can enamel rater hd131c

Transcription

CAN ENAMEL RATER
HD131C
Operation, Calibration and Servicing
Manual Version 1, Revision C
HD131C CAN ENAMEL RATER
Warning
2
WARNING
THIS EQUIPMENT CONTAINS HAZARDOUS MAINS
VOLTAGES, HIGH PRESSURE AIR AND POSSIBLE
CRUSHING FORCES
PLEASE FOLLOW ALL VERSATILE TECHNOLOGY
INSTRUCTIONS AND ALL HEALTH AND SAFETY
DIRECTIONS IN YOUR WORKPLACE
DO NOT DEFEAT ANY GAUGE SAFETY FEATURES OR
INTERLOCKS
DO NOT OPERATE THIS EQUIPMENT IF ANY PANELS,
SAFETY COVERS OR INTERLOCKS ARE MISSING OR
DAMAGED
INTERNAL SERVICE SHOULD BE PERFORMED BY
QUALIFIED
PERSONNEL ONLY
DO NOT OBSTRUCT ANY PNEUMATIC ORIFICE WITH
ANY PART OF THE HUMAN BODY
THE POWER SUPPLY SHOULD BE PROTECTED BY AN
R.C.D (EARTH LEAKAGE) DEVICE DURING SERVICE
THIS EQUIPMENT SHOULD BE REGULARLY SUBJECTED
TO A GAUGE SAFETY TEST (REFER TO CHECKLIST IN
SAFETY SECTION)
VERSATILE TECHNOLOGY
Contact Details
Head Office ........................................................................................................................................ 5
Representatives ................................................................................................................................ 5
Introduction
Things you should consider before starting ..................................................................... 7
Installation
Following the correct procedure ........................................................................................... 8
Safety
Overview .......................................................................................................................................... 10
Label Checklist ............................................................................................................................... 13
In Service Safety Inspection and Electrical Safety Testing ..................................... 14
Equipment Electrical Safety Testing Procedure .......................................................... 15
Part B: Earth Resistance or Protective Earthing Test ............................................... 16
Electrical Safety Certificate ..................................................................................................... 17
Operation
Main toolbar ................................................................................................................................... 18
Running an automatic test ...................................................................................................... 19
Pausing and stopping a test .................................................................................................... 21
Running out of samples unexpectedly ............................................................................. 21
Software Interface
Main Screen .................................................................................................................................... 22
Main Toolbar .................................................................................................................................. 22
Main Toolbar - Test ................................................................................................................... 22
Main Toolbar - File ...................................................................................................................... 23
Main Toolbar - Menu ................................................................................................................ 23
Menu - Settings ............................................................................................................................. 23
Menu - Profiles .............................................................................................................................. 29
Menu - Diagnostics ..................................................................................................................... 30
Gauge Output ............................................................................................................................... 31
Software Updates
Performing A Software Update ........................................................................................... 32
Backing Up Gauge Settings .................................................................................................... 33
Maintenance
Routine maintenance ................................................................................................................. 34
Drain Mist Separator .................................................................................................................. 34
Specific Maintenance .................................................................................................................. 35
System Voltages ............................................................................................................................ 36
HD149A Heavy Duty Power Supply ............................................................................... 37
Shop Air Regulator ..................................................................................................................... 38
Solenoid Maintenance ............................................................................................................... 39
Exploded Diagrams with Part Numbers ........................................................................ 41
Calibration
Calibration Overview ................................................................................................................ 46
Can Enamel Rater Calibration .............................................................................................. 46
Trouble Shooting
Remedies for common difficulties ...................................................................................... 48
3
Spare Parts
Calibration Pack ............................................................................................................................ 49
Annual Service Pack ................................................................................................................... 49
Recomended Spares .................................................................................................................. 49
Schematic Circuit
Drawing Number HD131C-001E: .................................................................................... 50
Pneumatic Circuit
Drawing Number HD131C-PC: ......................................................................................... 51
Hydraulic Circuit
Drawing Number HD131C-HY: ........................................................................................ 52
Specifications
Technical specifications ............................................................................................................. 53
4
Contact Details
5
Contact Details
Head Office
Versatile Technology
35 Cleeland Rd
Oakleigh South, Victoria 3167
Australia
Tel: +61 3 9548 8983
Fax: +61 3 9548 8958
Email: [email protected]
Web: www.versatiletechnology.com.au
United Kingdom and Europe
77 The Meadows
Messingham, North Lincolnshire, DN17 3UD
United Kingdom
Tel: +44 (0) 7530 465 680
Contact: Mr. Tim Bulman
Representatives
USA/Canada
Regal Metrology
4554 Popular Level Road
Louisville, KY 40213
USA
Tel: +1 502 962 3681
Fax: +1 502 805 0712
Contact: Mr. Brian Rohleder
Contact Details
6
China
Guangzhou Stolle-Denuo Machinery Co., Ltd.
RFirst Floor - Building E
Shibei Industrial Estate, No. 5 Anping Rd,
Dashi Town, Guangzhou, 511430
China
Tel: +86 20 34789252
Fax: +86 20 34789254
Contact: Fenny Gong
South Korea
ICM Leaders Co. Ltd.
