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.

062AZ005A
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.