Document Overview

This technical document details the electrical and control system design for WiBo 6, 7, and 8 control boxes used in TPV palletizing and wrapping units. It includes mechanical layouts, wiring diagrams, PLC integration, frequency inverter controls, safety systems, and optional wrapper modules. The version referenced is 11, dated December 2021.

1. Drawings and Layouts

Provides front cover and enclosure housing layouts, showing physical arrangement and mounting plates. Optional mounting plates and wrapper modules are referenced with specific part and sheet numbers. Although enclosure models may vary, the general layout and mounting principles remain consistent.

2. Wiring Diagrams

Includes multiple wiring diagrams covering 230VAC/400VAC power supply connections, 24VDC optional relays, and digital PLC inputs/outputs. Power wiring details main power switches, frequency inverter connections for X, Y, Hoist, and Gripper motors, and brake wiring. Terminal blocks are detailed for power supply, motor connections, wrapper interface, and sensor inputs. Voltage cables are generally 15mm² for power and 0.5mm² for control signals unless otherwise specified.

3. Frequency Inverters and Motors

Frequency inverters control X, Y, Hoist, and Gripper motors with specified power ratings (e.g., 0.55 kW). Brake circuits ensure safe operation and emergency stops. Wiring includes slow, fast, and inverse frequency signals for precise motor control.

4. PLC Digital Inputs and Outputs

Detailed mapping of PLC digital inputs and outputs covers conveyor belts, pallet detection, bag collector sensors, and emergency stops. Inputs and outputs are grouped by categories with terminal references. Special signals include wrapper start/stop, emergency stop requests, and sensor feedback for wrapping and palletizing.

5. Touch Panel Control

The system uses a Siemens S7-1200 PLC with a Siemens KTP700 colour touch panel interface for operator control and monitoring. Wiring and interface terminal blocks are specified, including Profinet hybrid cables. Control logic integrates emergency stop and optional wrapper module activation.

6. Optional Wrapper Module

This module includes additional terminal blocks, relays, and frequency inverter connections. Wrapper carriage motors and brakes are controlled separately with dedicated wiring diagrams. Interface signals include start, stop, emergency stop, and status feedback.

7. Safety and Emergency Systems

Emergency stop circuits are integrated throughout with clear wiring instructions for external devices. Safety relays are optional but recommended. Brake wiring ensures motors can be safely stopped during emergencies.

8. Cable Specifications and Installation Notes

Power cables are generally 15mm²; control and signal cables are typically 0.5mm². Emphasis is placed on proper cable routing, terminal block connections, and avoiding damage before measurements.

Additional Technical Details

1. Cable Coding and Wiring Specifications

Specifies cable designations, types, core counts, cross sections, and wiring types. Power supply lines use 5.0 mm² cables. Brake and motor connections have specific terminal assignments. Screening and shielding practices are noted for noise reduction and signal integrity.

2. Terminal Blocks and Interface Connections

Describes multiple terminal blocks (X1, X2, X3, X4, X5, X10) with pin assignments for power, sensors, actuators, and control signals. Includes valve controls, machine run signals, conveyor controls, and sensor inputs for axes, pallet detection, emergency stops, and wrapping system. Correct wiring order and specified terminal blocks are recommended for reliability.

3. Sensor and Control Signal Details

Enumerates sensor inputs related to palletizer axes (X, Y, Z), gripper, hoist, and conveyor systems. Includes sensor counts, roller lever positions, bag detection sensors, emergency stop buttons, and wrap system controls. Shielding and grounding are emphasized to prevent interference. Signal levels and terminal assignments are clearly defined.

4. Bill of Materials (BOM)

Lists major components including enclosures (Rittal LS Compact), terminal blocks (Phoenix Contact, Weidmüller), hybrid motor starters, relays, braking resistors, frequency inverters, main switches, phase monitoring relays, power supplies, circuit breakers, Siemens CPUs, digital I/O modules, memory cards, touch panels, emergency stop buttons, and Profinet cables. Catalog references and quantities support procurement and replacement.

5. Wiring and Shielding Practices

Emphasizes screened cables and proper grounding (PE-PEN shielding) for electromagnetic compatibility and signal integrity. Internal signal distribution uses spring cage terminals and jumper links for flexibility.

6. Control Interface and Touch Panel

Details touch panel housing, interface signals, power supply lines, emergency stop connections, and wrapping system signal wiring. The Siemens KTP700 Color touch panel integrates via Profinet.

Critical Information and Best Practices

• Ensure all emergency stop circuits are correctly connected and tested before operation.
• Verify frequency inverter wiring matches motor specifications and control signals for safe, precise operation.
• Use specified cable sizes (15mm² for power, 0.5mm² for control) to prevent faults and comply with safety standards.
• Install optional modules like the wrapper only if required, following provided wiring diagrams.
• Maintain documentation integrity; copying or modifying drawings requires authorization to protect intellectual property.
• Follow shielding and grounding guidelines to minimize electrical noise and ensure signal integrity.
• Use specified terminal blocks and maintain correct wiring order for system reliability.
• Refer to BOM for component identification and ordering.

Summary

This document serves as a comprehensive technical reference for the electrical and control systems of WiBo control boxes in TPV palletizing and wrapping machinery. It covers mechanical layouts, detailed wiring diagrams, PLC digital I/O mapping, frequency inverter integration, safety and emergency systems, and optional wrapper modules. Adherence to specified cable sizes, wiring practices, and safety connections is essential for reliable and safe machine operation. The structured information supports installation, maintenance, and troubleshooting, ensuring operational reliability and safety.