Satake Scan master ii User manual

OPERATOR’S MANUAL

ScanMasterII

SMII 800 IRF/IEF

SMII 810 IRF/IEF

SMII 820 IRF/IEF

SMII 830 IRF/IEF

(P/N 490128-90EMB)

REV 6/08J

MODELS 490128

490129

All rights to the written material, illustrations, parts lists, and circuit diagrams used

in this manual are reserved to Satake USA Inc. The material contained in this manual

is intended for the exclusive use of customers in the operation and maintenance of

the equipment described herein. No reproduction of this manual in part, or in

whole, shall be made without the written approval of Satake USA Inc.

Satake USA Inc. reserves the right to make design changes or modifications to any

product to improve performance or incorporate new functions. Every attempt is

made to ensure that the manual supplied with the equipment truly reflects the

physical and electrical characteristics of the equipment as delivered to the

customer. Manuals ordered to replace lost originals will reflect the latest revision in

print. Recovery of technical written material, illustrations, parts lists, assemblies,

etc., to a specific revision level, will not be provided for replacement manuals in

general. However, Satake USA Inc. is always concerned with serving its customers’

legitimate needs and will attempt to supply any information shown to be omitted,

missing, or not representative of the equipment due to revision not covered by

revised drawings or errata sheets.

Address all correspondence to:

Manager,TechnicalServices

Technical Publications Dept.

SatakeUSAInc.

10905 Cash Road

Stafford,Texas77477

Telefax: (281) 494-1427

Telephone: (281) 276-3600

490128-90EMB

6/08J

TABLE OF CONTENTS

ScanMasterII SMII 800, SMII 810, SMII 820, AND SMII 830 IRF/IEF

PARAGRAPH PAGE

SECTION 1 - GENERAL INFORMATION

1.0 SCOPE 1-1

1.1 SAFETY PRECAUTIONS 1-1

1.1.1 Voltages 1-1

1.1.2 Electrical Interlocks 1-1

1.1.3 Printed Circuit Card Removal 1-1

1.1.4 Disconnecting and Reconnecting Plugs and

Connectors

1-1

1.1.5 Compressed Air Cleaning 1-2

1.1.6 Removing and Installing Air Ejectors 1-2

1.2 BRIEF DESCRIPTION OF SORTING 1-2

1.3 INSTALLATION OF THE ScanMasterII 1-8

1.3.1 Location 1-8

1.3.2 Transporting the ScanMasterII 1-8

1.3.3 Installing the Feeders and Input Hopper 1-11

1.3.4 Connecting the Power 1-12

1.3.5 Connecting the Compressed Air 1-12

1.3.6 Dust Extraction 1-13

1.3.7 Other Considerations and Precautions

(WELDING, ETC...)

1-13

SECTION 2 - IDENTIFICATION AND FUNCTION OF PARTS

2.0 SCOPE 2-1

2.1 LOWER POWER ENCLOSURE 2-1

2.1.1 Cooling Fans 2-1

2.1.2 Power Transformer 2-1

2.1.3 Lower Power Supply 2-1

2.1.4 Lamp Ballasts 2-1

2.1.5 Lamp Current Sensor 2-3

2.1.6 Low Air Pressure Switch 2-3

2.1.7 System Interface PCB 2-3

2.2 CONTROL PANEL 2-3

2.2.1 Power On-Off Switch 2-3

2.2.2 Status Indicator 2-5

2.3 TOUCH SCREEN OPERATOR INTERFACE 2-5

2.3.1 Security Level 2-5

2.3.2 Language Options 2-7

2.4 MAIN SCREEN 2-7

2.4.1 Dark Trip Control 2-7

2.4.2 Light Trip Control 2-10

2.4.3 Feed Rate Control 2-10

2.4.4 Feeder On-Off Button 2-10

2.4.5 Hopper-Sensor Button 2-10

2.4.6 Ejectors On-Off Button 2-10

2.4.7 Wipe Button 2-12

2.4.8 Trip Rate Bar Graph 2-12

2.5 SETUP SCREENS 2-12

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TABLE OF CONTENTS

ScanMasterII SMII 800, SMII 810, SMII 820, AND SMII 830 IRF/IEF

PARAGRAPH PAGE

SECTION 2 - IDENTIFICATION AND FUNCTION OF PARTS (CONTINUE)

