TABLE OF CONTENTS - LinearGS · 2019-11-21 · 6 Revision Number: LV4000CE-01.01 Emergency Stop Buttons: Press either of the emergency stop buttons in any situation that causes concern

Revision Number: LV4000CE-01.01

OPERATION MANUAL

Model LV4000CE

Linear GS High Performance Inspection Systems Original Instructions

Per 2006/42/EC and ANSI/PMMI B155.1-2006

“From concept to finished product, the shortest distance is through Linear GS"

Linear GS, 1819 Thunderbird, Troy, MI 48084 USA Phone: 1-248-655-2729 • Fax: 1-248-244-8581 www.lineargs.com • email: [email protected]

http://www.lineargs.com/�

2 Revision Number: LV4000CE-01.01

TABLE OF CONTENTS

Introduction and Description ...................................................................................................... 3 Important Safety Information ..................................................................................................... 4 Safety and Guarding ................................................................................................................... 5 Transportation and Installation ................................................................................................... 8 Unpacking Your Equipment ....................................................................................................... 9 Inspection Machine: .................................................................................................................. 10 Feed System: ............................................................................................................................. 11 Hopper System: (Optional) ....................................................................................................... 12 Packaging Conveyor: ................................................................................................................ 13 Remote Connectivity: ............................................................................................................... 16 Electrical Information ............................................................................................................... 18 Controls and Machine Operation .............................................................................................. 19 Controls Description ................................................................................................................. 19 Boundary Sample Part Verification .......................................................................................... 27 Machine Capabilities ................................................................................................................ 28 LV4000CE Inspection Machine Set-Up ................................................................................... 29 Feeder System (Bolt) ................................................................................................................ 29 Hopper System (Optional) ........................................................................................................ 31 Part Inspection Set-Up .............................................................................................................. 32 Preventative Maintenance ......................................................................................................... 40 Troubleshooting Guide ............................................................................................................. 41 Decommission........................................................................................................................... 42 Recommended Spare Parts ....................................................................................................... 43 Warranty ................................................................................................................................... 44

Revision Number: LV4000CE-01.01 3

Introduction and Description This manual offers a detailed explanation of the Linear GS Model LV4000CE high performance inspection system. To ensure efficient and safe operation, please read through this complete manual prior to operating the equipment. The LINEAR GS model LV4000CE is a high performance inspection system designed and built to meet the needs of 21st century manufacturing. Constructed for flexibility, the LV4000CE is able to inspect a vast array of bolts, nuts, washers, studs and stampings. Each machine consists of one or two feeder systems, variable upper and lower conveyor belts, and an enclosed inspection module. Parts flow from each feeder unit to either of the two conveyors, depending on part type. Bolts and studs are placed into the lower split belt, which travels past an optional head inspection camera until reaching the magnetic pickup wheel, where the part is lifted and positioned onto the upper conveyor. Nuts, washers, and stampings are deposited directly onto the top belt. Up to four inspection cameras can be used simultaneously, although more camera systems can be positioned within the case, as an option. Visual inspection software determines if a part passes or fails. Pass (Good) parts are air blown down a chrome chute, demagnetized, and sent to a bin or packaging system. Failed (Bad) parts are ejected at the end of the line. Mounted to the end of the enclosure cabinet is a Microsoft Windows-based computer and touch screen monitor, which is used to create, modify, and access all part-specific programs. Each program is populated with a set of basic sample part data containing a variety of inspection characteristics and parameters. New part-specific inspection programs can be created by accessing an existing program and modifying its inspection parameters to fit the new requirements and part criteria. Operating your program is as easy as feeding a boundary part through the system, reviewing on–screen results, adjusting tolerances, resetting the part count, and running the machine.


Important Safety Information

1. Read and follow all instructions. 2. Follow all warning and instructions marked on your inspection equipment. 3. Do not overload power source or use extension cords. Do not install your

equipment where personnel will walk on the power cord

4. Always wear personal protective equipment when this machine is in operation. This includes safety glasses, gloves and hearing protection.

5. Keep all loose clothing away form conveyor belts.

6. Strong magnets can be harmful to people with pace makers and other medical

implants. Personnel should be stationed at least 6 inches from the magnet.

7. To avoid damage, keep magnetic media such as computer disks and credit cards away from magnetic field.

Warning – There is hazardous voltage inside the main control panel. Disconnect power before opening enclosure.

Practice safe electrical “Lock out Tag out “ procedures when working on

electrical components. Ref ANSI Z244.1-1982 Lock Out Tag Out of Energy Sources.

In an emergency or at any time it appears necessary to stop all machine operation without subjecting yourself to harm, press the EMERGENCY STOP BUTTON located at the front or rear of the machine.

In an effort to reduce the possibility of injury to personnel working around the INSPECTION SYSTEM equipment, warning signs are placed at various points on the equipment to alert them of potential dangers.

Please check equipment and note all warning signs. Make certain you and others are alerted and understand these warnings. Shown below are typical signs that may be attached to this equipment.

Warning: This machine emits sound pressure of approximately 107 dB. Suitable hearing protection must be worn by all personnel at all times.


