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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Written by Masrè Roberto/11/112

Date of issue 23/07/2018

Checked by Gualandi Fabrizio Revision 02 Denomination Number of pages 34 Operator interface and PLC-based control system operating instructions

Service code CCE12V Code CHS100.86.011

GENERAL INFORMATION INTRODUCTION Carefully read the entire Instructions Manual before working on the machine and/or the packaging of the various parts. The Instructions Manual contains important information for safeguarding all personnel who work on the machine as well as the machine itself. The company using the machine must always assure all operators have completely read and become familiar with the operating instructions. Notwithstanding the machine is equipped with active and passive safety devices, all risks resulting from incorrect use cannot be avoided. SACMI shall not be held responsible for failure to heed safety precautions and accident prevention rules and standards specified throughout this manual and property damage and personal injury caused by unintended, inappropriate and erroneous use of the machine. Any changes to the machine must be duly authorized by SACMI in advance. All operations on the machine (maintenance, adjustments, repairs, cleaning) must be performed by suitably trained personnel and according to the instructions of this manual. 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. This publication or parts thereof may not be reproduced, stored, transmitted, transcribed, or translated into any language, either common or computerized, in any form or by any means without the express written permission by SACMI. SACMI reserves its rights on drawings and technical documentation according to the law. SACMI ensures the contents of this publication. It is absolutely prohibited to use this publication for other purposes, whatever they may be, that are extraneous to operation of the machine for which this publication has been written. The information contained herein is guaranteed as being correct only if the user carefully follows all the guidelines and instructions provided in this publication

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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;

− must always be available and close by so that operators are able to consult them rapidly at any time.

CRITERIA FOR SEARCHING FOR AND REFERENCING INFORMATION The information and instructions are collected and organized in chapters, sub-chapters and paragraphs and can be found by referring to the index. Information provided with alert, warning or danger symbols must be carefully read. The notes critical to the health and safety of employees are within a box, marked with warning, prohibition and/or mandatory signs and in italics as shown below.

WARNING! It is especially important to read sections dealing with SAFETY carefully and repeatedly, since they contains important information and warnings for operators. USERS OF THE MANUAL For the purposes of the manual, the persons in charge of the machine are divided into:

− operator: person responsible for supervising and operating the machine; − maintenance worker: in charge of scheduled machine maintenance.

The exact definition of these operators is given in the OPERATOR TRAINING paragraph in chapter 3 (SAFETY EQUIPMENT AND PRECAUTIONS) in the INSTRUCTIONS manual.

WARNING! The term “operator” is generically used to identify a person who has to work on the machine: operator, maintenance worker, etc.

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SAFETY DEVICES SAFETY DEVICES & GUARDS The machine is provided with a number of electrical and/or mechanical safety devices in order to safeguard the operators and the machine itself. It is forbidden to tamper with, modify or try to bypass in any way the safety systems of the machine. For clarity of the descriptions, some illustrations in this manual show the machine or parts of it without guards or with the guards removed. It is always forbidden to use the machine without guards or with guards disabled. Warning signs are provided on the machine to indicate any hazards in the zone where the sign is attached. In addition, plates with important safety information and/or symbols that advise on correct and safe machine operation are provided. Always take all necessary safety precautions and follow the guidelines when working on the machine. SACMI disclaims any liability arising from tampering or failure to use safety devices. The presence of safety devices does not exempt the operators from exercising extreme caution during work, avoiding actions that may endanger him/herself or damage the machine at all times. In particular, the workers must never come into contact with the moving parts of the machine. SAFETY DEVICES INSTALLED - Locking devices Locking devices detect and signal an operating anomaly and prevent starting up or stoop operation. - Signaling of shutdown Every time a blocking condition occurs, it is signaled by a flashing light placed above the electrical cabinet. The cause of the alarm which caused the machine to shut down is shown on the control keyboard screen. The meanings of the alarm messages are described in the TYPE B INSTRUCTIONS manual. - Operator safety devices Machines are generally equipped with a number of mobile safety guards which are connected to electrical locking devices. Moreover there are fixed mechanical guards that prevent accidental access to all moving parts of the machine and dangerous parts, that are either live or hot. - Emergency stop buttons The machine can be stopped with emergency shutdown buttons. 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 this manual to the emergency stop circuit of the line it will be inserted in.