Rm 1812, Hyundai Tower Bldg, 917-9,
Mok-1dong , Yangchun-Gu, Seoul, 158-050
Korea (South)
Tel: +822-2642-1375~6
Fax: +822-2642-2218
Contact: Ms Juliet Heo
Introduction
7
Introduction
Things you should consider before starting
Thank you for specifying Versatile Technology equipment. All industrial equipment requires regular maintenance to
maintain the safety and performance throughout its service life. This manual will assist you in this process. We ask that
you read and consider the following.
Safety:
Your safety is a paramount concern to Versatile Technology. You will find safety notices throughout the manual.
Please read and understand at least the “Operation” and “Safety” sections of this manual before using this gauge. If
servicing or calibrating please also read and understand the “Servicing Information” section from this manual. Refer
to the 'Safety Test Sheet', which describes testing of the gauge safety features that should be regularly tested.
Maintenance:
Regular maintenance will ensure the gauge maintains its specified performance. Spare parts and support are available
through our office.
Calibration:
Calibration of measurement devices on the equipment ensures that measurement errors are minimized. The
calibration of the gauge should be checked at regular intervals, of no longer than one year. As part of the regular
calibration, a Safety Checklist should be completed to ensure that the safety systems on the gauge operate correctly.
Capability:
Gauge capability tests check that the equipment is capable of measuring your manufacturing process with a minimum
of variation.
Continuing Support:
Please contact us with any questions you have about the manual or equipment. Your feedback will assist us in
improving our products and result in a better service to you.
Continuous Improvement:
Due to our policy of continuous improvement, service procedures may change. Contact our office to obtain the latest
service data and information.
Please maintain contact with our office:
If the equipment is transferred or disposed of we ask that you advise our office of its new location so that we may
amend our records. This is especially important in the event we have to send a safety alert bulletin alerting you of an
unforeseen safety issue.
Thank you,
The Versatile Team
Installation
8
Installation
Following the correct procedure
1. Unpack the gauge and conveyor from the shipping crates. Unpack the equipment and accessories. Check against
the Shipping List to ensure that all parts have been delivered.
2. Install the gauge on a level, flat surface away from excessive moisture and vibration. Ensure there is at least one
meter clearance around the gauge for operation and service access.
1m
1m
3. Fix the conveyor to the gauge. Ensure the conveyor sits centrally below the test head.
4. Fill the gauge tank with test fluid. Ensure the dial on the Test Fluid gauge is above 1/4.
5. Connect the shop air supply to the inlet port labelled SHOP AIR. The pneumatic supply should be filtered and
non lubricated and have a pressure range of between a minimum of 600Kpa/85psi and a maximum of 900 Kpa/
90psi.
6. Connect the power lead to the connector on the gauge back panel and plug into an earthed (grounded) AC
voltage outlet. Ensure that the correct voltage has been delivered. Note the voltage on the rating plate on the
back panel. For maximum reliability a mains filter should be fitted to the mains supply to remove excessive
voltage fluctuations often found in industrial environments.
Installation
9
7. Connect the network cable to the ethernet port on the back of the gauge.
Safety
10
Safety
Overview
Your safety is a paramount concern to all at Versatile Technology. Operator and maintenance safety has been
considered throughout all the design and manufacturing processor. The following steps have been taken to ensure
that the gauge is safe to use and service.
Gauge Safety Checklist
Information and a checklist to allow regular testing of gauge safety features.
Feedback
Despite our best efforts, we may have missed something. If during the use of the gauge you notice any hazard that
we have not found or foreseen please immediately inform us so we can work with you to eliminate the problem on
your equipment and prevent it recurring on new equipment.
Inspection Performed By:
Comments:
Signed:
Date:
Safety
11
Gauge Safety Checklist
Features
Tasks
Cabinet
Check that all panels are in place and fastened with the correct
number of screws.
Power Supply Module
Supply Module Cover is in place and Mains wiring is inaccessible.
Warning labels are fitted.
Water Pump Power Supply
Mains cover is fitted on the water pump power supply.
Electrical Safety Test
Perform Electrical Safety test and record results. (Refer to the
'Electrical Safety' section of the manual.)
'Tested for Electrical Safety' adhesive label is affixed.
Door Interlocks
Opening each door during normal gauge operation causes
gauge to stop as per emergency stop activation.
With door open the gauge does not start and the LCD alerts
the user.
Test only operates when all doors are fully closed.
Comments
Safety
Features
Tasks
Emergency Stop
During normal gauge operation press the emergency stop button.
Test immediately stops and the LCD alerts the user.
All gauge movement ceases instantly.
Gauge automatically vents internal air pressure to eliminate high
force hazards from moving pneumatic cylinders.
Safety Relay
Run gauge ‘Diagnostics’ and find input ‘Safety Relay’ under ‘Input
Bank 1’.
Press E-Stop, ‘Safety Relay’ input should change to green.
Remove signal wire into input 41 of the safety relay.
‘Safety Relay’ input should change to red.
Replace signal wire to input 41.
‘Safety Relay’ input should change back to green.
