsHytrol Conveyor Co., Inc.2020 Hytrol DriveJonesboro, AR 72401Phone: 1-870-935-3700FAX: 1-800-852-3233http://www.hytrol.com
Page 2The A-B-C Conveyor Book No.TABLE OF CONThe Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3What Are Electrical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3The Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3“Pushbutton” Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3How the “Light Switch” Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Now! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4The Most Common Types of Control Conveyors Are . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Type One — Manual Pushbutton Switches . . . . . . . . . . . . . . . . . . . . .How a Manual Pushbutton Switch Is Used to Turn a Conveyor OnAdvantages of a Manual Pushbutton Switch . . . . . . . . . . . . . . . . .Disadvantages of a Manual Pushbutton Switch . . . . . . . . . . . . . .Type Two — Manual Reversing Drum Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .How a Manual Reversing Drum Switch Is Connected to a Powered ConveyorAdvantages of a Manual Reversing Drum Switch . . . . . . . . . . . . . . . . . . . . . .Disadvantages of a Manual Reversing Drum Switch . . . . . . . . . . . . . . . . . . . .Typical Uses for Reversing Drum Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.4.4.5.5.5.5.5.6.6.6.6Type Four — Reversing Magnetic Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How the Reversing Magnetic Starter Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Advantages of the Reversing Magnetic Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Typical Uses of Reversing Magnetic Starters and Pushbutton Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Can Be Adapted to Automatic Control Setup for a Large Conveyor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7.7.7.7Type Three — Non-reversing Magnetic Starters . . . . . . . . . . . . . . . . . . . . . . .How the Non-reversing Magnetic Starter Works . . . . . . . . . . . . . . . . . . . .Advantages of the Non-reversing Magnetic Starter . . . . . . . . . . . . . . . . . .Typical Uses of Non-reversing Magnetic Starters and Pushbutton Stations.Type Five — Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Types of Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Typical Limit Switch Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Type Six — Photo-electric Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Photo-electric Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9How a Photo-electric Switch Controls a Powered Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Technical Reference . . . . . . . . . . . . . . . .Introduction — Photoelectric SensorsModes of Detection . . . . . . . . . . . . .Thru-Beam Sensing . . . . . . . . . . . . .Reflex Sensing . . . . . . . . . . . . . . . . .Diffuse Reflective Sensing . . . . . . . .10.10.10.10.10.10Technical Reference . . . . . . . . . . . . . . . . . . . . .Introduction — Inductive Proximity SensorsMounting . . . . . . . . . . . . . . . . . . . . . . . . . .Ultra Range Sensors . . . . . . . . . . . . . . . . .11.11.11.11
The A-B-C Conveyor Book No.Page 3HOW THE “LIGHT SWITCH”THE PURPOSE OF THIS MANUALELECTRICAL CONTROLS are always needed whenpowered conveyors are used. The power is suppliedthrough the conveyor drive (which is the motor andreducer). The motor must be turned ON and OFF.ELECTRICAL CONTROLS are used to turn the motorsON and OFF.What controls are how they are used is the purposeof this Basic Training Manual No. 2. However, we willcover only those simple and basic types which are mostcommonly used.The explanation of complicated and sophisticatedelectrical control setups can be obtained from your localElectrical Contractors.ONElecticPowerSourceOFFSwitchin OFFPositionWHAT ARE ELECTRICAL CONTROLS?The most commonly known electrical control is found inthe home The Light Switch115V1 Phase60 CycleIt controls thelights in eachroom. It turnsthe electricpower tothe lightsON and OFF.OFFSome older type homes use a “Pushbutton” Light SwitchSwitch inON PositionThis also turns the electric power ON and OFF to controlthe lights in the room.ONElecticPowerSourceONOFFOFF115V1 Phase60 CycleOFF
