INTRODUCTION

In accordance with the box presentation specifications for a CSEG machine, the box before to go to the machine must have the top flaps open to permit the folding and sealing processes. However, in specific facilities, the production line is configured to accommodate both pre-sealed/closed boxes and open boxes on the same conveyor before they reach the sealing machine.

In these situations, a CSEG machine provides a bypass feature that can be activated by installing a bypass sensor kit. By incorporating this kit into the machine, we acquire the capability to bypass the pre-sealed boxes and still sealing the open standard boxes.

PARTS & TOOLS

The bypass kit, along with all the associated part numbers that constitute the kit are compatible with all CSEG and CSEGA models. The assembly and connection steps are identical for all models.

Part list for bypass kit

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.-Utilizing the M4 Allen key, add a corner bracket on both sides of the bypass sensor's bracket by employing the provided screws and washers.

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

3.-Use a minimum of two adhesive-backed mounts to secure the cord with zip ties, ensuring that both the wire and the adhesive-backed mounts are directed towards the machine's electrical cabinet.

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

 

HOW TO MOUNT THE BYPASS SENSOR KIT ON THE MACHINE

1.-Plot the following dimensions on the side bars, located at the entry of the machine, and use the center punch to mark the points.

2.- With the drill, first use the M2 drill bit, followed by the M4.5 drill bit, to create the holes. Once the holes are prepared, utilize the metric tap M5 to thread them for M5 screws.

3.- Using the M4 Allen key, attach the bypass kit to the machine using the provided screws and washers.

4.- Route the shield cord to the electrical cabinet.

 

HOW TO CONNECT THE BYPASS SENSOR

For this application, only three wires from the sensor's cord are required to be connected to the machine:

1. Brown wire: Positive (+).
2. Blue wire: Negative (-).
3. Black Wire: Signal (I:3/06+).

1.- Identify and connect these specified wires to the machine.

2.- Crimp the Y-Type connectors onto the wires. Before crimping, it is strongly recommended to add labels to the wires for easy identification.

3.- Connect the brown wire to the positive terminals, the blue wire to the negative terminals, and locate the connector labeled I:3/06+ for the black wire.

 

HOW TO CONNECT THE RELAY FOR THE ULTRASONIC SENSOR

1.- To acquire the signal from the ultrasonic sensor and transmit the ON/OFF data to the Programmable Logic Controller (PLC), it is necessary to incorporate a 24-volt relay for initiating the input signal while safeguarding the PLC input concurrently. The components required for installing the relay are as follows:

• P/N: 2830110 | Qty: 1 | RELAY, OMRON LY-2NJ DC24V
• P/N: 2831204 | Qty: 1 | SOCKET, RELAY STF-08AM

2.- Connect the relay to the socket and position it alongside the other relays.

To identify the connectors of the relay, refer to the following schematic diagram:

3.- Identify the black wire with the label I:3/06+ originating from the ultrasonic sensor. Subsequently, attach another wire to the opposite side of the connector and route this wire to the positive terminal of the relay (No. 8).

4.- Proceed by establishing an electrical bridge between one of the negative wires of the control panel and the negative terminal of the relay (No. 7).

5.- Connect the PLC input I:3/06 to one side of the Normally Open switch of the relay (No. 4), and attach a negative wire to the common connector of the N/O switch (No. 6).

HOW TO PROGRAM THE ULTRASONIC SENSOR

1.- To access the Pepperl+Fuchs website where the software for the ULTRA-PROG-IR is located, please use the following link:

ULTRA-PROG-IR Software

Get the necessary software by downloading the link located in the "Software Tools" option, then proceed with the installation.

Once you download and install the ULTRA-PROG-IR software, you will identify the program on your computer by this icon:

2.- To obtain information from the sensor and adjust internal parameters, you must use the interface cable UC-PROG-IR-USB.

To establish infrared communication between your computer and the sensor, attach the interface cable UC-PROG-IR-USB to the Ultrasonic sensor on this way:

 

3.- Once you have connected the Interface cable UC-PROG-IR-USB to the Ultrasonic sensor, click on the "Connect sensor" option.
NOTE: If the screen displays an issue with the infrared detection, ensure that the Interface cable UC-PROG-IR-USB is properly placed on the Ultrasonic sensor.

4.- There are three parameters that need to be adjusted to detect the specific box we are targeting for bypassing while simultaneously avoiding false bypass detections with other boxes:

• Analog output 1
• Control Elements
• Sensing range

ANALOG OUTPUT 1: In this section, you must set the analog range from the Ultrasonic sensor to the Indexer surface. In a standard CSEG222/CSEGA222, the range starts at 150mm and ends at 700mm.

CONTROL ELEMENTS: In the "Adjustment range" section, we must set the same range that we set on the previous screen (Start: 150mm - End: 700mm).

SENSING RANGE: Set the sensing range to 700mm, then click the "Indicate distance" option.

5.- After selecting the "Indicate distance" option, place the box that you would like to bypass on the indexer for detection by the Ultrasonic sensor.

Once you place the box, you will see the detection distance on the ULTRA-PROG-IR screen.

6.-The purpose of the blind zones is to avoid detections of box sizes that we do not want to bypass. It is strongly recommended to set a ±15mm tolerance with the box you would like to bypass. Additionally, you can place the rest of the box sizes on the indexer. If these boxes are not being detected after setting the blind zones, it means the configuration is correct for your equipment. If needed, you can reduce the detection tolerance.

Once you have successfully completed these steps, the installation of the bypass kit is considered complete!