Window
The Polycarbonate Safety Panels arenot excessively scratched
and securly fixed to the door.
Clean and replace the panel if any scratches are greater than
0.25mm (10thou) deep
Labels
All labels are affixed and legible. (See “Label Checklist” on
page 13)
Pneumatic Setting
Ensure that air pressure is set within guidelines and does not
exceed recommended maximum.
12
Comments
Safety
13
Label Checklist
Labels
Qty & Location
Versatile Technology
1 off Front of Gauge (Bottom Door)
Gauge Model & Serial Number plate
1 off Right Side of Gauge
3 in 1 Label - Calibrated, Safety Tested, Capability Trials
1 off Front of Gauge
Power Supply Label
1 off Power Supply module (rear)
Tested for electrical safety sticker
1 off Power supply module (rear)
Warning - Disconnect Supply
2 off Power supply module (top)
1 off Power supply module (rear)
2 off Pump power supply (top)
Earth point Sticker
1 off Power supply module
1 off Case earth point
CE Sticker
1 off Front of Gauge(if applicable)
Ethernet Port
1 off Back of Gauge
RS232 Port
1 off Back of Gauge
SHOP AIR INLET
Set 60-10 BAR (90-145)PSI
1 off Back of Gauge (Next To Pressure Regulator)
Power Colour Code Legend
1 off (Next To Distibution Rail)
Emergency Stop
1 off Emergency Stop
Continuity Relay
1 on Continuity Relay
Present
Safety
14
In Service Safety Inspection and Electrical Safety Testing
Purpose
In service testing is necessary for the safety of persons using the equipment. In conjunction with AS3760:2001, this
document specifies in-service safety inspection and testing protocols and criteria for the testing of Versatile
Technology Gauging equipment.
Action
Such equipment, without being dismantled, needs to be subjected to routine inspection and testing to detect
obvious damage, wear or other conditions which may render it unsafe.
Equipment identified to be faulty needs to be withdrawn from service and either Versatile Technology or qualified
personnel contacted to arrange repair or disposal.
In accordance with AS3760:2001, the equipment must be subjected to:
• Visual Inspection
• Protective Earthing test
• Insulation Resistance test
• Documentation of all tests
Frequency
We recommend protectively earthed equipment installed in a Factory or workshop be inspected every 6 months.
Safety
15
Equipment Electrical Safety Testing Procedure
To ensure that a gauge does not become an electrical hazard to the operator, servicing agent or builder Versatile
Technology, an electrical safety test must be performed on the gauge prior to commissioning and a test record must
be completed and shipped to the customer.
Test Equipment Required.
Insulation and Earth Resistance Tester. Lutron DI6200 or equivalent.
Testing standards. Based on Australian Standards AS 3760:2001.
Test Procedure.
Part A: Insulation Test.
Connect the Tester as shown in the following diagram. The tester applies 500 volts and measures the resistance
between the mains circuit and the gauge earth, which is the gauge case. Record all results on Electrical Safety
Certificate
The Minimum Resistance allowed between the Active supply and case is 1 M.
Note: If the resistance is below 5 M then the gauge should be
serviced as there may be an electrical fault.
Safety
16
Part B: Earth Resistance or Protective Earthing Test
This check measures the resistance between the earth conductor and the external case and metal parts that may
become live due to a failure of the internal wiring. Connect the Tester as shown in the following diagram. Test with
mains switch both ON and OFF. Record all results on Electrical Safety Certificate.
If a gauge fails the electrical safety test?
In the event of a gauge failing any element of the electrical safety test the gauge should be immediately repaired. If
this is not possible it should be segregated so that it cannot be used.
Under no circumstances can a gauge be used without passing
the electrical safety test.
Safety
17
Electrical Safety Certificate
This is to certify that the Versatile Technology gauge listed below was tested in accordance with AS3760:2001, “In
Service Safety Inspection and Testing of Electrical Equipment” published by Standards Australia.
Refer to the Electrical Safety section for guidance in checking electrical safety.
Gauge Description
Model Serial Number
Date of Certification
1. Visual Inspection
Refer Clause 2.3.2 of AS3760:2001 p12
All mains wiring in good condition, and inaccessible during normal operation. Mains cables
properly anchored
Electrical Voltage and Fuse rating plate fitted.
Rating Plate Label
Vac
A Slo Blo FUSE
All electrical warning labels fitted. Flash stickers on power module.
Separate Earth stud / Earth lead longer than Active/Neutral.
All controls, safety covers, guards and safety facilities are secured and in good working
order
2. Protective Earth/Resistance Test
Refer clause 2.3.3.1 of AS 3760-2001 p13
Resistance between Earth connector and exposed metal parts that may become live in the event of an internal
insulation failure. The resistance shall not exceed 1 ohm.
Test Result
OHMS
3. Insulation Resistance Test
Refer clause 2.3.3.2 of AS 3760-2001 p13
Resistance between live supply conductors and exposed metal parts with a 500Vdc applied voltage. Minimum
Resistance 1 Mega ohm.
MEGA OHMS
Test Result
4. Affix Label
Sign and date 'ELECTRICAL SAFETY' label and affix to gauge acknowledging that it passes in accordance with the
above specifications.
