SKOV DOL 192 Egg Counter User Guide

Product and Documentation Changes
SKOV A/S reserves the right to change this document and the product herein described without further notice.
In case of doubt, please contact SKOV A/S.
The date of change appears from the front and back pages.
Note

• All rights belong to SKOV A/S. No part of this manual may be reproduced in any manner whatsoever without the expressed written permission of SKOV A/S in each case.

• All reasonable efforts have been made to ensure the accuracy of the information contained in this manual.
  Should any mistakes or imprecise information occur in spite of this, SKOV A/S would appreciate being notified thereof.

• Irrespective of the above, SKOV A/S shall not accept any liability with regard to loss or damage caused or alleged to be caused by reliance on any information contained herein.

• Copyright by SKOV A/S.

Product description

The DOL 192 egg counter is intended for automatically counting eggs with an egg diameter of 36-55 mm, on a conveyor belt.
It is designed for touch-free operation, using infrared light. It reduces the risk of eggshell fractures and contamination and ensures an unhampered flow of eggs on the conveyor belt.
DOL 192 egg counter is available in 5 different scan widths (12, 20, 40, 50, and 80 cm) to suit different types of conveyors.
A connection box with and without display is available.
DOL 192 egg counter has an accuracy of at least 99.5% when correctly fitted.

Figure 1: Example of egg counter mounting option.

Product survey

130383 DOL 192 egg counter, 12 cm Scan width 120 mm
130384 DOL 192 egg counter, 20 cm Scan width 216 mm
130385 DOL 192 egg counter, 40 cm Scan width 408 mm
130386 DOL 192 egg counter, 50 cm Scan width 504 mm
130387 DOL 192 egg counter, 80 cm Scan width 792 mm
Cable length 2 m
The DOL 192 is suitable for counting eggs on conveyor belts that collect eggs from multiple longitudinal conveyor belts.
Used for counting eggs with an egg diameter of 36-55 mm.

130388 DOL 192 bracket L+L
130389 DOL 192 bracket S+L
Brackets with clamps and screws are used for mounting the egg counter.
L+L is used for placement above longitudinal conveyor belts.
S+L is used when egg belt guides are applied on longitudinal conveyor belts.
SKOV A/S does not supply the egg belt guide.

130391 DOL 192 box 24 V f/2 counters
Egg counter connection box that provides data to the production controller.
Up to 2 DOL 192 egg counters can be connected.
Requires external power supply 24 V DC (135752).

130392 DOL 192 box w/display 230 V f/1 counter
Egg counter connection box with a display that provides data to the production controller. The number of eggs can be read locally via the display.
You can connect 1 DOL 192 egg counter.

2.1 Accessories

135752 Power supply 24V, 2.1A in box
Extra power supply.
Voltage 90 – 264 V
Frequency 47-63 Hz
Power 160 VA/ 80 W
Current 0.7 A
Output
Voltage 24 V +/- 10 %
Current 2.1 A

136470 BlueControl extension box 10RL
Extension box with 1 pcs. I/O module, 10RL 8AI 10RL, type 3.
0-10 V input or DOL 12 input or digital input (8)
0-10 V outputs (8)
Relays (10)
Used when more I/O modules are needed than are available in the standard hardware.
The inputs can with a jumper be configured individually for either DOL 12,
DI (digital input) for water meters or AI (analog input, 0-10 V).
Includes rubber sleeves and ribbon cable
The controller’s standard software/hardware supports 13 I/O modules in total. BlueControl extension box 10RL counts for 1 module

136471 BlueControl extension box 20RL
Extension box with 2 pcs. I/O module, 10RL 8AI 10RL, type 3.
0-10 V input or DOL 12 input or digital input (16)
0-10 V outputs (16)
Relays (20)
Used when more I/O modules are needed than are available in the standard hardware.
The inputs can with a jumper be configured individually for either DOL 12, DI (digital input) for water meters or AI (analog input, 0-10 V).
Includes rubber sleeves and ribbon cable
The controller’s standard software/hardware supports 13 I/O modules in total. BlueControl extension box 20RL counts for 2 modules.

