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Address:
BMC Controls Ltd
The Factory
Silk Mill Lane
Winchcombe
Gloucestershire
GL54 5HZ
ENGLAND
Tel: (0)1242 604040
Fax: (0)1242 603987
Copyright 2006 BMC Controls Ltd. All rights reserved. No part of this publication may be reproduced, or
distributed without prior written permission of BMC Controls Ltd., The Factory, Silk Mill Lane, Winchcombe,
Gloucestershire, GL54 5HZ.
The majority of equipment designed and manufactured by BMC Controls Ltd is protected by patents and
industrial design copyright.
Examples of this include our PLASMA leak testing technique, stepper motor and adaptive control of conveyor
movement, box inverting devices, all software, electrical and pneumatic circuits.
DOC 584 Issue A
AQS610-EU-SF
SIX HEAD LEAKTESTER WITH SCREW FEED
TECHNICAL GUIDE
ISSUE A
COPYRIGHT
AQS610-EU/SF (V2 H/W)
TECHNICAL GUIDE
Page 1
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Table of Contents
Summary of Contents for BMC Controls AQS610-EU-SF
- Page 1 Fax: (0)1242 603987 COPYRIGHT Copyright 2006 BMC Controls Ltd. All rights reserved. No part of this publication may be reproduced, or distributed without prior written permission of BMC Controls Ltd., The Factory, Silk Mill Lane, Winchcombe, Gloucestershire, GL54 5HZ.
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Page 2: Table Of Contents
Contents GENERAL DESCRIPTION............................3 ..............................3 EAKTEST STATION PRINCIPLES OF OPERATION ..........................4 ..............................4 EAK TEST CYCLE ..............................4 URGE UNCTION ..............................5 EJECT LOWER ............................6 YSTEM LAYOUT DRAWING SET-UP PROCEDURE..............................7 AQS S .................................7 ETTINGS ..............................7 ROXIMITY ENSOR ...........................8 OUCH HOTOSWITCHES ............................9 ETECTOR ............................11 EJECT STATION SET ) ........................11 AM DETECTION SET OPTIONAL... -
Page 3: General Description
1. General Description The AQS610-EU-SF is a new high speed leaktesting system designed to leaktest containers up to 10L capacity. It features a six head leaktester with an infeed / outfeed screw driven from a stepper motor. Failed containers are rejected as they leave the screw. -
Page 4: Principles Of Operation
2. Principles of operation On start-up, the position of the infeed / outfeed screw is checked, regardless of whether the screw is in the correct start position or not, the screw is slowly rotated ( at approx. 10 RPM ) until the home position is found ( a proximity sensor detects a metal insert in the screw body ), while this process is ongoing a status message ‘HOMING SCREW’... -
Page 5: Reject Blower
2.3 Reject Blower During the homing of the screw and the first in-screw of bottles at power up, the reject blower will activate to reject any bottles which may have been left in the screw at previous power down, as these bottles will be of unknown status. -
Page 6: System Layout Drawing
2.4 System layout drawing NOTE: The reject position is the last position where the bottle is still held in position by the screw. Leaktest Detection Reject Blower Bottle indexing screw Direction Of Travel Test heads Reject Start Dead plate AQS610-EU/SF (V2 H/W) DOC 584 Issue A TECHNICAL GUIDE Page 6... -
Page 7: Set-Up Procedure
3. Set-up Procedure 3.1 AQS Settings Initially, set the unit with the following parameters: Start Time 1.0 second Head Delay 1.0 second Fill Time 3.0 seconds Test Time 3.0 seconds TestPress 30 mB Reject Delay 0.17 seconds Reject On Time 0.10 seconds Reject Off Time 0.06 seconds... -
Page 8: Touch-Set Photoswitches
3.3 Touch-set Photoswitches All photoswitches are Baumer touch-set background suppressed photoswitches. They have a range 20mm to 430mm when used with smooth opaque components, they should not need re-adjusting when the component colour is changed. Clear or textured components will reduce the range of these photoswitches. In extreme conditions, careful adjustment may be required. -
Page 9: Leak Detector Set-Up
3.4 Leak Detector Set-up The regulators described in this section are labelled for ease of identification. The start photoswitch position can be set at any point upstream from the leaktest screw, the height should be such that it detects bottles at ‘body’ height, the start photoswitch works off a timer, when a bottle is detected as stationary in front of the photoswitch for a set time the screw-in sequence begins. - Page 10 Send bottles through the system, if at this point any channel is failing the leaktest as Underfill ‘U’, increase the Fill Valve restrictor associated with that channel until correct pressurisation is achieved. ( adjust the restrictor in ¼ turn increments and re-check ). When the bottle handling is correct, the leak detector can be "Fine tuned".