Page 4The A-B-C Conveyor Book No.Now! Electrical controls (used on powered conveyors) doexactly the same thing as Light Switches.TYPE ONEManual PushbuttonTurn the conveyor This is just like the lightswitch.It only turns the conveyorON and OFF.STARTONandOFFThis switch is ideal forsmaller motors at lowervoltage. Motors up to andincluding 3/4 Horsepower(hp), 115 or 230V.STOPThere are many different types of controls (or switches)used for different reasons.The Most Common Types of Control ConveyorsAre:1. Manual Start Switches.How a Manual Pushbutton Switch Is Used toTurn aConveyor on:2. Reverse Drum Switches.Belt moves in ONE direction only!3. One direction Magnetic Starters used with oneor more Pushbutton Stations (two button).4. Reversible Magnetic Starters used with one ormore Pushbutton Stations (three button).5. Limit Switches.ElectricPowerSourceTypes of ConveyorCordMotorMotor CordSTARTManual PushbuttonReducerSTOPManual Reversing DrumAdvantages of a Manual Pushbutton Switch Easily available usually in Cutler-Hammer stock. Small can be mounted on most conveyors. Easy to install and operate. Plugs into wall outlets or can be connected permanently. Inexpensive.Disadvantages of a Manual Pushbutton SwitchNon-reversing MagneticReversing Magnetic No overload protection for motor (if too much weight isput on conveyor belt and conveyor is overloaded, motorcould BURN OUT!) Maximum recommended — 230V, 3/4 hp. Only one switch can be used and in one location only. No high voltage protection to operator. Cannot be used for “automatic” control setup. No protection in hazardous atmosphere conditions(dust water etc.)
The A-B-C Conveyor Book No.Page 5TYPE TWOManual Reversing DrumHow a Manual Reversing Drum Switch IsConnected to a Powered Conveyor:ReversingDrumSwitchRemoteControl Rod(Optional)Forward PositionOFF PositionReverse PositionDrum SwitchMotorCordThis type is most commonly used on all portable typebelt conveyors but can also be used with permanentbelt conveyors.Power ElectricCord PowerSourceRemote ControlRod (Optional) Readily available.Disadvantages of a Manual Reversing DrumSwitch Reversible. Can be mounted on most conveyors.No overload protection for motor (if conveyor isoverloaded by user motor could BURN OUT!). Easy to install and operate. Maximum recommended 230V, 3/4 hp.Plugs into wall outlet or can be wired permanantly. No high voltage protection to operator. Inexpensive. Cannot be used for “automatic”. When used with remote control rod, conveyorcan be controlled from either end. No protection from contaminents (dust water etc.).Advantages of a Manual Reversing Drum Switch Typical Uses for Reversing Drum Switch1.Operator can select Forward, OFF, or Reverse from onelocation only.Reversing DrumSwitch Mountedon ConveyorNear ConveyorDrive2.With remote control rod conveyor can be controlledfrom EITHER end.ReversingDrum SwitchRemoteControlRod
Page 6The A-B-C Conveyor Book No.Typical Uses of Non-reversing Magnetic Startersand Pushbutton StationsTYPE THREENon-reversing Magnetic1. Controls mounted on conveyor.Operator can turn conveyor ON or OFF at either end ic Magnetic Starter Used withPushbutton ions*Start and Stop OnlyHow the Non-reversing Magnetic Starter Works Pushbutton stations CONTROL magnetic starter.2. Controls mounted on building columns. Magnetic starter CONTROLS motor.Conveyor can be turned ON or OFF at either location. If conveyor is overloaded, the magnetic starter will stopthe conveyor.Advantages of the Non-reversing Magnetic StarterOne or more pushbutton stations can be used, allowingconveyor to be “controlled” from many locations. Overload protection to conveyor prevents motorburnout. Can be used with ALL Horsepower motors (must be usedwith 460V or more). Adaptable to automatic control setups.See page StarterUPONLY Wiring inConduitStart-StopPushbuttonStation
The A-B-C Conveyor Book No.Page 7TYPE FOURReversing MagneticTypical Uses of Reversing Magnetic StartersandOperators Can TurnConveyor ON or OFFor Reverse Belt FromEither End of rsing MagneticStarter Used withPushbutton Stations*MagneticStarterPushbutton Stations**Pushbutton Stations Can Be Ordered with“Up-Stop-Down” or “Forward-Stop-Reverse” LegendsHow the Reversing Magnetic Starter Works Pushbutton stations CONTROL magnetic starter. Magnetic starter CONTROLS Belt movement may be reversed by pushing “STOP”button and then pushing “REVERSE” button. If conveyor is overloaded, the magnetic starter will stopthe conveyor.motor.Advantages of the Reversing Magnetic Starter One or more pushbutton stations can be used,allowing conveyor to be “controlled” from manylocations. Overload protection prevents motor burn out. Can be used with ALL Horsepower motors (must beused with 460V or more). Adaptable to automatic control setups.See photo at right.Or Operator at AnotherLocation Can ControlEntire Flow of MaterialCan Be Adapted to Automatic Control Setup for a LargeConveyor SystemMany conveyors can be controlled from a panel which housesmany magnetic starters (one for each conveyor) and pushbutton stations. Each startup button energizes or deenergizes itsrespective starter.
