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CI Vision Side Grips User

Manual

Rev. 04

Customer: WCRX

Order No.: P30004UP1

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Table of Contents

1. GENERAL INFORMATION ....................................................................................................................... 4

2. SAFETY INSTRUCTIONS ......................................................................................................................... 5

2.1. EXPLANATION OF SYMBOLS....................................................................................................................... 5

2.2. BASIC SAFETY MEASURES......................................................................................................................... 5

2.3. ELECTRICAL SYSTEM SAFETY ..................................................................................................................... 5

2.4. MECHANICAL SYSTEM SAFETY ................................................................................................................... 6

2.5. CUSTOMER RESPONSIBILITY ...................................................................................................................... 6

3. ABOUT THIS MANUAL ............................................................................................................................ 7

3.1. GENERAL .............................................................................................................................................. 7

3.2. SCOPE ................................................................................................................................................. 7

4. COMPONENT SPECIFICATIONS .............................................................................................................. 7

4.1. PLC & HMI.......................................................................................................................................... 7

4.2. SERVO MOTORS ..................................................................................................................................... 7

4.3. GEAR BOXES ......................................................................................................................................... 7

4.4. PRODUCT SENSOR .................................................................................................................................. 8

4.5. UV INSPECTION CAMERA.......................................................................................................................... 8

4.6. KBA PRINT HEAD .................................................................................................................................. 8

4.7. REJECT STATION WITH COUNTERCHECK ...................................................................................................... 8

4.8. EXTERNAL ENCODER ............................................................................................................................... 9

5. SOFTWARE SPECIFICATIONS ................................................................................................................. 9

5.1. I/O HANDSHAKE & TIMING CHART ............................................................................................................. 9

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5.2. REMOTE VNC CONNECTION ................................................................................................................... 10

5.2.1. Windows 7 or Higher .................................................................................................................. 10

6. OPERATION ........................................................................................................................................ 11

6.1. MENU STRUCTURE ................................................................................................................................ 11

6.1.1. Main Menu .................................................................................................................................. 11

6.1.2. Config Menu ................................................................................................................................ 13

6.2. CUSTOM SIGNALS ................................................................................................................................. 21

7. PRODUCTION ..................................................................................................................................... 21

7.1. MANUAL START OF PRODUCTION ............................................................................................................. 21

7.2. REMOTE START OF PRODUCTION ............................................................................................................. 21

8. HMI ALARMS DEFINITION .................................................................................................................... 21

9. SYSTEM DRAWINGS ............................................................................................................................ 22

9.1. ELECTRICAL DRAWINGS ......................................................................................................................... 22

9.2. MECHANICAL DRAWINGS ....................................................................................................................... 22

10. RECOMMENDED SPARE PARTS LIST & PRICE ...................................................................................... 22

11. TROUBLESHOOTING GUIDE ................................................................................................................. 22

12. RECOMMENDED PREVENTATIVE MAINTENANCE ................................................................................... 22

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1. General Information

These operating instructions will aid in the correct and safe operation of your CI Vision equipment. Therefore,

please observe the following instructions. It is necessary to read the complete operations instructions before

operating the CI Vision machine in order to avoid injury or improper use.

For your own safety, please observe the safety instructions in this operating manual. Please read the instruc-

tions carefully even if you are already trained in the application and operation of CI Vision equipment.

This symbol displays safety instructions or danger of injury or danger of product & environmental damage.

< Signal >

< type of danger >

< consequences >

< measures >

The following symbol indicates important instructions and specific information

<important instructions>

This user manual (or a copy of) must always be available for the operator, in full, where the machine is

installed.

These operating instructions do not replace installation and service by trained personnel! These operating

instructions are to be treated as strictly confidential. The information given herein shall not be copied, trans-

ferred, misused or made available in any way to third parties without CI Vision's prior written consent.

CI Vision is continuously enhancing its products. Redesigns and improvements to both technique and con-

figuration are subject to change. We appreciate your understanding that no claims can be made from infor-

mation and illustrations of this operation manual.

<Note>

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<Note>

2. Safety Instructions

2.1. Explanation of Symbols

The following symbols and notes are warning signals of possible damage to person or property or assist

you as guidelines.

