Alps Electric FLEX PITCH Quick Start Manual
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Alps Electric FLEX PITCH Quick Start Manual

Linear leak tester
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ALPS
Air Logic Power Systems, LLC
2440 W Corporate Preserve Drive Unit 600
Oak Creek, WI 53154 - USA
Phone: 414-574-4151 Fax: 414-574-4152
24 Hour Service Hotline: 800-325-8717
www.alpsleak.com and
info@alpsleak.com
FLEX PITCH LINEAR
LEAK TESTER
QUICK-START MANUAL
A quick reference guide for quick setup and startup.
FLEX PITCH  QUICK-START MANUAL
i
TM 2012-005 REV01 © 5/26/2016

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  • Page 1 Oak Creek, WI 53154 - USA Phone: 414-574-4151 Fax: 414-574-4152 24 Hour Service Hotline: 800-325-8717 www.alpsleak.com and info@alpsleak.com FLEX PITCH LINEAR LEAK TESTER QUICK-START MANUAL A quick reference guide for quick setup and startup. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV01 © 5/26/2016...
  • Page 2 AIR LOGIC POWER SYSTEMS (ALPS) NOTICES...
  • Page 3 All products or product names mentioned in the manual are trademarks of their respective companies. The name Flex Pitch™ is protected under copyright laws of the United States. Flex Pitch™ is a registered patent and is protected by US patent laws.

  • Page 4: Table Of Contents

    Container-Present and Reject Photo-Eyes ......................13 Test Probe Carriage ............................14 Reject Cylinder Position ............................15 Section 5: Flex Pitch Quick Start Operations 16 About The Quick Start Manual ..........................16 Section 6: HMI Control Panel Touchscreen Description Section 7: HOME Screen and Main Menu Description Home Screen Button Features and Functions TABLE.
  • Page 5 AIR LOGIC POWER SYSTEMS (ALPS) TABLE OF CONTENTS Start Production ..............................22 Monitoring Production ............................22 Production Quick-View .......................... 22 Accessing Online Information ........................ 22 Counters ..............................23 Recent Results ..............................23 Self-Tests................................24 Recent Rejects ..............................24 Cycle Timers ................................ 25 Bottle Pressure ..............................

  • Page 6: Section 1: General Information

    The Flex Pitch has built in flexibility with 2-4 test heads for a variety of container sizes up to 350oz. This makes the Flex Pitch ideal to leak test difficult containers.

  • Page 7: Machine Designation And Serial Number Location

    Enclosure door: ID plaque, ALPS 24 Hour service phone number, and UL Panel rating label. TABLE 1 Identification and rating labels. LABEL ALPS 24-hour service hotline phone number ALPS ID ALPS Rating Label UL Certification Sticker FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 10/16/2012...

  • Page 8: Section 2: Safety

    Notify authorized personnel. RISK OF HOT SURFACES HAZARD This symbol can be found in areas where a potential burn hazard exists. Flex Pitch servo motors have hot surfaces. Do not touch motor surfaces while in operation or after being recently shut down.

  • Page 9: Lock Out / Tag Out

    DANGER: STARTS AUTOMATICALLY This warning is displayed on all plexiglass doors as a warning that the machine starts and stops automatically as a function of its normal operating scheme. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 10/16/2012...

  • Page 10: Safety: Warning Messages

    PROCEDURES. THE POTENTIAL OF SERIOUS PERSONAL OR FATAL BODILY INJURY EXISTS! VOLTAGE HAZARD! THE FLEX PITCH LINEAR MACHINE USES 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 11: Lockout-Tag Out Air Supply

    Lock main Power in the OFF position when the machine is down for maintenance Lockout-Tag Out Air supply Lock airflow in the OFF position when the machine is down for maintenance FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 10/16/2012...

  • Page 12: Safety: Machine Is Installed And Ready For Production

    HMI Emergency Stop Palm Button- The Flex Pitch™ is equipped with two emergency stop (E-Stop) palm-buttons: one located on the HMI panel and one located on the control enclosure. The E-Stop button has an LED to indicate the status of the safety system or sensor.
  • Page 13 Machine stopped, door ajar or waiting for operator to press START. The circuit is open, interrupted, e-stop has been pressed or a fault has occurred. Clear (No Color) Waiting for run or start condition. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 10/16/2012...

  • Page 14: Section 3: Theory Of Operations

    The machine waits for the probe take-off delay when the container is under the appropriate head to initiate the test cycle. When the test cycle begins, the Flex Pitch test probes will extend and fill valves will execute simultaneously pressurizing the containers. During this process, the container is electronically monitored to ensure the sealed container reaches the specified test settings for the recipe loaded on the Flex Pitch.

  • Page 15: Test Probes Carriage/Slide Introduction

    Important: Please do not attempt to service the probe carriage or attempt any modifications. Contact the 24 –hour ALPS SERVICE HOTLINE for help with service questions. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 10/16/2012...