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GENERAL REGULATIONS

WARNING! Before performing any operation on the machine, all personnel who are to operate on it shall:

− make sure the machine cannot be accidentally started up by shutting off all the power supplies (electrical power, air supply, etc..) with personal locks (for example pad locks) stamped with the name of the worker who put it on;

− remove and personally store the keys of the locking devices

WARNING! The electrical cabinets, like the junction boxes on-board the machine contain parts that may be live. Access as set forth by standard EN 60204-1 is only allowed with a specific tool. Only skilled personnel trained to access live components shall possess said tool. When the electrical panel is live, the skilled personnel may only restore the electrical circuit protections.

WARNING! Wherever “socket-plug” connections are present, either in electrical panels or shunting boxes fitted on board the machine, it is obligatory to perform any disconnections only with the machine stopped and after isolating the electrical system from the mains.

WARNING! Some safety devices may have to be temporarily removed or made inoperative to carry out certain maintenance operations and/or to adjust parts. Always put these devices back into place after maintenance and/or adjustments have been completed before attempting to start the machine.

WARNING! 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.

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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 power is cut off. Start the machine only after all the safety devices function efficiently.

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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 Connection

State LED indication

Push-button N.O. Pressed LED ON Available LED off N.C. Pressed LED OFF Available LED ON Selector Closed in position X LED ON Open in position X LED off Limit switch N.O. Activated LED ON Deactivated LED off N.C. Activated LED OFF Deactivated LED ON Proximity switch N.O. Closed in position X LED ON Open in position X LED OFF Direct detection photocell N.O. Activated LED ON Deactivated LED off Reflex photocell or N.O. Activated LED off light impulse retroreflex Deactivated LED on Dark impulse retroreflex photocell

N.O. Activated LED on

dark impulse retroreflex Deactivated LED off Contactors - Relays N.O. Energized LED ON De-energized LED off N.C. Energized LED OFF De-energized LED ON Level sensor N.O. Above the threshold LED on Pressure switch Below threshold LED off Flow meter N.C. Above the threshold LED off Thermostat Below threshold LED ON Vacuum meter N.O. Above pressure limit LED ON Below pressure limit LED off N.C. Above pressure limit LED OFF Below pressure limit LED on

KEY: N.O. = NORMALLY OPEN N.C. = NORMALLY CLOSED

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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; − Electrical wiring;

OPERATOR INTERFACE.

This is the device used for communication between the operator and microprocessor-based control system.

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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. CPU card Contains the microprocessor and unit that processes the program; the CPU has an RS232C serial port for connection to the interface computer. Memory card It includes a memory module MMC which stores the program. Digital input modules Their function is to acquire the state of the limit switches, proximity sensors, photocells, etc... Output modules These devices pilot the machine actuators.

SWITCHBOARD THAT SUPPLIES POWER TO THE MAIN POINTS OF USE This part houses all the devices that control the electric motors. The controls for the motors and the transformers are protected with magnetic thermal cut-outs. All the power components are mounted on a bus bar. The entire electric system is tested according to current safety regulations. The entire electric system has been designed and developed in compliance with current international electrical codes and regulations regarding safety of machinery.

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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...).

MACHINE CONTROL KEYBOARD

(Version with standard colors)

(Version with special colors)

PUSH-BUTTON DESCRIPTION

1 Emergency stop button. 2 Reset button to clear shutdown or fault conditions. 3 Automatic cycle stop button 4 Automatic cycle start button 5 Manual start/stop button for cap timing device (M13) 6 Manual start/stop button for cap conveyor belts M15 and M25 (if provided) 7 Manual start/stop button for suction devices and blowers 8 Machine state selector (MANUAL – LOCAL - REMOTE)

2 1 3 4 5 6 7 8

2 1 3 4 5 6 7 8

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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

Button for accessing the page used to view and set the data items regarding the Spark Tester (if present)

Button for accessing the page used to view the data items regarding the motors

Button for accessing the page regarding machine configuration data

Button that accesses the page regarding the fault log

Button that accesses the page regarding PLC inputs and outputs

Button that accesses the page with program versions

Button for accessing the page used to select the local language

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Button used to quit the application

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- 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. Hardware controls regarding operator safety are always operative.

