GNS-100C1 NUT-CCD

Optica Sorting Machine

Operating Manual

GEM INTERNATIONAL CO., LTD.

No. 34, Lane 105, Ho Chang Road Nan-Tze,
Address Kaohsitung, Taiwan
Tel 886-7-3659133. 886-7-3662451
Fax 886-7-3631837. 886-7-3652925
E-mail [email protected]
1. Preface------------------------------------------------------------------------------------------------- 1-1
2. General Safety Rule-------------------------------------------------------------------------------- 2-1
2-1 Safety of information--------------------------------------------------------------------------2-1
2-2 Location of warning sign, CE mark, and nameplate----------------------------------2-3
2-3 All safety related elements------------------------------------------------------------------2-5
2-4 Checklist of electrical and safety function---------------------------------------------2-10
3. Machine Description------------------------------------------------------------------------------- 3-1
3-1 General characteristics and features-----------------------------------------------------3-1
3-2 Specifications-----------------------------------------------------------------------------------3-2
3-3 Overall dimensions----------------------------------------------------------------------------3-3
3-4 Working space required and operating position---------------------------------------3-4
3-5 Main units and names------------------------------------------------------------------------3-5
3-6 Noise Level-------------------------------------------------------------------------------------3-6
4. Pre-use Preparation-------------------------------------------------------------------------------- 4-1
4-1 Warning inspection and use notice beginning operation----------------------------4-1
4-2 Expected use and limits of use------------------------------------------------------------4-2
5. Transportation, Installation and Disassembly Manual--------------------------------- 5-1
5-1 Transportation-----------------------------------------------------------------------------5-1
5-2 Installation and disassembly-----------------------------------------------------------5-2
6. Operator Manual------------------------------------------------------------------------------------ 6-1
6-1 control device: panel---------------------------------------------------------------------6-1
6-2 Machine operation procedure----------------------------------------------------------6-2
7. Maintenance and Adjustment Manual------------------------------------------------------- 7-1
7-1 Maintenance-------------------------------------------------------------------------------7-1
7-2 Adjustment size---------------------------------------------------------------------------7-3
7-3 Troubleshooting---------------------------------------------------------------------------7-8
8. Drawing and Part List----------------------------------------------------------------------------- 8-1
8-1 General electrical system drawings and parts list--------------------------------8-1
8-2 General pneumatic system drawings and parts list-----------------------------8-12
8-3 General drawings and parts list------------------------------------------------------8-14
9. How to Change the Belt -------------------------------------------------------------------------- 9-1
9-1 Belt Change and Disassemble -------------------------------------------------------9-1
9-2 Belt Change and Disassemble Steps -----------------------------------------------9-2
10. CCD Troubleshooting and Setup ----------------------------------------------------------10-1
10-1 Check CCD is normal -----------------------------------------------------------------10-1
10-2 CCD drive troubleshooting -----------------------------------------------------------10-2
10-3 Choose CCD Working Station ------------------------------------------------------10-5
【Appendix】
】 SIGITAL FIBER SENSOR-------- FS-V31/32 ---------Instruction Manual
 GEM INTERNATIONAL CO., LTD.
1. Preface

GNS-100C1 Optical Nut Sorting Machine is designed for nut manufacturers. It
can film the nuts images and expel defects quickly by measuring, inspecting,
and analyzing. Therefore, GNS-100C1 makes sure the quality of nut parts. The
functions of GNS-100C1 are flexible, and it expands the functions without limits.
Before using this machine, users need to read the operating manual in advance.
General safety rules need to be read in detail and operate them distinctly.

This machine has been designed and built in fall compliance with EN 60204-1
and EN1050 standard on machine and further modification, with high-quality
materials and particularly studying the possibilities to reduce as much as
possible the risks of accident.

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2. General Safety Rule
2-1. Safety of information

Safety of Environment

For setting the machine, please depend on your productive procedure, factory
space, the place of raw material and finished products, and packing position to
find a suitable place.

For setting the machine, please consider the illumination, ventilation system
and extinguish facility.

Do not set the machine beside any expected danger zone such as
inflammables.

Do not set the machine in damp position.

Please offer sufficiency space for machine operation and rotation.

Please keep the working zone clean.

Safety of Electric
（20A）

After setting the machine, please depend on actual load（ ）to distribute
electric current. Take care that the grounding must be connected in order to
avoid accident.

After connecting the power supply, check the rotate direction is correct or not,
if false, please exchange power supply cord.

Check the function of emergency stop switch is normal or not. The emergency
stop switch is used for disconnect the machine in urgent moment. Please keep
normal function. (When customers test the machine, they always forget to turn
off the emergency stop switch, and misunderstand the machine is broken)

In order to increase the security, the electric personnel must comply with the
needed electricity voltage（（380V） ）of each accessory. Please install a safety
switch on the wall of the main power source.

Examine the PC boards inside electric control box and electric accessory box.
Check the screw is loosened or not, if you found, please screw it tightly.

Before operation, please examine all the electric components are safety.

Please turn off the main power before maintenance, repair and cleaning.

Make sure the grounding policy to prevent the dangerous events.

Safety of Machine

On the basis of safety, any untrained person is prohibited operating the
machine.

Please confirm that all the operator or maintenance person have read the
operating manual and comprehend all the detail information.
Do not remove fixed warning signs, CE mark and nameplates.
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Do not modify the machine structure; the original design brings the best
efficiency and safety operation environment.

The rotation wheel axles contain the involving danger, operator must take care
the following situations: no larger clothes, wear working sleeves or gloves, no
necklaces, or longer hair must be fixed or bound by suitable accessory.

Keep both feet on the ground during operation, in order to prevent unstable
gravity from falling down.

Please conform to the instructions of this manual, in order to keep best
performance.