Safety and Guarding This machine is equipped with many safety features. Among these are two emergency stop buttons, solenoid-locking safety switches, and force-guided safety relays. The machine is well guarded to protect personnel from hazardous areas. However, nothing can prevent accidents as well as a safety conscious employee. Make sure to follow common safety practices, such as wearing proper eye and ear protection at all times. Also, keep the machine and surrounding area clean and free of loose parts. A clean work environment is a safe one. Primary Guarding: The machine has perimeter guarding to prevent access to potentially hazardous areas. Do not attempt to alter this guarding in any way, as it serves both as a safety feature and as a shield to prevent ambient light from affecting the inspection process.

Device Guarding: Certain devices that are located outside of the machine’s primary guarding could also be potential safety hazards. These devices are also guarded to prevent the possibility of injury. These guards should only be removed, temporarily, for maintenance access, by qualified personnel. Do not attempt to run the machine without these guards properly in place.

MACHINE GUARDING

DEVICE GUARDING


Emergency Stop Buttons: Press either of the emergency stop buttons in any situation that causes concern. This will make everything on the machine stop immediately. These two buttons are located on the front and rear of the machine. Do not hesitate to use this feature.

Safety Switches: This machine contains access doors in the front and rear of the machine. These doors are equipped with safety switches to detect when they are open. The safety switches have electric solenoids that lock the doors while the machine is running. To unlock the doors, the emergency stop button must be depressed.

EMERGENCY STOP BUTTONS

SAFETY SWITCHES


Safety Circuits: There are two safety circuits on this machine to provide a two-level protection system. The primary system is the E-Stop (emergency stop) circuit. This circuit disables the entire machine when either Emergency Stop button is depressed. The secondary system is the access door circuit. This system disables potentially hazardous devices when the access doors are open. Each system contains two safety relays, and a safety monitoring relay. The status LED’s on the safety monitoring relays usually indicate the following conditions:

A) ENABLED/CLOSED: 3 Green LED’s - Circuit is complete and machine is enabled. B) DISABLED/OPEN: 1 Green LED - Circuit is open and machine is disabled. C) MALFUNCTION: 1 Amber LED - Safety relay has malfunctioned. Contact Linear GS.

D) FAULTED: 1 Amber LED & 1 Green LED - Circuit is faulted, but relay is functioning properly. Attempt to reset circuit by cycling Emergency Stop and/or machine power. Contact Linear GS if system cannot be reset.

Maintenance Key Switch: There is a “Maintenance” switch located inside the main electrical panel at the front of the machine. This switch requires a key that should only be possessed by authorized personnel. When this switch is turned to the right the access doors may be opened while the machine is running. This feature is for troubleshooting purposes only, and is only intended for temporary use by a qualified technician.

A) STATUS: ENABLED/CLOSED

B) STATUS: DISABLED/OPEN D) STATUS: FAULTED C) STATUS: MALFUNCTION

MAINTENANCE SWITCH


Transportation and Installation Transporting of the machinery The LV inspection unit is shipped via customer preferred shipping methods. The unit will ship banded down either on a pallet or in an overseas shipping crate. Crate Dimensions: 2.4m x 1.8m x 2.1m (8’L x 6’W x 7’H) Crate Weight: 1,115Kg (2,459 Lbs.) Pallet Dimensions: 2.4m x 1.8m (8’L x 6’W) Pallet Weight: 680 Kg (1,500 Lbs.) Installation of the Machinery: You may elect to use Linear GS Service Department to install your new unit. Our Field Service Technician can be scheduled in advance to arrive at your facility to assure that your equipment is correctly and efficiently installed. Prior to a scheduled installation, we ask that you identify the floor site of the inspection machine and have all components stationed at that spot. Factory air and electrical power must be able to reach the location of the inspection machine prior to the arrival of the Linear GS Field Service Technician. Factors to consider as you determine where to install your inspection system:

• Availability and suitability of proper AC power. • Proximity to the work area for air connections. • Sufficient working, ventilation and temperatures around the equipment. • Facility operating temperature to be between 40 degrees to 100 degrees

Fahrenheit and 4.4 degrees to 37.7 degrees Celsius. • Pneumatic air line @ 80 psi (5.5 Bars). • Lighting and ground conditions. • Lifting equipment to unload and place equipment. Hi-lo is recommended but a

minimum 2000lb. pallet truck is acceptable to move this equipment. • Direct machine accessibility to an Ethernet connection, in order to utilize

Linear GS's remote troubleshooting capability. A dimensional layout of the complete Linear GS LV4000CE Inspection Machine is included within your information packet.


Unpacking Your Equipment 1. Carefully receive and uncrate all equipment. 2. Carefully remove packing material. 3. In most cases the inspection system, (with the exception of the stack light), feeder bowl, and hopper are completely assembled. The packaging conveyor consists of two conveyors that must be assembled together as one unit. 4. Inspect all equipment for any damage that may have occurred during shipment. Location of the machine: Inspected parts will leave the machine at one of two locations. Pass (Good) parts exit via the chute located at the front of the machine. Rejected (Bad) parts are sent down a rear channel. Place the inspection machine where you have enough room to easily move pallets in and out of the machine's finished goods and rejected parts areas.

Pass (Good) Parts Exit Rejected (Bad) Parts Exit


Inspection Machine: 1. Once you have determined the appropriate location for your inspection machine, set up the machine's components in their expected final location. 2. Install stack light on top of cabinet.

3. Level machine base machine by adjusting the leveling mounts with an adjustable wrench.

4. Electrical Connection: 5. Dry Compressed Air Connection: Connect your main air supply into power outlet “air connection” located on main machine.

A power cord will be provided with your equipment. See electrical information for your power requirements.