DANGER! This symbol can be found in the operations manual at all refer-

ences concerning operational safety, if not adhered to there will

be danger.

body and life of persons. Always observe the instructions carefully and perform with ex-

treme attention and wariness.

This symbol indicates the appropriate handling of PCE-components.

2.2. Basic Safety Measures

For safe operation of the CI Vision system the following points must be observed:

The system must be mounted on a stable concrete floor.

The system must be kept level (e.g. away from extreme vibration).

All factory installed safety equipment must be kept in place (e.g. machine guarding,

door interlocks, E-Stop switches, etc.).

When installing the device in an industrial environment, this should be done where

dust, moisture, temperature and vibration are at their very lowest.

2.3. Electrical System Safety

The CI Vision System Is powered by externally supplied (user supplied) 480 VAC 3-Phase electrical

power. This should only be connected / disconnected by an authorized installation engineer or trained

electrician.

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DANGER!

The system is operated with supply voltage! Contact with live

parts can cause perilous state of shock and severe burns.

Operate system with duly mounted housing only.

Unplug electric supply prior to cleaning and care.

In case of liquid has been spilled on the system, immediately

switch off the system and unplug electric supply.

2.4. Mechanical System Safety

The CI Vision Side Grips System uses very powerful motors and has numerous pinch points. Use caution

at all times and never operate the system without the proper protective machine guarding in place.

2.5. Customer Responsibility

It is the customer's responsibility to:

Read the user manual and ask questions for items you do not understand.

Know the intended functions on the machine and how to properly use them.

Keep the user manual in readable condition and always accessible.

Regularly test, at acceptable intervals, the safety features of the system.

Ensure the Preventative Maintenance Schedule is followed and the system is in proper

working order.

DANGER!

Rotating axes!

Rotating axes! Can pull in and tear hair, clothing and jewelry.

Do not operate machine with opened housing! Keep away

long hair, loose clothing, jewelry etc. from machine!

DANGER!

Danger of injury by movable and rotating parts! Always ad-

here to the following rules:

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3. About this Manual

3.1. General

This operating manual describes the CI Vision Side Grips conveyor system. The main components, over-

view and detailed functions are described as well as system drawings, recommended spare parts list

and a TPM schedule. The following chapters will describe the beginning of operation and use in produc-

tion.

3.2. Scope

Side Grip Conveyor. It is intended for those who operate / setup / program or maintain the system.

This includes:

Operators

Supervisors

Administrators

Engineers

4. Component Specifications

4.1. PLC & HMI

PLC is a B&R 1585 with B&R Touch Screen

4.2. Servo Motors

B&R

4.3. Gear Boxes

Neugart

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4.4. Product Sensor

Sick Thru-Beam (PCE provided) – This is a sensor provided by PCE which interfaces directly to PCE's

PLC on the BSS 360 machine. It is used for identifying when a bottle is entering our combined system.

Once identified, the 360's PLC will track it through the combined system. By doing so, the cameras can

be triggered at the most opportune time to capture the best inspection images as well as reject at the

proper position (if necessary).

*NOTE: The Product Sensor is a CRITICAL COMPONENT for proper timing of the line. Adjustment / re-

placement of this sensor should ONLY be done by qualified, trained personnel. Please consult the PCE

BSS 360 or PCE directly for more information.

4.5. UV Inspection Camera

PCE provided and controlled as this is the 7th camera of the BSS 360 array and as such, it is completely

controlled by PCE's BSS 360. Its purpose is to verify, decode and inspect the UV helper code.

4.6. KBA Print Head

PCE provided and triggered. The CI Vision Side Grips provides a continuous raw output of Side Grips

encoder signal to this printer for tracking purposes but all other functionality and handshaking are done

directly with the PCE system (both PLM and PLC). Its purpose is to print a UV helper code on the bot-

tom of the bottle to assist in aggregation further down the line.

4.7. Reject Station with Countercheck

This station is provided by CI Vision but is built to PCE's specifications. It is completely controlled by

PCE via PLC. This is an SMC pneumatic cylinder reject station and two Sick thru-beam sensors for coun-

tercheck or "counter verification". Counter verification is preformed to ensure the proper bottle is ejected

at the proper time. One sensor is placed in front of the reject pusher and one after. The logic is such

that the first verifies alignment between the physical part and the PLC's shift register. The second verifies

that rejection has successfully taken place.