Please properly conserve the spare parts and tools, and avoid damp and
damage.

General

All operators and foremen should read carefully and make sure they understand
the details before starting operation and/or maintenance.

Handing of waste materials: The waste should be handled in accordance to the
environmental safety regulations of the local authority and relevant
international provisions.

Machine should not be operated under potential explosive surrounding.

Ventilation and fire extinguisher should be installed in the production site.

For safety reasons, un-trained operators are not allowed to operate the
machine.

Power supply switch should be turned off during maintenance, repair, and
cleaning.

Before starting the machine, make sure all the electrical components are
securely grounded.

Do not remove the warning signs, CE mark, and nameplates fixed on the
machine.

The working environment must use adequate ambient lighting.

Keep all guards in place and in working order.

Remove adjusting keys and wrenches from the machine.

Wear proper apparel. Avoid loose clothing, gloves, neckties, rings, bracelets, or
jewelry which could be caught in moving parts. Non-slip footwear is
recommended. Wear protective hair covering to contain long hair.

Do not over reach. Keep proper footing and balance at all times.

Maintain machine in top condition. Keep machine clean for best and safe
performance. Follow instructions for lubricating and changing parts.

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2-2. Location of Warning Sign, CE Mark, and Nameplate

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2-3. All Safety Related Elements
1. All safety related elements

ITEM Electrical Part Name Part NO Material Qty

1 Emergency stop switch EM1 1
2 Main power switch QS1 1
3 Continuity of the protective
BA1 1
bonding circuit

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2. Pictures

Emergency stop button

Emergency stop button:

1. It’s used for prevent the hazard in emergency situation.
2. The emergency stop button is according with the EN60947-5-4.
3. After pressing emergency stop button, operator has to solve troubleshooting and
make sure there are no personnel in danger zone. Operator has to restore the
emergency stop button and then restart the machine.

Grounding plate

Grounding plate:
1. All exposed conductive parts of the electrical equipment and the machine shall
be connected to the protective bonding circuit.
2. Only use yellow-green grounding wire.

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Door with locker

Door with locker:

1. There is a door locker attached to the door of electrical box.
2. Make sure the power supply is OFF before opening the control box.
3. Only authorized or trained technicians can maintain and repair the machine.

Electric box, IP4X

Electric box, IP4X (with door locker):

1. The degree of protection for electric cabinet must be more than IP4X.
2. The ventilating electric fan equipped with electric cabinet could decrease the
inside temperature.
3. There is a door locker attached to the door of electric box. If you would like to
open the electric box, the main power switch must be cut off in advance, and
then unlock the door locker.

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Control panel, IP5X

Control panel, IP5X:

1. The degree of protection for control panel must at least reach IP5X.
The control panel wiring must be covered by isolation sheath, and fix the inlet and

2. outlet by nuts.

Protecting cover

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1. Each of above cover cannot be dismantled.
2. The protecting cover protects operator from clamping, injecting, striking and
etc.
3. Before operating the machine, make sure all the protecting covers are closed
indeed.

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2-4. Checklist of electrical and safety function

Item Inspection and Safety Measurement Result Remark

1 Is every terminal protected by isolation plate (IP2X)? YES
2 Does technician follow the procedure number to wire? YES
3 Are the diameter of grounding wire and each circuit accord with
YES
safety requirement of designed electrical circuit?
4 Is fuse accord with safety requirement of designed electrical
YES
circuit?
5 Are these screws on electric box fixed tightly? YES
6 Is the electric box equipped with a ventilator (e.g. fan)? YES
7 Does the design of electric box conform to IP requirement? YES
8 Is all the function of every control switch and component
YES
described specifically on this operation manual?
9 Are input voltage, frequency, and phase marked correctly? YES
10 Is the machine earthed? YES
11 Is there an independent earth copper plate equipped inside
YES
electric box?
12 Is every function of control device regular? YES
13 Is the emergency stop device functional? YES
14 Is the safety control device functional? (e.g. interlocking switch) YES
15 Is the rotary direction of motor or transmission correct? YES
16 Is the cover functional (fixed or movable)? YES
17 Is the machine set stable? YES
18 Have all the acute angle and fur been ground? YES
19 Has the machine been pasted a CE mark? YES
20 Has the machine been pasted a nameplate? YES
21 Has the machine been pasted related warning marks? YES
22 Have the listed related safety parts in TCF 1.6 been installed
YES
indeed?
23 Have all the safety information and attentions been provided
YES
completely for user?
24 Does the written language of manual and machine conform to
YES
local country?
25 Has the operation manual been provided? YES
26 Has the EC Declaration of Conformity been signed? YES

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3. Machine Description
：
3-1. General Characteristics and features：

The machine has three systems.

A. Feeding System B. Inspecting System C. Packing and Counting System

：Feeding System（
A： （as follows）
）

It is composed of one hopper and one vibrating feeder. The parts can be
fed and neat automatically through this system.

：Inspecting System（
B： （as follows）
）

It is composed of four CCD optical cameras. It measures the size of the

parts and analyzes the characteristics, and expels the defects automatically.
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：Packing and Counting System（
C： （as follows）
）

It counts the parts from the inspecting system, and pre-sets the numbers.
When the numbers are done, it lays another carton automatically.

3-2. Specifications

Item GNS-100C1 footnote

The outer diameters can’t be more
Inspect parts size M5~M14
than 30mm.
It is based on 10*10mm square
nuts, and the actual speed will be
Inspecting speed ：600PCS/MIN
Max：
determined by the vibrating
feeder.
5 empty cartons
Carton number
4 finished cartons
Electricity voltage AC380/50HZ 1ψψ 10KVA
Machine size（ （mm） ） ：4250 W：
L： ：1850 H：：2220 Includes A.B.C.
Machine weight（ （kg）） 1035

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3-3. Overall dimensions

L:4250mm
A
B
C
W:1850mm
H:2220mm

Unit:mm
Length Width Heigth
Type
A 1220 1440 2080
B 1850 1750 2220
C 1960 860 800
TOTAL 4250 1850 2220

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3-4. Working Space Required and Operating Position
In order to have sufficiency space for repair, it is suggested to set the
machine as follows.

