Sacmi Imola CHS Series User manual

INSTRUCTIONS MANUAL
062AZ005A
INSPECTION SYSTEM FOR PLASTIC/ALUMINUM CAPS
CHS
TECHNICAL
DOCUMENTATION
ENGLISH
Translation of the original instructions

062AZ005A
INSTRUCTIONS MANUAL
INSPECTION SYSTEM FOR PLASTIC/ALUMINUM CAPS
CHS
MANUFACTURER
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALY
www.sacmi.com
RELEASE DATE
09.03.2015
VERSIONS
CHS100 - CHS200

062AZ005A

062AZ005A
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 MACHINE AND/OR IN THE MANUAL ...... 1-4
1.8 MACHINE NAMEPLATE ............................................................................................................ 1-6
1.9 CONFORMITY DECLARATION.................................................................................................1-8
2FEATURES .................................................................................................................................................... 2-1
2.1 MACHINE DESCRIPTION .........................................................................................................2-1
2.1.1 MAIN DEVICES..........................................................................................................................2-1
2.1.1.1 Spacer........................................................................................................................................2-4
2.1.1.2 SPARK TESTER device.............................................................................................................2-7
2.1.1.3 Standard conveyor belt ..............................................................................................................2-8
2.1.1.4 Overturned conveyor belt...........................................................................................................2-9
2.1.1.5 Electrical cabinet ......................................................................................................................2-10
2.1.1.6 Pneumatic system....................................................................................................................2-10
2.1.1.7 Diverter (optional)..................................................................................................................... 2-11
2.1.1.8 Top inspection system.............................................................................................................. 2-12
2.1.1.9 Bottom inspection system ........................................................................................................2-13
2.1.1.10 360° inspection system (optional) ............................................................................................ 2-14
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE................................................ 2-15
2.2 OVERALL DIMENSIONS ......................................................................................................... 2-16
2.2.1 CHS100 OVERALL DIMENSIONS ..........................................................................................2-16
2.2.2 CHS200 OVERALL DIMENSIONS ..........................................................................................2-17
2.3 TECHNICAL FEATURES .........................................................................................................2-18
2.3.1 CHS100/CHS200 TECHNICAL DATA......................................................................................2-18
2.3.2 SPARK TESTER DEVICE TECHNICAL DATA......................................................................... 2-18
2.3.3 ACCEPTABLE FLUCTUATIONS FOR THE INDICATED VARIABLES.................................... 2-19
2.3.4 RATING PLATE........................................................................................................................ 2-19
2.3.5 PRODUCT CHARACTERISTICS............................................................................................. 2-21
2.3.6 AIRBORNE NOISE LEVEL EMITTED BY THE MACHINE...................................................... 2-23
2.3.6.1 CHS100 sound pressure level .................................................................................................2-23
2.3.6.2 CHS200 sound pressure level .................................................................................................2-24
2.3.7 DATA SHEET............................................................................................................................2-25
2.4 DIAGRAMS ..............................................................................................................................2-28
2.4.1 PNEUMATIC SYSTEM DIAGRAM...........................................................................................2-28