Page 8The A-B-C Conveyor Book No.TYPE FIVELimit SwitchesThese must be used with Magnetic Starters but in addition toPushbutton Controls. Limit Switches allow the material beingmoved to activate the switch and STOP the conveyor.B. PLUNGER OR PUSH TYPE needs no lever depression of “BUTTON” on top of switch activatesmagnetic motor starters.SealedTypes of Limit SwitchesA. LEVER TYPE can be used with several types of levers.*Typical Limit Switch Applications“Rat Tail” Mountedon Angle End StopSteel Spring“Rat Tail”BasicSwitch* erLeverA. END STOPLimit switch connected to magnetic starter when cartonreaches end of unit, conveyor stops.This type of switch can be supplied either as standard or witha time delay function.B. DEPRESSED ROLLERWhen roller is depressed by carton limit switch is activated, conveyor is stopped.
The A-B-C Conveyor Book No.Page 9C. POP-OUT ROLLERTYPE SIXPhoto-electric SwitchesPhoto-electric switches (or photocells as they arecommonly called) are used exactly like limit switches, however, instead of moving or depressing a lever, the packageblocks a light beam. When the beam is blocked, theswitching part of the photocell is activated and the conveyor is stopped.“Rat Tail” SwitchBent So Roller HoldsLever DownIf a hand or objects gets caught between pulley and roller,roller POPS-OUT stopping conveyor.As with the limit switch, photocells are used in addition tomagnetic starters and pushbutton stations. Photocellsmust also have a reflective disc to bounce back the lightbeam to the “eye.”Because there is no physical contact between the photocell and the packages being conveyed, the size andweight of the packages are NOT factors as with limitswitches (a very light package may not activate a limitswitch).How a Photo-electric Switch Controls a PoweredConveyor:When the beam is blocked, the switching part of the photocell is activated and the conveyor is stopped.PushbuttonStationTime Delay Limit SwitchLight BeamD. ACCUMULATIONReflectorCartons passing over Limit Switch DO NOT stop conveyor,but when carton rests on Limit Switch for a period of time(usually several seconds) Limit Switch is activated and beltstops.IMPORTANT — All Limit Switches can stop conveyors.Pushbutton switch MUST be pushed to turn power backon after Limit Switch is cleared.CordE. AUTO RESTARTBelt conveyors can be re-started AUTOMATICALLY ONLYif contactor is torMotor CordReducerWhen This Boxis Moved.Magnetic StarterFor additional Technical Reference see PhotoelectricSensors on page 10.Contactor.Belt Conveyor Starts Up AutomaticallyA contactor is another type of electrical control used withLimit Switches and Magnetic Starters.