60cm

60cm 60cm

80cm

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3-5. Main Units and Names

Item Unit
1 （600mm*600mm）
Hopper（ ）
2 Vibrating feeder
3 Inspecting machine
4 17” touch screen
5 （IPC）
Industrial PC（ ）
6 Operating panel
7 Unloading valve
8 Empty carton pushing cylinder
9 Finished carton pushing cylinder
10 Empty carton conveyer

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3-6. Noise Level
Test equipment
1. TES-1352A Programmable Sound Level Meter.
2. Calibration due date: 2007/10/23
Test condition
1. The installation and mounting conditions are following the normal use of the
machine.
2. The test is carried out in the following conditions:
(1) Main driving motor: 400W
(2) Source: 1-phase 380V, 50/60Hz
Test procedure
The noise test is carried out in compliance with ISO/DIS 3746.2-1995 and
98/37/EC Directive.
Test result
The equivalent continuous A-weighted sound pressure level as below:

B D

C
UNIT: db
A B C D
TYPE
GNS-100C1 69 67 68 66

Name Signature Date

Tested by 03/08/09

Approved by 03/08/09

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 GEM INTERNATIONAL CO., LTD.
4. Pre-use Preparation
4-1. Warning Inspection and Use Notice Beginning Operation

Before operating machine, it would be suitable to carry out the following check
safety and preparation.

First of all, inspect the machine and accessory, in particular all projecting parts.

Check the motion of clamping mold.

Movable machine parts on the machine should be lubricating and wipe away
the dust.

Check if there is leaking in the air pressure system, and if there is enough air
pressure.

Record normal operating sound and check the abnormal sound.

Check if the electrical system is broken or bad connecting.

The operating staff should make sure that they have already understood the
operating of the machine completely.

The operating staff should know the position and function of safety equipment
perfectly.

Warning: Anyone who is not passed through the safety training should not
operate the machine.

Cylinder is on the right place.

The connector should connect correctly.

Inspecting nuts need to have degreased process before using.

Only skilled operator can adjust the mold parts in the machine.

Please operate the procedures when there is any unusual information.

Make sure the grounding policy to prevent the dangerous events.

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4-2. Expected Use and Limits of Use

If the machine has the abnormal sound during operating, the machine should
stop immediately. It may cause the operator in danger, and can find the source
of making abnormal sound. If it is needed, change the parts at once.

Before operating the machine, all the operator or maintenance person have
read and comprehend all the detail information. The operators are required to
familiar with the working environment.

Operator and maintenance person, includes all the company staff is requested
to have knowledge of the safety section of the machine, includes the position
and function of all safety equipment.

Before starting up or setting the machine in motion, make sure that nobody is at
risk.

The operator and maintenance person need to wear suitable working clothes
such as long hair must be tied back or have hair net on, and garments must be
close-fitting.

It is necessary to follow the directions of the warning signs.

The machine is only allowed for the inspecting nuts and relevant parts. Do not
put other foreign parts in.

The inspecting nuts need to have degreased process before using. The
machine is allowed for a little anti-rust oil on parts.

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5. Transportation, Installation and Disassembly Manual
5-1 Transportation
Make sure the forklift capacity is enough to lift the machine. Below table shows
net weight and gross weight for each model of machine. Before moving the
machine, make sure the forks of the forks of the forklift must completely protrude
over the machine bottom, and keep the machine well-balanced when lifting.

TYPE A B C
（kg）
Weight（ ） 540 500 180
、B、
A、 、C check from 3-3

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5-2 Installation and Disassembly
Installation Percedure:
1. First, fix the machine A (the inspecting machine), then lift four shock
resistance mats, and level them well by gradienter.
2. Place the feeder of machine B（the hopper and the vibrating feeder） ）into the
opening of the machine A.（（as follows））

3. （the counting and packing feeder）

Then, place the machine C（ ）into the
（as follows）
opening of the machine A, and then lock the wheels.（ ）

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 GEM INTERNATIONAL CO., LTD.
4. （two）
Connect the connectors of the machine C and the machine B（ ）, and
（one）
connector the air pressure（ ）. （as follows））

5. Connect the electricity voltage source and air pressure source.

Disassembly Procedure:

1. Disconnect the connector of the machine C and machine.

2. Push out the mahcine C.
3. Level down the four shock resistance mats of the machine B to the
movable level, and then push the machine B out.
4. Level down the four shock resistance mats of the machine A to the
movable level, and then push the machine A out.

Handing of waste materials: The waste should be handled in authority and

relevant international provisions.

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6. Operator Manual
6-1. Control Device: Panel

：Turn to ON, and start the machine. Turn to OFF, and turn off the

POWER：
machine.
：
Notice：
1. After turning off the power, do not turn the machine on immediately, and
wait for 5 seconds to restart.
2. Before turning off the power, please make sure the WINDOWS XP is off,
and
then turn off the power.
：The light is in the inspecting machine. It is recommended to

LAMPADA：
turn it off when the machine is operating or filming by CCD.
：The warning sound starts when it is not usual. It can be set up from

ALARME：
NUTVISON by manually.
：DIP SWITCH on the bottom can set the preset packing numbers,

CONTADOR：
and when the numbers are reached, the system changes the cartons
automatically, and the numbers turn to zero. If not to use the machine C, the
machine B stops immediately when the numbers are reached. Press RESET,
the numbers turn to zero.
：Press START, and the machine starts.