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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 machine operation ............................................ 3-1
3.1.2 INSTALLED SAFETY DEVICES ................................................................................................3-2
3.1.2.1 Shutdown devices ......................................................................................................................3-2
3.1.2.2 Shutdown signals .......................................................................................................................3-2
3.1.2.3 Devices to safeguard the operator .............................................................................................3-2
3.1.2.4 Emergency stop buttons ............................................................................................................3-2
3.2 SAFETY RULES FOR HANDLING ............................................................................................3-5
3.2.1 LIFTING......................................................................................................................................3-5
3.2.2 MOVEMENT...............................................................................................................................3-5
3.2.3 PLACING THE LOAD.................................................................................................................3-5
3.2.4 USING THE LIFT EQUIPMENT ................................................................................................. 3-6
3.3 INSTALLATION ..........................................................................................................................3-7
3.3.1 GENERAL STANDARDS ...........................................................................................................3-7
3.4 OPERATOR TRAINING .............................................................................................................3-8
3.4.1 COMPANY USING THE MACHINE ...........................................................................................3-8
3.4.2 THE OPERATOR .......................................................................................................................3-8
3.4.3 THE MAINTENANCE WORKER.............................................................................................. 3-10
3.5 OPERATION, ADJUSTMENTS AND MAINTENANCE ............................................................ 3-11
3.5.1 GENERAL STANDARDS ......................................................................................................... 3-11
3.5.2 OPERATION, ADJUSTMENTS AND MAINTENANCE ............................................................3-14
3.5.2.1 Lights: residual risks from light discharge ................................................................................3-14
3.5.2.2 Access to the machine through the cap exit area ....................................................................3-14
3.5.2.3 Safety guards with mechanical lock .........................................................................................3-15
3.5.2.4 Pneumatic drive risks ...............................................................................................................3-15
3.5.2.5 Risks from excessive air pressure ...........................................................................................3-16
3.6 DECOMMISSIONING AND DISMANTLING THE MACHINE...................................................3-17
3.6.1 DECOMMISSIONING ..............................................................................................................3-17
3.6.2 DISMANTLING......................................................................................................................... 3-18
4INSTALLATION .............................................................................................................................................4-1
4.1 SHIPPING AND HANDLING ......................................................................................................4-1
4.1.1 MACHINE BLOCKS ...................................................................................................................4-2
4.1.2 DIMENSIONS AND WEIGHTS ..................................................................................................4-2
4.1.3 PART HANDLING.......................................................................................................................4-2
4.2 ASSEMBLING THE MACHINE (CHS100/CHS200)...................................................................4-3
4.3 CONNECTIONS......................................................................................................................... 4-5
4.3.1 CONNECTION TO THE PNEUMATIC SYSTEM .......................................................................4-5
4.3.2 ELECTRICAL CONNECTION .................................................................................................... 4-6
4.3.2.1 Connecting the electric cables ...................................................................................................4-7
4.3.2.2 Ground connection.....................................................................................................................4-9
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 OPERATION CHECK.................................................................................................................5-2
5.2.3 OPERATION OF THE PANEL OF THE SPARK TESTER DEVICE ........................................... 5-2
5.2.3.1 Operating principles ...................................................................................................................5-2

