Tech Doc – Carrier Blockage Version 1.

1 12/5/2005 3:59 PM Page 1 of 3

Sensor

TechDoc – Carrier Blockage Sensor Installation

Written By: Technicians Date: Carrier Blockage Sensor
Department: Service Version: 1.1
Valid From: Dec. 5, 2005

1. Carrier Blockage Sensor Overview

1.1. Feature Description

The carrier blockage sensor detects problems with carriers on a running sorting
machine. Carrier blockage sensors are mounted by the carrier returns at the front
and back of the sorting machine. They identify the following types of blockage as
the carriers are returned on their chain:

• Carriers colliding

• Item/s jammed on the carrier chain

• Loose or stuck carriers

• Any other blockages in the carrier return area.

If the Carrier Blockage sensor is blocked by any of these problems, it will shut
down the sorting machine.

To install carrier blockage sensors:

SAM 4000 Version 6.11e or better is required.

SAM 4020 Version 1.03e or better is required.

1.2. Functional Description

The Carrier Blockage sensor is mounted looking at the carriers on a lane. Each
half of the sensor is mounted to detect the beam of the other half of the sensor. If
the sensor half does not receive the beam from the other sensor half, it assumes
the carrier chain is blocked. It is connected to a SAM with its I/O point configured
for this feature. This can be I/O linked to an OUTPUT that shuts down the sorting
machine. The timing on this is .3 of a second before the Carrier Blockage signal
shuts down the sorting machine.

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2. Carrier Blockage Sensor Installation

Instructions

2.1. Physical Installation Requirements

Each lane of the sorting machine receives one carrier blockage sensor. The
sensor must be mounted above the carriers. A bracket is supplied for mounting
each carrier blockage sensor.

A 24 volt supply is usually required to power the missing carrier sensors.

2.2. IO Point Configuration

1. Log into SCP. Change to the full Technician access level.
2. Go to the SAM and configure the IO points to which the Carrier Blockage
Sensors are attached. The values are as follows:
• Each SAM IO point that is used as a missing carrier sensor must be
configured to MODE 07. The MODE bytes, with a value of 7, set the IO
point that is activated when a missing Carrier is detected.

• The IOL FLAG also needs to be set to(1).

• Set MODE = 06 for each lane of carrier blockage sensors that is to link to
SAM IO 13.
IOL TB IN AC IO A3 A2 A1 CS CON MODE INDEX
1 1 1 0 0 0 1 0 0 0 7 06
In the Tab-Tab-Tab screen the ASYNC_NOTIFY TIME should be set to 6. This is
the time between the SAM sending consecutive messages from the same IO
point in 50 ms counts, and the value of 6 gives a minimum of 300ms between
messages.

3. The Shutdown and Alarm Outputs

The Shutdown output is configured in SCP; the Alarm output is configured in SSP.
They are used to shut down the sorter via a relay and to flash a warning alarm
when this is done.

It is recommended that the ALARM output be slaved from the SHUTDOWN

output so that if the sorter shutdown is activated, the alarm goes on.

3.1.1.1. The Shutdown Output in SCP

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The shutdown output is inverted so that it energizes the shutdown relay in the
normal running condition and de-energizes it when the computer needs to stop
the sorter. This is a fail safe in that if the SAM power supply is OFF then the sorter
cannot run either.
IOL TB INV AC IO A3 A2 A1 CS CON MODE INDEX
0 0 1 0 1 0 0 0 0 0 00 00

3.1.1.2. The Alarm Output in SSP

1. Log into SSP and change the Access level to log in as a technician. In the
Configuration menu, select Alarms. The Alarm Setup screen displays.
2. To create a new alarm, click New. A new alarm displays with a default name
of Item#, for example, Item1.
3. Enter the values for the Carrier Blockage alarm in the Alarm Properties
frame, based on the screen values below.
4. To test the alarm, click it and select Test Alarm. The following should
happen: a screen in Sizer will pop up with the alarm notification, including
the name and message. Once this is done, click OK to save this new alarm.
Carrier Blockage Shutdown Values
Information
Message A blockage has beend etected in the carrier path at the load
belt area. Check under the load belts for any blockages,
debris, or damaged or missing carriers before re-starting.
Name Carrier Blockage Sensor
Misc
ID Automatically assigned; do not change.
Sam Location
Channel Sol1
IOPoint 7
SamAddress 1

3.2. Testing the Carrier Blockage Sensor

Once the SCP system has been configured with the values above, you must test
each set of carrier blockage sensors.
1. Run the sorter without blocking the carrier blockage sensors. This should not
shut the sorting machine down.
2. Block the signal between the carrier blockage sensors. This should shut down
the sorting machine and the alarm light should flash.

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- Carrier Blockage Sensor Installation.doc
Copyright © 2005 Compac Sorting Equipment Ltd.