Related Manuals for PRESSCO TECHNOLOGY Intellispec 6R Series
Summary of Contents for PRESSCO TECHNOLOGY Intellispec 6R Series
- Page 1 Intellispec™ Hardware Guide Vision Processor SOFTWARE VERSION: 6.0 AND UP MANUAL PART NUMBER: 84425 REV. 01 HARDWARE MODEL NUMBER(S): MULTIPLE. USING FAMILY F2199. ©2023 Pressco Technology Inc. All rights reserved.
- Page 2 Pressco Technology Inc. The contents of this manual are furnished for informational use only, are subject to change without notice, and should not be construed as a commitment by Pressco Technology Inc. Written and designed at: Pressco Technology Inc.
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Page 3: Table Of Contents
Chapter 3 System Specifications Environmental Conditions Sound Pressure Level Electrical Specifications - Vision Processor Series 6R Dimensions - Intellispec 6R Vision Processor Chapter 4 Declaration of Conformity - Vision Processor 6R Chapter 5 Installation Shipping and Handling ©2023 PRESSCO TECHNOLOGY INC. - Page 4 Accessing the Internal Components with the Power Off S6R Chapter 7 Components and Wiring Diagrams External Connections Included Components Power Supplies 6R Fuse Replacement Wiring Diagrams Chapter 8 Troubleshooting Rebooting the Intellispec System Chapter 9 Extended I-O S6 Extended I-O Board S6 ©2023 PRESSCO TECHNOLOGY INC.
- Page 5 Extended I-O Signals S6 Extended I-O Switch SW1 Selection Extended I-O Circuits S6 Extended I-O Configuration Chapter 10 Maintenance Frequency Maintenance Cautions Clean the Air Conditioner Filter ©2023 PRESSCO TECHNOLOGY INC.
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Page 6: Chapter 1 Pressco Introduction
Chapter 1 Pressco Introduction Welcome! Congratulations on your purchase of an Intellispec system! The Intellispec is a high-speed machine vision system designed specifically for product and online process monitoring. It is a powerful tool that provides inspection much more reliably than the human eye or sampling methods. The latest PC technology, powerful inspection algorithms, online adjustment capability, and inspection data storage allow the Intellispec to automatically inspect parts with extreme accuracy on high-speed lines. -
Page 7: Safety Considerations
Chapter 1 IMPORTANT - Indicates prerequisites or information that must be observed to complete or understand a concept or task. TIP: Provides helpful hints for completing a task. Safety Considerations Observe the following safety warnings when operating the system or working near it: WARNING - Potential for projectiles to strike persons and cause injury. -
Page 8: Chapter 2 Safety Information
Chapter 2 Safety Information This section contains operator safety information that must be read before operating or servicing the system. WARNING - This product contains no operator serviceable parts. Refer servicing to qualified personnel. To prevent electrical shock do not open cabinet doors whilst power is connected. WARNING - Do not, under any circumstances, tamper with sealed machine parts or devices. -
Page 9: Symbols Used With This System
Chapter 2 If you encounter something that might trigger epileptic symptoms or seizures without warning: Do not close your eyes (this could cause a flicker effect) Do not look directly at the flashing lights or trigger source Do cover one eye with the palm of your hand immediately Do turn away from the flashing lights or trigger source Symbols Used With This System The following symbols are used on or near the Pressco system. -
Page 10: Arc Welding Warning
Chapter 2 Warning: UPS Disconnect Warning: Electrical interlock Danger: shock and arc flash explosion hazards Arc Welding Warning WARNING - Potential equipment damage can occur if the vision equipment is not fully powered down prior to any arc welding performed on the line where the vision equipment is installed, specifically but not limited to our encoders. -
Page 11: Warning Devices
Chapter 2 Warning Devices The Pressco system has warning devices that indicate system failure or report excessive defects or warnings for your production line. These include an optional light tree, alarms and indicators on screen, and audible warnings (depending on system). Light Tree The optional light tree is mounted on a pole in a customer-specified location. -
Page 12: Personal Protective Equipment
Chapter 2 Use in an explosive environment Use in a flammable environment Use in a damp, moist, or wet environment, except where specifically indicated Personal Protective Equipment Important - Always follow the safety requirements of your plant in addition to the recom- mendations below. -
Page 13: Lifting Heavy Objects
Chapter 2 When carrying out maintenance or repair work: Disconnect master switch. For switch locations, refer to the Power Up and Power Down section. Before starting the machine, ensure that no person is close to the machine. If maintenance or repair requires the disconnection or removal of safety or protection systems, this operation must be supervised by authorized personnel who must ensure the prevention of personal injury or damage to the machine. -
Page 14: Authorized Users
(if applicable). Repairs: - Any repair on the system shall be carried out exclusively by Pressco Technology Inc. service personnel or by other service expressly authorized by Pressco Technology Inc. - Page 15 Before resuming production, make sure all safety devices are in working order. Pressco Technology Inc. shall not be liable in any way if any of the above-described directions are not complied with. To obtain a spare parts list, contact the customer service department at Pressco.
