Sacmi CVS Series Guide

INSTRUCTIONS MANUAL
004AZ011B
VISION SYSTEM FOR AUTOMATIC INSPECTION OF
CAPS
CVS
TECHNICAL
DOCUMENTATION
ENGLISH
Original Instructions

004AZ011B
INSTRUCTIONS MANUAL
VISION SYSTEM FOR AUTOMATIC INSPECTION OF
CAPS
CVS
MANUFACTURER
S.C.
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALY
www.sacmi.com
RELEASE DATE
21.12.2015 - 21.09.2017
VERSIONS
CVS001 - CVS051 - CVS052 - CVS053 - CVS054

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TABLE OF CONTENTS
Page
0-5
1GENERAL INFORMATION............................................................................................................................1-1
1.1 INTRODUCTION ........................................................................................................................1-1
1.2 WHERE TO KEEP THE MANUAL...............................................................................................1-1
1.3 HOW TO USE THE MANUAL.....................................................................................................1-2
1.4 USERS OF THE MANUAL..........................................................................................................1-2
1.5 WARRANTY ...............................................................................................................................1-3
1.6 ATTACHMENTS..........................................................................................................................1-3
1.7 KEY TO THE SAFETY SYMBOLS USED ON THE ELECTRONIC EQUIPMENT AND/OR IN
THE MANUAL ............................................................................................................................1-4
1.8 POSITION OF THE SAFETY SIGNS...........................................................................................1-5
1.9 IDENTIFICATION PLATE FOR THE ELECTRONIC EQUIPMENT ...............................................1-6
1.10 CONFORMITY DECLARATION ..................................................................................................1-7
1.10.1 NON-INTEGRATED VISION SYSTEM ........................................................................................1-7
1.10.2 INTEGRATED VISION SYSTEM .................................................................................................1-7
2FEATURES.....................................................................................................................................................2-1
2.1 DESCRIPTION OF THE ELECTRONIC EQUIPMENT.................................................................2-1
2.1.1 MAIN DEVICES ..........................................................................................................................2-2
2.1.1.1 Main electrical cabinet (optional) ...............................................................................................2-2
2.1.1.2 Industrial-grade Personal Computer..........................................................................................2-3
2.1.1.3 PCI S32P I/O board ...................................................................................................................2-4
2.1.1.4 Image capture card....................................................................................................................2-6
2.1.1.4.1 Type “D - E - F” image capture card..........................................................................................2-6
2.1.1.5 Additional electrical cabinet.......................................................................................................2-7
2.1.1.6 Image shooting station ..............................................................................................................2-8
2.1.1.6.1 Cameras and lenses ..................................................................................................................2-9
2.1.1.6.2 Lighting units .............................................................................................................................2-9
2.1.1.7 Auxiliary equipment .................................................................................................................2-10
2.1.1.7.1 Image shooting sensors...........................................................................................................2-10
2.1.1.7.2 Ejection stations ......................................................................................................................2-10
2.1.1.7.3 Encoders..................................................................................................................................2-10
2.1.1.7.4 Indicator tower.........................................................................................................................2-10
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ..................................................2-11
2.2 OVERALL DIMENSIONS ..........................................................................................................2-12
2.3 TECHNICAL FEATURES ..........................................................................................................2-13
2.3.1 TECHNICAL DATA....................................................................................................................2-13
2.3.2 ACCEPTABLE FLUCTUATIONS ...............................................................................................2-14
2.3.3 RATING PLATE.........................................................................................................................2-14
2.4 DIAGRAMS...............................................................................................................................2-15
2.4.1 BLOCK DIAGRAM ILLUSTRATING HOW THE EJECTION DEVICES AND LED LIGHTING
UNITS ARE PILOTED...............................................................................................................2-16
2.4.2 BLOCK DIAGRAM ILLUSTRATING THE IMAGE SHOOTING SENSORS AND ENCODER
INTERFACE..............................................................................................................................2-17
2.5 OPERATIONAL FEATURES ......................................................................................................2-18
2.5.1 TYPE OF CHECKS...................................................................................................................2-18
2.5.1.1 Standard checks......................................................................................................................2-18