Feed System: 1. Set in place in accordance to floor plan. 2. The feeder bowl is placed on the right end of the machine and set roughly to the height of machine. The feeder bowl discharge exit should rest approximately ½” to ¾” above the down-track as indicated below. 3. After the machine has been leveled, raise the conveyor down track until it is even with the feed system discharge by turning the bottom rail adjustment knobs.

4. Level the feeder bowl by adjusting the leveling mounts. Once the rough height is set, a final height can be set via the bottom rail adjustment knobs located underneath the base. 5. Electrical Connection: Once the bowl is in place, connect the two power cords from the feeder bowl directly into the power outlet located on the main machine.


6. Air Connection: Connect your air supply to the feeder bowl blue mac valve.

Hopper System: (Optional) 1. The hopper is positioned to the right of the feeder bowl and the hopper exit chute will be positioned directly above of the feeder bowl approximately 1/3 forward to the feeder bowl. Do not position to the center of the bowl.

2. Connect the hopper power cord directly into the feeder bowl electrical box.


Packaging Conveyor: The packaging conveyor consists of three parts: Roller Conveyor Powered In-Feed Electronic Connection Mini Mover Conveyor

Installation instructions: 1. Locate the connector rod on the powered in-feed mini mover conveyor. Using a hex key, loosen the set screws on the collars that secure the connector rod. Remove the two collars and connector rod.


2. To connect the two conveyors, first align the hook on the roller conveyor with the connector rod holes in the powered in-feed mini mover conveyor. Then slide the connector rod and two collars that you removed in Step 1 through the connector rod holes.

3. Secure the connector rod in place by using a hex key to tighten the set screws on the two collars.

4. Connect male power connector on mini mover conveyor to female connection on roller conveyor.


5 Install loose tie bar support to packaging base.

6. Now you are ready to position the complete conveyor in front of machine. Set packaging conveyor in place in accordance to the floor plan.

7. Attach packaging conveyor tie bar from Step 5 to the main machine.

8. Connect two power cords from the conveyor directly into power outlets located under the pass (good) fastener exit chute.


Remote Connectivity: 1. The LV4000CE Inspection Machine utilizes a Microsoft Windows-based operating system that can be remotely accessed via Ethernet connection. 2. The ethernet connection setup is as easy as plugging in your Ethernet cable directly into the LV4000CE Ethernet port located on the main machine. 3. Windows will automatically detect when the Ethernet connection is made. If the machine is not able to access the internet after the connection is made, most likely the problem in going to exist in your shops connection. The connection should be tested and verified by your Information Technology (I.T.) personnel. It is possible that a local network could conflict with the machine's local network address range, which is 192.168.222.x. If this occurs, the machine's local network address range can be changed. Contact Linear GS for resolution.

Ethernet Connection


Congratulations! You have successfully completed the installation.


Electrical Information The electrical controls consist of the following: LV4000CE E-00 - Drawing Index

• LV4000CE-E01 - Electrical Controls Bill of Materials • LV4000CE-E02 - 220VAC Control Wiring • LV4000CE-E03 – 110VAC Control Wiring • LV4000CE-E04 – Motor Control Wiring • LV4000CE-E05 – Feeder and Hopper Controls • LV4000CE-E06 – Safety Circuit Wiring • LV4000CE-E07 – 24VDC/SS Relays/Vision Light Wiring • LV4000CE-E08 – 24VDC/Encoders/Strobe Modules • LV4000CE-E09 – PC I/O & Triggers Interface Modules Wiring • LV4000CE-E10 – Feeder System Wiring • LV4000CE-E11 – Packaging System Wiring • LV4000CE-E12 – PLC Base Wiring • LV4000CE-E13 – PLC Modules #1 and #2 Wiring • LV4000CE-E14 – PLC Module #3 Wiring • LV4000CE-E15 – Electrical Layout Diagram

Note: See electrical schematic “brown book” supplied with equipment.


Controls and Machine Operation

Controls Description In an emergency, always operate the emergency stop button. Do not use the Human-Machine Interface (HMI). This control setup is continuously improved and manuals are only periodically released, creating conditions where this manual may not match the controls layout or logic exactly. The machine controls consist of electrical contacts, the HMI (PC, Touchscreen, Inspection hardware and code, HMI code), the Programmable Logic Controller (PLC) and its logic. The touch screen allows the operator to interface with the machine. This interface allows most of the operation of the machine. It is used to start the machine and setup the inspection programs and PLC. Some faulty event conditions have been included in the HMI code to assist in preventing further damage to machine components and to aid in trouble resolution.

Main Screen

Controls


A) Main Menu Screen The Main Menu screen is the screen normally viewed while the machine is in operation. It contains the necessary data to evaluate the current inspection. It also contains button controls to select sub-menus and the conveyor and feeder start/stop controls.

Conveyors – Starts and stops the conveyors. Feeder Bowls – Starts and stops the feeder bowl. The feeder will not run unless

the conveyors are on and no fault or setup condition is active. Advanced Settings – Allows access to a sub-menu that was the location of

inspection measurement pass limits. The control now gives access to several important settings that are not inspection limits but are critical to the inspection.

Adjust Tools – Used to adjust the ROI settings. Location; size; threshold; visibility; density; angle to name them.

