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Sacmi CHS Series Instructions Manual

Operator interface and plc-based control system operating instructions
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D O C U M E N T A Z I O N E
T
E
C
N
I
C
A
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

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Summary of Contents for Sacmi CHS Series

  • Page 1 D O C U M E N T A Z I O N E 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...

  • Page 2: General Information

    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.
  • Page 3 CHS100.86.011 Rev.02 Date 23/07/2018 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;...
  • Page 4 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...

  • Page 5: General Regulations

    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.
  • Page 6 CHS100.86.011 Rev.02 Date 23/07/2018 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...
  • Page 7 CHS100.86.011 Rev.02 Date 23/07/2018 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 State LED indication Push-button N.O. Pressed LED ON Available LED off N.C.

  • Page 8: Operator Interface

    CHS100.86.011 Rev.02 Date 23/07/2018 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; −...
  • Page 9 CHS100.86.011 Rev.02 Date 23/07/2018 MICROPROCESSOR SYSTEM FOR CONTROLLING AND MONITORING MACHINE OPERATION This is the machine control and processing unit; its task is to control 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.

  • Page 10: Electrical Wiring

    CHS100.86.011 Rev.02 Date 23/07/2018 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...).
  • Page 11 CHS100.86.011 Rev.02 Date 23/07/2018 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...
  • Page 12 CHS100.86.011 Rev.02 Date 23/07/2018 Button used to quit the application...
  • Page 13 CHS100.86.011 Rev.02 Date 23/07/2018 - 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.
  • Page 14 CHS100.86.011 Rev.02 Date 23/07/2018 - 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.
  • Page 15 CHS100.86.011 Rev.02 Date 23/07/2018 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).
  • Page 16 CHS100.86.011 Rev.02 Date 23/07/2018 - 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.
  • Page 17 CHS100.86.011 Rev.02 Date 23/07/2018 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.
  • Page 18 CHS100.86.011 Rev.02 Date 23/07/2018 - 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.
  • Page 19 CHS100.86.011 Rev.02 Date 23/07/2018 - 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.

  • Page 20: Machine Setup Menu

    CHS100.86.011 Rev.02 Date 23/07/2018 - MACHINE SETUP MENU CHS model (CHS100 or CHS200): enter either 100 or 200 to activate the set-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.
  • Page 21 CHS100.86.011 Rev.02 Date 23/07/2018 Diameter of the spacing starwheel: enter the dimension for the diameter of the spacing starwheel, expressed in millimeters. Diameter of the spacing roller: enter the dimension for the diameter of one of the spacing rollers, expressed in millimeters. Conveyor motor M15/M25 rated speed: enter the number of rated revs/min, referred to the cap conveyor motor.
  • Page 22 CHS100.86.011 Rev.02 Date 23/07/2018 Enable SQ7 (0=disabled, 1=enabled): enter 0 to disable the use of the maximum level photocell (SQ7) to activate the flow of caps, and 1 to enable it. If this value is set to 0, the flow through the CHS starts when the minimum level photocell (SQ2) is activated, whereas if it is set to 1, the flow starts when both the minimum level (SQ2) and maximum level (SQ7) photocells are activated.

  • Page 23: Alarm Menu

    CHS100.86.011 Rev.02 Date 23/07/2018 - ALARM MENU The log regarding operator messages and faults with dates and times of activation and deactivation is saved in this page.
  • Page 24 CHS100.86.011 Rev.02 Date 23/07/2018 - I-O MENU The state of the inputs and outputs in the PLC is displayed on this page in real time. Input or output deactivated Input or output activated...
  • Page 25 CHS100.86.011 Rev.02 Date 23/07/2018 - INFO MENU The PLC program version and the operator interface program (HMI) are displayed in this page.

  • Page 26: Language Menu

    CHS100.86.011 Rev.02 Date 23/07/2018 - LANGUAGE MENU The language of the operator interface can be selected in this page.

  • Page 27: Maintenance And Troubleshooting

    CHS100.86.011 Rev.02 Date 23/07/2018 MAINTENANCE AND TROUBLESHOOTING Two banners and two lines are present on all the operator interface pages that are used to display alarms (red banner) and operator messages (yellow banner) MESSAGES The message with highest priority is displayed on the operator interface. Each message is identified by a four digit number (the first digit represents the category of the message).

  • Page 28: Shutdown Messages

    CHS100.86.011 Rev.02 Date 23/07/2018 SHUTDOWN MESSAGES 1001 EMERGENCY STOP BUTTON (SHUTDOWN) An emergency stop button on the machine or along the line may have been pressed. If this is not the case, verify the emergency device to which the button is connected works properly.
  • Page 29 CHS100.86.011 Rev.02 Date 23/07/2018 1009 MODE SELECTOR IN WRONG POSITION (SA100) (SHUTDOWN) Mode selector SA100 was turned to a different position during the automatic cycle. The machine immediately shuts down. 1010 SPACER GUARD (SQ42) (SHUTDOWN) The guard of the cap spacer is open. Make sure the guard is in the correct position and limit switch SQ42 works properly or is properly connected.
  • Page 30 CHS100.86.011 Rev.02 Date 23/07/2018 STOPPAGE MESSAGES 2001 CYCLE STOP BUTTON (STOPPAGE) The automatic cycle stop button was pressed during the automatic cycle. 2002 CAP FEED LINE NOT READY (OKR3M) (STOPPAGE) The cap feed line did not provide the trigger pulse signal in “Automatic-Local” mode. Input OKR3 is open;...
  • Page 31 CHS100.86.011 Rev.02 Date 23/07/2018 2010 CHECK SPACER (SQ6) (STOPPAGE) Sensor SQ6 malfunctioning was detected during the automatic cycle while the cap feed starwheel (M13) was rotating. SQ6 input is permanently off or on. Make certain sensor SQ6 is in the correct position and works properly. Make certain there are no mechanical obstructions that prevent M13 rotation.
  • Page 32 CHS100.86.011 Rev.02 Date 23/07/2018 2022 FIRST CONVEYOR BELT REJECT CHECK CONTAINER PRESENT CHECK (SQ9B) (STOPPAGE) The first conveyor belt reject check container was not detected or not in the correct position during the automatic cycle. Make sure photocell SQ9B is in the correct position and is properly set. 2023 SECOND CONVEYOR BELT REJECT CONTAINER PRESENT CHECK (SQ9C) (STOPPAGE) The second conveyor belt reject container was not detected or not in the correct position...

  • Page 33: Operator Messages

    CHS100.86.011 Rev.02 Date 23/07/2018 OPERATOR MESSAGES 3001 CAP REQUEST WAIT (KA307) (MESSAGE) The cap request input KA307 is off during the automatic cycle. The machine switches over the stand-by. 3002 TRIGGER PULSE WAIT FROM CVS VISION SYSTEM (MESSAGE) The vision system is not inspecting. Check the CVS settings and data items. The machine switches over the stand-by.
  • Page 34 CHS100.86.011 Rev.02 Date 23/07/2018 3010 CHECK SPACER (SQ6) (MESSAGE) Sensor SQ6 malfunctioning was detected while the cap feed starwheel (M13) was rotating with the machine set to “manual” mode. SQ6 input is permanently off or on. Make certain sensor SQ6 is in the correct position and works properly. Make certain there are no mechanical obstructions that prevent M13 rotation.

This manual is also suitable for:

Chs100Chs200

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