Tested By
Signed
Operation
18
Operation
Main toolbar
The main toolbar allows access to the load/save, gauge options and test features.
• File - load and save test data, see “Main Toolbar - File” on page 23.
• Menu - configure gauge settings, see “Main Toolbar - Menu” on page 23.
• Test - start a test, see “Running an automatic test” on page 19.
Operation
19
Running an automatic test
Click on the TEST icon in the tool bar to open the TEST SETUP screen, see “Main toolbar” on page 18
A test step.
The automatic can enamel rater operates by running test steps. A test step holds all the parameters required to run
a test. Multiple test steps can be combined to make test sequences.
A Test Step
A test step contains the following parameters,
• Bin - the conveyor lane to load samples from.
• Group - the group the lanes and profiles belong to, see “Groups” on page 28 for information on groups.
• Lane - the lane the samples were taken from. Available lanes are defined by the selected group.
• Sprayer - the sprayer the samples were taken from. Available sprayers are defined by the selected lane.
• Profile - a profile representing the can parameters to be used for testing.
• Check Type - type of check results should be labelled as in SPC.
Starting a test in sequence test mode.
Test Sequence List
1. Select a pre-defined test sequence from the list.
2. Press ADD, the test steps specified by the
selected test sequence will be added to the
table.
3. Load the required cans onto the conveyor
lanes/bin, with the first can to be tested first in
the lane/bin.
4. Press Start to begin the test.
Add Sequence Button
Test Table
Create custom test button, touch to enter custom test mode
Operation
20
Starting a test in custom test mode.
1. Click on the Create icon in the toolbar.
2. From the six test parameters select the conveyor lane/bin, the group, the lane, the sprayers, the profile and
check type. Selections can be made by touching the text box, available options will be displayed.
• Selecting a group will auto-fill a list of available presses.
• Selecting a lane will define a list of available heads.
3. Press ADD, a test step will be added to the table using the currently selected test parameters.
4. Repeat steps 2 & 3 to create more steps in the test sequence.
5. Load the required cans onto the conveyor lanes/bins, with the first can to be tested first in the lane/bin.
6. Press Start to begin the test.
Text box, touch to
expand list of
available options
Save and delete test sequences (only available in supervisor mode)
Saving the test steps as a test sequence.
If you are logged in to supervisor mode you may save test steps as a test sequence.
1. Follow the instructions in “Starting a test in custom test mode.” on page 20 to create required test steps.
2. Touch the Save button and enter a sequence name at the prompt.
Operation
21
Pausing and stopping a test
Pausing the gauge.
Push ESC on the gauge keypad to pause the test. The pause icon will appear on the top statusbar.
After pressing the pause button you MUST wait for the gauge to finish testing the current sample.
Continue Testing
Continue the current automatic test cycle.
Finish Testing
The current automatic cycle will be aborted.
Running out of samples unexpectedly
Should a shortage of samples be placed on the conveyor and the gauge does not have enough samples to continue
the planned test sequence, gauge operation will halt and an error message is displayed.
The following message will be displayed on the screen giving you 3 choices: Retry Can, End Test & Skip Lane.
Retry Can
Load the conveyor lane/bin with enough samples to complete the test step, then select ‘Retry’.
End Test
Select ‘End Test’ to abort the Test Sequence.
Skip Lane
Jump to the next test step in the Test Sequence select ‘Skip Lane’. Any other test steps scheduled to run from the
current conveyor lane will also be skipped.
Software Interface
22
Software Interface
Main Screen
The main screen shows results for tests that have been completed. Results can be scrolled through using the up and
down arrows on the keypad or by touching the desired result in the results table. The table can be paged through by
pressing left and right on the keypad.
All results that fall outside specified limits are shown in RED.
Main Toolbar
The main toolbar allows access to the load/save, gauge options and test features.
Main Toolbar - Test
See “Running an automatic test” on page 19.
Software Interface
23
Main Toolbar - File
Opens the file menu.
Load Test Results
Load previously saved test data from internal gauge memory.
Save Test Results
Save the current test data to internal gauge memory.
Export Table To USB
Save the current test data to a USB stick Test data will be saved in csv format. Only the test results will be saved,
Charts/Graphs will not be saved.
Main Toolbar - Menu
Note: You must log in as a supervisor to gain access to the main menu. The supervisor access code is 22085.
Once logged in the main menu will appear.
Menu - Settings
Opens the settings menu.
Software Interface
24
Settings Menu - Operation
The OPERATIONAL SETTINGS screen allows editing of general gauge settings.
Load Settings (Conveyer)
• Load Delay Sensor 1 (msec): delay between sensor 1 detecting a can and the conveyor stopping.
• Load Delay Sensor 2 (msec): delay between sensor 2 detecting a can and the conveyor stopping.
Fill Settings
• Can Filled Analogue Value: A2D reading used during the fill can routine to check if the can has been filled.
WACO Settings
• Calibration Offset: used to offset WACO reading if calibration does not pass.
Fluid Tank Settings
• Fluid Tank Low Error (%): if fluid tank reading is below this value the gauge will display an error.