Exposure – Used to adjust exposure times for each individual camera. Save Inspection - Saves current changes. Change Part – Switch the inspection to a previous setup. Speeds – Used to adjust speed for the feed wheel, feeder bowl and hopper. Parts Counter - Displays the total number of parts ran, passed, failed, and

speed rate.

Revision Number: LV4000CE-01.01

B) Advanced Setting Screen The Advanced Setting screen allows the operator to reset all counts, box counts and reset controller. The Reset All Counts function as a secondary warning preventing the user from accidentally clearing all part counts.

Reset All Counts - Resets all counts except box count. Reset Box Count - Resets only box count. Reset Controller Fail Counts – This button resets the comments on this form. This is the failing part data at each step in the inspection process. It is useful for inspection troubleshooting. Reset Fault – This is a secondary method for clearing fault conditions the system can detect. Enable Air Fault - This button enables the low air pressure fault condition. After build or servicing the machine may be left with this fault condition bypassed. Test Controller - This screen use to evaluate the machine controller IO is not yet implemented. Inspection Configuration - The inspection configuration screen allows the user to select which inspection methods will be used as criteria for the part evaluation. Machine Data - The machine data screen gives the user access to controller data. This data can be used to set the part tracking positions and the enable the camera inspections. Additionally, there is the boxing’s selection, box count and set up triggers in this section. C) Exposure Screen The exposure time is used to set the intensity of the image. The minimum exposure is 20 micro seconds and the maximum exposure time is 1000 micro seconds. The best exposure time is the setting which gives the specific features the highest contrast.


D) Machine Data Screen The machine data screen allows the user to change settings found in the machine controller.

At the top left is the inspection and auto trigger enable section. The top row are the enable buttons for each inspection and are green if inspection is enabled. Directly below that are the auto trigger enabled buttons. Enabling and auto trigger on an inspection will cause the inspection to cycle at their rate in milliseconds in numeric entry box above the button. The fist column of controls is for inspection one, the second for inspection two and the third for inspection three. Below the enabled buttons are numeric entries used to set data for part tracking in the controller. Going down the left column there is a maximum part width and minimum part gap setting for the lower conveyor system.


Next are the bottom camera trigger position and the transition location settings. The bottom camera trigger position controls the point at which the part will trigger inspection number one. The transition location is the point on the lower conveyor that the part transfers to the upper conveyor system. Next is the transition allowance setting. The transition allowance represents the amount of acceptable offset in that part tracking location when the part transitions from the lower system to the upper system. The logical entry point into the upper system is set by the top load location. This setting is very helpful for adjusting changes in the transition of the parts from the lower to upper systems. The alignment between the lower system and the upper system is verified when the part passes the upper system optic. The difference between the tracked part location and the actual part location is indicated in the alignment feedback reading. Continuing, the enable Set-up trigger check box turns on a function that aids in setting the transition and the top optical location. When the enables Set-up trigger check box is checked the side inspection will trigger when the part reaches the transition set point and the top optic location set point. This allows the person setting up the machine to see the visual feedback of the data. To properly setup the transition location, the flashing strobe lights from the side inspection should be synchronized with the transition of the part. Below are data points associated with the top conveyor part tracking. The top optic location setting indicates in logic where the part should be in part tracking when it crosses the top optic. If the bottom part tracking is used then this optic is used to test the part transition through the machine, otherwise it is used as an initial indicator of the part position. There are separate maximum part width and minimum part gap settings for the upper system. Moving to the upper right of the data screen continues the upper part tracking system data points starting with the side inspection trigger location followed by the top inspection trigger location. Adjusting these values change is the location that the inspection is triggered. The next two entries are associated with the blow off of passing parts. The first is the blow off position and the second is the blow off cycle time in milliseconds. In the middle right side of the data screen are the boxing options. The customer boxing unit option selects a simplified method of coordinating the part count, cycle box, and boxing error signals. The Linear GS boxing unit option controls the operation of the box conveyor and the chute door. The bulk pack is a less accurate method for counting large quantities of parts. Its function is only two turn off the feed system when the count


is reached. If no boxing option is selected then the box count will not increment. The box count is located at the bottom of the right side. This is followed by the lower and upper conveyor speeds. The consecutive rejects setting adjusts the number of consecutive failing inspections necessary to activate the consecutive rejects fault that causes the feed to turn off. The PC input output screen is used to troubleshoot issues relating to the transfer of data from the inspection system back to the machine controller. The close button closes this screen. E) Program Select Screen The Program Select screen allows the operator to manage part programs. From this screen you can use an existing program, copy an existing program to a new program or create a new program. You can also delete part programs from this screen.

F) Settings Screen The setup screen gives the operator access to functions and data associated with specific inspections. There are two main features of the inspection process that are covered in this setting screen. The first is the data that is to be used in the inspection. This data is the data that is displayed on the main screen of the HMI. The second feature covered by the settings screen is the “feature enables". The inspection program


has several functions that can be bypassed. These functions, the alignment of the tools associated with these functions and the data variables have to coordinated correctly.

G) Speeds Adjust Screen The Speed Controls allows operator to adjust the feed wheel, feeder bowl and hopper speed. Click on the specific equipment you wish to adjust and slide bar to the left to decrease speed and to the right to increase speed.

H) Tool Select Screen The tools screen gives the user accesses to the adjustments that can be made to the inspection tools. The inspection tools, or Region of Interest, are the measuring areas that are placed over the part in the image. This screen has Region of Interest threshold, alignment, learn features, and display a state.