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3SAFETY EQUIPMENT AND PRECAUTIONS...............................................................................................3-1
3.1 SAFETY DEVICES ......................................................................................................................3-1
3.1.1 GENERAL STANDARDS.............................................................................................................3-1
3.1.1.1 Required environmental conditions for correct electronic equipment operation ......................3-1
3.1.2 LOCKOUT/TAGOUT...................................................................................................................3-2
3.2 SAFETY RULES FOR HANDLING..............................................................................................3-4
3.2.1 LIFTING ......................................................................................................................................3-4
3.2.2 MOVEMENT ...............................................................................................................................3-4
3.2.3 PLACING THE LOAD .................................................................................................................3-4
3.3 INSTALLATION ...........................................................................................................................3-5
3.3.1 GENERAL STANDARDS.............................................................................................................3-5
3.4 OPERATOR TRAINING...............................................................................................................3-6
3.4.1 COMPANY USING THE EQUIPMENT........................................................................................3-6
3.4.2 THE OPERATOR ........................................................................................................................3-6
3.4.3 THE MAINTENANCE WORKER .................................................................................................3-6
3.5 OPERATION, ADJUSTMENTS AND MAINTENANCE ................................................................3-7
3.5.1 GENERAL STANDARDS.............................................................................................................3-7
3.5.2 GUIDELINES FOR OPERATION AND MAINTENANCE..............................................................3-9
3.5.2.1 Residual electric risks ................................................................................................................3-9
3.5.2.2 Residual risks from light flashes ................................................................................................3-9
3.6 DECOMMISSIONING AND DISMANTLING THE MACHINE ....................................................3-10
3.6.1 DECOMMISSIONING...............................................................................................................3-10
3.6.2 DISMANTLING .........................................................................................................................3-11
4INSTALLATION..............................................................................................................................................4-1
4.1 SHIPPING, LIFTING AND POSITIONING THE MACHINE..........................................................4-1
4.1.1 DIVISION OF THE ELECTRONIC EQUIPMENT .........................................................................4-1
4.1.2 DIMENSIONS AND WEIGHTS ...................................................................................................4-1
4.1.3 PART HANDLING .......................................................................................................................4-2
4.2 INSTALLATION ...........................................................................................................................4-3
4.3 CONNECTIONS .........................................................................................................................4-4
4.3.1 ELECTRIC CONNECTIONS .......................................................................................................4-4
4.3.1.1 Connecting the electric cables ..................................................................................................4-4
4.3.1.1.1 Plugging in the power cords for the cameras............................................................................4-5
4.3.1.1.2 Plugging in the cables for the led-type lighting units ................................................................4-5
4.3.1.1.3 Connecting the cables for the sensors and actuators...............................................................4-5
4.3.1.1.4 Connecting the secondary electrical cabinet ............................................................................4-5
4.3.1.1.5 Plugging in the display...............................................................................................................4-5
4.3.1.2 Ground connection ....................................................................................................................4-7
4.3.1.3 Electric energy connection ........................................................................................................4-7
4.3.1.4 Conditioner connection .............................................................................................................4-7
4.4 SOFTWARE INSTALLATION.......................................................................................................4-8
5START-UP......................................................................................................................................................5-1
5.1 GENERAL INFORMATION..........................................................................................................5-1
5.2 START-UP...................................................................................................................................5-1
5.2.1 PRELIMINARY CHECKS ............................................................................................................5-1
5.2.2 START-UP PROCEDURE ...........................................................................................................5-2

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6USE OF THE ELECTRONIC EQUIPMENT...................................................................................................6-1
6.1 START-UP/SHUTOFF.................................................................................................................6-1
6.1.1 NORMAL START-UP ..................................................................................................................6-1
6.1.2 START-UP WITH MODIFICATIONS MADE TO THE SOFTWARE CONFIGURATION.................6-1
6.1.3 START-UP WITH MODIFICATIONS MADE TO THE SOFTWARE CONFIGURATION
AND THE IMAGE SHOOTING STATION ....................................................................................6-2
6.1.4 SHUTTING OFF THE SYSTEM ..................................................................................................6-2
7ADJUSTMENTS ............................................................................................................................................7-1
7.1 CHECKING CVS VISION SYSTEMS ..........................................................................................7-1
7.1.1 PROCEDURE FOR CHECKING THE CAPTURE AND EJECTION DEVICES .............................7-1
7.1.1.1 Adjusting the front-back image shooting station.......................................................................7-1
7.1.2 PROCEDURE FOR CHECKING THE CAPTURE AND EJECTION MECHANISM ......................7-2
7.1.3 PROCEDURE FOR CHECKING PRODUCT INSPECTION.........................................................7-3
7.1.4 PROCEDURE FOR CHECKING VISION SYSTEM OPERATION ................................................7-3
8MAINTENANCE.............................................................................................................................................8-1
8.1 SCHEDULED MAINTENANCE ...................................................................................................8-2
8.1.1 ROUTINE MAINTENANCE .........................................................................................................8-2
8.1.1.1 Lighting unit cleaning.................................................................................................................8-2
8.1.1.2 Cleaning the camera cover........................................................................................................8-2
8.1.1.3 Cleaning the Touch Screen........................................................................................................8-2
8.1.1.4 Replacing the fuses ...................................................................................................................8-2
8.2 SPECIAL MAINTENANCE OPERATIONS...................................................................................8-3
9DISMANTLING ..............................................................................................................................................9-1
9.1 DECOMMISSIONING.................................................................................................................9-1
9.2 DISMANTLING ...........................................................................................................................9-2