START：
：Press STOP, and machine stops working after inspect all inspections

STOP：
on the conveyer.
： All the operating parts and power stop at once when turns on

EMERGENCIA：
the emergency switch. When the screen shows “Emergency”, switches to right,
and it cancels the emergency condition.

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6-2 Machine Operation Procedure
：
Manual Operate：
、Turn on the power
1、
、Turn on the screen.
2、
、Turn on WINDOWS.
3、
、Press NUTVISION on the desktop, and it shows as follows：
4、 ：

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、Press “Test Data”, and it shows as follows:
5、

、Press “SETTING”
6、 ”(below the picture), and it shows as follows:

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、Press “Manual”, and it shows as follows:
7、

Press Forward Conveyer: The buffer conveyer rotates.

Press Main Conveyer: The inspecting conveyer rotates.

。
Press Unloading: The unloading valve opens。

Press Box Move: The packing machine moves the cylinder.

Press Carton Pushing: The packing machine pushes the cylinder.

。
Press Vibrating Feeder: The vibrating feeder rotates。

：When the packing machine uses, the packing machine
Carton operate/stop：
needs to push the fixed place, and then connect the connector and air
pressure connector. If not, Carton needs to switch to stop direction.

：It is optional to use it when there is something not
Buzzer operate/ stop：
normal.

：The time to expel the defects. The shorter time can expel the
Expel Time：
smaller parts, and the longer time can expel the bigger parts.

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、Expel altitude too high or too low.（
1、 （can’t reach the centre of the parts）。
）。
（as follows）
）

EXPLE STRONG/WEAK ADJUSTOR MANUAL WIPING BELT

、When NUTVISION has too many programs or the operating time is long, the
2、
solve way to fix it is to slow down the speed of the inspecting conveyer.
（Please contact with the company for details）
）

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 GEM INTERNATIONAL CO., LTD.
：
Automatic Operate：
：
1. Press NUTVISION on the desktop, and it shows as follows：

、Set the relevant parameter numbers.

2、
、Press START.
3、

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7. Maintenance and Adjustment Manual
7-1 Maintenance
The arrows on the pictures are maintenance places.
week
Maintenance Content Picture Maintenance Way
（day）
）
Inspecting machine conveyer Use lubricator Lube 2000 from
A 7
（X8）
bearing（ ） WURTH
Use lubricator Lube 2000 from
）
Packing machine bearing (X4） B 30
WURTH
Inspecting machine width Use lubricator Lube 2000 from
adjuster C 30
WURTH
Inspecting conveyer belt Use Stain Remover 7
Use Air-compressed Dust Off
Computer dustproof net D 7
to clean or change a new one.
Clean with lens-cleaning fluid
CCD lens （a）
E（ ） and lens-cleaning paper. 3
(sold from the camera shops） ）
Clean with lens-cleaning fluid
LED （b）
E（ ） and lens-cleaning paper. 1
(sold from the camera shops） ）
Clean with lens-cleaning fluid
Fiber （c）
E（ ） and lens-cleaning paper. 1
(sold from the camera shops） ）
Use lubricator Lube 2000 from
surface of the machine 1
WURTH

（Picture A）
） （Picture B）
）

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（Picture C）
） （Picture D）
）

a
a

c
b

b
a
（Picture E）
）

c c

（Picture F）
）

NOTE for maintenance person:

Please put the mask on when cleans the machine according to 4-1.
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7-2 Adjustment
：
Forward Conveyer Adjust：

BUFFER
CONVEYER

MOTOR
WIDTH
ADJUSTOR

：How to adjust the speed of the buffer conveyer?

Q：
：The buffer conveyer is connector of the forward vibrating feeder and the
A：
inspecting conveyer. If the speed is too slow, it jams the vibrating
feeder, and if the speed is too fast, the distance is too short when the
inspecting parts go into the inspecting conveyer. So the proper speed
is that the vibrating feeder feeds smoothly, and also has the sufficient
（at least 15mm）
space for inspecting conveyer.（ ）

Inspecting Conveyer Adjust: The Inspecting conveyer conveys parts on a single

conveyer (as follows). When changing inspecting
parts, the operator rotates width adjustor to fit
inspecting parts.

WIDTH
ADJUSTOR

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：
Optical CCD System Adjust：
The parts are movable on the conveyer. The moment when
the red light of the sensor is on to off, CCD takes the
pictures. One picture for the PC system and it is its basic
function. The CCD has three adjustable switchers.
(A) Aperture(Bright) (B) Zoom (C) Focus(Clear/Blurry)
：
As follows：

：How to adjust and offer the best picture?

Q：
：1、
A： 、Go to main screen and click “Test Data”, and press “Sequence”.
Then the light flashes, switch the light flasher to “Normal”. The
（as follows）
light keeps on.（ ）

（Front）
） （Back）
）
、Adjust the aperture and the focus to the best rate.
2、
、Press Sequence first and then press Trigger. The inspecting
3、

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conveyer starts rotating. Then switch to Trigger, place a nut as a
trigger, and the screen shows a picture.（the image will be darker）
）.
Then adjust the aperture or the strobe. Replace a nut as a trigger
to get the best picture.
：What is the best picture?
Q：
：The picture below is the best picture. It is clear, and no blur. The
A：
measurement is accuracy and correct.

The picture below is not focused. Please adjust the focus of the
camera.

：It is composed of one or two strobes. （as follows）

Light System： ）
The value of light is bigger, the image is brighter; the value of the
light is smaller, the image is darker. Light emitting value is
bigger, the flash time is longer; light emitting value is smaller,
the flash time is shorter. (When emitting, DO NOT move!)