• Fluid Tank Zero Offset: A2D reading when fluid tank is completely empty.
Software Interface
25
Settings Menu - Connection
The CONNECTION screen allows you to edit TCP parameters and access USB features. Swap between TCP and
USB by touching the icons on the toolbar down the left side of the screen.
Connection - TCP
•IIP Address - displays the current gauge IP address.
•Change IP Address - edit the gauge IP address.
•Configure XPORT - sets the TCP parameters to
default values.
•Send Test Data - send a sample string of text out the
TCP and RS232 ports.
Connection - USB
•USB Status - displays if a USB stick is currently plugged
into the gauge.
•Update Driver From Internal Memory - updates the
firmware in the interface IC. The new firmware must be
placed in the internal gauge memory first. Contact Versatile Technology for further instructions if necessary.
•Backup Gauge Firmware To USB - see “Backup Gauge
Firmware To USB” on page 33.
•Backup Gauge Settings To USB - see “Backup Gauge
Settings To USB” on page 33.
•Restore Gauge Settings From USB - see “Restore
Gauge Settings From USB” on page 33.
Software Interface
26
Settings Menu - Touch Screen
The TOUCH SCREEN CALIBRATION screen page is used to calibrate the touch feature. Follow the prompts on
the screen.
Settings Menu - Date & Time
The DATE & TIME SETUP screen is used to edit the time and date.
Settings Menu - Edit Lanes
The EDIT LANES screen is used to create lane definitions. A lane definition contains the following parameters,
Lane List
see “Lists” on
page 27
Lane Parameters
Lane Toolbar
see “Toolbars” on
page 27
Lane Parameters
• Belongs To Group - the group to which the lane will be associated.
• Number Of Sprayers - the number of sprayers on the lane. Lanes are defined as either 1,2,3... or A,B,C...
depending on the gauge type.
Software Interface
27
Lists
Available items on Lane / Profile / Check Type screens are listed down the left hand side. Items can be selected by
touching them on the screen. The current item is hi-lighted blue.
Toolbars
The toolbar is used to edit the list of items available in Lane / Profile / Check Type screens. The following functions
are available.
• Add - add a new item with default parameters.
• Delete - delete currently selected item.
• Rename - rename currently selected item.
• Exit - close the screen.
Groups
The group parameter is used in lane setup, profile setup and when running a test. It is used to group or associate lanes
and profiles together.
Example - a factory has three lanes, two lanes for 202 (P1,P3) and one for 200 (P2) sizes. We will use group to force
the user to select a valid size and lane combination.
1. In the lane setup screen (“Settings Menu - Edit Lanes” on page 26) add three lanes called L1, L2 and L3.
2. Edit the ‘Belongs To Group’ parameter for each lane to the following
• L1 - 1
• L2 - 2
• L3 - 1
3. Close the lane setup screen and open the profile screen (“Menu - Profiles” on page 29).
4. Add two profiles called 200 and 202. Touch on the Parameters tab, then Edit Groups. Touch on the available
groups to deselect/select to the following
• 200 - 1
• 202 - 2
5. Close the profile screen and open the TEST SETUP screen. Touch the Create button in the bottom left to create
a new test step.
6. Touch on the Group selection box and select 1. You will see that,
• Only L1 and L3 are available in the Lane selection box.
• Only 202 is available in the Profile selection box
7. Touch on the Group selection box and select 2.
Software Interface
28
• Only L2 is available in the Lane selection box.
• Only 200 is available in the Profile selection box.
Using the grouping system the gauge can be configured to reflect the setup of your factory which will result in more
efficient usage by operators with fewer entry mistakes.
Settings Menu - Check Types
The CHECK TYPE SETUP Screen is used to add and remove check types. Check types are used to tag result data.
The tag can be used by SPC software to ignore data or place data in separate databases. Common check types could
be
• Production
• Trial
• Machine Setup
Software Interface
29
Menu - Profiles
Use the PROFILES screen to create new profiles or adjust properties current profiles. A profile defines the way a can
will be tested and how the results will be displayed.
Profile List
see “Lists” on
page 27
Profile Toolbar
see “Toolbars” on
page 27
Test Parameters
• Samples Per Sprayer: number of cans to be tested for each sprayer.
• Fill Timeout: if the can is not filled in this time the gauge will timeout with a error.
• Drain Delay: delay at the end of the test to allow draining of the can to complete.
• Lane Stop Sensor: select between using Lane Stop Sensor 1 or Lane Stop Sensor 2 when loading can from
conveyor.
• Can Type: select between Finished or Trimmed can.
Tolerances And Offsets
• mA (Lower, Upper, Offset): lower/upper measurement tolerances and offset to be added to measurement.
Associated Test Lines
• Set Associated Lines: the profile can be assigned to different groups/lines, see “Groups” on page 27. This will
control the choices available when starting an automatic test.
Software Interface
30
Menu - Diagnostics
The diagnostics screen is used for troubleshooting problems, making adjustments to the gauge and calibrating the
gauge.