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6OPERATING INSTRUCTIONS ...................................................................................................................... 6-1
6.1 OPERATOR INTERFACE ..........................................................................................................6-1
6.1.1 CHS OPERATOR INTERFACE..................................................................................................6-1
6.1.2 INDICATOR TOWER..................................................................................................................6-2
6.1.3 SPARK TESTER DEVICE OPERATOR INTERFACE................................................................ 6-3
6.2 WORK CYCLES......................................................................................................................... 6-4
6.2.1 WORK CYCLE IN MANUAL MODE...........................................................................................6-4
6.2.2 LOCAL MODE (AUTOMATIC)....................................................................................................6-4
6.2.2.1 Normal cycle...............................................................................................................................6-4
6.2.2.2 Product configuration change ....................................................................................................6-4
6.2.2.3 Cycle with modifications made to the software configuration and image shooting station......... 6-5
6.2.3 REMOTE CYCLE (AUTOMATIC)...............................................................................................6-5
6.3 MACHINE STOPPAGE ..............................................................................................................6-6
6.3.1 SHUTDOWN DURING OPERATION ......................................................................................... 6-6
6.3.2 EMERGENCY STOP .................................................................................................................6-6
6.4 RESTORING OPERATION AFTER AN EMERGENCY SHUTDOWN ....................................... 6-6
7ADJUSTMENTS ............................................................................................................................................7-1
7.1 ADJUSTING THE VISION SYSTEM.......................................................................................... 7-1
7.1.1 PROCEDURE FOR CHECKING THE ACQUISITION AND EJECTION DEVICES ................... 7-1
7.1.2 PROCEDURE FOR CHECKING THE ACQUISITION AND EJECTION DEVICES ................... 7-1
7.1.3 PROCEDURE FOR INSPECTING PRODUCTS........................................................................7-2
7.2 PNEUMATIC SYSTEM ADJUSTMENT......................................................................................7-3
7.2.1 PNEUMATIC CONTROL UNIT ADJUSTMENTS ....................................................................... 7-3
7.2.2 PRESSURE ADJUSTMENT.......................................................................................................7-4
7.2.3 PRESSURE SWITCH SETTING................................................................................................ 7-4
7.3 SIZE CHANGEOVER PROCEDURES ......................................................................................7-5
7.3.1 ADJUSTING THE 2-WHEEL SPACER ...................................................................................... 7-5
7.3.2 ADJUSTING THE TURN-PLATE SPACER ................................................................................7-6
7.3.3 ADJUSTING CYLINDER YV3 AND TIMING SENSOR SQ6 IN THE TURN-PLATE SPACER .. 7-7
7.3.4 ADJUSTING THE SPARK TESTER TURN-PLATE ................................................................... 7-9
7.3.5 ADJUSTING THE BLOWERS FOR THE SOLENOID VALVE AND SENSORS
ON THE CONVEYOR BELT.....................................................................................................7-10
7.3.6 ADJUSTING THE OVERTURNED CONVEYOR BELT (CHS200) .......................................... 7-11
7.3.7 ADJUSTING THE FINAL DIVERTER (OPTIONAL)................................................................. 7-13
7.3.8 ADJUSTING THE CAP SLIDE PLATE.....................................................................................7-13
7.3.9 ADJUSTING THE REJECT CONVEYOR ................................................................................7-15
7.3.10 REPLACING THE SENSORS.................................................................................................. 7-16
7.3.11 ADJUSTING THE IMAGE CAPTURE......................................................................................7-18
8MAINTENANCE.............................................................................................................................................8-1
8.1 ROUTINE MAINTENANCE........................................................................................................8-2
8.1.1 ROUTINE MAINTENANCE TABLE............................................................................................8-2
8.1.2 ROUTINE MAINTENANCE OPERATIONS................................................................................8-4
8.1.2.1 Cleaning of the lenses, focus lenses and mirrors ......................................................................8-4
8.1.2.2 Cleaning the conveyor belts.......................................................................................................8-4
8.1.2.3 Conveyor belt tensioning............................................................................................................ 8-5
8.1.2.4 Replacing the belt ......................................................................................................................8-6
8.1.2.5 Cleaning/replacing the pneumatic system filter.......................................................................... 8-8
8.1.2.6 Cleaning the electrical cabinet and electrical cabinet fans......................................................... 8-9
8.1.2.7 Checking operation of the SPARK TESTER device brush.........................................................8-9
8.1.2.8 Check operation of the safety microswitch SQ42 in the turn-plate spacer............................... 8-10
8.2 SPECIAL MAINTENANCE OPERATIONS...............................................................................8-10
8.3 TORQUES (NUTS & BOLTS) .................................................................................................. 8-11
8.4 TROUBLE-SHOOTING............................................................................................................8-12
8.4.1 TROUBLE-SHOOTING FOR THE MACHINE..........................................................................8-12

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9DISMANTLING ..............................................................................................................................................9-1
9.1 DECOMMISSIONING ................................................................................................................9-1
9.2 DISMANTLING........................................................................................................................... 9-2