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- 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. Conveyor belt reference speed: the percentage factor of the ratio between the cap timing device speed (M13) and the conveyor belt is set. Cap step theoretical distance: the distance between caps during production is displayed, expressed in millimeters. Motor reference in manual mode: the shift percentage of motor speed in manual mode is set. Second speed reference in automatic mode: the shift percentage of production speed in automatic mode is set. Second speed duration: the second speed duration in automatic mode is set.

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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). The filter time setting on SQ7 signal during the automatic cycle increases machine speed so as to drain the channel. If the length is set to zero, the cap request signal is related to machine cycle; this signal will always be active during cap inspection, regardless of the state of the maximum level photocell SQ7. Timing device start delay: setting of the timing device start filter. During this delay a downstream feeder reaches the full speed. If the value typed in is greater than 1 second, the signal for downstream cap request (KA207) is active when the machine is in automatic mode. Extraction shutdown timer: this setting is used to define the delay between the moment a shutdown (code n. 10xx) occurs and the moment the extraction function (M11/M11B) is shutdown, with the exception of the shutdown caused by an emergency stop (code n. 1001). If the value is set to 0, the blowers stop immediately in the event of a shutdown. If the value is greater the 0, it is possible to anticipate the shutdown by pressing the button SB11, after a shutdown message has been generated. CVS rejects check blow duration: this parameter is used to define the duration of the reject blow function (YV30), expressed in tenths of a second. The blower is activated by the CVS reject check signal, via the PLC input CH3 – 04 – CVS Check.

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- 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. Cap count cannot be reset during the automatic cycle. Length of box change pulse (KA1): setting regarding the duration of box pulse signal to indicate box deviation to a downstream cartoning machine. If the length is set to zero, the relay operation is bistable (one cycle ON and one cycle OFF) Delay of box change signal: length of time after which the downstream machine receives the signal KA1. It indicates that the cap setpoint has been reached in the box. Box change length: time for box change length in the downstream machine is set. This length of time controls the closing duration of the cap storage unit. Vibration setpoint: the number of caps between two activations of the box vibration signal is set. The signal control is disabled when the setpoint is zero. Box vibration: the activation time of the box vibration length is set. Cap feed channel drained: button used to activate the drainage of the cap feed channel. This command is used to drain the feed channel. It is to be activated when the machine is in automatic mode and stops the machine after drainage.

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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. To reset this counter, press the corresponding RESET button. CHS outfeed closures total counter: displays the total number of caps fed out of the machine. To reset this counter, press the corresponding RESET button on the “Machine Set-up” page. CHS outfeed closures partial counter: displays the partial number of caps fed out of the machine. To reset this counter, press the corresponding RESET button.

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- 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. If the data item is set to 1, 3 caps will be rejected: the defective cap, the previous cap and the next cap. Set this value to 1 or to a greater value. Distance between YV3 and SPARK TESTER: the number of caps between the feed cylinder (YV3) and the high voltage electrode of the Spark tester is set. Distance between YV3 and YV30: the number of caps between the feed cylinder (YV3) and the reject valve (YV30) is set. Distance between YV3 and SQ11: the number of caps between the feed cylinder (YV3) and the count photocell (SQ11) is set. Reject blow duration (YV30): the activation time of the blow for reject (YV30) is set, expressed in milliseconds.

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- 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. M15 speed: the number of revs/min of the cap conveyor belt is displayed. Inverter U15 reference frequency: the reference frequency of the inverter in the cap conveyor belt is displayed. Analog input voltage. Inverter U15: the voltage transferred to the inverter of the cap conveyor belt by means of the analog input is displayed. Linear speed, Cap conveyor belt: the linear speed of the cap conveyor belt is displayed in mm/s.

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- 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. Motor M13 rated speed: enter the number of rated revs/min, referred to the cap timing motor. Motor M13 gearbox: enter the value of the reduction ratio for the gearbox referred to the cap timing device. Inverter M13 maximum frequency: enter the maximum frequency value for the inverter in the cap timing device. Number of cavities, Starwheel M13: enter the number of cavities found in the feed starwheel.

