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Alps Electric SPEEDGLIDER Operator's Manual

Linear leak tester
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Air Logic Power Systems, LLC
th
1745 S. 38
Street, Suite 100 Milwaukee, WI. 53215-1732
Phone: 414-671-3332 Fax: 414-671-6645
24 Hour Service Hotline: 800-325-8717
www.alpsleak.com and info@alpsleak.com
ALPS SPEEDGLIDER LINEAR
LEAK TESTER
ADVANCED OPERATOR
MANUAL

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Summary of Contents for Alps Electric SPEEDGLIDER

  • Page 1 Air Logic Power Systems, LLC 1745 S. 38 Street, Suite 100 Milwaukee, WI. 53215-1732 Phone: 414-671-3332 Fax: 414-671-6645 24 Hour Service Hotline: 800-325-8717 www.alpsleak.com and info@alpsleak.com ALPS SPEEDGLIDER LINEAR LEAK TESTER ADVANCED OPERATOR MANUAL...
  • Page 2 Notices: Documentation Air Logic Power Systems, LLC; (ALPS), reserves the right to make changes or improvements to the SpeedGlider ™ Linear Leak Tester at any time. These changes may not be immediately reflected in the manual accompanying your system. If you notice any inaccuracies or oversights in this manual, please contact the ALPS Service Department.

  • Page 3: Table Of Contents

    Operational Status: Conditional status of the machine..................12 Glossary of Terms SpeedGlider Advanced Operator Advanced Operator Introduction ......................... 14 SpeedGlider Main Features..........................15 Viewing and editing HMI Displays ........................16 Password Protected Options and Settings ......................16 Creating and changing On-Screen Variables, Values, and Settings ..............16 Changing settings and values using the TENKEY screen .................
  • Page 4 AIR LOGIC POWER SYSTEMS (ALPS) NOTICES The Settings Menu Settings Introduction ............................20 Test Pressures & Reject Limits Introduction ....................... 20 Test Timers, Reject Limits & Test Pressures Navigation and Use..............22 Probe Take Off Introduction ..........................23 Probe Take Off Navigation and Use ........................24 3 and 4 Head Probe Alignment ..........................

  • Page 5: General Information

    GENERAL INFORMATION General Information The SpeedGlider linear machine is designed for medium to high speed production lines requiring leak inspection. The SpeedGlider is built to accommodate the customers’ conveyor equipment. Molded containers are captured and fed into the test area by a timing screw located adjacent to the line conveyor. The timing screw, conveyer and test probes are synchronized so that a smooth transition occurs from test cycle to test cycle.

  • Page 6: Machine Designation And Serial Number Location

    AIR LOGIC POWER SYSTEMS (ALPS) GENERAL INFORMATION Machine Designation and Serial Number location This individual machine is identified with an ID and Serial Number plaque affixed to the inside door surface of the High Voltage control enclosure as shown below. Along with it are the 24 Hour service hotline phone number and the UL Panel Rating plate.

  • Page 7: Hoisting And Transport Of This Machine

    Hoisting and Transport of this Machine The SpeedGlider machine must be hoisted in the manner shown by a fork-lift. Forks must be of sufficient length to support the entire machine. Warning! This machine has a high center of gravity. Do not transport with forks tilted forward! Forks must remain parallel with the floor.

  • Page 8: Safety

    Tag-Out procedures to secure the machine. Notify authorized personnel. RISK OF HOT SURFACES HAZARD This symbol can be found in areas where a potential burn hazard exists. SpeedGlider servo motors have hot surfaces. Do not touch motor surfaces while in operation or after being recently shut down.
  • Page 9 AIR LOGIC POWER SYSTEMS (ALPS) SAFETY Safety-continued LOCK OUT / TAG OUT This decal appears prominently next to the main power switch on the side of the High Voltage Control cabinet at the rear of the machine. Lock-out and tag-out procedures are covered in the service and maintenance manual. WARNING! WATCH YOUR HANDS AND FINGERS This warning is seen on the front of the discharge chute.
  • Page 10 AIR LOGIC POWER SYSTEMS (ALPS) SAFETY Safety-continued DANGER! DO NOT OPERATE WITHOUT GUARDS IN PLACE This warning is located on the lower front portion and rear plexiglass guard of the machine. It cautions the operator not to attempt to operate this machine without a plexiglass guard panel in place. The potential for severe injury exists while the machine is operating.

