Sacmi CHS Series User manual

DOCUMENTAZIONE
TECNICA
CHS
INSTRUCTIONS B
OPERATOR INTERFACE AND PLC-BASED
CONTROL SYSTEM OPERATING
INSTRUCTIONS
CHS100.86.011 Rev.02 Date 23/07/2018
TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACIÓN TÉCNICA
DOCUMENTAÇÃO TÉCNICA

CHS100.86.011 Rev.02 Date 23/07/2018
2
Written by
Masrè
Roberto/11/112
Date of issue
23/07/2018
Checked by
Gualandi Fabrizio
Revision
02
Denomination
Number of pages
34
Operator interface
and PLC-
based control system operating
instructions
Service code
CCE12V
Code
CHS100.86.011
GENERAL INFORMATION
INTRODUCTION
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 assure 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 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.
All operations on the machine (maintenance, adjustments, repairs, cleaning) must be performed by
suitably trained personnel and according to the instructions of this manual.
SACMI reserves the right to make any technical modifications to this manual and to the machine
without giving prior notice.
Any request for more copies of this manual must be addressed to the customer service of SACMI.
All rights reserved; copy is forbidden.
This publication or parts thereof may not be reproduced, stored, transmitted, transcribed, or
translated into any language, either common or computerized, in any form or by any means without
the express written permission by SACMI.
SACMI reserves its rights on drawings and technical documentation according to the law.
SACMI ensures the contents of this publication. It is absolutely prohibited 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 written.
The information contained herein is guaranteed as being correct only if the user carefully follows all
the guidelines and instructions provided in this publication

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CARE OF THE MANUAL
CAUTION!
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 stored near the machine, in an easily accessible place and protected from
environmental agents which might affect their integrity and duration;
−must always be available and close by so that operators are able to consult them rapidly at
any time.
CRITERIA FOR SEARCHING FOR AND REFERENCING INFORMATION
The information and instructions are collected and organized in chapters, sub-chapters and
paragraphs and can be found by referring to the index.
Information provided with alert, warning or danger symbols must be carefully read.
The notes critical to the health and safety of employees are within a box, marked with warning,
prohibition and/or mandatory signs and in italics as shown below.
WARNING!
It is especially important to read sections dealing with SAFETY carefully and repeatedly, since they
contains important information and warnings for operators.
USERS OF THE MANUAL
For the purposes of the manual, the persons in charge of the machine are divided into:
−operator: person responsible for supervising and operating the machine;
−maintenance worker: in charge of scheduled machine maintenance.
The exact definition of these operators is given in the OPERATOR TRAINING paragraph in
chapter 3 (SAFETY EQUIPMENT AND PRECAUTIONS) in the INSTRUCTIONS manual.
WARNING!
The term “operator” is generically used to identify a person who has to work on the machine:
operator, maintenance worker, etc.

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SAFETY DEVICES
SAFETY DEVICES & GUARDS
The machine is provided with a number of electrical and/or mechanical safety devices in order to
safeguard the operators and the machine itself.
It is forbidden to tamper with, modify or try to bypass in any way the safety systems of the
machine. For clarity of the descriptions, some illustrations in this manual show the machine or
parts of it without guards or with the guards removed.
It is always forbidden to use the machine without guards or with guards disabled.
Warning signs are provided on the machine to indicate any hazards in the zone where the sign is
attached. In addition, plates with important safety information and/or symbols that advise on correct
and safe machine operation are provided. Always take all necessary safety precautions and follow
the guidelines when working on the machine.
SACMI disclaims any liability arising from tampering or failure to use safety devices. The presence
of safety devices does not exempt the operators from exercising extreme caution during work,
avoiding actions that may endanger him/herself or damage the machine at all times. In particular,
the workers must never come into contact with the moving parts of the machine.
SAFETY DEVICES INSTALLED
- Locking devices
Locking devices detect and signal an operating anomaly and prevent starting up or stoop
operation.
- Signaling of shutdown
Every time a blocking condition occurs, it is signaled by a flashing light placed above the electrical
cabinet. The cause of the alarm which caused the machine to shut down is shown on the control
keyboard screen.
The meanings of the alarm messages are described in the TYPE B INSTRUCTIONS manual.
- Operator safety devices
Machines are generally equipped with a number of mobile safety guards which are connected to
electrical locking devices. Moreover there are fixed mechanical guards that prevent accidental
access to all moving parts of the machine and dangerous parts, that are either live or hot.
- Emergency stop buttons
The machine can be stopped with emergency shutdown buttons.
These buttons are manually actuated and cause the immediate stop of the machine.
WARNING!
In the event SACMI does not supply the complete assembly the machine is to be incorporated in, it
is the final user's responsibility to connect the emergency stop circuit of the machine covered by
this manual to the emergency stop circuit of the line it will be inserted in.