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7-3 Fault Expelling

：
Fault Chart：
Fault Direction Symbol Result
Place empty cartons on the convey or adjust
Place empty cartons X16
sensor X16.
Production cartons full X20 Take production cartons away
Air pressure is not
enough, and jumps off the X11 Check air pressure.
emergency press.
Cartons expelling fault X21 Check cartons expelling sensor.
Check the conveyer, and if parts stick in it, take
Serve motor fault X23
them out and restart the computer.
Emergency stop switch is pressed. Switch to right
Emergency Condition X10
way and go back to the normal condition.
Pre-set number is reached When pre-set number is reached, the packing
X13
and presses the start. conveyer will stop. Please press the start.

：
Footnote：
The way to adjust fiber sensor:
This machine is divided into two fiber amplifiers. ( Series K and Series S)

1. Series K fiber amplifier:

DON’T TOUCH

MANUAL
BUTTON
DON’T
TOUCH
DON’T TOUCH

The number on the left is the check sensor. There is “TRIGGER” on the surface of
the box. Press▼ or ▲, the preset number flashes immediately. Press again, the
preset number changes. Leave for 3 seconds, the numbers turns normal.
：Do NOT press SET or MODE , SEL, L/D ON!
NOTE：

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：What are the best numbers to set？
Q： ？
： As the picture above shows, the number on the left is thickness inspecting
A：
trigger. It is 1185 now, and the preset number is better to be around 200. (If set
the number too big, it might have the image cut problem). The second one on
the left is thread inspecting and inside and outside diameter trigger. It is 118.
The third one on the left is bottom defect inspecting trigger, and its sensibility
is 58. The right one is the finished production packing number, and present
number is 698.

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 8-1 General Electrical System Drawings and Parts List
AC380V/60HZ QS1 TM1 TH2 2.0mm2 KM2
R RT R1 R2
L1
TO

GEM INTERNATIONAL CO., LTD.

S 220VAC
L2 ST S1 S2 P-02

L3 RL
110VAC
SL
PE (page P-05)

1.25mm2

8. Drawings and Parts List

2.0mm2 1.25mm2 1.25mm2 1.25mm2

TH3 TH4 TH5

TM1-Power Transformar.
Roted Capacity:22KVA RA R4 R5
Primary Voltage:380VAC
TH1 SL1
Secoudary Voltage:220VAC RL1 EMI2
Power frequency:50/60Hz
8-1

RL1 SL
ML1
KM3 KM1 Y5A S2A
SL2 R5A
U V RL2 SL2 Part feeder
RB PH
EMI1 controler
Servo KM1
MOTOR RL3 SL3 HF Hopper feeder PLC Power Power
SD1 KM2 controler Supply Supply
DRIVER PLC PS1 PS2
FX2N-48MT S-50-24 D-50A
(page P-03)
FM +V 0V +V 0V
U1 V1 W1 KM3
BA1

P N 12V 5V COM
SM1 SM
400W
TO Page
06~09
(page P-04)

Circuit Diagram DEBBY 07/03/15

NUT-CCD Optical
GNS-100 Sorting Machine GEM INTERNATIONAL CO., LTD. 07/01/30 Page P-01
 EM1
R6
R2

From
S2

GEM INTERNATIONAL CO., LTD.

P1
1.25mm2
PE

TH6

R7

R7 S2
RL2

RL3 Y6A S2
8-2

Y13A S2 Boffer COUNTER

Motor CA-51P
US1 CN1
Control
Y US-602-2 +V 0V

Carton
M2 MOTOR
40W Y22 N X13 N

M3 MOTOR
6W

Circuit Diagram DEBBY 07/03/15

NUT-CCD Optical
GNS-100 Sorting Machine GEM INTERNATIONAL CO., LTD. 07/01/30 Page P-02
 MR-J2S40A Driver (SD1)

GEM INTERNATIONAL CO., LTD.

15 N
U L1 16
17
V L2
10
PE 20
5 Y7
EM1 7
18 X23
13 P
L21 9
L21
L11 CN1-B
8-3

U1
U
V1
V SM1
W1
W

Servo Motor Diagram DEBBY 07/02/06

NUT-CCD Optical Page P-03
GNS-100 Sorting Machine GEM INTERNATIONAL CO., LTD. 07/01/30
 GEM INTERNATIONAL CO., LTD.
BA1

RL2
From
P1 SL2

PE

Industrial T705 Strobe Strobe

IPC1 Compoter LCD1 LCD SB1 Control SB1 Control
8-4

Moniter

Led1 Led2 Led3 Led4

Receptacle system DEBBY 07/03/15

NUT-CCD Optical GEM INTERNATIONAL CO., LTD.
GNS-100 Sorting Machine 07/01/30 Page P-04
 GEM INTERNATIONAL CO., LTD.
2.0mm2 1.25mm2 1.25mm2 0.75mm2 0.75mm2 0.75mm2 1.25mm2

2.0mm2 2.0mm2 0.75mm2 0.75mm2 0.75mm2 1.25mm2

PE
M2 EMI2
8-5

Servo Part Feeder Power Carton COUNTER

Driver Hopper Feeder Supply MOTOR
SD1 PS1

M3

TRANSFORMER BA1 PLC Power Boffer EMI1

Supply MOTOR
PS2

GROUNDING SYSTEM DEBBY

07/03/15
NUT-CCD Optical
GNS-100 Sorting Machine GEM INTERNATIONAL CO., LTD. 07/01/30 Page P-05
GEM INTERNATIONAL CO., LTD.

Page P-06
07/03/15
From P1

N P
COM
X0
X0 PY0 From PC CCD1 ok
X1
X1 PY1 From PC CCD3 ok
X2
X2 PY2 From PC CCD2 ok

07/01/30
X3 X3
CCD1 expel
PA1

PA2

GEM INTERNATIONAL CO., LTD.