  • Page 11: Safety: Warning Messages

    PROCEDURES. THE POTENTIAL OF SERIOUS PERSONAL OR FATAL BODILY INJURY EXISTS! VOLTAGE HAZARD! THE SPEEDGLIDER LINEAR MACHINE USES 110/220 VOLTS AC POWER WHICH CAN CAUSE SERIOUS INJURY OR DEATH ON CONTACT. DO NOT DEFEAT THE SAFETY FEATURES OF THIS EQUIPMENT TO GAIN ACCESS TO INTERNAL VOLTAGES.

  • Page 12: Jokab Door Sensors: Positions

    AIR LOGIC POWER SYSTEMS (ALPS) SAFETY Jokab Door Sensors: Positions TABLE 1: Door Mounted Safety Switch Locations (from previous page). ITEM COMPONENT FUNCTION Jokab Door Switches Category 4 rated-pulsed signal non-contact switch. These work the same as the one in the emergency stop on HMI touch screen panel. Guard Assembly Protects personnel during operation from moving components that are located inside the enclosure.

  • Page 13: Safety-Operational Status/Conditional Status

    AIR LOGIC POWER SYSTEMS (ALPS) SAFETY Safety-Operational Status/Conditional Status Operational Status: Conditional status of the machine. TABLE 2: HMI Status LED: Color Code Indicates Running Status. COLOR STATUS/CONDITION Green Normal operating status. Yellow Machine in bypass Mode or in Pause Condition Machine stopped, door ajar or waiting for operator to press START.

  • Page 14: Glossary Of Terms

    Fill Pressure The pressure used to fill the container. This pressure is set in PSI. When blocked by a backlog of containers, the SpeedGlider will accelerate to Fast Fast Speed Photo-Eye speed or decelerate to Normal speed when unblocked or when the backlog is cleared.

  • Page 15: Speedglider Advanced Operator

    Contains the ON/OFF and e-stop palm buttons. Reject Chute Area where discarded containers are channeled. Emergency Stop E-Stop palm-button. ON/OFF Switches Controls ON/OFF operation of the machine. LED Pictorial Display Touch-screen command center. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...

  • Page 16: Speedglider Main Features

    Electrical Enclosure Contains essential electronics to run the machine. Airflow Shut-Off and Filter System Airflow pressure control and filtration. Main Power Switch Controls incoming power to the machine. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...

  • Page 17: Viewing And Editing Hmi Displays

    Viewing and editing HMI Displays A password is required for viewing and editing some displays. If not previously logged in, when attempting to edit or change settings a password login pop up box and keyboard will appear. The SpeedGlider ships with a default password.

  • Page 18: This Advanced Operator Manual Overview

    AIR LOGIC POWER SYSTEMS (ALPS) INTRODUCTION This Advanced Operator Manual Overview 1. Theory of Operations In-depth coverage on all the possible SpeedGlider Menu Sections (procedures, navigation, and definition). Settings Menu Test Results Menu Maintenance Menu Supervisor Menu 3. Change Over and Setup...

  • Page 19: Theory Of Operations

    Leak Test Operations Untested Containers are transferred from line conveyor to the SpeedGlider through the timing screw. When 1 to 4 container(s) are detected by the speed glider photo eye the probes will extend and fill valves will execute simultaneously. At this time pressurization of the containers occurs.

  • Page 20: Container Handling

    AIR LOGIC POWER SYSTEMS (ALPS) THEORY of OPERATIONS Container Handling Containers transition from the production line conveyor into the SpeedGlider timing conveyor for leak testing. During this transition containers will be monitored and controlled by various photo eyes, hold and reject cylinders.

  • Page 21: The Settings Menu

    Settings Introduction The leak tests performed by the SpeedGlider depend on the proper settings of the Test Timers, Pressures, and Reject Limits. The Settings Menu is where all the perimeters for the required leak test as well as machine speeds and timing can be viewed and edited.
  • Page 22 When the test pressure in the container reaches the pressure value entered the “Fill time” will start counting. Range: 1 to 10 IWC Probe force (POUNDS) Shows the actual probe force on the container SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...

  • Page 23: Test Timers, Reject Limits & Test Pressures Navigation And Use

    Select to enter the new value or the key to cancel the entry. Select the Information button to Access helpful information on the current menu display SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...