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GENERAL REGULATIONS
WARNING!
Before performing any operation on the machine, all personnel who are to operate on it shall:
−make sure the machine cannot be accidentally started up by shutting off all the power
supplies (electrical power, air supply, etc..) with personal locks (for example pad locks)
stamped with the name of the worker who put it on;
−remove and personally store the keys of the locking devices
WARNING!
The electrical cabinets, like the junction boxes on-board the machine contain parts that may be
live. Access as set forth by standard EN 60204-1 is only allowed with a specific tool. Only skilled
personnel trained to access live components shall possess said tool. When the electrical panel is
live, the skilled personnel may only restore the electrical circuit protections.
WARNING!
Wherever “socket-plug” connections are present, either in electrical panels or shunting boxes fitted
on board the machine, it is obligatory to perform any disconnections only with the machine stopped
and after isolating the electrical system from the mains.
WARNING!
Some safety devices may have to be temporarily removed or made inoperative to carry out certain
maintenance operations and/or to adjust parts. Always put these devices back into place after
maintenance and/or adjustments have been completed before attempting to start the machine.
WARNING!
In order to assure the machine’s efficiency and its correct and safe operation it is essential to
comply with SACMI’s instructions and perform maintenance of the machine according to the
planned schedule and methods. In particular, it is recommended to periodically check correct
operation of all safety devices, insulation of electrical cables (which must be replaced if damaged)
and the efficiency of the earthing connection.

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WARNING!
it is forbidden to remove nameplates and labels from the machine; it is obligatory, and the user's
responsibility, to restore and clean any markings (of lead wires, terminals, devices, etcetera),
nameplates and labels that have become illegible.
WARNING!
Never use the machine if any of the safety devices are malfunctioning under any circumstances,
immediately shut down the machine locking the power shut off switches in the position in which
power is cut off. Start the machine only after all the safety devices function efficiently.

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INTRODUCTION
The following chart shows the operational state of the LEDs corresponding to the inputs of
an ID card in the most frequently encountered cases.
Device
Connecti
on
State
LED indication
Push-button
N.O.
Pressed
LED ON
Available
LED off
N.C.
Pressed
LED OFF
Available
LED ON
Selector
Closed in position X
LED ON
Open in position X
LED off
Limit switch
N.O.
Activated
LED ON
Deactivated
LED off
N.C.
Activated
LED OFF
Deactivated
LED ON
Proximity switch
N.O.
Closed in position X
LED ON
Open in position X
LED OFF
Direct detection photocell
N.O.
Activated
LED ON
Deactivated
LED off
Reflex photocell or
N.O.
Activated
LED off
light impulse retroreflex
Deactivated
LED on
Dark impulse retroreflex
photocell
N.O.
Activated
LED on
dark impulse retroreflex
Deactivated
LED off
Contactors - Relays
N.O.
Energized
LED ON
De-energized
LED off
N.C.
Energized
LED OFF
De-energized
LED ON
Level sensor
N.O.
Above the threshold
LED on
Pressure switch
Below threshold
LED off
Flow meter
N.C.
Above the threshold
LED off
Thermostat
Below threshold
LED ON
Vacuum meter
N.O.
Above pressure limit
LED ON
Below pressure limit
LED off
N.C.
Above pressure limit
LED OFF
Below pressure limit
LED on
KEY:
N.O. = NORMALLY OPEN
N.C. = NORMALLY CLOSED

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MAIN FEATURES OF THE ELECTRICAL SYSTEM.
The electrical system basically consists of four sections:
−Operator interface;
−Microprocessor-based system for controlling and monitoring machine operation;
−Section for delivering power to the main points of use;
−Electrical wiring;
OPERATOR INTERFACE.
This is the device used for communication between the operator and microprocessor-based
control system.

