INTRODUCTION

According to the requirements for box presentation for a CSF/CSD machine, the box sent to the machine should be open at the top to perform the folding and sealing process. However, in certain facilities, the production line is designed to handle both pre-sealed/closed boxes and open boxes on the same conveyor before they reach the sealing machine.

In such scenarios, a CSF/CSD machine offers a bypass feature that can be activated by installing a bypass sensor kit. By integrating this kit into the machine, we gain the ability to use the machine for sealing open boxes and bypassing closed or pre-sealed boxes.

PARTS & TOOLS

CSF/CSD machines are models with specific dimensions depending on what is the box range that customer is looking for. Before installing a bypass sensor, we must verify the configuration of our machine (222 Config or 333 Config) and select the suitable kit. 

Part list for 222 Configuration 

Part list for 333 Configuration 

Parts needed

Tools

1. Adjustable wrench.
2. Crimper/Wire stripper.
3. Tap wrench.
4. Metric tap M5
5. Metric drill bit M2
6. Metric drill bit M4.5
7. Center punch tool
8. Metric Allen key M4
9. Zip ties
10. Zip tie adhesive-backed mounts
11. Drill

HOW TO ASSEMBLE THE BYPASS KIT

1.- With the M4 Allen key and using the screws and washer, add a corner bracket in both sides of the bypass sensor’s bracket.

2.- Use the adjustable wrench to mount the bypass sensor in the bracket’s center hole and connect the shielded 5 pins cord to the sensor.

3.- Use at least 4 adhesive-backed mounts to hold the cord with zip ties (The wire and the adhesive backed mounts must go to the machine electrical cabinet’s direction).

After this step, the bypass kit is completely assembled and is ready to be mount on the C-Serie machine.

HOW TO MOUNT THE BYPASS SENSOR KIT ON THE MACHINE

1.- Remove the analog sensors’ cover.

2.- Plot the following dimensions on the covers and use the center punch to mark the points.

3.- With the drill, use the M2 drill-bit and then the M4.5 drill-bit to create the holes, once you have the holes ready, use the metric tap M5 to make a thread for M5 screws.

4.- Mount the covers back on the machine.

5.- With the Allen key M4 and using the screws and washer, add the bypass kit on the machine.

6.- Send the shield cord to the electrical cabinet.

HOW TO CONNECT THE BYPASS SENSOR

The sensor’s cord has 5 wires but for this application, we only need to connect 3 wires on the machine:

Brown wire: Positive (+).

Blue wire: Negative (-).

Grey wire: Signal (IN2+).

1.- Identify the wires that we need to connect to the machine.

2.- Crimp the Y-Type connectors on the wires (Before crimping the wires, we strongly recommend adding labels on the wires to be easy to identify).

3.- Connect the brown wire with the positive terminals, the blue one with the negative terminals and look for an available connection for IN2+.

4.- Connect the sensor in the PLC’s analog module on the following way:

Analog module: IN 2(-) --> Machine connection: -

Analog module: IN 2(+) --> Machine connection: IN2+

Once you are done with the connections, the bypass sensor will be ready for calibration and bypass testing.