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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. Motor M15/M25 conveyor gearbox: enter the value of the reduction ratio for the gearbox referred to the cap conveyor. Inverter M15/M25 maximum frequency: enter the maximum frequency value for the inverter in the cap conveyor. Type of cap diverter (0=deactivated, 1=std, 2=side): enter 0 if the cap diverter is not provided, 1 to activate the configuration of a standard diverter and 2 to activate the configuration of a side diverter. Overturned cap control with starwheel (0=not present, 1=present): enter either 0 or 1 if the overturned cap control is not present or present respectively. Camera on spacing starwheel (0=not present, 1=present): enter either 0 or 1 if an image capture station is not present or present on the starwheel timing device. This setting activates photocell SQ53b for CHS100. Enable Spark Tester (0=disabled, 1=enabled): enter 0 and 1 to disable or enable the signal exchange between PLC and Spark Tester. Production speed minimum limit: type in the value for the minimum level of production speed to which the machine can be set. Production speed maximum limit: type in the value for the maximum level of production speed to which the machine can be set. Feedback presence U25 (0=absent 1=present): enter 0 if the Inverter U25 ready signal (READY U25) is absent, and 1 if it is present. This signal is displayed on the page I/O CH2 11- READY U25. Reject boxes presence check enabling (0=disabled 1=enabled): enter 0 to disable the reject boxes present check, and 1 to enable it. When enabled the sensors SQ9A/B/C/D must be used. CHS infeed closures total counter: displays the total number of caps fed into the machine. To reset this counter, press the corresponding RESET button. CHS outfeed closures total counter: displays the total number of caps fed out of the machine. To reset this counter, press the corresponding RESET button.

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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.

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- ALARM MENU

The log regarding operator messages and faults with dates and times of activation and deactivation is saved in this page.

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- 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

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- INFO MENU

The PLC program version and the operator interface program (HMI) are displayed in this page.

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- LANGUAGE MENU

The language of the operator interface can be selected in this page.

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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). The message categories below are provided: SHUTDOWN MESSAGES (1xxx) When these messages appear, the machine stops immediately. They can be cleared by pressing the RESET button on the machine keyboard only after the fault has been remedied. STOPPAGE MESSAGES (2xxx) The machine stops at the end of the cycle in progress when these messages are displayed. They can be reset by pressing the RESET button on the machine keyboard once the automatic cycle has been completed. OPERATOR MESSAGES (3xxx) These messages do not affect the work cycle or operations in manual mode. These messages are automatically cleared once the cause for which they were displayed has been eliminated.

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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. Make sure the emergency stop buttons are properly connected and work correctly. 1002 CHECK COMPRESSED AIR (SP1) (SHUTDOWN) The compressed air pressure measured is too low in order for the machine to operate correctly. Input SP1 is open. Check the pressure actually present in the circuit under normal work conditions. If the above mentioned condition is not present, make sure the device is properly connected and works efficiently. 1003 CHECK CAP OUTFEED IN THE FIRST CONVEYOR BELT (SQ11) (SHUTDOWN) No caps were detected in front of photocell SQ11 during the automatic cycle. SQ11 input is permanently off or on. Make certain sensor SQ11 is in the correct position and works properly. 1004 CHECK CAP OUTFEED IN THE OVERTURNED CONVEYOR BELT (SQ11B) (SHUTDOWN) No caps were detected in front of photocell SQ11B during the automatic cycle. SQ11B input is permanently off or on. Make certain sensor SQ11B is in the correct position and works properly. 1005 CHECK CAP INFEED IN THE FIRST CONVEYOR BELT (SQ53) (SHUTDOWN) No caps were detected in front of photocell SQ53 during the automatic cycle. SQ53 input is permanently off or on. Make certain sensor SQ53 is in the correct position and works properly. 1006 CHECK CAP INFEED IN THE OVERTURNED CONVEYOR BELT (SQ53B) (SHUTDOWN) No caps were detected in front of photocell SQ53B during the automatic cycle. SQ53B input is permanently off or on. Make certain sensor SQ53B is in the correct position and works properly. 1007 CHECK SPACER INVERTER (U13) (SHUTDOWN) Drive U13 shutdown was detected. Make sure there are no faults in the drive. Make certain there are no mechanical obstructions that impede motor M13 from working properly. 1008 CHECK INVERTER IN THE FIRST CONVEYOR BELT (U15) (SHUTDOWN) Inverter U15 shutdown was detected. Make sure there are no faults in the drive. Make certain there are no mechanical obstructions that impede motor M15 from working properly.

