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Alps Electric Flex Pitch DUO Operator's Manual

Leak tester
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Operator Manual
Flex Pitch DUO Leak Tester
Original Instructions [English]
2206220752 Rev A

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  • Page 1 Operator Manual Flex Pitch DUO Leak Tester Original Instructions [English] 2206220752 Rev A...
  • Page 2 Copyright © 2021 ALPS All rights reserved. Printed in the USA. Due to continued product development this information may change without notice. The information and intellectual property contained herein is confidential between ALPS and the client and remains the exclusive property of ALPS. If you find any problems in the documentation, please report them to us in writing.

  • Page 3: Table Of Contents

    2.8 Danger! Do not operate Without Guards in Place ..............5 2.9 Danger! Starts Automatically ....................... 5 2.10 Safety: Warning Messages ......................6 3 Flex Pitch DUO Specifications ....................6 4 Safety-Operational Status/Conditional Status ..............7 4.1 Operational Status: Conditional status of the machine ............7 5 Glossary of Common Terms .....................
  • Page 4 10 How to Edit Settings with the HMI ..................16 10.1 Changing settings and values ....................16 10.2 Test Pressures & Reject Limits Overview ................20 10.3 Test Pressures & Reject Limits Helpful Hints ..............20 10.4 Container Size and Stroke Overview ..................21 10.5 How to Use Container Size and Stroke ................22 10.6 Probe Take Off Overview ......................24 10.7 How to Use Probe Take Off .....................24 10.8 Reject Timing ..........................26...
  • Page 5 16.6 Interface I/O Screen ........................53 17 How to Use Inputs and Outputs ..................54 17.1 How to Use Analog Inputs .......................55 17.2 How to Use Digital Inputs......................55 17.3 How to Use Analog Outputs ....................55 17.4 How to Use Digital Outputs .....................55 18 Station Diagnostic overview ....................55 19 How to use Station Diagnostic .....................56 19.1 Station Diagnostics Results ......................56...
  • Page 6 31.12 Output Mode ..........................77 31.13 Set for judgment value (P.V.) ....................77 32 Maintenance Menu .........................78 32.1 Flex Pitch Routine Maintenance Schedule ................79 33 HMI Reference Tables ......................80 33.1 Software............................80 34 HMI Navigation and Information ..................80 34.1 Screen Navigation ........................81 34.2 Home Screen..........................82 34.3 Information ..........................85 34.4 Alarm Screen ..........................86 34.5 Event History ..........................87...
  • Page 7 www.alpsleak.com...

  • Page 9: Introduction

    The Flex Pitch DUO has a smaller footprint to perform leak testing on an existing conveyor line, requiring no conveyor line modifications. The Flex Pitch DUO has built in flexibility with 2 test heads for a variety of container sizes up to 4”...

  • Page 10: Machine Designation And Serial Number Location

    1.4 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 control enclosure as shown below. Along with it are the 24-Hour service hot-line phone number 1-800-325-8717 and the UL Panel Rating plate.

  • Page 11: Safety

    CAUTION Read the instructions before using the machine. Only qualified personnel should operate the Flex Pitch DUO. WARNING High pressure hoses, fittings and couplings are important for the safety of the machine. Use only hoses, fittings and couplings recommended by ALPS.

  • Page 12: Safety: Warning Labels And Descriptions

    2.3 Safety: Warning Labels and Descriptions Safety is always critical. The ALPS FlexPitch machine is equipped with a full complement of warning decals and labels. A standard series of warning and caution labels are in place to inform the operator of certain hazards relative to the function of this machine. Please observe these warnings. 2.4 Danger! Arc, Shock, and Flash Hazard: The potential for serious or fatal injury exists.

  • Page 13: Warning! Watch Your Hands And Fingers

    2.7 Warning! Watch Your Hands and Fingers This warning is seen on the front of the discharge chute. Do not thrust your hand up this chute while the machine is operating. Contact with moving container material poses a slight to moderate threat of injury.

  • Page 14: Safety: Warning Messages

    WARNING Only trained and or certified personnel should operate or rig the Flex Pitch DUO for shipment or movement. 3 Flex Pitch DUO Specifications Dimensions W-D-H 96.5” x 50” x 96” (2451 mm x 1270 mm x 2348 mm) Weight...

  • Page 15: Safety-Operational Status/Conditional Status

    4 Safety-Operational Status/Conditional Status 4.1 Operational Status: Conditional status of the machine Figure 1: Operational Status Lights 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 16 Term Description End of T2 Pressure Test result displays the pressure in the container at the end of Test 2. Fill Pressure The pressure used to fill the container. This pressure is set in PSI. Fill Valve The Solenoid valve that controls the air used to pressurize the container. An acronym meaning: Human Machine Interface.