  • Page 24: Probe Take Off Introduction

    Notice: The adjustment displays and procedure for aligning the test probes for a 3 or 4 heads SpeedGlider will be different than a 2 head SpeedGlider.

  • Page 25: Probe Take Off Navigation And Use

    3. If necessary adjust the photo-eye so it is in the center of the largest and flattest section of the bottle. At any time select the Information button to access helpful information on the current menu display. The help screens for Probe Take-Off. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...
  • Page 26 Container At C. If situation (C) exists the timing screw and test Test. The indicator must turn ON probes are aligned. No adjustment is necessary. between encoder counts 1500 and SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...
  • Page 27 14. Continue to rotate the timing screw forward by hand. Notice at some point near or before 2000 the Container At Test indicator turns OFF. 15. This procedure is complete SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...

  • Page 28: Recipes Introduction

    3. Upon selecting the DELETE icon, a prompt appears, asking you to DELETE YES/NO. Delete the selected recipe and exit. DO NOT SELECT IN THE TEXT AREA AT RIGHT (). RECIPES IN THIS FIELD CAN BE MISTAKENLY CORRUPTED IF CARE IS NOT EXERCISED HERE. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...

  • Page 29: Creating A New Recipe

    Create & Save Recipe process. DO NOT SELECT IN THE TEXT AREA AT RIGHT (). RECIPES IN THIS FIELD CAN BE MISTAKENLY CORRUPTED IF CARE IS NOT EXERCISED HERE. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...

  • Page 30: Load Recipe To Memory Card

    1. HMI: SpeedGlider program 2. Eject DO NOT SELECT IN THE TEXT AREA AT RIGHT (). RECIPES IN THIS FIELD CAN BE MISTAKENLY CORRUPTED IF CARE IS NOT EXERCISED HERE. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...

  • Page 31: Load Recipe From Memory Card To Hmi

    4. Eject memory card. DO NOT SELECT IN THE TEXT AREA AT RIGHT (). RECIPES IN THIS FIELD CAN BE MISTAKENLY CORRUPTED IF CARE IS NOT EXERCISED HERE. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...
  • Page 32 6. After the selection is made, press: Step 2 (save options to HMI and complete the transfer, right). 7. Re-open the control enclosure and remove the memory card. Secure the enclosure. Step One Step Two Note: It is vitally important that both steps be followed in order SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV02 © 03/19/2013...

  • Page 33: Reject Timing Introduction

    Reject Timing Introduction Reject timing contains the encoder positions that tell the SpeedGlider when and where to reject a defective container. When making changes to these setting it is very important to test and verify that the failed leak test container is being rejected and not good containers.

  • Page 34: Machine Speeds Introduction

    PE must be setup for proper delays. The PE on delay must be set long enough to where at least a back log of container can occur before the SpeedGlider begins to run. In other words one container by itself passing by the speed PE should not trigger the PE.

  • Page 35: Machine Speed Navigation And Information Help Screens

    AIR LOGIC POWER SYSTEMS (ALPS) THE SETTINGS MENU Machine Speed Navigation and Information help Screens Next Page SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...
  • Page 36 AIR LOGIC POWER SYSTEMS (ALPS) THE SETTINGS MENU Machine Speed Navigation and Information help Screens continued SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...

  • Page 37: Photo Eye Settings Introduction

    Photo Eye Settings Introduction The proper set up timing of the photo eyes is critical to the speed mode operations of the SpeedGlider. The CURRENT PHOTO-EYE STATUS can help set up the proper delays described in the speed mode section. The delays are set on the photo eyes themselves (not HMI) and usually accomplished by an ALPS Technician at installation.

  • Page 38: Test Results Menu

    Servo Times: These time are used to help determine servo Alarms the key is to have “Spare Time at Start and End” to avoid Servo timing Alarms. See information help screens on SpeedGlider HMI on how to use spare time. •...
  • Page 39 AIR LOGIC POWER SYSTEMS (ALPS) THE RESULTS MENU Available Help Screens for TEST RESULTS Test Result Display Help Screens SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...

  • Page 40: Last Test Detail Navigation

    Select Test Result Menu then Detail Timers to navigate to the Detail Timers screen Counters Navigation Select Test Result Menu then Then the Arrow buttons will naviagte between all three displays. Select “Reset Counters” to zero out all counters. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...