In order to make any of these adjustments on a Region of Interest, the specific Region of Interest must be selected in the select tool drop down box at the top of the screen. In addition to the Region of Interest adjustments, there is a reset alignment function available at the bottom of the screen. On occasion it may happen that the alignment becomes skewed. To correct this, the operator must set up all the tools in use with this inspection and then press the reset alignment button. After this all of the angles of the tools or Region of Interest should be corrected.


Boundary Sample Part Verification PURPOSE: To verify pert inspection characteristics as required by the customers of

Linear GS. SCOPE: To ensure optimum part inspection program stability for quality assurance. REQUIREMENTS:

1. Preliminary boundary samples should be discussed prior to set-up and process development to determine quality expectations and process capability.

2. Preliminary boundary samples or expectation achievement should be verified

through the production trial activity with final boundary sample approval prior to supplier Quality Control Systems.

3. Proposed boundary samples must be representative of the supplier’s confirmed

process capability and be consistently achieved. 4. Boundary sample approval is based on internal Customer quality standards,

consumer acceptance impact, part design characteristics, and supplier process capability.

WHEN: Boundary samples should be verified and tested at each and every new part set-up.

FREQUENCY: Boundary samples should be verified and tested every hour to ensure equipment is functioning properly. Boundary samples should also be verified and tested at the beginning and end of each shift. Failure to comply with the above recommendations may result in passing bad parts.


Machine Capabilities

Top Image • Perimeter and open burst cracks, open cracks, open cracks visible at OD, in

silhouette view of part, parts standing on head viewed down. • Diameter; minimum / maximum / average • Ovality/Roundness of head OD • Hex(no flange) min/max diameter

Bottom Image • Drive Recess fill/Missing area • Surface defects • Riverbed cracks

Side

• Length • Head Height • Shank Length • Shoulder Diameter: min/max/avg/angle and variance • Dog Point Diameter (Pilot) • Incomplete formation of bolt tip (area) • Threads

• Major diameter • Major Variance • Thread Angle

• Minor diameter • Maximum • Average

• Thread Match % of setup Pattern detection of filled or missing threads

90 Degree View • Turned Head; Side view comparison and average of hex head width • Bolt straightness, features of bolt can affect reading Vision System Resolution Detection Capability to 0.0005", dependent on measurement


LV4000CE Inspection Machine Set-Up Feeder System (Bolt) The feeder system supplies parts to the inspection machine. A) Tooling Rail System Adjustment – The feeder unit consists of a four section rail system. During any new part set-up, it may be necessary to adjust the rails based on part diameter. This will require an M5 hex key to loosen the rail's screw and raise or lower the rail section until a gap is created that is slightly larger than the part diameter. The parts must travel freely around the bowl. Once each rail section is positioned with the desired gap opening, retighten the rail screws.


B) Air Assist Adjustment – This will provide air assistance to move parts through the rail system, if required. Individual airline pressure can be adjusted at the manifold block. Turn the adjustment knobs clockwise to decrease air flow and counterclockwise to increase air flow. Note: Parts must travel freely at a high rate of speed.

Rail Air Support Air Manifold Block

C) Horizontal Base Adjustment – This will provide part centerline alignment to the inspection machine down track. Adjustment lever and latch Discharge to down track


Hopper System (Optional) The bulk parts hopper supplies metered parts to the feed system. A) Limit Switch Adjustment and Actuation Arm – Set rod approximately ½” from bottom of feeder bowl.

B) Door Opening/Closing Adjustment and Actuation – Door opening will allow for part flow from hopper into tray. Ratchet catch will allow for door movement up or down. Note: In order to move the crank wheel, the latch lever must be in either the forward or back position. The latch lever must be in the forward position after the final adjustment has been made.

C) Control Bulk Hopper Setting – Use the HMI screen on the monitor to adjust the hopper speed. Click on the slide bar and move it to the left to decrease speed and to the right to increase speed. This will supply metered parts to the feed system.

Latch lever back position for closed adjustment.

Latch lever forward position for open adjustment.


Part Inspection Set-Up Step 1: Initial Preparation Of The Lower Conveyor Rail System The Front and Rear Stabilizer Screws (Image 1-A) on the Lower Conveyor Rail System must be loosened to prepare the inspection machine for the belt gap adjustments necessary for fastener inspection. (1-A) Rear Stabilizer Screw Front Stabilizer Screw

Each Stabilizer Screw is locked in place by a lock nut located on the shaft of the Screw. Loosen the lock nut by turning it counter-clockwise until it stops under the head of the Stabilizer Screw Knob (Image 1-B). Next, turn the Knob counter-clockwise until the Stabilizer Screw has pulled away from the inner rail by approximately one-half inch (13 mm) (Image 1-C). Loosen both the Front and the Rear Stabilizer Screws in this manner.

