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

© 2008 Satake USA Inc. INDEX - PAGE 1 OF 6
(ALL RIGHTS RESERVED)
COPYRIGHT © 2008
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: [phone]
Telephone: [phone]

490128-90EMB
6/08J
TABLE OF CONTENTS
ScanMasterII SMII 800, SMII 810, SMII 820, AND SMII 830 IRF/IEF
PARAGRAPH PAGE
© 2008, Satake USA Inc. INDEX - PAGE 2 OF 6
(ALL RIGHTS RESERVED)
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

490128-90EMB
6/08J
TABLE OF CONTENTS
ScanMasterII SMII 800, SMII 810, SMII 820, AND SMII 830 IRF/IEF
PARAGRAPH PAGE
© 2008, Satake USA Inc. INDEX - PAGE 3 OF 6
(ALL RIGHTS RESERVED)
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

490128-90EMB
6/08J
TABLE OF CONTENTS
ScanMasterII SMII 800, SMII 810, SMII 820, AND SMII 830 IRF/IEF
PARAGRAPH PAGE
© 2008, Satake USA Inc. INDEX - PAGE 4 OF 6
(ALL RIGHTS RESERVED)
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

490128-90EMB
6/08J
LIST OF ILLUSTRATIONS
ScanMasterII SMII 800, SMII 810, SMII 820, AND SMII 830 IRF/IEF
FIGURE PAGE
© 2008, Satake USA Inc. INDEX - PAGE 5 OF 6
(ALL RIGHTS RESERVED)
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
© 2008, Satake USA Inc. INDEX - PAGE 6 OF 6
(ALL RIGHTS RESERVED)
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
© 2008, Satake USA Inc.
(ALL RIGHTS RESERVED)
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
© 2008, Satake USA Inc.
(ALL RIGHTS RESERVED)
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
© 2008, Satake USA Inc.
(ALL RIGHTS RESERVED)
FIGURE 1-1
ScanMasterII, FRONT VIEW