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Page 16: Chapter 3 System Specifications
Environmental Conditions The Intellispec system is designed to be safe in the following environmental conditions: Note: Please consult Pressco Technology Inc. if your environmental conditions are outside of those listed. Condition Specifications... -
Page 17: Electrical Specifications - Vision Processor Series 6R
Electrical Specifications - Vision Processor Series 6R The following are electrical specifications for the vision processor: 115 VAC Unit Series 6R Vision Processor Air Conditioner Voltage Range 115 VAC 115 VAC Frequency 60Hz 60Hz Current (FLA) 6A @ 115VAC, 100% Load Power Consumption 700W 700W... -
Page 18: Dimensions - Intellispec 6R Vision Processor
Dimensions - Intellispec 6R Vision Processor The measurements are in inches. The numbers in brackets are in millimeters. CHAPTER 3 SYSTEM SPECIFICATIONS... - Page 19 Chapter 3 This page left blank intentionally CHAPTER 3 SYSTEM SPECIFICATIONS...
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Page 20: Chapter 4 Declaration Of Conformity - Vision Processor 6R
The Technical Documentation demonstrates the fulfillment of the essential requirements as set out in Annex I of the above Directive. Pressco Technology Inc. 29200 Aurora Road Cleveland, Ohio 44139-1847 Manufacturer This declaration of conformity is issued under the sole responsibility of the manufacturer. - Page 21 Chapter 4 Date: 14 February 2023 CHAPTER 4 DECLARATION OF CONFORMITY - VISION PROCESSOR 6R...
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Page 22: Chapter 5 Installation
Pressco Technology Inc. with the means and equipment necessary for the unloading, lifting, and handling of machine parts. Pressco Technology Inc. deems it important to have one of their tech- nicians supervise the process of unloading, handling, and lifting the machine. The technician can give useful advice as to the logical sequence in which the components should be unpacked and positioned for ease of assembly. -
Page 23: Utilities To Be Supplied By Customer
Chapter 5 The space and height required for installation are actually available Only the components included in the installation layout are present in the area where the machine is to be mounted. Ensure no machines or components have been added at a later stage that might hinder mounting or make it more difficult. -
Page 24: Electrical Connections 6R
This is of vital importance for correct machine operation. WARNING - Pressco Technology Inc. shall not be liable in case of failures or damage to prop- erty and/or personal injury resulting from or connected with assembly if this has been carried out by unauthorized personnel, or is not in compliance with the indications given in this manual. -
Page 25: Ventilation
Chapter 5 Ventilation Place the Pressco Intellispec components in a position with adequate ventilation to allow proper air flow through the air filters. Component Spacing User Interface Leave 1 meter [39 inches] clear around machine Cluster box (not used on all systems) Leave 100 mm clear in front of the fan and vent Stability of User Interface and Control Cabinet Install lag bolts through the holes in the base to secure the user interface to the floor. -
Page 26: Commissioning
Chapter 5 10mm bolt/ post can be used, but the holes are designed to have clearance for M8 bolts in the con- trol cabinet. Commissioning Before placing the machine into operation, make sure the following checks are completed: Completed Positioning and leveling of the unit Connection of compressed air line to con- nection points Connection of power supply to vision processor... -
Page 27: Chapter 6 Intellispec Control Enclosure And User Interface S6R
Chapter 6 Intellispec Control Enclosure and User Interface S6R This section contains an overview of the components in the control enclosure and user interface. Intellispec User Interface S6R This is the user interface, which includes the monitor, keyboard, and biometric login device (optional). -
Page 28: 5-Light Tree
Chapter 6 Specifications/ Notes The 6R system can be configured with one to four (1-4) lanes with six (6) cameras total. If you have one lane with six cameras, that is the maximum configuration for that system. You cannot add another lane with more cameras. Your system will have a different number of components in the cabinet depending on your configuration Some connectors on the outside of the cabinet may be capped... -
Page 29: Power On And Off At The Control Enclosure
Chapter 6 Light 5-Light Tree Condition What it means color On - steady Alarm condition Part tracker board lost communication with On - blinking the host PC or has an error and needs to ini- tiate an alarm No alarm (OK) Amber On - steady Warning alarm condition Amber Off... -
Page 30: Usb Ports S6R