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GENERAL INFORMATION 1
1-1
1 GENERAL INFORMATION
1.1 INTRODUCTION
D0003276_00
SAFETY
INSTRUCTIONS
Carefully read the entire User’s Manual before working on the electronic equipment and/or the packaging of the
various parts.
The Instructions Manual contains important information for safeguarding all personnel who work on the electronic
equipment as well as the electronic equipment itself.
The company using the electronic equipment must always assure all operators have completely read and become
familiar with the operating instructions.
Notwithstanding the electronic equipment is equipped with active and passive safety devices, all risks resulting from
incorrect use cannot be avoided.
SACMI shall not be held responsible for failure to heed to safety precautions and accident prevention rules and
standards specified throughout this manual and property damage and personal injury caused by unintended,
inappropriate and erroneous use of the electronic equipment.
Any changes to the electronic equipment must be duly authorized by SACMI in advance.
Only properly trained personnel are authorized to work on the electronic equipment (performs maintenance,
adjustments, repairs, cleaning) closely following the directions contained in this manual.
D0003275_00
NOTICE
SACMI reserves the right to make technical changes to the electronic equipment and this manual without giving prior
notice.
Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department.
Copyright. All rights reserved.
This publication or parts of it are valuable trade secrets and must not be copied, stored, reproduced, disclosed,
transferred or translated into any language, spoken or computer, in any form or by any means without the express
written consent of SACMI.
SACMI shall prosecute violations of rights on technical documentation and drawings.
SACMI guarantees the contents of this publication. It is severely forbidden to use this publication for other purposes,
whatever they may be, that are extraneous to operation of the electronic equipment for which this publication has
been drawn up.
The information contained herein is guaranteed as being correct only if the user carefully follows all the guidelines
and instructions provided in this publication.
1.2 WHERE TO KEEP THE MANUAL
D0003276_00
SAFETY
INSTRUCTIONS
The manual and supplements:
- are to be considered an essential part of the electronic equipment and must be kept along with it even if the
machine is sold;
- must always be kept within easy reach near the electronic equipment and protected against environmental agents
that may ruin or damage them;
- must always be available and close by so that operators and maintenance staff are able to consult them rapidly
at any time.

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1GENERAL INFORMATION
1-2
1.3 HOW TO USE THE MANUAL
The information and instructions provided in this manual are grouped together organized in chapters and paragraphs.
The subject of interest can be easily located by consulting the table of contents.
Read the information preceded by the symbols below with care as they are essential for the health and safety of the
operators as well as for the efficiency of the electronic equipment.
D0003272_00
DANGER
DANGER Risk of death or serious injuries.
D0003273_00
WARNING
CAUTION Probable risk of death or serious injuries.
D0003274_00
CAUTION
ATTENTION Risk of minor injuries.
D0003275_00
NOTICE
WARNING Warnings not related to physical injuries.
D0003276_00
SAFETY
INSTRUCTIONS
SAFETY INSTRUCTIONS Safety instructions or procedures.
D0003276_00
SAFETY
INSTRUCTIONS
Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS must be carefully read in its entirety as it contains
important information and warnings regarding safety.
1.4 USERS OF THE MANUAL
Electronic equipment operators are defined as follows in this manual:
- operator: person responsible for supervising and operating the electronic equipment;
- maintenance worker: person responsible for performing routine maintenance.
The exact definition of these operators is given in the OPERATOR TRAINING paragraph in chapter 3 - SAFETY
EQUIPMENT AND PRECAUTIONS.
D0003275_00
NOTICE
The term “operator” is a generic term used to identify a person who has to work on the electronic equipment:
operator, maintenance worker, etc.