  • Page 41: Recent Rejects Navigation

    2. To select an individual listing to delete: To delete, touch the DELETE icon ( 3. To select a group of listings: touch the MARQEE SELECT icon ( 4. To de-select a group of listings: touch the MARQEE DE-SELECT icon ( SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...

  • Page 42: Maintenance Menu

    In addition to this a Manual Test and Manual Self-Test is used to determine the proper test settings for a new container which has not run on the SpeedGlider. See the new container setup guide in this manual for leak testing a new container.

  • Page 43: Manual Test Display Description

    If the container is out range one of the indicator will turn red and stay red until a successful in range test is accomplished. The manual test result displays will indicate the reason. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...
  • Page 44 Select manual test to perform a leak test on a container when production is stopped. Select manual self-test to perform a leak test on a container with a simulated hole SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...

  • Page 45: Manual Test Navigation

    From the Home screen select the maintenance button. Then select the manual test button. From the manual test index select the station number to test. Stop production and place a container underneath proper test probe. Select Manual Test or Manual Self-Test to leak test container. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...

  • Page 46: Input And Output Diagnostics

    From the home screen select maintenance and then desired diagnostics display Use the to navigate between screen 1 and 2. About For information on the ALPS software versions and the machine serial number view the ABOUT display. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...

  • Page 47: Supervisor Menu Introduction

    (Not shown above) This option if selected allows the SpeedGlider to perform manual self-test every certain number of containers possessed. The stop & Alarm selection means the SpeedGlider will stop if the container is not reject after an auto self-test is done.

  • Page 48: Supervisor Screen Flow And Navigation

    The following supervisor menus flow in the order shown. Selecting the navigation arrow will prompt the next supervisor option display. Supervisor Information Help Screens Reject Verification Manual Mode Secondary Reject System Bypass SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...

  • Page 49: Container Change Over And Setup

    Turn clockwise to raise, counter-clockwise to lower. C. Place the container that will run on the SpeedGlider underneath a test probe. Raise or lower the probe carriage to a level just ¼ inch above the top of the container opening.
  • Page 50 AIR LOGIC POWER SYSTEMS (ALPS) CONTAINER CHANGE OVER Step Procedure Description 2. Railing Place container to run on the SpeedGlider in timing screw pocket. Allow for 1/16 of a gap as Adjustment shown below. Vertical Adjustment Horizontal Adjustment 1/16 inch gap...
  • Page 51 Left: Scale at left end. Right: Scale at right end (shown with timing screw removed). Inset: Close-up view of scale. Reading here shows a setting of 74 mm. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...
  • Page 52 Speed: Is not used no adjustment is necessary. S/R: Acceleration: Set this so bottles accelerate smoothly. Do not set excessively long. If the SpeedGlider is not controlling conveyor speed it very important to reduce this timer to a minimum. S/S: Deceleration: Set this so bottles stop smoothly.

  • Page 53: New Container Setup Guide For Test Settings

    If the guage display is similar to this one then the Fill prssure probaly does not need adjsutment. If any of the indicators turned red or the peak pressure did not fall within range proceed to the applicable step 5-9. Otherwise proceed to Step 10 SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...
  • Page 54 25 IWC. Decrease the Fill Regulator until the Over Pressure Fill is no longer present after performing a manual test. SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...
  • Page 55 The machine speed along with the use of the Detail Timers menu will help determined to the appropriate test times. 11. Enter the CPM Enter the appropriate CPM. The CPM range for the SpeedGlider is 50 to 275. 12. Run a few containers Watch the “Spare Time At End”...
  • Page 56 FILL TIME expires but the FILL TIME will not start until the START FILL is reached. Maxium Peak 1 to 25 Pressure Start Fill Time 1 to 10 Pressure SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...
  • Page 57 B. Check for consistency by performing several Manual Self Tests. Doing this will ensure the test settings are accurate. 18. Poocedure is Complete SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...
  • Page 58 AIR LOGIC POWER SYSTEMS (ALPS) CONTAINER CHANGE OVER This concludes the Advanced Operator Manual SPEEDGLIDER  ADVANCED OPERATOR MANUAL TM 2012-005 REV00 © 10/25/2012...

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