Chapter 6 one minute before turning it back on. This allows the electronic com- ponents to correctly reset. USB Ports S6R There are two USB ports on the side of the cabinet. The USB port is not for charging your phone! Only use these ports to import or export data. -
Page 31: Accessing The Internal Components With The Power Off S6R
Chapter 6 Accessing the Internal Components with the Power Off S6R To access the components inside of the control cabinet, you will need the keys (supplied by Pressco). WARNING - When the system is powered down, there is still voltage present at the UPS. Only AUTHORIZED PERSONNEL should attempt to open the sys- tem. -
Page 32: Chapter 7 Components And Wiring Diagrams
Chapter 7 Components and Wiring Diagrams This section provides a list of components in the control enclosure, as well as wiring diagrams. External Connections The connectors are on the sides of the Intellispec Series 6R cabinet. 1) USB1 and USB2 - for data transfer 2) VNC - Ethernet connector 3) P1 - Incoming power 4) E1 block connector - inspection module connections... -
Page 33: Included Components
Chapter 7 Included Components The components in the diagram are installed in your system. Note: Your system will be configured for your application. You may have more or fewer com- ponents than this illustration. 1) UPS 1500VA Rack Mount CHAPTER 7 COMPONENTS AND WIRING DIAGRAMS... -
Page 34: Power Supplies 6R
Chapter 7 Part number 81717 for 120V model Part number 81718 for 230V model 2) Air Conditioner 2500 BTU 230V 50C limit (part number 72649) 3) Extended I/O board (part number 75626) 4) Part Tracker assembly (part number 78524) 5) Assembly TB1 (part number 83619) Wiring diagrams: Wiring diagram for systems with 115VAC power: "F2199W Sheet 1 of 10"... -
Page 35: Fuse Replacement
Chapter 7 Item Pressco Part Number Description POWER SUPPLY 12V 200W 80-264VAC 80175 47-63HZ POWER SUPPLY 24V 200W 80-264VAC 80176 47-63HZ POWER SUPPLY 48V 200W 80-264VAC 80177 47-63HZ POWER SUPPLY COMPUTER 550W 83752 Fuse Replacement The fuses are located in Terminal Block TB2, which is located on the main electronics panel inside the control enclosure. -
Page 36: Wiring Diagrams
Chapter 7 For fuse rating, refer to the table below. Pressco part number Fuse Number Value 7, 8, 9, 10, 11, 12, 13, FUSE 3A 250V 5X20 MM GLASS FAST 26943 - quantity 9 14, 15 ACTING 51818 FUSE .5AMP 5 X 20MM 250VAC 63725 - quantity 4 2, 3, 4, 5 FUSE 2 AMP TIMED 5X20MM GMC-2-R... - Page 37 Chapter 7 F2199W Sheet 1 of 10...
- Page 38 Chapter 7 Components and Wiring Diagrams F2199W Sheet 2 of 10...
- Page 39 Chapter 7 F2199W Sheet 3 of 10...
- Page 40 Chapter 7 Components and Wiring Diagrams F2199W Sheet 4 of 10...
- Page 41 Chapter 7 F2199W Sheet 5 of 10...
- Page 42 Chapter 7 Components and Wiring Diagrams F2199W Sheet 6 of 10...
- Page 43 Chapter 7 F2199W Sheet 7 of 10...
- Page 44 Chapter 7 Components and Wiring Diagrams F2199W Sheet 8 of 10...
- Page 45 Chapter 7 F2199W Sheet 9 of 10...
- Page 46 Chapter 7 Components and Wiring Diagrams F2199W Sheet 10 of 10...
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Page 48: Chapter 8 Troubleshooting
Chapter 8 Troubleshooting This section contains some basic troubleshooting tips to use if the system is not working properly. Rebooting the Intellispec System You may need to reboot the system if power or communication has been lost between the Vision Processor and the inspection modules. -
Page 49: Rebooting The Computer
Chapter 8 1. Log in. 2. Take the system offline. (Repeat for all lanes if necessary) Exit the software: Home | Tools | Shut Down Intellispec and Restart Computer. Click the OK button. The Intellispec software and computer shuts down and restarts. Your system may be configured to go online at startup. -
Page 50: Chapter 9 Extended I-O S6
Chapter 9 Extended I-O S6 This section contains information about the optional Extended I/O board in Intellispec Series 6 sys- tems. Note: In some systems, such as FHCP inspection systems, the Extended I/O board is always included (not optional). Extended I-O Board S6 This optional module provides additional input and output ports for communicating with the Intel- lispec Series 6 system. -
Page 51: Extended I-O Signals S6
Chapter 9 Extended I-O Signals S6 Switch SW1 selects Intellispec 24V power supply or User 24V power supply. Labels used on the board: Series 6 Signal Label Signal Label User +24VDC System State User 24VRET Part Present +24VDC Part Good 24VRET Part Bad Generic Input n... - Page 52 Chapter 9 Note: some signals are not currently used All Extended I/O inputs are PNP. Outputs are selectable to be either open collector or open emitter. However, that selection applies to ALL output signals. The input and power LEDs are visual indicators. The maximum current output is 50mA. See also information about Extended I/O circuits.
