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MAINTENANCE

• Lubrication

BEARINGS

A) NO GREASE FITTING - Prelubricated - No lubrication required.
B) WITH GREASE FITTING - Relubricate approximately every 10 to 12 weeks with
lithium base grease suitable for ball bearing service.

RECOMMENDED CHAIN LUBRICANT

A good grade of clean non-detergent petroleum or synthetic oil is recommended.
See chart for proper viscosity.

REDUCERS

See recommendations by manufacturer.

OILER BRUSH ADJUSTMENT

It is very important that the oiler brush comes in contact with the chain for proper
lubrication and increased chain life. This can be done by using the adjusting nuts
and support brackets.

• Controlling the ProSort

A good software package is essential for the proper operation of the ProSort sorter.
With proper controls, the sorter will provide accurate, efficient, reliable sorting for
many years. Inadequate controls, however, may result in poor sorter performance
and other mechanical failures of the sorter itself, including “crashes”. Hytrol
recommends using the Hytrol ProLogix software package.
Every sortation system is different, which means that the controls for the system
are custom and unique to that system. These custom controls are provided either
by Hytrol, the Hytrol Integration Partner or a third party.
Hytrol has built into the sorter some of the controls necessary to operate the divert
switches, eliminating the need to control this function externally. Other electrical
control components are provided with the sorter to allow the external controls to
monitor critical items and to provide an interface between the electrical controls
and the mechanical sorter. Still other control components must be provided by the
supplier of the custom controls package to insure proper sorter operation.
This section of the manual includes the following information for the custom
controls provider:
1. A description of the divert switch control components supplied, their function, and
how to interface with them.
2. A description of the other control components provided with the sorter and their
intended function.
3. A description of control components that are not included with the sorter that
must be provided by the controls supplier.
4. Some control do’s and dont’s to assist in the design and installation of the
controls package.
Please read this section thoroughly and share this information with the controls
provider.

DIVERT SWITCH CONTROL

Proper control of the divert switch is critical to the safe and reliable operation of
the sorter. Failure to properly control the divert switch is one of the most common
causes of switch damage and can cause “crashes.”
The divert switch functions similar to a switch on a train track to cause the divert
shoes to travel either in a straight-through, “non-divert” track or diagonally across
the sorter along a “divert track” to push product off of the sorter. When the switch is

in the “home” position, the divert shoes travel through the switch along the straight-
through track. When the switch is in the “divert” position, the shoes are caused to
move along the divert track.
The transition of the switch between the “home” and “divert” positions must be
accurately timed to prevent sorter crashes. Just as a train track switch cannot
be safely operated while a train is passing through the switch, the divert switch
cannot be safely operated while a divert shoe is passing through the switch. If the
movement of the switch mechanism is not timed to occur

only when no shoe is

present in the switch

, the guide pin of the shoe may collide with the point of the

divert block, resulting in damage to the switch and potentially costly downtime.
The ProSort has two control components at each divert switch that work together
to accurately time the divert switch movement or operation, eliminating the need
for the controls provider to do so. These components are the

smart prox

and the

high-speed solenoid air valve

SMART PROX

The “smart prox” is a special inductive proximity sensor developed exclusively for
Hytrol that has the “intelligence” needed to control the switch timing built-in. The
prox plugs to the y-cable. See Figure 6A.

Brown

—+24VDC power input to the prox.

Blue

—Ground (-) lead for the prox.

Gray

—Divert enable input lead for the prox. When a 24VDC (high) signal is given

to this lead by the system controls, the prox waits for the next time it detects a
divert shoe, at which time it provides a 24VDC output through the y-cable to the
high speed solenoid air valve. The solenoid air valve then causes the switch to
move to “divert” position. All shoes traveling through the switch will then follow the
divert track as long as the enable signal is active (held high). When the divert signal
is removed (taken low) the prox waits for the next time it detects a divert shoe, at
which time it will turn off the output to the solenoid air valve. The switch then returns
to the “home” position, and subsequent shoes will follow the “non-divert” track.

The

enable signal to this lead is the only signal that the system controls must
provide to control divert switching.

Y Cable

The y-cable is used to connect the smart prox, solenoid air valve and the system
controls. The male micro cord set from the smart prox connects to the terminal
#1 of the y-cable. The pico pigtail, of the y-cable, connects to the male plug on
the solenoid air valve at divert switch. The micro cord set with female end, plugs
to terminal #2 of the y-cable. The leads from the terminal #2 cord set have the
following functions (Fig. 6A). NOTE: Y-cable not used on dual divert sections.

Black

—Standard prox output lead. This lead provides a 24VDC (high) signal each

time the prox detects a divert shoe. This is an optional output and is to be used at
the discretion of the controls provider.

Ambient Temperature

Degrees F

SAE

ISO

20-40

40-100

20
30

46 or 68

100