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MICROPROCESSOR SYSTEM FOR CONTROLLING AND MONITORING
MACHINE OPERATION
This is themachine control andprocessing unit; its task is tocontrol the work cycle, acquiring
the signals from the various devices installed in the machine.
This system includes a programmable controller along with a number of input and output
modules:
Power supply card
It supplies power to the various parts inside the system.
CPU card
Contains the microprocessor and unit that processes the program; the CPU has an RS232C
serial port for connection to the interface computer.
Memory card
It includes a memory module MMC which stores the program.
Digital input modules
Their function is to acquire the state of the limit switches, proximitysensors, photocells, etc...
Output modules
These devices pilot the machine actuators.
SWITCHBOARD THAT SUPPLIES POWER TO THE MAIN POINTS OF USE
This part houses all the devices that control the electric motors.
The controls for the motors and the transformers are protected with magnetic thermal cut-
outs.
All the power components are mounted on a bus bar.
The entire electric system is tested according to current safety regulations.
The entire electric system has been designed and developed in compliance with current
international electrical codes and regulations regarding safety of machinery.

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ELECTRICAL WIRING
This section includes the junction boxes and cables that connect the various devices and
actuators installed in the machine to the electrical cabinet.
The power section (motors, power supply to points of use) should always be kept separate
from the control section (photocells, sensors, solenoid valves, limit switches, etc...).
MACHINE CONTROL KEYBOARD
(Version with standard colors)
(Version with special colors)
PUSH-
BUTTON
DESCRIPTION
1
Emergency stop button.
2
Reset button to clear shutdown or fault conditions.
3
Automatic cycle stop button
4
Automatic cycle start button
5
Manual start/stop button for cap timing device (M13)
6
Manual start/stop button for cap conveyor belts M15 and M25 (if provided)
7 Manual start/stop button for suction devices and blowers
8
Machine state selector (MANUAL – LOCAL - REMOTE)
2
1
3
4
5
6
7
8
2
1
3
4
5
6
7
8

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DESCRIPTION OF THE INTERFACE VIDEO-PAGES
- MAIN MENU
Button that accesses the page with machine layout
Button for accessing the page containing the manual operations
Button that accesses the page regarding display and setting data items
for the machine
Button for accessing the page used to view and set the data items
regarding cap count
Button for accessing the page used to view and set the data items
regarding the Spark Tester (if present)
Button for accessing the page used to view the data items regarding
the motors
Button for accessing the page regarding machine configuration data
Button that accesses the page regarding the fault log
Button that accesses the page regarding PLC inputs and outputs
Button that accesses the page with program versions
Button for accessing the page used to select the local language

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Button used to quit the application

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- MANUAL COMMANDS MENU
The individual machine pneumatic actuators can be operated separately from this page.
CAUTION: the motion software controls are enabled when the machine is set to manual
mode. Nevertheless, it is fundamental to exercise extreme caution when parts are operated.
It is highly advisable to use this mode only to set the parts or run tests.
Hardware controls regarding operator safety are always operative.

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- CHS DATA MENU
Set parameters for machine operation in this page
Outside diameter of the cap to be processed: the outside diameter of the cap to be
processed is set.
Machine speed required: the average number of caps inspected per minute of production
is set and displayed.
Conveyor belt reference speed: the percentage factor of the ratio between the cap timing
device speed (M13) and the conveyor belt is set.
Cap step theoretical distance: the distance between caps during production is displayed,
expressed in millimeters.
Motor reference in manual mode: the shift percentage of motor speed in manual mode is
set.
Second speed reference in automatic mode: the shift percentage of production speed in
automatic mode is set.
Second speed duration: the second speed duration in automatic mode is set.

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Full channel signal delay: setting regarding the filter when the photocell that detects the
maximum level in the cap feed channel is activated.
If the caps remain above the maximum level after the preset length of time has elapsed
during the automatic cycle, the signal for requesting caps to the upstream machine is
deactivated (KA307). The filter time setting on SQ7 signal during the automatic cycle
increases machine speed so as to drain the channel.
If the length is set to zero, the cap request signal is related to machine cycle; this signal will
always be active during cap inspection, regardless of the state of the maximum level
photocell SQ7.
Timing device start delay: setting of the timing device start filter. During this delay a
downstream feeder reaches the full speed. If the value typed in is greater than 1 second,
the signal for downstream cap request (KA207) is active when the machine is in automatic
mode.
Extraction shutdown timer: this setting is used to define the delay between the moment
a shutdown (code n. 10xx) occurs and the moment the extraction function (M11/M11B) is
shutdown, with the exception of the shutdown caused byan emergency stop (code n. 1001).
If the value is set to 0, the blowers stop immediately in the event of a shutdown. If the value
is greater the 0, it is possible to anticipate the shutdown by pressing the button SB11, after
a shutdown message has been generated.
CVS rejects check blow duration: this parameter is used to define the duration of the
reject blow function (YV30), expressed in tenths of a second. The blower is activated by the
CVS reject check signal, via the PLC input CH3 – 04 – CVS Check.