062AZ005A
GENERAL INFORMATION 1
1-1
1 GENERAL INFORMATION
1.1 INTRODUCTION
E0004 WARNING!
Carefully read the entire Instructions Manual before working on the machine and/or the packaging of the various
parts.
The Instructions Manual contains important information for safeguarding all personnel who work on the machine as
well as the machine itself.
The company using the machine must always make sure all operators have completely read and become familiar
with the operating instructions.
Notwithstanding the machine 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 machine. Any changes to the machine must be duly authorized by SACMI in
advance.
Only properly trained personnel are authorized to work on the machine (perform maintenance, adjustments, repairs,
cleaning) closely following the directions contained in this manual.
SACMI reserves the right to make technical changes to the machine 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 machine 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
E0004
WARNING!
The manual and supplements:
- are to be considered an essential part of the machine and must be kept along with it even if the machine is sold;
- must always be kept within easy reach near the machine and protected against environmental agents that may
ruin or damage them;
- must always be available and close by so that operators 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, subchapters
and paragraphs. The subject of interest can be easily located by consulting the table of contents.
Information provided with alert, warning or danger symbols must be carefully read.
Notes fundamental for the safety or health of operators are given inside a block pointed out by alert, warning and/or
danger symbols and written in italics, as shown below.
E0004 WARNING!
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
Machine operators are defined as follows in this manual:
- operator: person responsible for supervising and operating the machine;
- maintenance worker: person responsible for performing routine maintenance.
For detailed information on the personnel qualifications, refer to paragraph OPERATOR TRAINING in chapter 3 -
SAFETY EQUIPMENT AND PRECAUTIONS.
E0004
WARNING!
The term “operator” is a generic term used to identify a person who has to work on the machine: operator,
maintenance worker, etc.

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GENERAL INFORMATION 1
1-3
1.5 WARRANTY
SACMI shall be held responsible only for the machine as it was configured at the time of delivery and to the subject
that stipulated the sales contract with SACMI, or, in the case of leased machines, to the user named by the leasing
purchaser.
Any operations that alter the configuration of the machine or work cycle must be carried out or duly authorized by
SACMI.
SACMI shall not be held responsible for damages deriving from the use of non-original spare parts or any jobs done
by the purchaser’s technicians or, in the case of leased machines, by the user named by the leasing company and/
or technicians not duly authorized by SACMI and operations not described in this manual and/or for which SACMI
supervision is required and/or which were not expressly authorized by SACMI.
The warranty is valid only if the machine 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 machine are used;
- if changes are made.
SACMI shall not be held liable for machine damage caused by misuse or malfunctioning of other equipment connected
to the machine.
The warranty covers only machine 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.
Any warranties different from that granted to the machine purchaser by SACMI in the contract, or in the case of
leased machines, the user named by the leasing company are excluded.
E0004 WARNING!
The machine 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 manufacturer's specially
trained technicians. For this reason, these types of operations are not dealt with in this manual. The machine
purchaser or, in the case of leased machines, the user named by the leasing company should contact SACMI to
plan the work or receive the necessary instructions.
1.6 ATTACHMENTS
The documents listed below supplement this instructions manual.
- VISION SYSTEM INSTRUCTIONS,
- INSTRUCTIONS B
(this document may be split into several handbooks containing information on how to use the control system and
electric and electronic components installed in the machine).
- INSTRUCTIONS C.
- MAINTENANCE INSTRUCTIONS FOR THE ELECTRIC EQUIPMENT.
- WIRING DIAGRAMS.
- AIR CONDITIONER DOCUMENTATION (if provided).
- ADHESIVES AND LUBRICANTS DATA SHEET.

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1GENERAL INFORMATION
1-4
1.7 KEY TO THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE
MANUAL
WARNING SIGNS
E0004 General hazard.
D0000785_00 Pinch point - keep hands and fingers clear.
E0007
Electric shock hazard.
E0014 Risk of fingers getting caught in moving rollers.
D0000006_00 Risk of falling.
DANGER SIGNS
E0001 Never perform maintenance or lubrication jobs on moving parts.
D0000784_00 Do not put arms in the openings.

062AZ005A
GENERAL INFORMATION 1
1-5
ALERT SIGNS
E0006 Indicated point must be effectively grounded.
E0142 Lift point.
OTHER SIGNS
E0133
Dispose in accordance with current laws and regulations.