130183 DOL 100 digital 8l box
130184 DOL 100 digital 16l box
130191 DOL 100 digital 24l box
130192 DOL 100 digital 32l box
External I/O box for connection of water meter, egg counter, or capacitive sensor.
The DOL 100 converts the signals into digital signals and transmits them to the production controller using CAN bus communication.
The standard software/hardware of the BlueControl series supports 13 I/O modules in total. DOL 100 counts as one module.
0-24 V inputs terminals: 8, 16, 24 or 32.
Is used with the CAN bus module (132245) and a CAN bus cable (130121-130128).

132245 CAN-bus module
Always use the CAN-bus module when using external CAN bus communication.
One for each controller.

130121 CAN bus cable 50 m
130125 CAN bus cable 100 m
130126 CAN bus cable 250 m
For indoor use.
Must be used with external units using CAN bus communication.

130123 CAN bus cable UV 50 m
130127 CAN bus cable UV 100 m
130128 CAN bus cable UV 250 m
For outdoor use.
Must be used with external units using CAN bus communication.

Mounting guide

3.1 Recommended tools
A list of tools recommended for the installation of your egg counter can be seen below.

3.2 Mounting the egg counter
The egg counter is mounted on the bracket directly over the conveyor belt.
For the egg counter to count optimally, place it where the eggs cannot roll or move sideways. Eggs that move around may be counted more than once.
When the conveyor belt stops, it must not move backward.
A sharp light, especially sunlight and fluorescent light, may affect the accuracy of the egg counter. Place the egg counter, so it is not exposed to direct (sun)light or protect it from light.

This is an example of which brackets can be used.
A: L+L is used for placement above longitudinal conveyor belts.
B: S+L is used when egg belt guides are applied on longitudinal conveyor belts.

Install the large bracket to the side of the conveyor belt.

Slide the cable end of the egg counter into the bracket.
Slide the opposite bracket (small or large) into the egg counter.
Attach the large opposite bracket to the other side of the conveyor belt.
Secure the egg counter to the brackets with clamps and screws.

Mount the egg belt guide to the small bracket.
Mount the opposite end on the conveyor belt.

The distance from the longitudinal conveyor belt to the egg counter must be approximately 400 to 500 mm, so the eggs remain stationary before being counted.

Flat conveyor belt
Based on an egg size of 44 mm, adjust the height of the bracket so that the distance is 30 mm between the bottom edge of the bracket and the top of the egg.
Adjust the height of the egg counter when the size of the egg changes.

Bar conveyor belt
Based on an egg size of 44 mm, adjust the bracket height so that the distance is 30 mm between the bottom edge of the bracket and the top of the egg.
Adjust the height of the egg counter when the size of the egg changes.

Adjust the egg counter to fit the conveyor belt. Tighten all Ubolts.

Install the DOL 192 box as close to the egg counter as possible.
Do not extend the supplied 2-meter cable.

Installation guide

Installation, servicing and troubleshooting of all electrical equipment must be carried out by qualified personnel in compliance with the applicable national and international standard EN 60204-1 and any other EU standards that are  applicable in Europe.
The installation of a power supply isolator is required for each motor and power supply to facilitate voltage-free work on the electrical equipment. The power supply isolator is not included.

4.1 Connecting the egg counter to the DOL 192 box
4.1.1 Cable diagram egg counter

4.1.2 DOL 192 box 24 V

4.1.3 DOL 192 box w/display 230V

4.2 Connecting pulse and standby functions
Pulse:
The egg counter is connected to a production controller as an electrical pulse generator. An electrical pulse is generated to the output of the egg counter when an egg is detected. The pulse output is an NPN output.

Standby input:
The standby input is activated when the conveyor belt under the egg counter stops. When the standby input is active, the LED emits an orange light or –/h (display), and the egg counter ceases to count eggs.

• When an NC relay is switched off during conveyor operation, eggs are counted.
• When an NC relay is activated in case the conveyor belt is stopped, eggs are not counted.

Failure to use the standby input may adversely affect the accuracy. The standby input ensures that eggs are only counted when the conveyor belt is running.
We recommend using the standby input at all times to ensure maximum accuracy.
The standby input is common when there are 2 egg counters installed.

4.3 DIP switch settings

Select how many egg counters are connected to the box.

• DIP switch #7 (OPT 1):
  – OFF: When 1 DOL 192 egg counter is connected to a DOL 192 box 24V.
  – ON: When 2 DOL 192 egg counters are connected to a DOL 192 box 24V.
  Select whether the DOL 192 box uses one pulse per egg or one pulse per five eggs (a maximum of 5 pulses per second).