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Page 11: Reject Station Set-Up
3.5 Reject station set-up Because of the high speed nature of the throughput on this kind of tester, the Reject routine is complex and can be tricky to set-up correctly, it is important that this part of the set-up procedure is followed particularly carefully. -
Page 12: Operator Control Panel
4. Operator Control Panel LIQUID CRYSTAL DISPLAY PARAMETE FUNCTIONS SETTINGS PAGE SELECT KEYS KEYPAD CURSOR KEYS 4.1 Liquid Crystal Display Used to display information. Allows a visual indication of test results and settings in the form of various pages. Each page can display up to 4 items regarding a particular mode. Visual indication is given in the top left corner of the display when a key is pressed. -
Page 13: Display
5. Display Pages 5.1 Parameters 5.1.1 Test Information On the right hand side of the parameter display page can be seen the Bargraph pressure displays and the test status “flashes”, the bargraph displays will rise as pressure in the containers rises, the top of the bargraph, 100% is equal to the Test pressure set by the user. -
Page 14: Test Parameters
5.1.2 Test Parameters On the left hand side of the display values such as passed and failed counts and measured pressure readings are displayed. The values can be zeroed by pressing the ‘0’ key when the parameter to be zeroed is selected. For this program the following parameters may be seen: 1. -
Page 15: Functions
5.2 Functions This page features the I/O forcing function as well as any additional function which maybe specific to a particular unit. For this program the following functions are present: I/O Forcing only. 5.2.1 I/O Forcing The I/O Forcing feature allows the operator to view the current status of each of systems Inputs and Outputs and also to manually override the system control and Individually force any Input or Output on or off. - Page 16 Also displayed on this page, on the very bottom line of the display is an I/O Status map, this gives a visual indication of the current status of all the system Inputs and Outputs. Each Input and Output has a single digit display associated with it, there are four possible status’s for each individual input or output 0 : The input / output is under normal machine control and is currently off.
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Page 17: Settings
5.3 Settings Display the various settings and allows them to be changed. By pressing the right/left keys, the setting value will be increased/decreased by a fixed amount. Pressing the ‘E’ key will allow the value to be entered directly with the keypad numbers. Wrongly entered values can be changed by using the left/right keys to move the cursor to the digit to be changed. -
Page 18: The Lvd2 Motor Driver / Controller
6. The LVD2 Motor Driver / Controller The LVD2 driver is situated in the main pneumatic cabinet, it controls all aspects of the motor operation, it can be used to vary certain parameters associated with the motor’s operation. During normal operation the unit will display the current operating mode ( also known as Pr0 ), the two states for Pr0 are: Idle –... -
Page 19: User Parameters
6.4 User Parameters NOTE: Through the LVD keypad you have full access to all system Parameters, DO NOT adjust any parameters other than those show below as this may have a serious adverse affect on the operation of the unit. Pr01 Homing Speed &... -
Page 20: Troubleshooting
7. Troubleshooting 7.1 Inconsistent leaktest results Could be due to: 1. Bad neck sealing. Check that the screw is positioning bottles directly under test heads and that sealing pads are undamaged. 2. Clamp pressure too low. Causes poor neck seal with bottle neck. Increase clamp pressure regulator slightly. -
Page 21: Rejects Good Bottles
If any problems persist or cannot be solved, contact BMC Controls sales office for technical advice or a visit by a service engineer. -
Page 22: I/O List
8. I/O list 8.1 AQS I/O Information INPUT FUNCTION HARDWARE LEAKTEST_START_PS PHOTOSWITCH LEAKTEST_JAM_PS PHOTOSWITCH SCREW_PX PROXIMITY DETECTOR UNUSED UNUSED UNUSED UNUSED REVERSE_DISPLAY LINK TO IP TO 24V NB: All inputs are PNP, i.e. switch 24V onto the signal line. OUTPUT FUNCTION HARDWARE HEAD_CLAMP... -
Page 23: Lvd Drive I/O Information
8.2 LVD Drive I/O Information Inputs INPUT LVD REF. FUNCTION HARDWARE 90.0 ENABLE LINK TO 24V TO RUN 90.1 HOME_SCREW RELAY IP N/O CONTACT AQS OP 6 90.2 6_REVS_SCREW RELAY IP N/O CONTACT AQS OP 7 90.3 Unused 90.4 Unused 90.5 Unused 90.6... -
Page 24: Emergency Stop
9. Emergency Stop If the unit is supplied as a complete system, i.e. already mounted on a conveyor, an emergency stop button will already be fitted. If the unit is supplied in kit form the emergency stop circuitry is still fitted in the cabinet but is linked out, if an emergency stop button is required it should be a normally closed switch and should be fitted in place of this link. -
Page 25: Control Panel Connections
10. Control Panel connections INPUT 1 INPUT 2 INPUT 3 NOT USED PRESS. SENSE 1 NOT USED PRESS. SENSE 2 NOT USED CABLE TO PNEUMATIC CABINET PRESS. SENSE 3 RS232 PORT PRESS. SENSE 4 INPUT EXPANSION PORT PRESS. SENSE 5 PRESS. -
Page 26: Parts List
As required Cylinder **** As required Motor / Gearbox / Inverter **** Supplier Codes BMC – BMC Controls FEC – Farnell Electronic Component suppliers RS – RS Electronic suppliers ANY – These parts should be available from any electrical outlet. NOTES: * Certain parts of the system are specific to a particular model of tester, when ordering these parts please order “part required for AQS xx-xx-xx Vx.x”... - Page 27 NOTES: ( continued ) ** When ordering Test head Seals the part number is formed as follows: THS – S – 54 - 5 Identifies the part Material Outer Diameter ( OD ) Inner Diameter ( ID ) As a Test Head ( see below ) The size of the Test The size of the hole in...
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