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- COUNT DATA MENU
Number of caps/box: this parameter may be used to set-up the desired number of caps for
each box. The box diverter is operated when the setpoint is reached.
The number of caps currently present in the box is displayed aside.
Cap diverter control is disabled when count is zero.
Cap count cannot be reset during the automatic cycle.
Length of box change pulse (KA1): setting regarding the duration of box pulse signal to
indicate box deviation to a downstream cartoning machine.
If the length is set to zero, the relay operation is bistable (one cycle ON and one cycle OFF)
Delay of box change signal: length of time after which the downstream machine receives
the signal KA1. It indicates that the cap setpoint has been reached in the box.
Box change length: time for box change length in the downstream machine is set. This
length of time controls the closing duration of the cap storage unit.
Vibration setpoint: the number of caps between two activations of the box vibration signal
is set.
The signal control is disabled when the setpoint is zero.
Box vibration: the activation time of the box vibration length is set.
Cap feed channel drained: button used to activate the drainage of the cap feed channel.
This command is used to drain the feed channel. It is to be activated when the machine is
in automatic mode and stops the machine after drainage.

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CHS infeed closures total counter: displays the total number of caps fed into the machine.
To reset this counter, press the corresponding RESET button on the “Machine Set-up” page.
CHS infeed closures partial counter: displays the partial number of caps fed into the
machine. To reset this counter, press the corresponding RESET button.
CHS outfeed closures total counter: displays the total number of caps fed out of the
machine. To reset this counter, press the corresponding RESET button on the “Machine
Set-up” page.
CHS outfeed closures partial counter: displays the partial number of caps fed out of the
machine. To reset this counter, press the corresponding RESET button.

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- OPTIONAL SPARK TESTER DATA MENU (if present)
Number of SPARK TESTER: the number of machine rejects for defects due to the micro-
holes are counted.
YV30 reject tolerance: the number of tolerance caps that will be rejected when one cap is
rejected. If the data item is set to 1, 3 caps will be rejected: the defective cap, the previous
cap and the next cap. Set this value to 1 or to a greater value.
Distance between YV3 and SPARK TESTER: the number of caps between the feed
cylinder (YV3) and the high voltage electrode of the Spark tester is set.
Distance between YV3 and YV30: the number of caps between the feed cylinder (YV3)
and the reject valve (YV30) is set.
Distance between YV3 and SQ11: the number of caps between the feed cylinder (YV3)
and the count photocell (SQ11) is set.
Reject blow duration (YV30): the activation time of the blow for reject (YV30) is set,
expressed in milliseconds.

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- MOTOR DATA MENU
M13 speed: the number of revs/min of the cap timing device is displayed.
Inverter U13 reference frequency: the reference frequency of the inverter in the cap timing
device is displayed.
Analog input voltage. Inverter U13: the voltage transferred to the inverter of the cap timing
device by means of the analog input is displayed.
M15 speed: the number of revs/min of the cap conveyor belt is displayed.
Inverter U15 reference frequency: the reference frequency of the inverter in the cap
conveyor belt is displayed.
Analog input voltage. Inverter U15: the voltage transferred to the inverter of the cap
conveyor belt by means of the analog input is displayed.
Linear speed, Cap conveyor belt: the linear speed of the cap conveyor belt is displayed in
mm/s.

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- MACHINE SETUP MENU
CHS model (CHS100 or CHS200):entereither100or200toactivatetheset-up for CHS100
or CHS200 respectively.
Type of cap timing device (1=starwheel, 2=double roller): enter either 1 or 2 to activate
the set-up for a starwheel timing device or a double roller timing device respectively.
Motor M13 rated speed: enter the number of rated revs/min, referred to the cap timing
motor.
Motor M13 gearbox: enter the value of the reduction ratio for the gearbox referred to the
cap timing device.
Inverter M13 maximum frequency: enter the maximum frequency value for the inverter in
the cap timing device.
Number of cavities, Starwheel M13: enter the number of cavities found in the feed
starwheel.