2.5.1 SETUP1 SCREEN 2-12

2.5.1.1 Lamp Level 2-12

2.5.1.2 Spot Size 2-12

2.5.1.3 Background Position 2-14

2.5.1.4 Ejector Timing 2-14

2.5.1.4.1 Delay Adjustment 2-14

2.5.1.4.2 Dwell Adjustment 2-15

2.5.1.5 Lamp Fault Bypass 2-15

2.5.2 SETUP2 SCREEN 2-15

2.5.2.1 Trip Mode 2-15

2.5.2.2 Sort Mode 2-15

2.5.2.3 Lamp Type 2-17

2.5.2.4 View Mode 2-17

2.5.2.5 Wiper Timing 2-17

2.5.2.6 Feeder Control 2-18

2.5.3 SETUP3 SCREEN 2-18

2.6 BACKGROUND ADJUSTMENT SCREEN 2-18

2.7 STATUS SCREEN 2-19

2.7.1 Feeder Run-Time Summary 2-19

2.7.2 Viewer Temperatures 2-25

2.7.3 Status Indicators 2-25

2.8 FRAME GRAB SCREEN 2-26

2.9 EJECTOR RATE NORMALIZATION SCREEN 2-26

2.10 MAINTENANCE1 SCREEN 2-29

2.11 MAINTENANCE2 SCREEN 2-29

2.12 PRINTED CIRCUIT CARD CAGE 2-32

2.13 TIMING PCB 2-32

2.13.1 Indicators 2-32

2.13.2 Test Points 2-32

2.14 AMPLIFIER PCB 2-32

2.15 AMPLIFIER INTERFACE PCB 2-37

2.16 EJECTOR INTERFACE PCB 2-39

2.16.1 Ejector Testing 2-39

2.16.2 Reset LED 2-39

2.16.3 Computer 2-39

2.16.4 Status 2-41

2.17 EJECTOR CONTROL PCB 2-41

2.18 EJECTOR DRIVER PCB 2-41

2.19 BACKGROUND CONTROL I/O PCB 2-41

2.20 MONITOR CONTROL PCB 2-44

2.21 CPU INTERFACE MODULE 2-44

2.22 FEEDER DRIVER PCB 2-47

2.23 EJECTOR CONNECTOR PCB 2-47

2.24 SYSTEM INTERFACE PCB 2-47

2.24.1 Remote Computer Connections 2-47

2.24.2 PLC Connections 2-51

2.24.2.1 Connecting the 4-20 Milliamp Control 2-51

2.24.2.2 Testing the Remote Feeder Control 2-52

2.24.2.3 Lamp Monitor PCB 2-52

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TABLE OF CONTENTS

ScanMasterII SMII 800, SMII 810, SMII 820, AND SMII 830 IRF/IEF

PARAGRAPH PAGE

SECTION 3 - OPERATION AND ADJUSTMENTS

3.0 SCOPE 3-1

3.1 PRE-OPERATIONAL CHECKS 3-1

3.1.1 Air Pressure 3-1

3.1.2 Switch Positions 3-1

3.1.2.1 Amplifier PCB 3-1

3.1.2.2 Ejector Interface PCB 3-2

3.1.3 Testing the Air Ejectors 3-2

3.2 OPERATING THE ScanMasterII 3-2

3.2.1 Normal Startup 3-2

3.2.2 Normal Shutdown 3-3

3.2.3 Power Failure 3-3

3.2.3.1 Restoring Power 3-3

3.2.3.2 Restoring Power After a Minimal

Power Failure 3-3

3.2.4 Adjusting the Background(s) 3-4

3.2.5 Adjusting the Gain of the Amplifiers 3-4

3.2.6 Adjusting Ejector Dwell Time 3-6

3.2.7 Adjusting Ejector Delay 3-6

3.2.8 Adjusting the Feed Rate 3-6

3.2.9 Adjusting the Dark Trip Control 3-7

3.2.10 Adjusting the Light Trip Control 3-7

3.2.11 Adjusting the Size Control 3-8

3.3 EVALUATION OF SORTING RESULTS 3-8

SECTION 4 - MAINTENANCE

4.0 SCOPE 4-1

4.1 CHECKING AND CLEANING THE FEEDER TRAY 4-1

4.2 CHECKING AND CLEANING THE CHUTES 4-2

4.3 CHECKING THE WINDOW WIPER 4-2

4.4 CHECKING AND CLEANING THE VIEWER 4-2