A2D Bars
Diagnostic
Commands
Input Banks
Output Banks
A2D Bars
The A2D bars show the current readings for the 2 analogue to digital inputs. Touch on the bar to zero the reading.
Inputs Banks
Shows the status of all the inputs connected to the gauge.
Output Banks
Shows the status of the outputs available on the gauge.
Use the left and right arrow keys on the keyboard to scroll though the output banks. The current bank is hi-lighted
in red. Use 1-8 on the keypad to toggle the respective output of the selected bank on/off.
Diagnostic Commands
The gauge provides a number of commands to help with diagnosing problems and calibration.
Software Interface
31
Gauge Output
The gauge can output results via RS232 or ethernet. Results are output after every sample has been completed.
RS 232 Output Specifications
RS232 serial output from the gauge that emulates Mitutoyo serial equipment. Only the measured results are output
over RS232. The ASCII serial output from the gauge has a fixed width of 13 characters.
eg. 01A+ 175.5[CR]
Char 1 - Gauge ID number [0]
Char 2 - Reading numeric tag [1]: 1 - mA
Char 3 - Constant [A]
Char 4 - Sign [+]
Char 5 to 12 - Measurement [ 175.5]
Char 13 - Terminating character [CR]
Baud Rate - 9600, Data Bits - 8, Stop Bits - 1, Parity - None
Ethernet Output Specifications
Ethernet output from the gauge follows the VT data processor specification. Data is output with comma separation.
Test parameters and results are output after each sample is completed. The fields are all variable width.
eg. Seq, 202, group 1, 2, 3, 1, PRODUCTION, 0.2
is output by the HD131. This would reflect the following fields:
Sequence, Profile, Group, Lane, Sprayer, Sample, Check Type, mA Reading.
Software Updates
32
Software Updates
Performing A Software Update
Updates to the gauge software may be made available by Versatile Technology. Updates may add new gauge
functionality or resolve gauge problems.
To update the gauge you will need a USB stick (thumb drive, jump drive).
It is recommended you do a backup of the current gauge software and gauge files before performing a software
update (See “Backup Gauge Settings To USB” on page 33.).
Use the following steps to update the software on the gauge.
1. Obtain binary file (*.bin) from Versatile Technology.
2. Copy binary file to USB stick.
The naming and location of the binary file on the USB stick is critical for the gauge to recognise the file and perform
an update.
• Plug the USB stick into computer.
• Create a folder on the USB stick called ‘UPDATE’.
• If the USB stick already had an UPDATE folder delete any files currently within it.
• Copy the binary file to the UPDATE folder. There should only be one file in the UPDATE folder.
• Rename the binary file to be less than 6 characters.
Versatile Technology will usually supply a binary file with the following naming format.
“AES098_29_1D.bin” where AES098 is the gauge name, 29 is the VT internal identification number
and1D is the software version.
Once copied to the USB stick the file can be renamed to “AES1D.bin”, “1D.bin”, “Gauge.bin”
or “New.bin”. Any name is ok as long as it is less than 6 characters (excluding the .bin extension).
• Remove the USB stick from Computer.
3. Perform gauge software update
• Plug the USB stick into SERVICE PORT of
gauge.
• Reset the gauge by turning off the gauge power
then turning it back on again.
• The gauge screen will display the prompt for
user verification to update once the gauge detects
the USB stick (shown in Fig. 1).
• Press ENTER on the keypad to update the
gauge software from the USB stick.
Welcome to V2 Bootloader
Version: 1.F
Compiled At: Feb 28 2012
Processor Core Speed @ 20Hz
Bus Speed @ 100MHz
V2: Initialising NAND
V2: Initialising Hardware
USB: Checking For USB HOST
USB: HOST Detected
SD: Initialising SD card
SD: Checking For SD Card
USB: Checking For USB Disk..
- USB Flash Drive Present
- Press ENTER To Update For USB
- Any Other Key To Skip
Fig. 1- Bootloader prompt for update
Software Updates
33
Update Failures.
When I turn on the gauge with a USB stick plugged into the SERVICE PORT the gauge does not prompt for update
- Some USB sticks do not work with the gauge. Find a different brand USB stick and retry from step 2.
After the update the software does not start and the last line on the screen is “Launching Application” - An invalid
file was copied to the gauge. Retry from step 2.
Backing Up Gauge Settings
The USB tab in the CONNECTION screen allows gauge settings to backed up to a USB stick. It is recommended
you make backup of the gauge settings on a USB stick. The backup can be used to restore to original settings if the
gauge settings are altered inadvertently or become corrupted during a software update.
Backup Gauge Firmware To USB
Makes a copy of the gauge software on a USB stick. The
copy is placed in a folder called FIRM.
The firmware copy can be copied back into the gauge in
the case of system failure or unsuccessful firmware
version update.
1. Plug the USB stick into SERVICE PORT of gauge.
2. Touch the “Backup Gauge Firmware To USB” button.
Backup Gauge Settings To USB
Copies all gauge files required for operation to USB stick.
Files are copied into folders called FONTS, IMAGES and
SETTINGS.