• DIP switch #8 (OPT 2):
  – OFF: 1 pulse per egg.
  – ON: 1 pulse per 5 eggs.
  Note that pulse per egg should be set the same way for both the DIP switch and Choice of egg counter in controller [} 15].

4.4 Choice of egg counter in controller

| Installation | Manual installation | Production | Installation | Egg counting and select Automatic.

| Installation | Manual installation | Production | Installation | Egg settings | Egg counters installed. Enter the number of egg counter to be installed.

| Installation | Manual installation | Production | Installation | Egg settings | Set up eggs per pulse.
Specify the number of eggs per pulse for each egg counter.
Note that pulse per egg is set the same way here and in the DIP-switch indstillinger [} 14].

| Installation | Show connections.
Indicates to which terminals the egg counter should be connected.
Ground terminal/minus terminal clamp for sensor and feedback is not displayed.

4.5 Clock setting DOL 192 box w/display
The clock must be set to the current time.
Use the up/down arrows to navigate to the clock display.
Time:

• Press arrow to the right. Adjust hours using the up/down arrow.
• Press arrow to the right. Adjust the minutes using the up/down arrow.
• Press Enter to confirm the adjusted time.

General information about circuit diagrams

Symbols are in accordance with the IEC/EN 60617 standard.
The classification of the symbols (“letter codes”) on the symbols is in accordance with the IEC/EN 81346-2 standard.
Reference designations are in accordance with IEC/EN 81346-1:2001 structuring principles and reference designations. This standard indicates structured methods for naming electrotechnical systems.

5.1 Color code

Letter codes to identify colors used on drawings, diagrams, labelling, etc.:
BN| Brown
RD| Red
OG| Orange
YE| Yellow
GN| Green
BU| Blue (incl. light blue)
VT| Violet (purple red)
GY| Grey (slate)
WH| White
PK| Pink
GD| Gold
TO| Turquoise
SR| Silver
GNYE| Green-and-yellow

5.2 Letter code
The letter codes used in accordance with standard IEC/EN61346-2.

Protective equipment RCCB /
Initial fuse Protective motor
switch| Controller
Contactor| Fan
Motor| Power supply
isolator| Switch| Motor con-
troller| Cable

Cable plans and circuit diagrams

6.1 Cable plan DOL 192 box 24V 1 egg counter

6.2 Circuit diagram DOL 192 box 24 V 1 egg counter

6.3 Cable plan DOL 192 box 24 V 2 egg counters

6.4 Circuit diagram DOL 192 box 24 V 2 egg counters

6.5 Cable plan Dol 192 box w/display 230 V

6.6 Circuit diagram DOL 192 box w/display 230 V

User Guide

7.1 Operating DOL 192 box w/display
Use the up/down arrows to navigate through the various views.

The number of eggs today:
The number of eggs counted per hour (in this example, 90 eggs per hour – ’90/h’).
Standby mode active is displayed with –/h.
This value appears when the keys have not been touched for 5 minutes.

The number of eggs counted on the days before today:
Select days from -1 (yesterday) to -7 (seven days ago).

The number of counted eggs in total.

Current time.

Manual change or reset

Manual change of the number of counted eggs:

• Press the arrow to the right.
• Adjust the number using the up/down arrows.
• Press Enter to confirm.

Reset eggs counted:

• Press the arrow to the right twice.
• Press Enter to confirm.

Maintenance instructions

8.1 Cleaning
The egg counter is maintenance-free but should be kept free of dirt and filth.
Clean the product with a cloth that has been wrung out almost dry in water and avoid using:

• high-pressure cleaner
• solvents
• corrosive/caustic agents

Preferably clean in standby mode to prevent the egg counter from making error counts.
Ensure that the egg counter is not damaged by high-pressure or steam cleaning. The egg counter should be on (standby mode) during washing. This way, the cabinet is heated from the inside and does not draw moisture.

8.2 Recycling/Disposal
Products suitable for recycling are marked with a pictogram.
It must be possible for customers to deliver the products to local collection sites/recycling stations in accordance with local instructions. The recycling station will then arrange for further transport to a certified plant for reuse, recovery  and recycling.