4.5 LAMP REPLACEMENT 4-2

4.6 ADJUSTING THE LAMP BALLASTS 4-3

4.7 CLEANING THE AIR EJECTORS 4-5

4.8 SERVICING THE COMPRESSED AIR FILTER SYSTEM 4-7

4.8.1 Servicing the Pre-Filter 4-8

4.8.2 Servicing the Oil Removal Filter 4-8

4.9 CLEANING THE TOUCH SCREEN DISPLAY 4-11

SECTION 5 - TROUBLESHOOTING

5.0 SCOPE 5-1

5.1 POSSIBLE PROBLEMS AND PROBABLE CAUSES 5-1

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LIST OF ILLUSTRATIONS

ScanMasterII SMII 800, SMII 810, SMII 820, AND SMII 830 IRF/IEF

FIGURE PAGE

SECTION 1 - GENERAL INFORMATION

1-1 ScanMasterII, Front View 1-3

1-2 ScanMasterII, Side View 1-4

1-3 ScanMasterII, Rear View 1-5

1-4 Viewer, Two-View 1-6

1-5 Viewer, Single-View 1-7

1-6 Service Access for the ScanMasterII 1-9

1-7 Transporting the ScanMasterII 1-10

1-8 Lower Power Supply 1-14

SECTION 2 - INDENTIFICATION AND FUNCTION OF PARTS

2-1 Lower Power Enclosure 2-2

2-2 Control Panel 2-4

2-3 Security Login Window 2-6

2-4 Keypad Window 2-8

2-5 MAIN SCREEN 2-9

2-6 “Ejector Off” Warning 2-11

2-7 SETUP1 SCREEN 2-13

2-8 SETUP2 SCREEN 2-16

2-9 SETUP3 SCREEN 2-20

2-9A MODBUS SCREEN 2-21

2-10 BACKGROUND ADJUSTMENT SCREEN 2-22

2-11 Background Setting 2-23

2-12 STATUS SCREEN 2-24

2-13 FRAME GRAB SCREEN 2-27

2-14 Ejector Rate Normalization 2-28

2-15 MAINTENANCE1 SCREEN 2-30

2-16 MAINTENANCE2 SCREEN 2-31

2-17 Printed Circuit Card Cage, Two-View Machine 2-33

2-18 Printed Circuit Card Cage, Single-View Machine 2-34

2-19 Timing PCB 2-35

2-20 Amplifier PCB 2-36

2-21 Amplifier Interface PCB 2-38

2-22 Ejector Interface PCB 2-40

2-23 Ejector Driver PCB 2-42

2-24 Background Control I/O PCB 2-43

2-25 Monitor Control PCB 2-45

2-26 CPU Interface Module 2-46

2-27 Feeder Driver PCB 2-48

2-28 Ejector Connector PCB 2-49

2-29 System Interface PCB 2-50

2-30 Lamp Monitor PCB 2-53

490128-90EMB

6/08J

LIST OF ILLUSTRATIONS

ScanMasterII SMII 800, SMII 810, SMII 820, AND SMII 830 IRF/IEF

FIGURE PAGE

SECTION 3 – OPERATION & ADJUSTMENTS

3-1 Flash Disk Orientation 3-4

SECTION 4 - MAINTENANCE

4-1 Cleaning the Air Ejector 4-6

4-2 Prefilter 4-9

4-3 Oil Removal Filter 4-10

Section 1—General Information 1-1

SECTION 1

GENERAL INFORMATION

1.0 SCOPE

This manual provides a brief description of sorting, installation instructions,

identification and function of parts, operating procedures, and trouble shooting

procedures.

The ScanMasterII is made in a two-view model for sorting products that must be

viewed from both sides. It is also made in a single-view model for sorting

translucent products that only require viewing from one direction.