Page 10The A-B-C Conveyor Book No.TECHNICAL REFERENCEIntroduction — Photoelectric SensorsReflex SensingPhotoelectric sensors use light to detect the presenceor absence of an object. The main advantages of photoelectrics are: Object can be detected without direct contact. Sensor can be a great distance from the object beingdetected.Modes of DetectionThru-beam: Separate source and detector elements arealigned facing each other across an area which the targetobject crosses. Detection occurs when an object blocks theentire effective beam (the column of light that travels in astraight line between lenses).SourceDetectorBeam CompleteSourceDetectorObject DetectedReflex photoelectric sensors (sometimes known as retroreflective) position the source and detector parallel to eachother on the same side of the object to be detected. The lightsource is directed at a retroreflector (a specially designeddevice that returns most of the light it receives back in thesame direction from which it came, an example is a bicyclereflector.) The detector receives the light returned from theretroreflector. An output occurs when an object breaks thebeam between the photoelectric sensor and the retroreflector.Because the light must travel in 2 directions (to the retroreflector and back to the control), reflex controls will typicallynot sense as far, nor will they have the optical performanceof a thru-beam control. Reflex controls do offer a powerfulsensing system that does not require electrical wire to be runto both sides of the sensing area. This combination of highsensing power and ease of mounting has made reflex sensors the most popular choice of all sensing modes.FEATURES Long rangeThru-beam Detection ModeThru-Beam Sensing High light/dark contrast ratio Easy installation and alignment Only one component must be wiredLIMITATIONS Can be false triggered by shiny surfaced objectsFEATURES Longest optical range Highest possible signal strength (excess gain) Greatest light/dark contrast ratio Surface reflectivity and color have little effect Best trip point repeatabilityDiffuse Reflective: The source and detector elements arepositioned on the same side of the object to be detected andaligned so that their fields of view cross. When the targetmoves into this area, light from the source is reflected off thetarget surface back to the detector, and detection occurs.LIMITATIONS Two components to wire across detection zone SourceSourceDetectorDetectorAlignment can be difficultBeam Not CompleteReflex: The source and detector are positioned parallel toeach other on the same side of the object to be detected.The light beam is transmitted from the source to aretroreflector that returns the light to the detector. Detectionoccurs when the target object blocks the entire rBeam CompleteObject DetectedReflectorDiffuse Reflective Detection ModeDiffuse Reflective SensingFEATURES Simple installation and alignment. Wire only one side ofsensing zone. Can detect differences in surface reflectivity.LIMITATIONS Limited sensing range. Reflex Detection ModeObject DetectedLight/dark contrast and sensing range are dependent onobject surface reflectivity.
The A-B-C Conveyor Book No.TECHNICAL REFERENCEIntroduction — Inductive Proximity SensorsThese sensors detect the presence or absence of a metallicobject without contact using an electromagnetic field.A number of factors should be considered when applyingproximity sensors. A detailed discussion of these factors canbe found in the following section. Presented below are a fewof the more important considerations for quick reference.Page 11MountingProximity sensors are available in two classifications: shielded (also known as embeddable or flush mountable) andunshielded (non-embeddable or non-flush mountable).Theseterms refer to the proximity to surrounding metal that thedevice can be mounted. An embeddable or shielded sensorcan be mounted with the sensor completely surrounded bymetal.dFEATURES Immune to dirty, greasy, adverse environmentalconditions Can detect lightweight or small objects that cannot bedetected by mechanical limit switches High switching rate for rapid response to object countingapplication Can detect metallic targets through non-metallic barriers(i.e. glass, plastic, etc.) Long operational life with virtually unlimited operatingcycles Solid state output provides a “bounce free” contact inputsignal to solid state logic devicesLIMITATIONS Limited sensing range — up to 4” maximum UnshieldedSensorA non-embeddable or unshielded sensor must have a metalfree zone provided when mounting the sensor as shownabove and below. The size of the metal free zone is dependent on both the size of the sensor and the type of sensingrange, i.e., standard or extended.Where a and b are the metal free dimensions.dDetects only metallic objectsGENERAL APPLICATION Part presence or absence detection Part counting Object position detectio
The Light Switch O F F It controls the lights in each room. It turns the electric power to the lights ON and OFF. Some older type homes use a “Pushbutton” Light Switch This also turns the electric power ON and OFF to control the lights in the room. O N O F F O F F HOW THE “LIGHT SWITCH” O N ON O F F OFF Electic Power Source Switch in .
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