062AZ005A
1GENERAL INFORMATION
1-6
FIGURE 1.8/A - CHS100 MACHINE IDENTIFICATION PLATE
1.8 MACHINE NAMEPLATE
E0004 WARNING!
The CE mark is affixed only in the European Union or in cases where required.
T6863
E0206

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GENERAL INFORMATION 1
1-7
FIGURE 1.8/B - CHS200 MACHINE IDENTIFICATION PLATE
T6864
E0206

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1GENERAL INFORMATION
1-8
1.9 CONFORMITY DECLARATION
(Only within the European Community or in cases in which it is required)
The declaration of conformity, when provided, accompanies the machine.
Compiled in accordance with Annex II, letter A of Directive 2006/42/EC and any subsequent amendments and/or
supplements. Fixed installation in compliance with Directive 2004/108/EC.
S.C. declares:
- that this machine is a machine in conformity with the provisions of Directive 2006/42/EC and any subsequent
amendments and/or supplements and carries the “CE” mark;
- that this machine is in conformity with the provisions of the following European Directives (the standard references
are intended to include any subsequent amendments and/or supplements):
- 2006/42/EC;
- 2004/108/EC;
- that S.C. is authorized to set up the technical file.

062AZ005A
FEATURES 2
2-1
2 FEATURES
2.1 MACHINE DESCRIPTION
The CHS family of machines control continuous plastic and aluminum cap quality.
The caps are analyzed by a computerized inspection system (Control Vision System) and are transferred to the
production cycle, if necessary.
The CHS system can be applied to any type of machine that produces caps (new or already in operation) provided
by any supplier, or it can be used as stand alone. The main parts of the machine are illustrated in the figure.
The family includes two types of machines:
- CHS100: single conveyor belt system that permits the inspection of caps coming from one direction;
- CHS200: in-line double conveyor belt system that permits the inspection of caps coming from several directions
and the check of the internal, external and side areas.
2.1.1 MAIN DEVICES
For CHS100 they can be summarized as follows:
- machine base
- spacer
- reject system
- electrical cabinet
- control panel
- monitor
- pneumatic system
- suction device
- air conditioner
- personal computer
- top guard (optional)
- final diverter (optional)
- bottom guard (optional)
- conveyor belt
- inspection system.
For CHS200 they can be summarized as follows:
- machine base
- spacer
- reject system
- electrical cabinet
- control panel
- monitor
- pneumatic system
- suction device
- air conditioner
- personal computer
- top guard (optional)
- final diverter (optional)
- bottom guard (optional)
- standard conveyor belt
- overturned conveyor belt
- top inspection system
- bottom inspection system.

T6865
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2FEATURES
2-2
FIGURE 2.1.1/A - CHS100 MAIN DEVICES
1Base
2Spacer
3Reject system
4Electrical cabinet
5Control panel
6Monitor
7Pneumatic system
8Suction device
9Air conditioner
10 Personal computer
11 Top guard (optional)
12 Final diverter (optional)
13 Bottom guard (optional)
14 Conveyor belt
15 Inspection system
1
2
3
4
55
6
7
8
9
10
11
12
13
14
15

T6866
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FEATURES 2
2-3
FIGURE 2.1.1/B - CHS200 MAIN DEVICES
1Base
2Spacer
3Reject system
4Electrical cabinet
5Control panel
6Monitor
7Pneumatic system
8Suction device
9Air conditioner
10 Personal computer
11 Top guard (optional)
12 Final diverter (optional)
13 Bottom guard (optional)
14 Standard conveyor belt
15 Overturned conveyor belt
16 Top inspection system
17 Bottom inspection system
14
2
3
3
4
5
1
6
7
8
8
9
10
11
12
13
15
17
16

T6869
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2FEATURES
2-4
2.1.1.1 Spacer
The spacer consists of a spacing system of the caps on the belt slide surface.
The double roller spacer is to be considered standard equipment; parts do not require to be replaced for cap size
change. It may be replaced by the model with turn-plate which requires size related parts according to the cap to be
inspected, shown in the figure TURN-PLATE SPACER (OPTIONAL) in this chapter.
FIGURE 2.1.1.1/A - DOUBLE ROLLER SPACER
1 Frame
2 Motor
3 Side guides
4 Upper guide
5 Side guide adjustment
6 Upper guide adjustment
7 Roller height adjustment
8 Rollers
9 Roller width adjustment
10 Flow stop piston
11 Guards
1
2
3
4
5
6
7
8
9
10
11