The two-view model has eight optical assemblies that view the product from the

front, and eight optical assemblies that view the product from the rear. It utilizes

eight Amplifier PCB assemblies, and two backgrounds.

The single view model has only eight optical assemblies that view the product from

the front. It utilizes only four Amplifier PCB assemblies, and one background.

1.1 SAFETY PRECAUTIONS

1.1.1 VOLTAGES

Dangerous voltages are present in the electronics cabinet, lower power enclosure,

and the viewer. Make sure that all power switches are in the OFF position before

doing service in these areas.

1.1.2 ELECTRICAL INTERLOCKS

The window wiper inside the viewing area operates automatically. An electrical

interlock switch located inside the viewing area on the right side of the machine

prevents operation of the feeders and window wiper when the front viewer is

opened. To prevent personal injury or damage to the wiper mechanism, never

attempt to bypass the interlock switch.

1.1.3 PRINTED CIRCUIT CARD REMOVAL

Before removing or installing printed circuit cards, turn all power OFF to prevent

damage to the cards.

1.1.4 DISCONNECTING AND RECONNECTING PLUGS AND CONNECTORS

When any plug or connector is disconnected or reconnected, always ensure that the

power to the circuit is OFF.

Section 1—General Information 1-2

WARNING: Do not disconnect the fluorescent lamps with power on the circuit,

as this will permanently damage the regulated power supply (lamp ballast), and

it will have to be replaced. Turn off the power switch on the front panel before

removing the lamps.

1.1.5 COMPRESSED AIR CLEANING

The compressed air used for operating the machine and for cleaning must be clean,

dry, and oil-free. It should also comply with ISO 8573-1 Class 442 for nonfood

applications and with ISO 8573-1 Class 341 for food applications. Always wear

protective goggles when using the air hose to blow off the machine.

1.1.6 REMOVING AND INSTALLING AIR EJECTORS

Before removing an air ejector, blow off the surrounding area to prevent dust or

other material from entering the ejector or air system.

Turn off the air supply using the valve located at the inlet of the Air System and

allow time for the pressure to discharge before removing an ejector.

After the air and power are turned off, unplug the ejector electrical connector by

squeezing the latch release tab, and pulling outward on the connector. Remove the

ejector from the ejector manifold assembly by squeezing the ejector latch release

tabs, and pulling the ejector away from the manifold.

Install the ejector by aligning its inlet and outlet ports with the corresponding ports

on the manifold and pushing in until the latches engage. Install the electrical

connector and push in until its latch engages.

1.2 BRIEF DESCRIPTION OF SORTING (See Figures 1-1 through 1-5)

The ScanMasterII is specially designed for the rapid and accurate sorting of small,

free-flowing, products that require selection to obtain an acceptable product of

uniform hue.

Product to be sorted is continuously supplied to the product input hopper (See

Figures 1-1 through 1-5).

Three vibratory feeders cause the product to flow out of the hopper and into eight

chutes, each of which is divided into channels. The rate of flow is determined by the

amplitude of the feeder vibration and the position of the product flow control gates.

As the product travels down the infeed chute, the particles are accelerated and

separated.

The viewer is illuminated by four fluorescent lamps: two in the front and two in the

rear. The optical assemblies measure the light received from each particle.

When particles of abnormal color are detected, they are diverted from the stream by

a small blast of air from the air ejectors. These unacceptable pieces are collected in

the reject chute.

Section 1—General Information 1-3

FIGURE 1-1

ScanMasterII, FRONT VIEW

Section 1—General Information 1-4

FIGURE 1-2

ScanMasterII, SIDE VIEW

Section 1—General Information 1-5

FIGURE 1-3

ScanMasterII, REAR VIEW

Section 1—General Information 1-6

FIGURE 1-4

VIEWER, TWO-VIEW

Section 1—General Information 1-7

FIGURE 1-5

VIEWER, SINGLE-VIEW

Section 1—General Information 1-8

Acceptable particles continue on their normal path into the accept chutes.

The sample tubes may be pivoted into the accept stream by pushing inward on the

top end of the tubes. By doing this, a sample of the accepted particles from a

particular chute can be collected for evaluation.