2. Touch the “Backup Gauge Settings To USB” button.
Restore Gauge Settings From USB
Fig. 2- USB tab in connection screen
Restores all gauge files previously saved to USB stick using
the “Backup Gauge Settings To USB” functionality.
2. Touch the “Restore Gauge Settings To USB” button.
Maintenance
34
Maintenance
Routine maintenance
Cleaning
Clean the gauge using a soft cloth moistened with non-corrosive oil such as WD-40. Keep the test head, including
the flange contacts clear of any buildup of dirt. This will ensure good contact with the can when testing and improved
reliability of the gauge.
Operator Feedback
Ask the operators to describe any difficulties using the gauge and note all concerns.
Drain Mist Separator
Inspect the Mist Separator located on the rear panel. every week and drain all liquid if required.
Push upwards on the pin on the bottom of the Mist Separator to allow liquid to drain out.
Maintenance
35
Specific Maintenance
Replacing Relays on VD108 and RLY030 Boards
Use the following guide to replace worn or faulty relays.
1. Cut the cable tie holding the relay in position.
2. Carefully remove the relay with your fingers.
3. Fit new relay ensuring the pin layout is correct. Replace relays with the same type or equivalent.
Note: The cable tie is used as a holding device during shipping. It is not necessary to replace this upon fitting a new
relay.
Maintenance
36
System Voltages
The following table lists all major internal system voltages.
Wire colour convention
WIRE COLOUR
VOLTAGE
YELLOW
+24VDC Protected
GREY
+24VDC Unprotected
GREEN
RETURN
RED
+12VDC
BLACK
-12VDC
ORANGE
+5VDC
Terminal Strip 1 (From Top to Bottom)
REF
POWER
1
+24VDC
2
RETURN
3
+24VDC
4
RETURN
5
+12VDC
6
-12VDC
7
RETURN
8
+5VDC
9
RETURN
10
(UNUSED)
11
(UNUSED)
12
(UNUSED)
V2 Microprocessor Board: +12VDC
VD108 Valve Driver Board +24VDC
RLY030 Relay Board: +24VDC
MC130 Motor Control Board: +24VDC
Maintenance
37
HD149A Heavy Duty Power Supply
WARNING: High Voltage
This module contains hazardous voltages. To be assembled, service and tested by qualified personnel only. Refer
Electrical Build Standard and Electrical Safety Test Procedure.
The power supply module supplies all low voltage power to the gauge and is located on the side or rear of the gauge..
Changing the Fuse
1. Disconnect the mains power cable.
2. Remove the fuse cage with a flat blade screw driverver.
3. Replace the worn fuse with new.
Maintenance
38
Shop Air Regulator
The Shop Air regulator should be set to 600kPa (85psi).
Rotate the adjusting knob clockwise to increase pressure
Rotate the adjusting knob anti-clockwise to decrease pressure.
The Shop Air regulator on the HD131C CAN ENAMEL RATER is located behind the Right-hand side panel.
Once pressure is set push down on the knob to lock it in position.
Maintenance
39
Solenoid Maintenance
Manual Over-ride
The solenoids may be manually driven to check their operation. This makes fault finding easier to help determine if
the fault is electrical or mechanical.
Press the orange button with a small pointed instrument to activate the solenoid.
Solenoid Replacement
Remove the air supply from the gauge.
Use a small screwdriver to loosen the Mounting Clamp at one end of the solenoid group
Gently part the solenoid group around the faulty solenoid.
Maintenance
40
Clip it off the Din rail.
Re-install the new solenoid and ensure the small circular tube gaskets (3 per side) all slide back in when you press the
group together again and tighten the mounting clamp.
Re-connect the air supply and check for leaks.
If leaks are detected, check the tube gaskets are oriented correctly and that the solenoids are all pressed tightly
together and the Mounting Clamp is tightened to hold them in place.
Maintenance
41
Exploded Diagrams with Part Numbers
Drawing No: HD131C-SD01
Maintenance
42
Maintenance
43
Maintenance
44
Maintenance
45
HD131B CAN ENAMEL RATER
Calibration
46
Calibration
Calibration Overview
All gauges used for the purpose of process control and acceptance inspections should be regularly tested to ensure
they are accurate, within calibration and capable of measuring the process.
Ensure that all equipment used to calibrate the gauge has been laboratory calibrated and its certification is traceable
to national measurement standards.
Calibration Report and Sticker
At the completion of the calibration the results should be studied to ensure all parts of the gauge operate within
specifications and a ‘calibrated’ sticker applied to the gauge indicating when the next calibration is due. Calibration
reports should be filed for future reference.
When and how often should I calibrate?
Calibration of the gauge should be conducted annually. It is recommended calibration be checked when the gauge is
first commissioned, when any repair work has been performed that would affect calibration or if test results are
suspect.
Can Enamel Rater Calibration
The following procedure is straightforward, however the procedure should be carefully followed to avoid damage to
the gauge and personal injury.
Please read the warning notice on page 2 before performing
any work on this equipment.
Calibration Setup
1. Remove any cans in the test or drain stations.
2. Enter the ‘Menu’ and select ‘Calibration’, this will bring up the calibration screen.
Calibration Procedure
1. The WACO test resistors have 4 labelled clips. Attach clip 1 to the Sense Positive(+). This is the rear flange
contact. Attach clip 2 to the Electrode Positive(+). This is the front flange contact.