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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. 1011 CHECK COMPRESSED AIR MAIN VALVE (SP1) (SHUTDOWN) With the safety device in shutdown conditions, the system has not checked that the compressed air circuit has actually been discharged. Verify that valve YV100 works properly. As this check is strictly related to operator safety, it is necessary to shut off the machine and then turn it back on in order to reset the alarm. 1012 CHECK CAP INFEED IN THE TURN-PLATE (SQ53C) (SHUTDOWN) No caps were detected in front of photocell SQ53C during the automatic cycle. SQ53C input is permanently off or on. Make certain sensor SQ53C is in the correct position and works properly. 1017 REJECT ON SPARK-TESTER ERROR (SHUTDOWN) No ejected cap with defect detected by the Spark Tester was detected during the automatic cycle. Make sure solenoid valve YV30 is in the correct position and works properly. Make certain sensor SQ11 is in the correct position and works properly 1018 OVERTURNED CONVEYOR BELT INVERTER (U25) CHECK (SHUTDOWN) Inverter U25 shutdown was detected. Make sure there are no faults in the drive. Make certain there are no mechanical obstructions that impede motor M25 from working properly.

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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; this input must be closed so as to start the cap feed line in automatic mode. 2003 OVERTEMPERATURE INSIDE CABINET (ST113) (STOPPAGE) The temperature inside the CHS cabinet has been higher than the threshold set for thermostat ST113 for 5 consecutive minutes. Make sure air conditioner EV113 works efficiently. Make certain thermostat ST113 is properly set and works efficiently. 2004 CHECK VACUUM PUMP/JET STREAM BLOWER (M11/M32) (STOPPAGE) A fault has been found in the feed circuit of the vacuum suction devices or of the blower (if provided). Make sure the overload cut-outs have not tripped. Make sure the suction circuits or the cap feed blower are operating efficiently. 2005 NO TRIGGER PULSE FROM THE LINE (OKR3) (STOPPAGE) The line did not provide the trigger pulse signal in “Automatic-Remote” mode. Input OKR3 is open; this input must be closed so as to start the line in automatic mode. 2006 NO TRIGGER PULSE FROM CVS (STOPPAGE) The vision system is not inspecting. Check the CVS settings and data items. 2007 OVERTURNED CAPS ENTERING MACHINE (SQ2, SQ2S)(STOPPAGE) An overturned cap was found in the machine infeed side during the cycle. An inconsistency was found in photocells SQ2 and SQ2S in the feed channel. Remove the overturned cap and restart the line. Make sure photocells SQ2 and SQ2S are in the correct position and are properly set. 2008 CHECK SPARK-TESTER (STOPPAGE) The control system for micro-holes (spark tester) is either off or deactivated. Make sure the spark tester is properly connected and operates efficiently. 2009 CHECK REJECT ON SPARK-TESTER (STOPPAGE) The spark tester consecutively rejected too many caps during the automatic cycle. Make sure the spark tester operates efficiently and test voltage is properly set.

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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. 2012 MAXIMUM LEVEL IN REJECT CONTAINER (SQ8) (STOPPAGE) The maximum level of caps was found in the reject container during the automatic cycle. Make sure photocell SQ8 is in the correct position and is properly set. 2013 OVERTEMPERATURE IN CVS COMPUTER (ST213) (STOPPAGE) The temperature inside the CVS cabinet has been higher than the threshold set for thermostat ST213 for 5 consecutive minutes. Make sure air conditioner EV113 works efficiently. Make certain thermostat ST213 is properly set and works efficiently. 2015 CHECK CAP INFEED IN THE FIRST CONVEYOR BELT (SQ53) (STOPPAGE) No caps were detected in front of photocell SQ53 during the automatic cycle. SQ53 input is permanently off or on. Make certain sensor SQ53 is in the correct position and works properly. 2016 CHECK CAP INFEED IN THE TURN-PLATE (SQ53C) (STOPPAGE) No caps were detected in front of photocell SQ53C during the automatic cycle. SQ53C input is permanently off or on. Make certain sensor SQ53C is in the correct position and works properly. 2018 CHECK SPARK-TESTER SETTING (STOPPAGE) Before the cap piston was opened, the test sparks of the micro-hole control device (spark tester) were not detected during the automatic cycle. Make sure the spark tester operates efficiently and test voltage is properly set. 2019 TIME OUT, CAP FEED CHANNEL EMPTY (STOPPAGE) If the feed channel is empty for more than 5 minutes during the automatic cycle, the machine stops and the drive units stop too. 2020 MAXIMUM LEVEL IN OVERTURNED CONVEYOR BELT REJECT CONTAINER (SQ8B) (STOPPAGE) The maximum level of caps was detected in the overturned conveyor belt reject container during the automatic cycle. Make sure photocell SQ8B is in the correct position and is properly set. 2021 FIRST CONVEYOR BELT REJECT CONTAINER PRESENT CHECK (SQ9A) (STOPPAGE) The first conveyor belt reject container was not detected or not in the correct position during the automatic cycle. Make sure photocell SQ9A is in the correct position and is properly set.

