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PRESSCO TECHNOLOGY INTELLISPEC 6 CSL+ Hardware Manual

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Hardware Guide
INTELLISPEC™ Series
6 CSL+
MANUAL PART NUMBER: 82334 REV. 01
HARDWARE MODEL NUMBER(S): 81732
©2021 Pressco Technology Inc. All rights reserved.

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Summary of Contents for PRESSCO TECHNOLOGY INTELLISPEC 6 CSL+

  • Page 1 Hardware Guide INTELLISPEC™ Series 6 CSL+ MANUAL PART NUMBER: 82334 REV. 01 HARDWARE MODEL NUMBER(S): 81732 ©2021 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.

  • Page 3: Table Of Contents

    Authorized Users Spare Parts Usage Chapter 3 System Specifications Environmental Conditions Sound Pressure Level Specifications - Intellispec Series 6 CSL Plus Chapter 4 Installation Shipping and Handling Recommendations Prior to Installation Utilities to be Supplied by Customer ©2021 PRESSCO TECHNOLOGY INC.
  • Page 4 Wiring Diagram 81732W Sheet 3 of 5 Wiring Diagram 81732W Sheet 4 of 5 Wiring Diagram 81732W Sheet 5 of 5 Chapter 8 Extended I-O S6 Extended I-O Board S6 Extended I-O Signals S6 Extended I-O Switch SW1 Selection ©2021 PRESSCO TECHNOLOGY INC.
  • Page 5 Extended I-O Circuits S6 Extended I-O Configuration Chapter 9 Maintenance Frequency Maintenance Cautions Clean the Vision Processor Filter - CSL Plus ©2021 PRESSCO TECHNOLOGY INC.

  • 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 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. Keep clear of reject devices.

  • 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 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. We recommend, at minimum, use of the following Personal Protective Equipment (PPE): Protective clothing Protective gloves Protective ear plugs or headphones...

  • Page 13: Lifting Heavy Objects

    Chapter 2 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. ser- vice personnel or by other service expressly authorized by Pressco Technology Inc.
  • Page 15 Chapter 2 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. Pressco's technicians are available to help customers, in their own plant, to solve any problem that might arise during use and maintenance of the system.

  • 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 Chapter 3 Electrical Specifications - Intellispec Series 6 CSL Plus Voltage Range 115 VAC, +/- 10% Frequency 60Hz Current 6A max 230 VAC Unit Voltage Range 230 VAC, +/- 10% Frequency 50/60Hz Current 4A max User Interface Measurements - CSL Plus The measurements are in inches.

  • Page 18: Chapter 4 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 19: Utilities To Be Supplied By Customer

    Work required by contract for the installation of the machine has been carried out The plant layout drawing that describes where the machine will be installed is the final draw- ing agreed to by Pressco Technology Inc. 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.

  • Page 20: Electrical Connection

    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 21: Ventilation

    Chapter 4 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 Commissioning Before placing the machine into operation, make sure the following checks are completed:...

  • Page 22: Chapter 5 Intellispec Control Enclosure And User Interface Csl S6

    Chapter 5 Intellispec Control Enclosure and User Inter- face CSL S6 The Intellispec CSL+ for Series 6 consists of a vision processor box and user interface. These items are selected depending on your plant's specifications and inspection needs. This means that some items shown in this manual may look different from what you have.

  • Page 23: Biometric Login Device

    Chapter 5 Biometric Login Device The Biometric Identification login device is used to log in and out of the Pressco system. This device is optional and must be purchased with the system. To log in with this device, press your finger to the device. The following are conditions for use: You must use the same finger as initially set up by your administrator If you do not know how your account was set up (or which finger you used), contact your administrator...

  • Page 24: Accessing The Internal Components With The Power Off

    Chapter 5 Accessing the Internal Components with the Power Off 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 system.

  • Page 25: Rebooting The Intellispec System

    Chapter 5 WARNING - Only AUTHORIZED SERVICE PERSONNEL should access the inside of the computer while the power to the unit is still applied. 1. Use a small, blunt tool to press the small button on the left side of the handle. A 3/32" or 2.5mm allen key works best, but you can use a ball point pen.