Trouble shooting instructions

9.1 Error messages LED on DOL 192 box

counter and the DOL 192 box.
| Flashes red| The egg counter detected an egg (detection = LED off), but there is a communication error between the egg counter and the DOL 192 box.
| Flashes red (8 Hz)| Selected incorrect number of egg counters.

9.2 Error messages DOL 192 box w/display
The DOL 192 box w/display checks the counter operations. The following error messages may occur.

settings, for instance the DIP switch settings.
Uncalibrated| Alarm| The egg counter is damaged.| Contact your distributor.
Internal error| Alarm| Communication error between the egg counter and the DOL 192 box.| Contact your distributor.
Unknown| Alarm| Unknown error.| Contact your distributor.
Dirty| Warning| The glass is dirty.| Clean the glass.
Warning| Warning| Light intensity is too high
(may occur when the sunlight reflects on the conveyor belt)| Place the egg counter where there is less light or change the light intensity at the position of the egg counter. Install the egg counter near a door or window.

9.3 Unexpected counting results

DOL 192 is not counting
enough eggs| Adjust mounting distance; see section Mounting the egg counter [9]
DOL 192 is counting too
many eggs| The eggs are moving around, for instance, because the egg supply is too
close, see section Mounting the egg counter [9]
The standby transverse conveyor belt is not connected. The error occurs when
the conveyor belt starts/stops; see section Connecting pulse and standby functions
[14]

Technical data

10.1 DOL 192 egg counter

| DOL 192 12| DOL 192 20| DOL 192 40| I DOL 192 50| DOL 192 80
---|---|---|---|---|---
Electrical
Rated voltage| V DC| 24 +/- 20%
Max. current| RMS A| 0.012| 0.025| 0.053| 0.066| 0.110
Peak A| 0.05| 0.10| 0.20| 0.25| 0.40
Measuring range
Scan width| mm| 120| 216| 408| I 504| I 792
Accuracy| %| 100.
Egg diameter| mm| 36 – 55
Scan height| mm| From bottom edge of bracket to the top of the egg 30
Appropriate speed of con- veyor belt| m/min| 0.3 – 12
Appropriate conveyor belt| | Bar conveyor belt
White jute conveyor belt
White PVC conveyor belt (with or without holes)
Environment
Temperature, operation| °C| 0 – 40
Protection class| IP| 54
Mechanical
Dimension HxWxD| mm| 40x125x60| 40x274x60| 40x466x60| 40x562x60| 40x850x60
Weight| g| 300| 390| 610| 720| 1050
Cable length| m| 2

10.2 DOL 192 box

| DOL 192 box 24 V| DOL 192 box w/display
---|---|---
Electrical
Rated voltage| V DC| 24 +/- 20%|
V AC| | 100-240
Max. power consumption| A| 0.083 + 2 connected egg counter| 0.75
Max. power| W| 2| 30
Standby input|
Standby input level| V DC| 24
Pulse output point|
Open collector transistor| | NPN
Egg per pulse| EGGS| 1 or 5
Max. pulse per second| Pulse| 5
Egg counter
Max. connected egg coun- ters| pcs| 2| 1
Environment
Temperature, operation| °C| 0 – 40
Protection class| IP| 54
Mechanical
Dimension HxWxD| mm| 120x123x55| 100x230x310
Weight| g| 300| 1400

10.3 Maximum number of devices connected to power supply

| Power consumption [A]| Max. number of boxes per 2.1A power supply
---|---|---
Power supply 24 V 2.1A in box (135752)
DOL 192 box 24 V +
2 pcs. DOL 192 12 cm egg counters| 0.107| 19
DOL 192 box 24 V +
2 pcs. DOL 192 20 cm egg counters| 0.133| 15
DOL 192 box 24 V +
2 pcs. DOL 192 40 cm egg counters| 0.189| 11
DOL 192 box 24 V +
2 pcs. DOL 192 50 cm egg counters| 215| 9
DOL 192 box 24 V +
2 pcs. DOL 192 80 cm egg counters| 0.303| 6

10.4 Dimensioned sketch
10.4.1 DOL 192 egg counter

10.4.2 DOL 192 box w/display 230 V f/1 egg counter

10.4.3 DOL 192 box 24 V f/2 egg counters

SKOV A/S • Hedelund 4 • Glyngøre • DK-7870 Roslev
Tel. +45 72 17 55 55 • www.skov.com • E-mail: skov@skov.dk

References

• SKOV website

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