  • Page 16: Reject And Reject Verify Pe's Introduction

    Settings screen for Reject Verification. Note: If a Reject Verification Failure occurs, any defective containers must be removed from the line manually! Reject Verification Sensor Reject Cylinder Reject Verification Reflector Reject Verification Photo-Eye FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 10/16/2012...

  • Page 17: Section 4: Getting Started

    Incoming Air Regulator Manual regulator for the main air supply. Air Pressure Verify The gauge should be set to 80 psi. Turn the adjustment ring to vary the outgoing air pressure FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 18: Access Guards

    To adjust the photo eyes, loosen the hand clamp device and adjust vertically to the scale reading indicated by the recipe. Left: Container Present Photoeye Middle: Reject Photoeye FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 19: Test Probe Carriage

    First unlock the slide by loosening the hand clamps on the left and right. Adjust the slide height using the manual crank until the slide scale reading matches the recipe. Retighten the slide lock hand clamps when finished adjusting the height. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 20: Reject Cylinder Position

    The Reject Cylinders position can be adjusted in and out. To adjust the reject cylinder, loosen the hand clamp device and adjust horizontally to the scale reading indicated by the recipe. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 21: Section 5: Flex Pitch Quick Start Operations

    About The Quick Start Manual The Flex Pitch™ Quick Start manual is a procedural instruction manual on how to run production on the Flex Pitch™ in a safe an efficient manner. This Quick Start manual will specifically cover loading recipes and running and monitoring production and assumes specific setup with regards to timing, photo eyes and mechanical setup has already been accomplished.

  • Page 22: Section 6: Hmi Control Panel Touchscreen Description

    Pulling red knob out resets the e-stop. The operator must press the green START button (shown at right) to restart the machine. LED changes back to GREEN.  Start/Stop buttons Starts and Stops machine operation. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 23: Section 7: Home Screen And Main Menu Description

    A compilation of the Total, Rejected, Passed and Reject Percentage of the self- Self-Test Counters tests performed Shows date and time, machine speed in CPM (containers per minute) and CPM Data Window (containers per hour). FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 24: Home Screen / Main Menu Directory Structural Hierarchy

    About ALPS Settings Bottle Size Alarm Close Button (Return to Close Button Main Menu) (Return to Close Close Main Menu) Button Button (Return to (Return to Main Menu) Main Menu) FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 25: Section 8: Loading A Recipe

    Overview Recipes Menu Command A recipe is the saved test setting perimeters for a particular container. The Flex Pitch™ Quick Start manual defines the process of downloading a recipe for the current container. Creating, deleting and loading from and to memory cards for recipes are defined in the Advanced Operator manual.
  • Page 26 If desired or if currently logged in the Log Out button will logout the current password level. Once pressed a log in password will now be required to load recipes or make setting changes. CLOSE Button: This button closes the menu. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 27: Section 9: Production

    It can also provide key information for making adjustment to test settings that may need tweaking from time to time. The Quick-View buttons are defined below: Accessing Online Information Select this button for Access to helpful Information on specific displays. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 28: Counters

    This screen shows recent test results for all four heads. Using Quick View recent results can help determine where container pressure failures may be occurring.  Pass/Fail indicator: Green = PASS and Red=FAIL  RESULT= Why the container failed FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 29: Self-Tests

    This screen shows a listing of the last five recent rejects, what type or cause of reject and at what station it occurred. Recent rejects is a helpful monitor that can quickly point out possible container issues that may need to be addressed. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 30: Cycle Timers

    This screen shows the actual bottle pressure reached for each station. The bottle pressure screen can help determine where the pressure percentages are for production runs as well as help possible test setting adjustments. FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 31: Alarms

    During production alarms may occur. This section of the manual lists all the Alarms that may occur and how to deal with them. Loss of Air Alarm Servo Alarm Servo Communications Alarm Total Reject Percent Alarm FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 32: Reject Verification Alarm

    AIR LOGIC POWER SYSTEMS (ALPS) PRODUCTION Reject Verification Alarm FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 33: H1 To H4 Consecutive Reject Alarms

    AIR LOGIC POWER SYSTEMS (ALPS) PRODUCTION H1 to H4 Consecutive Reject Alarms H1 to H4 Transducer Alarms Reject Percent Alarm H1 to H4 FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 34: Auto Self-Test Alarm Chute Intrusion Alarm

    AIR LOGIC POWER SYSTEMS (ALPS) PRODUCTION Auto Self-Test Alarm Chute Intrusion Alarm Container Present Photoeye Stuff OFF Container Present Photoeye Stuck ON Controller Error Heads Failed to Home FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

  • Page 35: Heads Too Close Reject Photoeye Stuck Off

    AIR LOGIC POWER SYSTEMS (ALPS) PRODUCTION Heads Too Close Reject Photoeye Stuck OFF Reject Photoeye Stuck ON FLEX PITCH  QUICK-START MANUAL TM 2012-005 REV00 © 7/24/2012...

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