(1-B) Stabilizer Knob and Nut (1-C) Gap at tip of Stabilizer Screw


Step 2: Belt Gap Adjustment - Center Rail Adjustment Screw The gap between the two parallel belts on the lower conveyor is determined by the size of the fastener to be inspected. Unlock the belt gap position by releasing the Center Rail Adjustment Screw's Locking Lever (Image 2-B). Turn the Center Rail Adjustment Knob clockwise to widen the belt gap. Turn the Adjustment Knob counter-clockwise to narrow the belt gap. Take one of the fasteners that the machine will be inspecting and place it between the belts, directly above the Adjustment Screw (Image 2-C). Adjust the belt spacing so the fastener moves freely but does not fall through the gap (Image 2-D). Once the proper belt spacing is achieved, secure the belt position by tightening the Locking Lever (Image 2-E). (2-A) Center Rail Adjustment Screw

(2-B) Center Adjustment Knob and Lever (2-C) Adjusting proper gap on a sample fastener

(2-D) Sample fastener with proper gap (2-E) Tighten the Locking Lever to secure the belt gap


Step 3: Belt Gap Adjustment - Front and Rear Stabilizer Screws Now that the Center Rail belt gap position has been set, the Front and Rear Stabilizer belt gaps need to be locked in. Front Stabilizer Screw: Make sure the Front Stabilizer Screw's lock nut has been loosened and is positioned under the head of the Stabilizer Screw Knob. (See Step 1.) Place a set-up fastener between the two parallel conveyor belts, directly over the Front Stabilizer Screw. (Image 3-A) Turning the Front Stabilizer Knob clockwise widens the belt gap. Turning the Front Stabilizer Knob counter-clockwise narrows the belt gap. Adjust the belt gap so that the fasteners can smoothly transition from the down track channel into the belt gap and along the conveyor. Once the desired belt gap is achieved, set the lock nut by turning it clockwise. Rear Stabilizer Screw: Make sure the Rear Stabilizer Screw's lock nut has been loosened and is positioned under the head of the Stabilizer Screw Knob. (See Step 1.) Place a set-up fastener between the two parallel conveyor belts, directly over the Rear Stabilizer Screw. (Image 3-B) Turning the Rear Stabilizer Knob clockwise widens the belt gap. Turning the Rear Stabilizer Knob counter-clockwise narrows the belt gap. Adjust the belt gap so that the fasteners can move along the lower conveyor belt and be lifted by the magnetic pick-up wheel. Once the desired belt gap is achieved, set the lock nut by turning it clockwise. (3-A) Fastener over Front Stabilizer Screw (3-B) Fastener over Rear Stabilizer Screw


Step 4: Vertical Adjustments - Feed System, Lower Conveyor, and Upper Conveyor The transition of fasteners moving from the feed system to the lower conveyor to the upper conveyor is managed by turning the lower conveyor carriage's Front and Rear Vertical Adjustment Knobs (Image 4-A). Rotating the Vertical Adjustment Knobs clockwise raises the conveyor. Rotating the Vertical Adjustment Knobs counter-clockwise lowers the conveyor. Front Vertical Adjustment Knob: Turn the Front Vertical Adjustment Knob until the top of the down track is aligned with the end of the feed system track (Image 4-B). Rear Vertical Adjustment Knob: The Rear Vertical Adjustment Knob will set the transition from the lower conveyor to the magnetic pick-up wheel. Place a sample fastener between the belt gaps. Adjust the height of the lower conveyor so that the sample fastener is able to freely move beneath the magnetic pick-up wheel, yet be lifted off the belt by the magnet (Image 4-C). Do not allow the fastener to be pinched between the lower conveyor belts and the magnetic wheel. When the inspection machine is in operation, the magnetic wheel should be able to pick up the fasteners from the lower conveyor with consistency. (4-A) Rear Vertical Adjustment Knob Front Vertical Adjustment Knob

(4-B) Feed System Aligned with Down Track (4-C) Magnetic Wheel


Step 5: Feed Wheel, Feed System and High Level Switch Feed Wheel Adjust the lever to loosen the feed wheel. Vertically position the feed wheel so that it will make contact with the head of each passing fastener and push it forward onto the split belt (Images 5-A, 5-B). (5-A) Adjusting Feed Wheel (5-B) Feed Wheel contacting fastener

High Level Switch The High Level Switch provides a cycling feature to the feed system which prevents the fasteners from overloading at the top of the down track. A bracket containing a laser beam sensor is positioned near the top of the track. If the sensor beam detects the lingering presence of a fastener, the feed system will not send down another fastener (Image 5-C). If a fastener is not detected, the feed system will continue to feed fasteners down the track. Adjust the height of the bracket so that the sensor’s beam crosses the head of a fastener awaiting inspection (Image 5-D). Retighten the lever once you have achieved the desired sensor height. (5-C) Sensor Detecting Fastener (5-D) Adjusting Sensor Bracket


Step 6: Upper Conveyor Trigger This sensor provides part tracking information to the inspection system software. Each fastener traveling along the conveyor belt must pass through and be detected by the sensor’s laser beam. Loosen the bracket’s lever and adjust the height of the sensor bracket (Image 6-A) so that the sensor’s beam crosses the fastener as it travels along the upper conveyor. Set the thru beam to cross at the lowest uniform edge of a boundary sample fastener, typically a location between the fastener head and the mid-point of the shaft. Retighten the lever once you have achieved the desired sensor height. (6-A) Sensor Bracket Adjustment


Step 7: Pass Part Blow-Off Valve The Air Valve Nozzle shoots a stream of air at a pass (good) fastener in order to blow it off of the conveyor and down the good parts chute. The air stream’s target location depends on the height and weight of the fastener being inspected. Ideally, the air stream should strike the fastener at a location between the fastener head and the mid-point of the shaft. Hitting the fastener too high or too low will cause the fastener to topple away from the chute. Modify the valve nozzle’s vertical position by loosening the adjustment lever behind the nozzle and sliding the valve nozzle (Image 7-A). Once the nozzle is at the desired position, retighten the adjustment lever. The Air Flow Control Valve (Image 7-B) sets the pressure needed to blow a pass (good) fastener off of the conveyor and down the good parts chute. The air pressure level on the air flow control valve will need to be adjusted based on the weight and height of the fastener being inspected. To decrease the level of air pressure, turn the valve clockwise. To increase the level of air pressure, turn the valve counter-clockwise. (7-A) Properly positioned Air Valve Nozzle