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GENERAL INFORMATION 1
1-3
1.5 WARRANTY
SACMI shall be held responsible only for the electronic equipment as it was configured at the time of delivery.
Any operations that alter the configuration of the electronic equipment or work cycle must be carried out or duly
authorized by SACMI's Engineering Dept.
SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.
The warranty is valid only if the electronic equipment has been correctly used in accordance with the instructions
provided by the manufacturer.
The warranty does not cover parts subject to wear and tear.
The warranty is void in the following cases:
- required maintenance jobs not performed;
- altering, tampering or misuse of the machine;
- if spare parts different from the ones originally installed in the electronic equipment are used;
- if changes and/or repairs are carried out by personnel not duly authorized by SACMI.
SACMI shall not be held liable for electronic equipment damage caused by misuse or malfunctioning of other
equipment connected to the electronic equipment.
The warranty covers only electronic equipment damage and/or malfunctions with explicit exclusion of compensation
for any additional damage. In any case, the seller shall not be held responsible for loss due to lack of or reduced
production, as well as any special, indirect or consequential loss of any nature whatsoever.
As regards any annexes or modifications to the above, in any case the general terms and conditions set forth in the
contract shall be abided.
D0003275_00
NOTICE
The electronic equipment operators and maintenance staff are not responsible for carrying out operations under
warranty, special maintenance and repairs. These operations are to be performed only by the manufacturers
specially trained technicians. For this reason, these types of operations are not dealt with in this manual.
1.6 ATTACHMENTS
The documents listed below supplement this instructions manual.
- INSTRUCTIONS B.
(This document may be split up into several handbooks. It contains information on how to use the control system
and about the electric and electronic components found in the equipment).
- WIRING DIAGRAMS.
- AIR CONDITIONER DOCUMENTATION (if provided).

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1GENERAL INFORMATION
1-4
1.7 KEY TO THE SAFETY SYMBOLS USED ON THE ELECTRONIC EQUIPMENT AND/
OR IN THE MANUAL
WARNING SIGNALS
E0004
General hazard.
D0000004_00
Risk of electrocution.
ALERT SIGNS
E0006
Indicated point must be effectively grounded.
E0038
Lift point
E0167 Instructions manual must be read.
OTHER SIGNS
E0168 When discarding electric and electronic equipment separate them to permit correct recycling and prevent
harm to human health and/or the environment.
Penalties may be applicable for incorrect disposal of this waste, in accordance with national legislation.
Contact the manufacturer for more information about correct disposal.

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GENERAL INFORMATION 1
1-5
1.8 POSITION OF THE SAFETY SIGNS
D0003275_00
NOTICE
The type of signs may vary in relation to the laws in force in the country the equipment is installed in.

T6779
Matr .Nr.
Serial No.
Cod.
Mat.
P a
M A D E I N I T A L Y
I a
04076375
W
A
f nHz
U nV
IP
O.d.V
Order No.
E0004
E0159
SACMI IMOLA S.C. VIA SELICE PROVINCIALE 17/A IMOLA - ITALIA
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1GENERAL INFORMATION
1-6
1.9 IDENTIFICATION PLATE FOR THE ELECTRONIC EQUIPMENT
If the electronic equipment is equipped with good sized cameras, identification plates are provided on them. The
serial number stamped on these plates is the same as the serial number given on the plate attached to the personal
computer or to the main cabinet with the addition of extensions /0/1 and so on.
FIGURE 1.9 - IDENTIFICATION PLATE FOR THE ELECTRONIC EQUIPMENT

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GENERAL INFORMATION 1
1-7
1.10 CONFORMITY DECLARATION
(Only in the European Economic Community or in cases where required)
The Declaration of Conformity, when provided, accompanies the electronic equipment.
1.10.1 NON-INTEGRATED VISION SYSTEM
S.C. declares:
- that this equipment complies with the European Directives indicated below (the references to standards are to
be considered extended also to the next amendments and/or supplements):
- 2014/30/EU;
- 2014/35/EU;
- that the equipment also meets standards:
- EN 61010_1:2011;
- EN 61326_1:2013.
1.10.2 INTEGRATED VISION SYSTEM
S.C. declares:
- that this equipment complies with the European Directives indicated below (the references to standards are to
be considered extended also to the next amendments and/or supplements):
- 2004/108/EC;
- 2006/95/EC;
- that the equipment also meets standards:
- EN 60204_1:2006.