X4
X4
CCD2 expe1

DEBBY
PA1

PA2

X5 CCD3 expe1
X5 PA1
FX2N-48MT PLC

PA2

X6
X6 START
PB1
X7

NUT-CCD Optical
Sorting Machine
X7 STOP

INPUT Diagraml
PB2
X10
X10 EMG
EM1
X11
X11 Pressure switch
P1

X12 X12
PY3 Form PC watch Dog
X13
X13 Counter
CN1
X14
X14
GNS-100

Count Sensor
PH1
X15
X15 PY4 Form PC AUTO/MUL

X16
X16
Carton Fix Sensor
PH2

X17

8-6
GEM INTERNATIONAL CO., LTD.

Page P-07
07/03/15
From P1

N P

X20
X20
Carton Full Sensor

07/01/30
PH2
X21

X22

X23
X23 Servo Alarm

X24
X24 PY5 Form PC NG Continuum

GEM INTERNATIONAL CO., LTD.

X25

DEEBY
X25
FX2N-48MT PLC

CCD1 expel Inspection sensor

PH1

X26
X26
CCD2 expel Inspection sensor
PH1

X27
X27
CCD3 expel Inspection sensor
PH1

NUT-CCD Optical
Sorting Machine
INPUT Diagram2

GNS-100

8-7
GEM INTERNATIONAL CO., LTD.

Page P-08
From P1

07/03/15
N P
COM1

Y0
Y0 CCD1 expel SOL
SOL1

Y1
Y1 CCD3 expel SOL
SOL1

Y2

07/01/30
Y2 CCD2 expel SOL
SOL1

Y3
Y3 PX2 TO PC Alarm

COM2

Y4

GEM INTERNATIONAL CO., LTD.

Y4 PX0 TO PC START

DEBBY
Y5
Y5 Part Feeder
RL1
Y6
Y6 Boffer Motor
RL2
Y7
Y7 MR-J2S40A (CN1B5.7.9) Servo Motor ON/OFF
FX2N-48MT

COM3

Y10
Y10 Unloading SOL
SOL2

Y11

NUT-CCD Optical
Sorting Machine
OUTPUT Diagram
Y11 Move Carton SOL
SOL2

Y12
Y12 Push Carton SOL
SOL2
Y13
Y13 Carton MOTOR
RL3
COM4

Y14
Y14 Stop Lamp
PB1
Y15
Y15 Work Lamp
GNS-100

Lamp1
Y16
Y16 Ready Lamp
Lamp1
Y17
Y17 Alarm Lamp
Lamp1
COM5

Y20
Y20 Buzzer
BZ1
Y21
Y21 PX1 TO PC Stop

Y22
Y22 CA-51P IN COUNT OUT

8-8
GEM INTERNATIONAL CO., LTD.

Page P-09
07/03/15
From P1

N P
Y3
IDI2 2 TO PLC Y3

Y21

07/01/30
IDI4 3 TO PLC Y21

ECOM 9

EGND 10

GEM INTERNATIONAL CO., LTD.

PCOM 19

向貴湘
Y4
IDI3 21 TO PLC Y4

X0
IDO0 11 TO PLC X0

X2
IDO2 12 TO PLC X2

X15
IDO4 13 TO PLC X15

X1
IDO1 30 TO PLC X1

X12

PLC & PC Link Diagram

IDO3 31 TO PLC X12

NUT-CCD Optical
Sorting Machine
X24
IDO5 32 TO PLC X24

TINA
IDI0 1 TO Trigger board #2

TINB
IDI6 4 TO Trigger board #7
ADHM-3937 (TB1)