(7-B) Air Flow Control Valve


Step 8: Auto Packaging System Conveyor Side Rail The conveyor side rails are used to guide the shipping containers along the conveyor. Each rail is held in place by rail brackets, which secure the rail onto the conveyor frame. To adjust the side rails, loosen the rail brackets by turning the lever on each bracket counter-clockwise. Then slide the side rail to the desired location. There should be approximately one half inch (13mm) of space between the shipping container and the side rails (Image 8-A). To secure the side rails, retighten the rail brackets by turning the levers clockwise. Exit Chute and Diverter Height The exit chute height can be vertically extended approximately 3 inches (75 mm). To prevent fasteners from bouncing or shooting out of the box, it is recommended that the exit chute be adjusted to a height of approximately one half inch (13 mm) above the highest part of the container. Turn the chute levers counter-clockwise to loosen the exit chute (Image 8-B). Once the chute is at the desired height, turn the levers clockwise to secure the chute. Container spacing When loading empty containers onto the conveyor, the operator should make sure to leave approximately one inch (25 mm) of space between each container (Image 8-C). This will allow the automated conveyor system to detect the next container. (8-A) Side Rail Adjustment (8-B) Exit chute and diverter height

(8-C) Container Spacing


Preventative Maintenance

LV4000CE INPSECTION MACHINE Daily Weekly Monthly Semi Annual Annual Clean Method

Clean upper belts and pulleys. ● Replace* Linear GS Belt Cleaner Kit

Clean lower belts. ● Replace* Formula 409®

or equivalent Clean belt tension (upper and lower). ●

Clean and wipe off all fiber optics. ● Formula 409® or equivalent

Clean and wipe off all pass part chute optics. ● Formula 409® or equivalent

Clean and wipe off all glass on camera enclosures. ● Glass Cleaner

Clean and wipe off back lights. ● Glass Cleaner Clean and wipe off all excess oil, grease and debris on inside of cabinet. ● Glass Cleaner

Clean and wipe off oil and grease on feed wheel. ● Replace* Dry cloth

Clean discharge chutes. ● Formula 409® or equivalent

Clean and wipe down exterior of machine. ● Glass Cleaner

Check and clean air regulator and filter. ●

Drain surge tank/Drip leg. ●

Remove, check and clean electrical cabinet filters and replace when needed. ● Air blow off.

Remove, check and clean machine enclosure filters and replace when needed. ● Air blow off.

*Replacement parts can be purchased directly from Linear GS. Contact your service representative.

FEED SYSTEM AND HOPPER Daily Weekly Monthly Semi-Annual Annual Clean Method

Clean the inside of the vibratory feeder bowl and hopper. ● Mineral

Spirits/Degreaser Clean the gap between the coil and magnet. ● Visual

Check and tighten all screws. ●

PACKAGING SYSTEM Daily Weekly Monthly Semi Annual Annual Clean Method

Clean belt and wipe off grease and oil. ● Formula 409® or equivalent

Check belt tension and alignment. ● Formula 409® or equivalent

Check side rail guides. ● Formula 409® or equivalent

Clean exit roller conveyor oil and grease. ● Formula 409® or equivalent


Troubleshooting Guide Different faults could occur that would cause the machine to malfunction. The following list of machine faults is by no means complete, but is intended to assist in solving the most common machine problems.

Problem Probable Cause Solution

MAIN AIR LOW message on screen

Main air pressure is low Main air pressure sensor is not set properly. Main air pressure sensor is not functioning

Check main gauge on back of machine and verify pressure Verify proper setting by adjusting the main regulator until the main air is at 60psi. Then, turn the orange pot on the pressure sensor until the red LED barely turns on. Then adjust the main air up to a minimum of 80psi Turn the orange pot on the pressure sensor fully in both directions (this is only a ¼ turn pot). The red LED should turn on & off

“PLC NOT RESPONDING” message at bottom of screen

PLC in main enclosure is faulted. This is indicated by a small red fault light on the PLC that will be flashing Communication cable is disconnected or damaged

Contact Linear GS at (248) 655-2570 Ensure cable is properly plugged into PLC Examine cable for any cuts or crimps

Screen is all black, but green power light at bottom of screen is on

30 minute screen saver is active

Touch screen to deactivate screen saver

Machine “POWER ON” light is on, but screen is not

24vdc circuit breaker may be tripped

Check circuit breakers in main panel


Decommission 1) Disconnect from energy supplies (electricity, compressed air). 2) Turn off main electrical disconnect and validate NO (0) voltage per LV4000CE-

03. 3) Lock out and tag out all energy supplies (electricity and compressed air). Ref

ANSI Z244-1-1982 Lock Out Tag Out of Energy Sources. 4) Remove electrical device and dispose of properly per local regulations. 5) Remove precious metals and dispose of per local regulations. 6) Remove magnet housing and dispose of magnets in accordance to local

regulations.

Electrical installations and decommissions must be made by a qualified electrician and must conform to applicable safety codes.