A window wiper periodically removes any dust that may have accumulated on the

viewer windows. This ensures consistent sorting results.

1.3 INSTALLATION OF THE ScanMasterII

1.3.1 LOCATION

The ScanMasterII should be installed in a location that is level and free of vibration.

The ambient temperature must be between 32°F and 110°F (0°C and 43°C). Avoid

places where it is humid and hot. Best operation and longer life of components will

be achieved where the temperature is between 70°F and 80°F (21°C and 27°C).

Avoid areas where direct sunlight or light from bright lamps will enter the optical

section.

The machine should be installed in the process line after a precision grader that

removes fines and dust. It should be installed in the line following all processing

operations, where the product has cooled, and is ready to be packaged.

The ScanMasterII weighs approximately 1100 pounds (500kg). The floor or

platform where the machine is located must be strong enough to adequately support

this weight.

The location should provide adequate space for operation, cleaning and

maintenance. Generally, we recommend an absolute minimum of two feet on all

sides of the ScanMasterII. If space constraints are severe, the clearance at the rear

and sides could be reduced slightly, but will make service more difficult. Additional

space in front of the ScanMasterII, up to three or four feet, is desirable. See Figure

1-6 for dimensions of the sorter with the service panels open.

1.3.2 TRANSPORTING THE ScanMasterII

After removing the machine from the crate, it can be moved to the installation site

by attaching a chain or cable to the lifting eyes at the top of the machine frame.

The hoisting angle should be 50 degrees or more as shown in Figure 1-7.

The machine can also be moved by placing the forks of a lift truck under the lower

cross members. Care must be taken to avoid sudden stops that may cause the

machine to tip over.

When moving the machine, care must be taken to not bump the machine against

other objects to avoid damage to control knobs, paint, etc.

Section 1—General Information 1-9

FIGURE 1-6

SERVICE ACCESS FOR THE ScanMasterII

Section 1—General Information 1-10

FIGURE 1-7

TRANSPORTING THE ScanMasterII

Section 1—General Information 1-11

When the machine is in place, it must be bolted to the floor or platform using the

anchor feet at the bottom of the frame. Insure that the machine frame is well

grounded to the platform. It may be necessary to grind away a small amount of

paint from the anchor feet and the platform in order to assure good metal-to-metal

contact. Also verify that the platform is grounded to earth with a ground rod or a

connection to a water pipe.

1.3.3 INSTALLING THE FEEDERS AND INPUT HOPPER

The vibratory feeders and input hopper are removed from the ScanMasterII for

shipping.

After the machine has been placed in its operating location, the feeders and hopper

must be re-installed.

When viewed from the rear of the machine the larger feeders are installed on the

right-hand side and the smaller feeder is installed on the left-hand side. Install each

feeder so that its base feet are located inside of the holes in the feeder plates (See

Figures 1-1 and 1-3). Be certain that the feeders match the serial number and

position indicated on the feeder tags.

The position of the feeders was adjusted at the factory so that the trays are centered

within their respective chute. The front end of each tray extends forward about 3/8

of an inch from the back outside edge of the top of the chute. Check feeder position

during operation. Generally, feeders should be located as far to the rear as possible

without spilling product at the back of the chute. This will insure minimum product

drop from the feeder to the chute.

Plug each feeder into its respective receptacle.

After the feeders are installed, the input hopper should be installed with the

product level sensors facing the front of the machine (See Figure 1-1).

The sensors are numbered 1,2 and 3 from left to right (as viewed from the front of

the sorter). The mating connectors are located on the inward side of the right-hand

frame member, and are numbered 1,2 and 3 from rear to front. The sensor

connectors should be plugged into their respective mating connector located on the

inward side of the right-hand frame member.

In some applications an additional level sensor (surge sensor) may be supplied. The

mating connector for this sensor is located below the connector for hopper sensor

number 1. This sensor should be mounted in the surge hopper above the smaller

feeder. When the product level falls below the hopper sensor, the feeder below it

will stop. When the product level rises above this sensor the feeder will restart. If

the surge sensor is present, the feeder will not restart until the product level rises

above the surge sensor. This feeder control strategy will minimize the number of

stop/start cycles and maximize the length of each ON cycle.