TINC
IDI8 5 TO Trigger board #10
GNS-100

8-9
 GEM INTERNATIONAL CO., LTD.
General Electrical Parts List
ITEM Description Specification Qty Part no Suppler Remark
QS1 Main power 3P20A 1 NSC100ROTE+EZC10 Schneider EN60947-1
switch 0B3020
TM1 Transformer 22KVA 1 AC380→AC220V, Shine EN61000-4-2
AC110V
TH1 Circuit breaker 1P10A 1 MY110 Hager EN60898
TH2 Circuit breaker 2P16A 1 MY216 Hager EN60898
TH3 Circuit breaker 1P4A 1 MY104 Hager EN60898
TH4 Circuit breaker 1P10A 1 MY110 Hager EN60898
TH5 Circuit breaker 1P6A 1 MY106 Hager EN60898
TH6 Circuit breaker 1P4A 1 MY104 Hager EN60898
KM1 Magnetic AC220V 1 L1D096M7 Tele EN60947-1
mecanique
KM2 Magnetic AC220V 1 L1D096M7 Tele EN60947-1
mecanique
SD1 Servo Driver AC220V 1 MR-J240A MITSUBIS EN50178
HI
SM1 Servo Motor AC220V 1 JC-KFS43 MITSUBIS EN60034-1
HI
BA1 Receptacle 125V 11A 1 TC-2306 Tsuin Chin
ML1 Lamp AC220V 1 L20446A2-2 SHE
SL1 Select Switch 1 E2S2K1A5LR.V META IEC61058-1
SL2 Select Switch 1 E2S2K1A.V META IEC61058-1
FM AC220V 1
RL1 Relay DC24 1 MK-2P OMRON
RL2 Relay DC24 1 RM2S-U DC24 IDEC EN61810-1
RL3 Relay DC24 1 RM2S-U DC24 IDEC EN61810-1
PH Part Feeder AC220V 1 CF-PH01 CIN FUL
Controller
HF Hopper Feeder AC220V 1 CF-PH02 CIN FUL
Controller
PLC PLC AC220V 1 FX2N-48MT MITSUBIS
HI
PS1 Power Supply AC220V DC24 1 S-50-24 MEAN
WELL
PS2 Power Supply AC220V, DC5 1 D-50A MEAN
DC24 WELL
M2 Motor 40W 1 5IK40G-C SESAME EN60034-1
8-10
 GEM INTERNATIONAL CO., LTD.
ITEM Description Specification Qty Part no Suppler Remark
M3 Motor 15W 1 M315-402 SESAME
CN1 Counter AC220V 1 CA-51P CONCH TUVAN
205634201
EM1 EMG STOP 1A2B 1 XB5AS8442 Tele EN60947-1
mecanique
US1 Speed Contro1 AC220V 1 US315-02 SESAME
IPC1 Industrial AC220V 1 ARC-640-W BEST
computer
LCD1 LCD Monitor AC220V 1 T705 BenQ
LED1 LED Lamp DC12 1 KDDM-60/60RT Kyoto
LED2 LED Lamp DC12 1 KDDB-50/11 Kyoto
LED3 LED Lamp DC12 1 LDL-TP43*35 CCS EN61010-1
LED4 LED Lamp DC12 1 LFV-50 CCS EN61010-1
PA1 Proximity Switch DC24 3 GL-18H SUNX EN55011
PA2 Proximity Switch DC24 3 QL-1808NA CONCH EN60947-5-2
PB1 Push Button DC24 1 01P-RM40Q1P+V+L24 META IEC61058-1
PB2 Push Button DC24 1 01P-RM40Q1P+W+L24 META IEC61058-1
P1 Pressure Switch DC24 1 GS1-50-DC KOGANEI
PH1 Fiber Sensor DC24 4 FS-V11 Keyence EN60947-5-2
PH2 Photo Sensor DC24 2 PZ-M31 Keyence EN60947-5-2
SOL1 Solenoid Value DC24 3 35A-AAA-DDAA-1BA MAC
SOL2 Solenoid Value DC24 3 RS2413-01-D24L KURODA
Lamp1 Color Lamp DC24 1 TPWL-5 LED DC24 Tend EN61000-3-2
BZ1 Buzzer DC24 1 E2B1.24 META
CCD Camera 640P*480P 3 XC-56 SONY
SB1 Strobe Control AC110V 2 GLS-302 DYNATEC
I/O Card 1 PCI-1730 ADVANTEC
H
I/O TB 1 ADAM-3937 ADVANTEC
H
Frame Grabber 3 PCI-1409 National EN-61000-4-2
Instruments
Grabber Cable 3 IMAQ-A8055 National
Instruments
Fan Cover 1 FU-9703 CHUKI
EMI1 EMI Filer 10A 1 FU2030-10-06 Schaffner
EMI2 EMI Filer 6A 1 FU2090-6-06 Schaffner

8-11
 8-2 General Pneumatic System Drawings and Parts List
Carton Exchang Device
4
3 1 2 12
5kg/cm2

GEM INTERNATIONAL CO., LTD.

SOL 7
Defect Expel Defect Expel Defect Expel

Packing Machine Packing Machine

10 11
SOL 1 SOL 2 SOL 3

5 5 5
SOL 5 SOL 6
8,9
8-12

Cleaning and Maintenance Device

Expel Part Device

6 7

SOL 4

AIR CIRCUIT TOM 07/04/03

NUT-CCD OPTICAL
GNS-100 SORTING MACHINE 07/03/02 NS100-AIR-CE
 GEM INTERNATIONAL CO., LTD.
General Pneumatic System Drawings and Parts List
ITEM Description Specification Qty Part no Suppler Remark
1 Pressure 1 B012W-4G KURODA
adjuster
2 Filter 1 SA602MD KURODA
3 Blow Off Valve 1 W-3-3/8”-A-ME POSU

4 Pressure DC24V 1 GS1-50-DL KOGANEI

Switch
5 Air adjuster 3 JDSCN8-01B

6 Overlock 1 1/4”overlock
7 Heater 1
8 Connector 1 ZCSP-20
9 Connector 1 ZCPP-20
10 Cylinder 1 DGP-25-400-PPV-A-B+HP FESTO
11 Cylinder 1 DAL40M300+FA HINAKA
12 Cylinder 1 DIC25M100+CB+PIN+PHS10 HINAKA
SOL1 Solenoid Valve DC24V 1 35A-AAA-DDAA-1BA MAC
SOL2 Solenoid Valve DC24V 1 35A-AAA-DDAA-1BA MAC
SOL3 Solenoid Valve DC24V 1 35A-AAA-DDAA-1BA MAC
SOL4 Solenoid Valve DC24V 1 RCS2413-01-DC24 KURODA EN-550
22
SOL5 Solenoid Valve DC24V 1 RCS2413-01-DC24 KURODA EN-550
22
SOL6 Solenoid Valve DC24V 1 RCS2413-01-DC24 KURODA EN-550
22
SOL7 Solenoid Valve DC24V 1 RCS2413-01-DC24 KURODA EN-550
22

8-13
 8-3 General Drawings and Part List
GEM INTERNATIONAL CO., LTD.
4250mm

A
B C
1850mm
8-14

2820mm

NUT-CCD Optical Sorting Machine GEM INTERNATIONAL CO., LTD.

 GEM INTERNATIONAL CO., LTD.
2080mm 1440mm

A-2

A-1
1220mm

A-3
A-4
8-15

NUT-CCD Optical Sorting Machine GEM INTERNATIONAL CO., LTD.

GEM INTERNATIONAL CO., LTD.

B-6
B-4 B-6

B-1-1 B-4
B-3-1
B-1-2 B-7
1750mm

B-2 B-7-1
B3-2
B-5

GEM INTERNATIONAL CO., LTD.

B-5
B-2 B-5 B-4

B-8
1850mm

NUT-CCD Optical Sorting Machine

2220mm

8-16
 1970mm

GEM INTERNATIONAL CO., LTD.