  • Page 17: Introduction To Components

    6 Introduction to Components Table 4: Working Components Ref # Components DOWNSTREAM JAM PHOTO EYE CARRIAGE HEIGHT ADJUSTER BAR STACK LIGHT EMERGENCY STOP PUSH-BUTTON USB PORT UPSTREAM PHOTO EYE ENCODER WHEEL & BRACKET SPACING WHEEL MOTOR SPACING WHEEL BRACKET EMERGENCY STOP PUSH-BUTTON DOOR HANDLE REJECT CHUTE www.alpsleak.com...
  • Page 18 Ref # Components CONVEYOR PNEUMATIC CONTROL AND FILTRATION UNIT ADDITIONAL PNEUMATIC FILTRATION RESTING PADS / MOUNTING FEET CASTERS Ref # Components LIGHT STACK CONVEYOR UPSTREAM PHOTO-EYE E-STOP CONNECTION BLOCK SPACING WHEEL TEST HEAD SERVO MOTOR AUTO CARRIAGE HEIGHT MOTOR www.alpsleak.com...

  • Page 19: Theory Of Operations

    Ref # Components RESTING PADS / MOUNTING FEET CASTERS CARRIAGE LEAD SCREW CARRIAGE HEIGHT ADJUSTER BAR CARRIAGE LOCKING HANDLES DOWNSTREAM JAM PHOTO-EYE ENCODER 7 Theory of Operations 7.1 Leak Test Operations Figure 1: Peak Pressure Chart 7.2 Pressure Test Untested containers are transferred from line conveyor to the FlexPitch. When the FlexPitch begins to detect containers the test-probes will extend to seal and pressurize the containers.

  • Page 20: Pressure Decay Values

    7.5 Pressure Decay Values Unless otherwise specified the pressure units of measurement entered or displayed in the HMI are shown in Inches of Water Column (IWC). Photo Eye Function and Position 7.5.1 Photo Eyes Introduction and Positions Containers transition from the production line conveyor into the FlexPitch conveyor for leak testing. During this transition containers will be monitored and controlled by various photo eyes.

  • Page 21: Emergency Door Sensors Positions

    8 Emergency Door Sensors Positions Figure 3: Door Mounted Safety Switch Locations Table 6: Doors and Guard Assembly Item Component Function Emergency Door Category 4 rated-pulsed signal non-contact switch. These work the same as the one in the Switches emergency stop on HMI touch screen panel. Protects personnel during operation from moving components that are located inside the enclosure.

  • Page 22: Alps Password Definitions Overview

    Table 7: ALPS default (shipped) password settings Item # Level Password Allowed Guest View displays Operator Loading recipes and view only Maintenance Set-Up Leak testing and calibration menus Supervisor All except ALPS 9.2 ALPS Password Definitions Overview Level 0 No password: No password is required. Viewing displays only is allowed. Level 1 Operator: Password is required.

  • Page 23: How To Enter Passwords

    9.4 How to Enter Passwords Figure 5: Login Lock for All Screens 1. From any screen, select the lock on the settings navigation menu on the right side of the screen. Figure 6: Basic Password Screen 2. A password prompt screen appears. Touch the white input area. 3.

  • Page 24: How To Edit Settings With The Hmi

    Figure 8: User Group Information There are three levels of permissions. Once signed in, the operator can press the lock button again to see the advanced login screen to make any necessary changes depending on the level of permissions given. Operator for day to day operations, Supervisor for day to day operations, reporting and overrides, and Technical for programming the HMI, troubleshooting, and machine installation.
  • Page 25 A popup screen will display the various screens the user can access. Figure 11: Popup Navigation Once a screen is selected changes can be made to the Flex Pitch Duo operations. When a setting is selected, a numeric key pad will popup.
  • Page 26 Figure 12: Numeric Key Pad All screens will have a key in the HMI Navigation section that will describe the functionality of each screen. See example below: Table 8: Settings Screen Key Example Label Test Settings Title Test Times Title Fill Time(s) Amount of time the Fill Valve will remain ON after the Start Fill Time Pressure is achieved Test Time 1 (s)
  • Page 27 Label Desired Speed (FPM) Desired Conveyor Speed (Feet per minute) Actual Speed(FPM) Actual Conveyor Speed (Feet per minute) Scalar Value Scalar Value for proper conveyor speed Potential Throughput Container per Minute based on Actual conveyor speed (CPM) Reject Timing Title Encoder Reject Position Distance from the Entrance Photo-Eye at which the Reject will occur, in INCHES (inches)

  • Page 28: Test Pressures & Reject Limits Overview

    changes can be entered The allowable minimum and maximum values are displayed in the following tables. Exceeding MAX and MIN limits is not permissible. Use the popup keyboard to make any changes 10.2 Test Pressures & Reject Limits Overview These Setting Screen contains the time settings, and pressures, and pressure limits required to perform leak tests on the FlexPitch.