- Page 53 Chapter 9 Terminal Signal and Indicator LED label Input (I) or Output (O) Comments J1-3 Generic Input 0 (IN0) Port 0 and Port 1 used in J1-4 Generic Input 1 (IN1) Remote Part Program J1-5 Generic Input 2 (IN2) Switching J1-6 Generic Input 3 (IN3) Generic Input bits may be...
- Page 54 Chapter 9 Terminal Signal and Indicator LED label Input (I) or Output (O) Comments J2-11 no connection J2-12 no connection J2-13 +24VDC (+VI) J2-14 +24VDC (+VI) J2-15 Group 8 (GP8) J2-16 Group 9 (GP9) J2-17 Group 10 (GP10) J2-18 Group 11 (GP11) See comments for Group 0 - 7 above J2-19...
- Page 55 Chapter 9 Signal and Terminal Indicator Input (I) or Output (O) Comments LED label (IA5) Inspection J3-9 Alarm 6 (IA6) Inspection J3-10 Alarm 7 (IA7) no con- J3-11 nection no con- J3-12 nection +24VDC J3-13 (+VI) +24VDC J3-14 (+VI) Inspection J3-15 Alarm 8 (IA8)
- Page 56 Chapter 9 Signal and Terminal Indicator Input (I) or Output (O) Comments LED label nection no con- J3-24 nection Terminal Signal and Indicator LED label Input (I) or Output (O) Comments J4-1 24VRET (-VI) J4-2 24VRET (-VI) Pulses for 12 ms when a J4-3 Not Processed 0 (NP0) part is not processed due...
- Page 57 Chapter 9 Terminal Signal and Indicator LED label Input (I) or Output (O) Comments Online = active. Offline = inactive. Pulses for 12 ms for each J4-17 Part Good (PG) part declared good by the inspection Pulses for 12 ms when J4-18 Part Present (PP) the part present sensor...
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Page 58: Extended I-O Switch Sw1 Selection
Chapter 9 Extended I-O Switch SW1 Selection Switch SW1 – 24VDC Selection: SW1 has three positions: XIO – In the XIO position 24VDC is supplied by the Intellispec power supply. 24VDC will be on terminals labeled +VI and 24VRET will be on terminals labeled –VI at J2, J3 and J4. Devices requiring 24VDC power should be connected to the +VI and –VI terminals. -
Page 59: Extended I-O Circuits S6
Chapter 9 Figure 2 - Switch SW1 in the CTR position Figure 3 - Switch SW1 in the EXT position Extended I-O Circuits S6 The following illustrations show typical input and output circuits you can use to communicate with your plant's PLC, or to connect external LEDs or light trees. Specifications: CHAPTER 9 EXTENDED I-O S6... -
Page 60: Extended I-O Configuration
Chapter 9 Minimum dwell time of the input device is 1.1 ms Maximum output load is 50 mA Default value of output pulse is 12ms. Some output signals, such as alarms, must be cleared on the Intellispec before they turn off. The following illustration shows a typical circuit that can be used to clear alarms. - Page 61 Chapter 9 Input Interrupts These signals produce an input pulse to the Intellispec to perform the following functions. Clear Alarms Interrupt - Clear the lane alarms. Clear Statistics Interrupt - Clear the lane statistics. Print Statistics Interrupt - Print the lane statistics to the currently configured printer or file. See also Schedule Reports.
- Page 62 Chapter 9 Example 1 below Group A is triggered when the part passes Rejector 2, and Group B is triggered when the part passes Rejector 4. The illustration below shows a basic block diagram with a con- veyor with four rejectors. Those rejectors output a signal to the Extended I/O board, based on the Extended I/O configuration.
- Page 63 Chapter 9 CHAPTER 9 EXTENDED I-O S6...
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Page 64: Chapter 10 Maintenance Frequency
Chapter 10 Maintenance Frequency Item Description Frequency Verify that defective parts are being rejected by Observe proper rejection inserting a known defective part through inspec- Daily tion Verify that no stray parts are stuck in or near the Observe Proper inspection Daily inspection module or reject station Verify that no buildup of dirt or contaminants... - Page 65 Chapter 10 This page left blank intentionally CHAPTER 10 MAINTENANCE FREQUENCY...
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Page 66: Maintenance Cautions
Maintenance Cautions When carrying out maintenance or repair work: Disconnect master switch. For switch locations, refer to the Power Up and Power Down section. Before starting the machine, ensure that no person is close to the machine. If maintenance or repair requires the disconnection or removal of safety or protection systems, this operation must be supervised by authorized personnel who must ensure the prevention of personal injury or damage to the machine. - Page 67 Chapter 11 5. Place the filter back inside the cabinet cover. 6. Replace the filter cover and snap the cover in place.
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