HD131B CAN ENAMEL RATER
Calibration
47
2. Attach clip 3 to the Sense and Electrode Negative(-). This is the fill shaft on the test head. Clip 4 can be left
disconnected. Refer to the image below to identify the Sense and Electrode connections.
3. Read the WACO by pressing the ‘PRESS TO READ WACO’ button.
4. Compare the gauge reading with that of the Test Resistor.
5. Perform the Calibration procedure for all 4 Test Resistors.
Calibration Adjustment
The ‘Calibration Offset’ value can be used to adjust the WACO reading. The value can be positive or negative.
Trouble Shooting
48
Trouble Shooting
Remedies for common difficulties
No
Symptom
Remedy
1.
Gauge Dead, no display, no movement.
• Check power outlet. Ensure mains connector is pushed home in inlet connector on
back panel of gauge.
• Check fuse. Remove mains cable from power and use a small screwdriver to remove
the fuse clip. Insert a new fuse of correct rating.
• Check air pressure at 80 psi / 580 kPa.
• Check that the regulator dial is indicating correct pressure.
• Check that the pressure is arriving at the cylinder.
2.
No display.
• Open gauge case, use voltmeter to check microprocessor voltage (+12VDC) both at
the microprocessor and terminal strip connectors.
• Check Display driver board DAB134 voltage (+12VDC).
3.
Display ok, no movement
• Open gauge case, use voltmeter to check voltages on power module connector
located on the front of the module.+ 24VDC +/- 1V Relay/Motor supply.
4.
Power supply voltages incorrect
• This can be due to either power supply failure or an external fault pulling the supply
down. Check by disconnecting the power module connector and rechecking the supply voltages. If the voltages are still incorrect, replace the power supply module.If the
voltages are now OK, check for shorts. Follow the circuit diagrams and selectively
remove circuit sections of the gauge and reconnect the power module connector until
the short can be found. Repair or replace the faulty module as required.
5.
Display ok, power supply ok, air ok, still
no movement
• Open gauge case. Watch the relays on the relay PCB and press a start button. Several relays should activate, if they don't, ensure all connectors are pushed home firmly
especially on the microprocessor boards. Replace if necessary.
6.
Display ok, Gauge functions ok gauge
gives suspect readings.
• Contact Versatile Technology.
7.
Gauge ok, no data output
• Check the Serial and Ethernet links via gauge menu.
Spare Parts
49
Spare Parts
Calibration Pack
Component ID
Description
WACO Test Resistor Set
QTY
1
Annual Service Pack
Component ID
Description
QTY
2455
DPDT 8A 24VDC Relay
11
7987
SPDT 16A 24VDC Relay
2
15163
Multi-Purpose Stainless Steel Spring
4
Stainless Steel Wire
5383
10ml BOTTLE LOCTITE 222
1
6492
10ml BOTTLE LOCTITE 262
1
Recomended Spares
Component ID
Description
QTY
19326
V2 Microprocessor Board
1
196
RLY030 Relay Board
1
7828
VD108 Valve Driver Board
1
10502
MC130 Motor Control Board
1
11914
HD149 Heavy Duty Power Supply
1
18616
12VDC Power Supply For Pump
1
324
24VDC 1200 RPM Motor
1
2455
DPDT 8A 24VDC Relay
10
7987
SPDT 16A 24VDC Relay
2
15163
Multi-Purpose Stainless Steel Spring
4
Stainless Steel Wire
979
Reed Switch NPN, Actuator Mounting
1
6032
Banner Sensor Emitter
1
6033
Banner Sensor Receiver
1
3073
Solenoid Valve 5 Port 2 Position, 6mm
1
3072
Solenoid Valve 5 Port 2 Position, 4mm
1
12684
Flojet Pump 4300-343
1
14901
Alignment Station Belt
1
Schematic Circuit
50
Schematic Circuit
Drawing Number HD131C-001E:
See next page for drawing.
Pneumatic Circuit
51
Pneumatic Circuit
Drawing Number HD131C-PC:
Hydraulic Circuit
52
Hydraulic Circuit
Drawing Number HD131C-HY:
Specifications
53
Specifications
Technical specifications
Gauge Model
Capacity
1 Lane, 15 cans per lane (approx.)
Resolution
0.1mA
Accuracy
Refer to WACO Enamel Rater II Specifications
Test Cycle Time
Under 20 seconds per can
Units
mA
Data Output
Direct to network or scripted output via Windows software
Safety
Fully enclosed cabinet
Sound Exposure
Level
Over one cycle, the equivalent continuous A-weighted Sound Pressure Level SPL < 70dB(A) at
a distance of one metre from the gauge.
Display
15” LCD Touch Screen
Dimensions
H2050mm x D750mm x W990mm (without conveyor). All measurements are approximate.
Weight
Requirement
Electrical Supply: Single Phase 100-250VAC Filtered Power
Filtered Shop Air: 600kPa (90psi) approx.

can enamel rater hd131c

Transcription

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