  • Page 26: Rebooting The Computer

    Chapter 5 1. Turn off the main power switch (DISC 1). The system will shut down, including a controlled shut down of the software. 2. Wait until the software and all the components have shut down, and then wait for about 40 more seconds to allow the electronic components to reset.
  • Page 27 Chapter 5 3. At the Windows Login Prompt, enter “pvpass“ as the password for the Intellispec user account. Once login is complete the application software will be launched. Note: The system reboot takes several minutes to complete. CHAPTER 5 INTELLISPEC CONTROL ENCLOSURE AND USER INTERFACE CSL S6...

  • Page 28: Chapter 6 Components And Interconnect Diagrams

    Chapter 6 Components and Interconnect Diagrams Internal Components 1) Power Entry Panel, includ- ing terminal block TB1 2) Vision Processor Assembly 3) Terminal block TB2 (see "Fuse Replacement CSL Plus S6" below) 4) Computer power supply 5) Power disconnect switch 6) Switch managed pro- grammable (81788) 7) Power Supply 60VDC 800W 90-264VAC 47-63HZ...

  • Page 29: 5-Light Tree

    Chapter 6 WARNING - Disconnect the product from the mains supply before replacing the fuse(s). For fuse rating, refer to the table below. See Wiring Diagram - "Wiring Diagram 81732W Sheet 3 of 5" on page 33 Pressco part number Fuse Value Location FU1 - FU8...

  • Page 30: Chapter 7 Wiring Diagrams S6

    Chapter 7 Wiring Diagrams S6 CHAPTER 7 WIRING DIAGRAMS S6...

  • Page 31: Wiring Diagram 81732W Sheet 1 Of 5

    Chapter 7 Wiring Diagram 81732W Sheet 1 of 5...
  • Page 32 Chapter 7 Wiring Diagrams S6 Wiring Diagram 81732W Sheet 2 of 5...
  • Page 33 Chapter 7 Wiring Diagram 81732W Sheet 3 of 5...
  • Page 34 Chapter 7 Wiring Diagrams S6 Wiring Diagram 81732W Sheet 4 of 5...
  • Page 35 Chapter 7 Wiring Diagram 81732W Sheet 5 of 5...

  • Page 36: Chapter 8 Extended I-O S6

    Chapter 8 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 37: Extended I-O Signals S6

    Chapter 8 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 38 Chapter 8 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 39 Chapter 8 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 40 Chapter 8 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 41 Chapter 8 Signal and Indic- Input (I) or Terminal Comments ator LED label Output (O) J3-13 +24VDC (+VI) J3-14 +24VDC (+VI) Inspection Alarm J3-15 8 (IA8) Inspection Alarm J3-16 9 (IA9) Inspection Alarm J3-17 10 (IA10) Inspection Alarm J3-18 11 (IA11) See comments for Inspection Alarm 0-7 above Inspection Alarm J3-19...
  • Page 42 Chapter 8 Terminal Signal and Indicator LED label Input (I) or Output (O) Comments ON = lane is online, no critical alarms are triggered, and no lost com- munication. OFF = lane is offline, a crit- ical alarm has been triggered, or com- munication is lost (example: part tracker...
  • Page 43 Chapter 8 Test Points Function Test Point +3.3V +3.3V Gnd +24VDC (+VI) 24VRET (-VI) +24VI GNDI CHAPTER 8 EXTENDED I-O S6...

  • Page 44: Extended I-O Switch Sw1 Selection

    Chapter 8 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 45: Extended I-O Circuits S6

    Chapter 8 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 8 EXTENDED I-O S6...

  • Page 46: Extended I-O Configuration

    Chapter 8 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 47 Chapter 8 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 48 Chapter 8 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 49 Chapter 8 CHAPTER 8 EXTENDED I-O S6...

  • Page 50: Chapter 9 Maintenance Frequency

    Chapter 9 Maintenance Frequency Item Description Frequency Verify that defective parts are being rejected by Observe proper rejection Daily inserting a known defective part through inspection 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 has...

  • Page 51: Clean The Vision Processor Filter - Csl Plus

    Chapter 9 CAUTION - Possible hazardous optical radiation from LEDs. Do not stare at lamps. Clean the Vision Processor Filter - CSL Plus Clean the filters at least once a month. To clean the filter: 1. Remove the outer cover. 2. Pull the filter out of the cover and clean it. If the filter contains only dry dust and dirt, rinse it in plain water If it contains oily dust and dirt, clean it in soapy water 3.

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