Recommended Spare Parts

Part Description Part #:

Adjustmet Regulator 1/2" Adjustment Regulator LGS-P32RA94BNGP

Adjustmet Regulator Filter 1/2" Filter W/Auto Drain LGS-P32FA94EGAN

Back Light 2" X 7" Back Light (Red) TBL-2X7-R-24-HHB2

Back Light 2" X 2" Back Light Infrared MB-BL201-IRL-24-HHB1

Belt Cleaner Kit Bottle of cleaner and sponge LGS-BCK

Camera Camera Prepped for install LGS-VCC-G20X30T1

Camera Cable Cable for camera LGS-CCX6601-5M

Camera Lens 25 or 35mm lens LGS HF25HA-1B/HF35HA-1B

Camera Lens Filter Filter for lens LGS -BP880-25.5

Coil Feeder or Hopper coil Prepped LGS-V101

Computer Computer prepped to drop in (includes lens) Call Linear GS (248-655-2570)

Cooling Fan Enclosure cooling fan LGS-1976K18

Cooling Fan Filters Replacement cooling fan filters LGS-19155K53

Cylinder Packaging Cylinder LGS -NCDGBN20-0300

Digital Sensor Digital Pressure Sensor LGS-SPAB-P10R-N18-PB-M8

Encoder Part Tracking Encoder LGS-TRD-NH500-RZWD

Feed Bowl Controller Vibratory Feeder Control, CE-45 Plus LGS-121-500-0781

Feed Wheel Foam Feed Wheel LGS 1609-16

Feed Wheel Rubber Wheel LGS 1609-16-A

Feed Wheel Motor Feed wheel motor LGS-159

Flow Control Inline Flow Control 3/8" LGS-7770-60-00

Framegrabber Camera Acquisition Board LGS-SH-X1A-QU

Good Part Exit Chute Repair LGS 0003-36

Good Part Exit Chute Fabricate and unpolished LGS 0003-36

Good Part Exit Chute Fabricate and polished LGS 0003-36

I/O Board Contec 16 x 16 Digital I/O Board LGS DIO-1616RL-PE

Leeson Conveyor Motor Conveyor Motor for upper and lower conveyors. LGS-M1135111

Leeson Motor Brushes Motor Brushes LGS-M1900010.47

Limit Switch Limit Switch LGS-802G-GP

Module Micrologix Output Module LGS-1762-0B16

Packaging Valve Packaging pneaumatic valve LGS-56C-13-611JJ

Part Removal Blow Valve Prepped LGS-411A-BOB-DM-DDAJ-1JM

Ring Light 4" Ring Light (Blue) MB-OARL211-B-24-HB4T

Timing Belt Timing Belt @$53 (Need two) LGS-1700H100NG

Top Conveyor Belt Linear GS made urethane belt LGS-SPVB09546

Tower Light Stack light on top of machine LGS -TL50GYRQ

UPS Battery Backup - Need in 3yrs Call Linear GS (248-655-2570) Replacement parts can be purchased directly from Linear GS. Contact your service representative.


Warranty LINEAR GS warranties the equipment and any services provided to be free from defects in material and workmanship under normal and recommended use and that the equipment will conform to LINEAR GS's published specifications, if any, or, if applicable, Buyer's specifications accepted by LINEAR GS in a separate writing. LINEAR GS's obligation under this warranty shall be limited to providing replacement services or replacement parts to the extent of any defective equipment or defective services, or replacing the entire equipment if the replacement of certain parts will not resolve the defect, or repairing the equipment, or the repayment or crediting of Buyer with an amount equal to the purchase price of such defective equipment or services, each at the election of LINEAR GS, regardless of whether such claims are for breach of warranty, breach of contract, or negligence. The equipment (or parts) shall be returned to LINEAR GS, at Buyer's expense, including transportation and handling costs, and the labor for repair, by LINEAR GS, will be at no additional cost. This warranty shall extend for six (6) months from date of the original purchase by the original buyer only, and shall apply only to those parts or equipment or services which upon LINEAR GS's examination disclose to its satisfaction that the parts or equipment or services in question were in fact defective. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON LINEAR GS’s PART. THIS WARRANTY SHALL NOT APPLY TO ANY PART WHICH HAS BEEN SUBJECT TO ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE OR MISUSE OR WHICH WAS PROVIDED BY A THIRD PARTY. LINEAR GS MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS OR COMPONENTS NOT SUPPLIED BY LINEAR GS. Notwithstanding the foregoing, any parts purchased by LINEAR GS from its vendors shall only carry the vendor's specific warranty, to the extent transferable to Buyer. No representation or warranty, expressed or implied, made by any sales representative or other agent or representative of LINEAR GS, which is not specifically set forth herein, shall be binding upon LINEAR GS. Buyer acknowledges that it has inspected the equipment and agrees to accept it in its current condition. Buyer agrees to indemnify and hold LINEAR GS harmless from any and all claims, costs, liabilities or expenses (including attorney fees) related to or arising out of the use, operation, transportation, design and construction of the equipment, including claims seeking damages for personal injury or property damage, whether sounding in contract, tort or strict liability. Buyer hereby assumes all risk related thereto.

Documents

TABLE OF CONTENTS - LinearGS · 2019-11-21 · 6 Revision Number: LV4000CE-01.01 Emergency Stop Buttons: Press either of the emergency stop buttons in any situation that causes concern