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1GENERAL INFORMATION
1-8

T6780
11
1
9
3
8
6
2
7
4
5
10
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FEATURES 2
2-1
FIGURE 2.1 - DESCRIPTION OF THE ELECTRONIC EQUIPMENT
2 FEATURES
2.1 DESCRIPTION OF THE ELECTRONIC EQUIPMENT
The CVS vision systems are electronic equipment used in the automatic and visual inspection of CAPS. They consist
of one or more cameras, either black/white and/or color, that check the quality of plastic and/or metal caps by means
of an image capture system.
The electronic equipment, in particular the mechanical and electronic parts that make it up, is dealt with in this chapter.
A CVS system may have one or more image shooting stations.
Some possible configurations of the vision system are dealt with below.
1 Personal computer
2 Image shooting station
3 Image shooting sensor
4 Ejection station
5 Encoder
6 Connecting cables
7 Additional electrical cabinet
8 Indicator tower
9 Camera and lighting unit
10 Main electrical cabinet (optional)
11 Touch screen (optional)

T6781
UPS
5
3
1
2
4
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2FEATURES
2-2
2.1.1 MAIN DEVICES
2.1.1.1 Main electrical cabinet (optional)
Open the front door of the main electrical cabinet to access the Personal Computer 1. The operator can interface with
it by entering data with the touch screen 3and can export data with the USB pen drive.
An air-conditioner 4is mounted in the front door. This unit ensures that the temperature inside the Personal
Computer never exceeds 35 °C regardless of the outside weather conditions. Further information regarding the air
conditioner is given in the enclosed documentation, as indicated in chapter 1 - GENERAL INFORMATION, paragraph
ATTACHMENTS.
An uninterrupted power supply 2ensures that power is constantly delivered to the Personal Computer. In fact, it
automatically supplies power to the equipment hooked up to it when the cabinet is turned on with the main switch 5
located on the front. Further information is given in the enclosed documentation, as indicated in chapter 1 - GENERAL
INFORMATION, paragraph ATTACHMENTS.
FIGURE 2.1.1.1 - MAIN ELECTRICAL CABINET (OPTIONAL)
1Personal computer
2Uninterrupted power supply
3Touch screen
4Air conditioner
5Main switch

UPS
T6759
Memory
CPU
2
3
6
5
9
4
1
8
7
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FEATURES 2
2-3
2.1.1.2 Industrial-grade Personal Computer.
The Personal Computer is the foundation of the vision system.
The exact configuration of the Personal Computer varies according to individual applications and vision system
version.
The Personal Computer 5 hardware includes an ATX main board 4equipped with CPU 8and memory 9.
The cards 1and 2 are mounted in the main board slots.
Card 2 is connected to card 1 with connecting cables.
Image capture card IP1 is inserted in the other slots, not indicated in the figure. The number and model provided is
strictly related to the vision system version.
In addition to the Personal Computer bus, the cards are connected to one another by cables that join the image
capture card 2to the I/O board 1.
Further information regarding the Personal Computer is given in the enclosed documentation, as indicated in chapter
1 - GENERAL INFORMATION, paragraph ATTACHMENTS.
FIGURE 2.1.1.2 - INDUSTRIAL-GRADE PERSONAL COMPUTER
1PCI S32P I/O board
2Image capture card
3Power supply
4Main board
5Personal computer
6Dvd Drive
7Hard disk
8Personal computer CPU
9Personal computer memory

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2FEATURES
2-4
2.1.1.3 PCI S32P I/O board
The S32P is a half-size board designed by SACMI to regulate light intensity and carry out the input/output interface
tasks during the process.
This board, interfaced with other peripherals, is used to:
- interface the vision system with the encoder;
- regulate the intensity of the LED lighting units;
- regulate the intensity of the white and stroboscopic lights;
- provide the optoisolated digital outputs and inputs for piloting the sensors, relays, ...;
- connect the image processing cards to the devices that pilot the lights.
The board is provided with the following:
- ten optoisolated digital inputs;
- 24 optoisolated digital outputs;
- 8 input/output connections to the image capture cards for trigger/strobe;
- 64 auxiliary 5 V digital inputs/outputs.
In addition, the operating logic of the board is determined by a program residing in the flash memory that is transfered
inside the EPLD whenever the PC is turned on.
The program can be different in relation to the configuration of the electronic equipment; each program corresponds
to a different board code.
The board is identified by a serial number stamped on the label 6attached to the front connector. This serial number
appears briefly on the monitor along with the EPLD program version when the PC is booting.
The PCI IO board, as each PCI device, is a Plug & Play type, i.e. resources (addresses, interrupts, etc...) do NOT
have to be assigned by hand as it is done automatically.
To this aim, leave PNP in all the BIOS PCI resources as indicated in “Software installation instructions for vision
systems, paragraph Hardware configuration”.