D O C U M E N TA Z I O N E

T E C N I C A

CAA200
INSTRUCTIONS B

LINE CAA200 OPERATING INSTRUCTIONS

CAA200.86.022 Rev. 00 Date 05.12.2007

TECHNICAL DOCUMENTATION

DOCUMENTATION TECHNIQUE

TECHNISCHE DOKUMENTATION

DOCUMENTACIÓN T éC N I CA

D O C U M E N TA Ç Ã O T É C N I C A

LISH
ENG
CAA200.86.022 Rev. 00 Date 05.12.2007

Written by : Masrè Roberto Written on : 05.12.2007

Last revised :

Revised by : Ferri Tonino Revision No. : 00

Title :
Number of pages : 10
LINE CAA200 OPERATING INSTRUCTIONS
Service code : 9512

Code : CAA 200.86.022

SACMI SHALL NOT BE HELD RESPONSIBLE FOR MACHINE FAILURE DUE TO UNAUTHORIZED
MODIFICATIONS.

ANY CHANGES THAT ALTER THE CONSTRUCTION OR THE WORKING CYCLE OF THE MACHINE MUST BE
CARRIED OUT OR AUTHORIZED BY SACMI’S AFTER-SALES DEPT.

SACMI RESERVES THE RIGHT TO MAKE ANY CHANGES TO THE MACHINE DESCRIBED HEREIN AT ANY TIME
WITHOUT NOTICE.

IF THERE ARE ANY PRINTING OR OTHER ERRORS, CORRECTIONS WILL APPEAR IN THE SUBSEQUENT
VERSION OF THE MANUAL.

SACMI SHALL BE HELD RESPONSIBLE ONLY FOR THE TEXT IN THE ORIGINAL ITALIAN VERSION.

THIS MANUAL IS PROPERTY OF SACMI. ONLY THE PURCHASER OF THE MACHINE IS AUTHORIZED TO USE
IT.

IT IS NOT TO BE COPIED OR REPRODUCED IN ANY FORM WITHOUT PRIOR CONSENT FROM SACMI. FAILURE
TO DO SO WILL ENTITLE SACMI TO TAKE LEGAL ACTION.

COPIES OF THIS MANUAL ARE AVAILABLE FROM THE AFTER-SALES SERVICE DEPT.


 CAA200.86.022 Rev. 00 Date 05.12.2007

SAFETY PRECAUTIONS TO BE OBSERVED WHEN OPERATING THE MACHINE

Copies of this manual should be given to all personnel in charge of machine maintenance and operation. It is
essential that the manual is read carefully in its entirety and fully understood, as it provides important instructions
on how to operate the machine properly and safely.

The machine must be used only for the tasks it was expressly designed for. Performing jobs other than those
recommended is hazardous.
SACMI shall not be held responsible for damage to the machine or injuries to personnel resulting from mishandling,
improper use or unauthorized modifications.
Any modifications made to the machine’s structure and/or work-cycle must be performed or authorized by SACMI’s
Service Dept.

The persons in charge of supervising and servicing the machine must read and fully understand the operating
instructions contained in the documentation provided.
Maintenance can be performed and the electrical parts and devices accessed only by competent well-trained
personnel.
The machine’s work-cycle can be set and controlled only by the persons in charge, or those who are duly
authorized.
Only well-trained personnel can operate, set-up and service the machine.

The machine can be started up only after all the safety devices have been activated.
Periodically inspect all the safety devices installed in the machine (stop pushbuttons, interlocks, proximity switches,
limit switches, safety guards, etc..) for proper functioning. Occasionally check to see whether the machine is still
efficiently grounded.

If any faults are found while the machine is being run, they must be reported to the person in charge without
delay.
If the personnel in charge find faults which could endanger the operators, the machine must be shut off immediately
and restarted only after it has been repaired.

Always unplug the machines from the electricity supply before setting up or servicing them if operations which
may endanger personnel are to be performed. Failure to do so may result in severe injury to personnel. Whenever
carrying out maintenance of any type, always shut off the machine and block all parts before starting. This must
be done even when minor jobs are performed.