*NOTE: The position of the reject verification & countercheck sensors, as well as the distance between

them, is a CRITICAL relationship that must be maintained. Moving either sensor will cause the system to

become inoperable. Adjustment / replacement of either sensor should only be done by qualified, trained

personnel. Please consult the PCE BSS 360 or PCE directly for more information.

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4.8. External Encoder

The Kubler / Turck external encoder is designed to allow the CI Vision Side Grip system to operate as a

slave and automatically adjust its speed or "track" your existing upstream equipment. Mount this encod-

er via the included 5/16-18" threaded shaft and secure the anti-rotation bracket on any acceptable loca-

tion on your upstream conveyor.

5. Software Specifications

5.1. I/O Handshake & Timing Chart

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5.2. Remote VNC Connection

It is possible to control and monitor the CI Vision Side Grips system remotely. This is done with the use

of a VNC client. We recommend UltraVNC 1.1.9.3 but any

VNC client should work. In order to connect, you must first

set the IP address of the connection you intend to use as

indicated. Once your IP address is set, direct your VNC

viewer as follows:

5.2.1. Windows 7 or Higher

For PCs running Windows 7 or higher, it is important to install the MIRROR VIDEO DRIVER.

IP: 192.168.0.3

Port: 5900

Password: c

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6. Operation

6.1. Menu Structure

6.1.1. Main Menu

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Through the Main Menu, the Status and Alarms may be accessed. When is select-

ed, the following information is displayed:

When is selected, any faults that have been activated are shown:

The Config Menu can be accessed by selecting .

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6.1.2. Config Menu

There are two tabs within the Config Menu: Configuration and Admin. Within the Configuration tab,

the following options are available: General, Conveyor and Sidegrip.

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Selecting "General" reveals the following screen:

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Selecting "Conveyor" reveals the following screen:

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Selecting "Sidegrip" reveals the following screen:

Select to save new settings and return to the Main Menu.

Select to save new settings and remain in the current menu.

Select to discard changes.

The Admin tab allows access to the following: Hardware, Data, Debugging and Custom Signals.

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Selecting "Hardware" reveals the following screen:

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Selecting "Data" reveals the following screen:

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Selecting "Debugging" reveals the following screen:

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Selecting "Custom Signals" reveals the following screen:

Select to save new settings and return to the Main Menu.

Select to save new settings and remain in the current menu.

Select to discard changes.

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6.2. Custom Signals

The system is equipped with 3 available free user definable I/O. These I/O can be configured in a variety

of ways to monitor inputs, activate outputs, and display custom alarms and more. Please contact your

CI Vision representative for more in-depth information on how to use these available signals.

*Not currently in use

7. Production

7.1. Manual Start of Production

7.2. Remote Start of Production

The CI Vision Side Grips system is provisioned for remote control via I/O handshake with other machines

on the line. It is integrated with the PCE BSS 360 so that it will start when a production order is initiated.

Additionally it will stop upon error as well as end of production order.

8. HMI Alarms Definition

Voltage Sag at Controller – There has been a temporary loss of voltage in the supply line

Emergency Stop – Either the E-Stop button or Door Interlock has been opened during operation

Starting production manually is actually

quite simple. Follow these 5 steps to

begin:

1. Ensure the Side Grips and out feed

conveyor are free of debris.

2. Ensure all safety doors are securely

closed and all E-Stop switches are fully

released.

3. Press the "Enable" button which en-

gages the servo drives. It should turn

green.

4. If set to Master, enter a system speed

(not necessary if tracking as slave).

5. Press the "Auto / Start" button. All

belts should begin to run and the Auto /

Start button should be green.

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9. System Drawings

9.1. Electrical Drawings

See Appendix A

9.2. Mechanical Drawings

See Appendix B

10. Recommended Spare Parts List & Price

See Appendix C

11. Troubleshooting Guide

See Appendix D

12. Recommended Preventative Maintenance

Inspect Method Frequency

Side Grip Belt (Inside & Outside) Visual Inspection Monthly

Side Adjustment Slides Remove Debris & Grease Quarterly

Pulleys (lifetime sealed) Visual Inspection Yearly

Gear Boxes (lifetime sealed) Visual Inspection Yearly