C-2

C-1

860mm
C-3

C-4

C-5
8-17

800mm

NUT-CCD Optical Sorting Machine GEM INTERNATIONAL CO., LTD.

 GEM INTERNATIONAL CO., LTD.
Assemble Parts List
ITEM Specifi- Qty Part no Suppler Remark
Description cation
A Feeding System 1 1220(L)*1440(W)*2080(H)
A-1 Hopper 1 600(L)*600(W)*720( H)
A-2 Line Feeder 1 LINE-1 MIN JUI
A-3 Feeder 1 FEED-1 MIN JUI
A-4 Man feeding stand 1
B Inspecting Machine 1 1850(L)*1750(W)*2220(H)
B-1 Speed Adjuster Device 1 For sorting nuts

B-1-1 Motor 1 15W*4P(rate1:9) SESAM

E
B-1-2 Belt 1 40(W)*975(L) LONGE
B-2 Adjustor Board 2 stroke 40
Device
B-3 Inspect Conveyer 1 For sorting nuts
Device
B-3-1 Motor 1 ASMTO4L250AK (400W) DELTA
B-3-2 Belt 2 33(W)*1780(L) LONGE
B-4 CCD Adjustor Device 4
B-5 Defect Expel System 3
B-6 Defects place 3
B-7 Unloading valve 1
B-7-1 Cylinder 1 DIC 25M100PPV+CB+PIN HINAK
A
B-8 Screen and Keyboard 1
C Packing System 1 1970(L)*860(W)*800(H)
C-1 Motor 1 90W*4P(rate1:25) SESAM
E
C-2 Belt 1 30(W)*2820(L)
C-3 Cylinder 1 DGP-25-400-PPV-A-B FESTO
C-4 Cylinder 1 DAL40M300 HINAK
A
C-5 Roller 1 ψ38*340(L)

8-18
 GEM INTERNATIONAL CO., LTD.
9. How to Change the Belt
9-1. Belt Change and Disassemble

9-1
 GEM INTERNATIONAL CO., LTD.
9-2. Belt Change and Disassemble Steps
1. Take off “cover” on the sprocket, as item 1.
2. Take off ”board light”, as item 2. (Place it on the proper place and not
damage it.)
3. Take off left/right side “front and back pressure plate”, as item 3,4.
4. Loose hex nuts on the right and left sides of conveyer, as item A/B.
Take off “washer”, as item 5,6.
5. Take off “driven axel、driven axel washer、driven wheel and rolling
element bearing”, as item 7,8,9,9a,9b.
6. Take off “driven timing pulley” and “washer”, as item 10,11.
7. Disassemble fixed nuts of axle center, as item 12.
8. Loose the fixed nuts on “driving wheel”, and then take off “ rolling
element bearing、axle center、and driving wheel”, as item
13,14a,14b,15.
9. Take off “middle board 4”, as item 16. (Do Not touch the sensors at the
side when taking out.)
10. Take off “middle board 3”, as item 17. (Do Not touch the sensors at the
side when taking out.)
11. Take off “Glass”, as item 18. (Place it on the proper place and not
damage it.)
12. Take off “middle board 2”, as item 19. (Do Not touch the sensors at the
side when taking out.)
13. Take “belt” out and replace a new belt, as item 20.
14. Repeat the steps from item 12 to item 1, and put back all devices on
the conveyer.
15. Adjust hex nuts on the right and left sides of conveyer. As item A/B.
adjust the belt to proper tightness.

9-2
 GEM INTERNATIONAL CO., LTD.
10. CCD Troubleshooting and Setup
10-1. Check CCD is normal
Please go to 「Control Panel」 「System」「Hardware」「Device Manager」
Each 1394 interface card should come with one CCD.

1394 interface card 2

CCD

10-1
 GEM INTERNATIONAL CO., LTD.
10-2. CCD drive troubleshooting

abnormal

Go to「D:\IC 3.04」, and click「setup.exe」

10-2
 GEM INTERNATIONAL CO., LTD.
Click「Driver」

Click「Install」

10-3
 GEM INTERNATIONAL CO., LTD.
Click「Continue Anyway」

Click「Finish」

Clic

10-4
 GEM INTERNATIONAL CO., LTD.
After checking the drive program, please return to「Control Panel」「System」1.
「Hardware」2.「Device Manager」to confirm whether the CCD is normal. The steps are as
following:

normal

10-3. Choose CCD Working Station

10-3-1. Go to the desktop, and click「NutVision」

10-5
 GEM INTERNATIONAL CO., LTD.
10-3-2 Run「Test Data」

10-3-3 Click「Setting」below the Camrea1.

10-6
 GEM INTERNATIONAL CO., LTD.
10-3-4 Click the blank place as points.

10-7
 GEM INTERNATIONAL CO., LTD.
10-3-5 Click「Camera Setting」

10-3-6 Click the right working station of Camrea1 CCD. For example, click「DMx
21BF04」.

10-8
 GEM INTERNATIONAL CO., LTD.
10-3-7 Click「Properites…」

10-9
 GEM INTERNATIONAL CO., LTD.
10-3-8
「Auto」 from「Gain」 and「Exposure」do not click.
Set 「Brightness」number 255,
Set 「Gain」number 1023,
Set 「Exposure」number between 1/2000~1/1000.
After setting, click 「Update」「OK」

3
4 1
5 2

6 7

10-10
 GEM INTERNATIONAL CO., LTD.
10-3-9 Choose「60.00024」「Update」「OK」

2 3

Click「Sequence」, and confirm the set CCD and working station link well.

If not, click「Camera Setting」again, and restart step 「10-3-6」. Choose「DMx 21BF04

1」or「DMx 21BF04 2」to run again.

10-11