CAA200.86.022 Rev. 00 Date 05.12.2007

1 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 Connections State LED indication

Pushbutton N.O. Pressed LED on

Released LED off
N.C. Pressed LED off
Released LED on

Selector switch Closed in position X LED on

Open in position X LED off

Miniature switch N.O. Activated LED on

Inactivated LED off
N.C. Activated LED off
Inactivated LED on

Proximity sensor N.O. Closed in position X LED on

Open in position X LED off

Direct detection
photocell N.O. Activated LED on
Inactivated LED off

Reflector photocell
activated
when illuminated N.O. Activated LED off
Inactivated LED on

Photocell
activated
when dark N.O. Activated LED on
Inactivated 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 threshold LED on

Pressure switch Below threshold LED off
Flow meter N.C. Above threshold LED off
Thermostat Below threshold LED on

Vacuum control 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


 CAA200.86.022 Rev. 00 Date 05.12.2007

PLANT LAY-OUT


CAA200.86.022 Rev. 00 Date 05.12.2007

DESCRIPTION OF AP1 SETTABLE TIMES

Use the trimmers located in the PLC’s CPU to set the following times:

t0 Delay time for stopping the automatic cycle to empty the conveyor belts (0÷2’);

t1 Timer to simulate the minimum level in the hopper for MACHINE 1 (0÷15’);
Timer to simulate the minimum level in the hopper for MACHINE 2 (0÷15’);

NOTE:
To set the timers used to simulate the minimum level for the downstream machines, follow the directions
given below:
1. Turn on the machine in question with the switches (SA1 and/or SA2).
2. Set the time with PLC trimmer t1.
3. Hold down key SB31 (ab-key) for 4 seconds.
If both the machines are turned on while this operation is being performed to set the times for
minimum level simulation in the hoppers, the time set with trimmer t1 will be used for both.


 CAA200.86.022 Rev. 00 Date 05.12.2007

ARRANGEMENT OF THE BUTTONS AND SELECTOR SWITCHES ON THE CONTROL

PANEL


CAA200.86.022 Rev. 00 Date 05.12.2007

CABINET OPERATION

MANUAL
Mode selector switch SA100 turned to MAN.
Each device can be operated individually in this mode.
To start each motor, press the relative start button along with the keyboard enable key (ab-key).
Simply press the same button to stop it.
Use potentiometer RP6 to adjust the strength at which the vibrator vibrates.
The diverters on the conveyors can be started individually with the on/off switches for the downstream machines.
The way in which the valves are activated is shown in table 1.

Attention: during manual operation of the cabinet, all the software controls are disabled; however, the safety devices
remain operative.

AUTOMATIC CYCLE - LOCAL (BIN UNLOADING)

Mode selector switch SA100 turned to LOC.
Under this condition, the automatic bin unloading cycle can be started.
General operating conditions:
- More than one machine can be loaded at a time;
- The enabled machines are loaded simultaneously;
- If an enabled machine is full, its loading cycle is automatically disabled;
- The machines are changed without interrupting the cap flow.

To start the loading cycle in local mode, enable at least one loading machine and press “start cycle” button SB30M
together with the keyboard enable key (“ab-key”).
When the automatic cycle starts, the conveyors and vibrator for cap discharge from bin are immediately started.
The diverters for directing the caps to the required destination are also started.
The machines are loaded until the maximum level is reached. Once the delay time has elapsed after the maximum
level signal was provided the machine’s loading cycle is automatically disabled.
To stop the hopper loading cycle by hand, simply press “stop cycle” button SB30A.

AUTOMATIC CYCLE - REMOTE

Mode selector switch SA100 turned to REM.
When set to remote mode, the cycle can be started only from the upstream press.
The operating conditions in remote mode are the same as those in local.
During the automatic cycle, caps can be taken out of the bin by pressing button SB6 at the same time as the key-
board enable key (“ab-key”) to start the vibrator.
Once the loading cycle for all the enabled machines has been completed, the bin is loaded.
Once the bin has been filled, the cap request signal is no longer sent to the PTC and the conveyors are emptied.


 CAA200.86.022 Rev. 00 Date 05.12.2007

TABLE SHOWING ACTIVATION OF THE MACHINE LOADING VALVES

(table 1)
Machines on
YV status 1 1+2 2
YV2 off on on
YV3 off off on

DESCRIPTION OF THE INTERFACE SIGNALS WITH THE PTC

KA100 Contact of PTC emergency shut off device; the line immediately shuts down in a safe condition
if one of the emergency stop buttons on the press is pressed

KA300 Trigger pulse for automatic operation from the PTC (BLMV)

KA301 Conveyor automatic start/stop signal from the PTC (AMV)

KA302 Defective caps detected signal; the magnetic elevator (RCD) immediately shuts down

KA308 Reset signal from PTC (AMV)

KA200 Contacts of CAA emergency stop button sent to the PTC; the press immmediately shuts down if
an emergency shut off device on the CAA is pressed

OKR2 Trigger pulse for PTx operation (line ready to run; CMV)

KA207 Cap request signal to the PTC; it prevents the press from starting the automatic cycle, it shuts it
down if the cycle is in progress

10