The input hopper must be positioned so that its outlet necks are centered, left to

right, in the feeder trays. The rear of each neck should be about 1/4 to 3/8 inch

forward of the back of the feeder tray. The necks of the hopper must not touch the

Section 1—General Information 1-12

feeder trays during operation, but should be positioned low in the feeder. If

necessary, lower the hopper level adjustment so that the bottom of the outlet necks

is no more than 1/2 inch above the bottom of the feeder pan.

The feed system must be thoroughly grounded to prevent static electricity buildup

in the product. Plastic tubes or chutes should never be used, as they greatly

increase the level of static electricity generated in the product.

1.3.4 CONNECTING THE POWER

The ScanMasterII is connected internally at the factory to operate at 105-125 V.A.C.,

50-60 cycle, 1 phase when it will be operated in a country that uses this voltage.

The machine is connected internally at the factory to operate at 210-250 V.A.C., 50-

60 cycle, 1 phase when it will be operated in a country that uses that voltage. Make

certain that the machine is properly connected to operate on the voltage that you

will be using.

The ScanMasterII uses high quality regulated power supplies for the electronics and

rugged power transformers for the lamp and ejectors. However, as for any

sophisticated electronics application, in areas where the line power is not stable, we

recommend a regulating type transformer installed in close proximity to the

machine.

The machine is equipped with a power cord that can be used, provided local

electrical codes permit its use. If the cord is used to plug into a receptacle, a plug to

match the receptacle must be installed on the end of the cord. The cord is

connected at the factory as shown in Figures 2-1 and 1-8.

If the power cord will not be used, connect power directly to the power lockout

switch in the lower power enclosure, and connect incoming power ground to the line

filter, also found in the lower power enclosure (See Figures 2-1 and 1-8).

Make certain that an EARTH GROUND is connected to the grounding point below

terminal block TB1 on the lower power supply assembly as shown.

1.3.5 CONNECTING THE COMPRESSED AIR

The compressed air used for operating the machine and for cleaning must be clean,

dry, and oil-free. It should also comply with ISO 8573-1 Class 442 for nonfood

applications and with ISO 8573-1 Class 341 for food applications. A refrigerated

dryer is recommended.

The pressure of the compressed air supplied to the machine must be a minimum of

90 psi at the machine to allow for pressure drops across the air filters, etc.

The air line to the machine must be 3/4 inch pipe or larger. If the compressor is

more than 50 feet from the machine, 1inch or 1 1/4 inch pipe should be used.

Before connecting the air line to the machine, it must be blown out to remove any

shavings or other foreign material.

The regulator on the machine should be set to 40 psi during normal sorting

operation. If the machine is being used to resort defective material from another

Section 1—General Information 1-13

machine or if the product being sorted contains a high percentage of defects, the

regulator should be set to 45 psi while the machine is operating.

1.3.6 DUST EXTRACTION

Two 4 inch outside diameter dust removal outlets are provided on the rear side of

the ScanMasterII just above the lower power supply enclosure (See Figure 1-3).

These outlets should be connected to an exhaust system to remove dust from the

viewing area. An air flow rate of 530 cubic feet per minute is recommended.

This will reduce the amount of manual cleaning required and provide more

consistent and efficient operation of the machine.

1.3.7 OTHER CONSIDERATIONS AND PRECAUTIONS

DO NOT WELD DIRECTLY TO THE MACHINE. Further, when welding or painting

around the machine, be sure to cover it. Special attention should be paid to avoid

cuttings, welding splatter or paint on the chutes.

Any hopper installed above the input hopper on the machine must not touch the

machine. If the hopper does touch the machine, it can transfer vibrations to the

machine that will cause the product to flow through the feeders, even if the feeders

are turned off. The vibration can also have other adverse effects.

A product cut-off gate must be installed between the plant input hopper above the

machine and the machine input hopper. This will permit the machine hopper to be

emptied for service if required.

Take-away chutes or conveyors also should not be directly connected to the

machine.

The take-away system should have provisions to take samples of both accepts from

each individual chute and rejects from each machine. This will enable the operator

to determine each machine’s performance and adjust it for highest efficiency and

best reject concentration.

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