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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 during the automatic cycle. Make sure photocell SQ9C is in the correct position and is properly set. 2024 SECOND CONVEYOR BELT REJECT CHECK CONTAINER PRESENT CHECK (SQ9D) (STOPPAGE) The second conveyor belt reject check container was not detected or not in the correct position during the automatic cycle. Make sure photocell SQ9D is in the correct position and is properly set.

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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. 3003 OVERTEMPERATURE INSIDE CABINET (ST113) (MESSAGE) The temperature inside the CHS cabinet is higher than the threshold set for thermostat ST113. Make sure air conditioner EV113 works efficiently. Make certain thermostat ST113 is properly set and works efficiently. 3004 CHECK CAP OUTFEED IN THE OVERTURNED CONVEYOR BELT (SQ11B) (MESSAGE) Photocell SQ11B is continuously active. Remove the caps from the conveyor before restarting the automatic cycle. 3005 CHECK CAP INFEED IN THE FIRST CONVEYOR BELT (SQ53) (MESSAGE) Photocell SQ53 is continuously active. Remove the caps from the conveyor before restarting the automatic cycle. 3006 CHECK CAP INFEED IN THE OVERTURNED CONVEYOR BELT (SQ53B) (MESSAGE) Photocell SQ53B is continuously active. Remove the caps from the conveyor before restarting the automatic cycle. 3007 CHECK CAP OUTFEED IN THE FIRST CONVEYOR BELT (SQ11) (MESSAGE) Photocell SQ11 is continuously active. Remove the caps from the conveyor before restarting the automatic cycle. 3008 CAP FEED LINE NOT READY (OKR3M) (MESSAGE) The line did not provide the trigger pulse signal in automatic mode. Input OKR3 is open; this input must be closed so as to start the line in automatic mode. 3009 FEED CHANNEL EMPTY (SQ2) (MESSAGE) The feed channel is empty. Photocell SQ2 does not detect any cap. The machine switches over the stand-by. Make certain there are no mechanical obstructions that prevent the caps from moving forward along the feed channel. Make sure photocell SQ2 is properly secured and set.

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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. 3011 CYCLE STOPPAGE WITH DRAINAGE OF THE FEED CHANNEL (MESSAGE) A request was made during the automatic cycle for cycle stoppage with drainage of the feed channel. 3012 CHECK THE MANUAL/AUTOMATIC SELECTOR (SA100) (MESSAGE) The mode selector SA100 is in the manual position when the button SB30M for automatic cycle start is pressed. Turn the selector SA100 to the automatic position and press the button SB30M to start the automatic cycle. 3013 OVERTEMPERATURE IN CVS COMPUTER (ST213) (MESSAGE) The temperature inside the CVS cabinet is higher than the threshold set for thermostat ST213. Make sure air conditioner EV113 works efficiently. Make certain thermostat ST213 is properly set and works efficiently. 3014 MACHINE SPEED CHANGE (UNDERSPEED) (MESSAGE) A second production speed is set during the automatic cycle. It is smaller than the main operating speed. 3015 MACHINE SPEED CHANGE (OVERSPEED) (MESSAGE) A second production speed is set during the automatic cycle. It is greater than the main operating speed. 3016CHECK CAP INFEED IN THE TURN-PLATE (SQ53C) (MESSAGE) Photocell SQ53C is continuously active. Remove the caps from the conveyor before restarting the automatic cycle. 3017 LAMP TEST (MESSAGE) The lamps for machine automation are tested. Tests occur every time the electrical cabinet is turned on. Reset in the control keyboard to complete the lamp test. 3019 CVS REJECT CHECK (MESSAGE) During the automatic cycle, the activate reject blower (YV30) signal is activated. The blower is activated by the CVS reject check signal, via the PLC input CH3 – 04 – CVS Check.

CHSMAIN FEATURES OF THE ELECTRICAL SYSTEM.OPERATOR INTERFACE.MICROPROCESSOR SYSTEM FOR CONTROLLING AND MONITORING MACHINE OPERATIONSWITCHBOARD THAT SUPPLIES POWER TO THE MAIN POINTS OF USEELECTRICAL WIRINGMACHINE CONTROL KEYBOARD

DESCRIPTION OF THE INTERFACE VIDEO-PAGES- MAIN MENU- OPTIONAL SPARK TESTER DATA MENU (if present)- MOTOR DATA MENU- MACHINE SETUP MENU- ALARM MENU- I-O MENU- INFO MENU- LANGUAGE MENU

MAINTENANCE AND TROUBLESHOOTINGMESSAGESSHUTDOWN MESSAGES (1xxx)STOPPAGE MESSAGES (2xxx)OPERATOR MESSAGES (3xxx)

SHUTDOWN MESSAGES1001 EMERGENCY STOP BUTTON (SHUTDOWN)1002 CHECK COMPRESSED AIR (SP1) (SHUTDOWN)

STOPPAGE MESSAGES2001 CYCLE STOP BUTTON (STOPPAGE)2002 CAP FEED LINE NOT READY (OKR3M) (STOPPAGE)2003 OVERTEMPERATURE INSIDE CABINET (ST113) (STOPPAGE)2004 CHECK VACUUM PUMP/JET STREAM BLOWER (M11/M32) (STOPPAGE)2005 NO TRIGGER PULSE FROM THE LINE (OKR3) (STOPPAGE)2006 NO TRIGGER PULSE FROM CVS (STOPPAGE)2007 OVERTURNED CAPS ENTERING MACHINE (SQ2, SQ2S)(STOPPAGE)2008 CHECK SPARK-TESTER (STOPPAGE)2009 CHECK REJECT ON SPARK-TESTER (STOPPAGE)2010 CHECK SPACER (SQ6) (STOPPAGE)2012 MAXIMUM LEVEL IN REJECT CONTAINER (SQ8) (STOPPAGE)2013 OVERTEMPERATURE IN CVS COMPUTER (ST213) (STOPPAGE)2018 CHECK SPARK-TESTER SETTING (STOPPAGE)2019 TIME OUT, CAP FEED CHANNEL EMPTY (STOPPAGE)2020 MAXIMUM LEVEL IN OVERTURNED CONVEYOR BELT REJECT CONTAINER (SQ8B) (STOPPAGE)2021 FIRST CONVEYOR BELT REJECT CONTAINER PRESENT CHECK (SQ9A) (STOPPAGE)2022 FIRST CONVEYOR BELT REJECT CHECK CONTAINER PRESENT CHECK (SQ9B) (STOPPAGE)2023 SECOND CONVEYOR BELT REJECT CONTAINER PRESENT CHECK (SQ9C) (STOPPAGE)2024 SECOND CONVEYOR BELT REJECT CHECK CONTAINER PRESENT CHECK (SQ9D) (STOPPAGE)

OPERATOR MESSAGES3001 CAP REQUEST WAIT (KA307) (MESSAGE)3002 TRIGGER PULSE WAIT FROM CVS VISION SYSTEM (MESSAGE)3003 OVERTEMPERATURE INSIDE CABINET (ST113) (MESSAGE)3010 CHECK SPACER (SQ6) (MESSAGE)3011 CYCLE STOPPAGE WITH DRAINAGE OF THE FEED CHANNEL (MESSAGE)3012 CHECK THE MANUAL/AUTOMATIC SELECTOR (SA100) (MESSAGE)3013 OVERTEMPERATURE IN CVS COMPUTER (ST213) (MESSAGE)3014 MACHINE SPEED CHANGE (UNDERSPEED) (MESSAGE)3015 MACHINE SPEED CHANGE (OVERSPEED) (MESSAGE)