  • Page 29: Container Size And Stroke Overview

    Table 12: Helpful Hint Chart Function Hint Action Increasing fill pressure will help pressurize the container faster which can allow for faster fill times. The Fill Time and Fill Pressure are Fill Time and Fill Pressure Keep fill times to a minimum related to container shape and volume.

  • Page 30: How To Use Container Size And Stroke

    10.5 How to Use Container Size and Stroke Figure 15: Settings Navigation Figure 16: Change Container Navigation Menu “Container Size” contains the container width and stroke settings that allow the FlexPitch to move the test probes accordingly. Open the change container screen as seen in figure 17-19. For more screen information please refer to the HMI Navigation section of this manual.
  • Page 31 3. Select Container Size Change 1 and enter the appropriate data and press the Change Container Size button. Figure 17: Change Container Screen Figure 18: Change Container Size Step 2 4. Enter the appropriate data and press the Confirm button. www.alpsleak.com...

  • Page 32: Probe Take Off Overview

    Figure 19: Change Container Size Step 3 5. Once the appropriate data is entered and step 2 is confirmed, then press the Complete button in step 3. Step 2 is primarily for setting up a new container and can be skipped as necessary 10.6 Probe Take Off Overview The Probe Take-Off adjustment is a setup aid for centering the test probes on the container.
  • Page 33 Figure 20: Screen for Probe Take Off Test Limits, Reject Timing, and Test Pressures can be entered on this screen. The conveyor speed should already be set prior to accessing this screen. Figure 21: Test Settings, Test Limits, and Test Pressure Section The auto set button on the Probe Take-Off Point will auto set heads 2 once head one is set and the auto button is pressed.

  • Page 34: Reject Timing

    Figure 22: Probe Take-Off Point 10.8 Reject Timing Reject timing can be adjusted from this screen. Reject timing contains the encoder positions that tells the FlexPitch when to reject a defective container. When making changes to this setting it is very important to test and verify that only the failed leak test container(s) are indeed being rejected.

  • Page 35: Conveyor Speed Setting

    Container Per Minute (CPM) rate. If the option for “Analog Output for Conveyor” is turned ON then PLC scaling and desired FPM selection will be visible and can be adjusted from this section. Conveyors are optional equipment and the Flex Pitch DUO may or may not be equipped with a conveyor..

  • Page 36: Spacing Wheel (Optional)

    Figure 25: Settings Option 1 Screen 11.1 Spacing Wheel (Optional) Figure 26: Options 1 Settings Screen The optional Spacing wheel will keep the in-feed of containers to the FlexPitch at a fixed distance. This can help with container control and help increase test times allowing the leak test to detect smaller holes.

  • Page 37: Automatic Rail Guide (Optional)

    11.2 Automatic Rail Guide (Optional) Adjust infeed rails automatically based on container size. Values are saved into recipes. The rails will adjust to width of the new container. Figure 27: Automatic Rail Guides Screen 1. Select to adjust rails to container size. 1/8-inch gap each side is recommended. 11.3 Automatic Carriage Height (Optional) The automatic height is recipe based and also settable on this screen.

  • Page 38: Reject Verification (Optional)

    The down stream jam timer is a photo eye that will watch the flow of containers. Should the photo eye be fixed on a single container, a timer is set to stop and alarm the Flex Pitch DUO indicating that there is a jam or that product has stopped.

  • Page 39: Recipes Overview

    12 Recipes Overview A Recipe is a saved data file that contains all the settings for a specific container. A recipe can be saved, created, deleted, and loaded. To access the recipe screen, press the settings icon and select Recipes on the menu bar. Figure 31: Recipes Menu Table 13: Recipe Overview Function...

  • Page 40: How To Use Recipes

    Figure 33: Save New Recipe Screen If a new container has been loaded and set up on the Flex Pitch DUO and when the recipe screen is opened, all the set up and operating parameters are automatically populated. Press the save button to save the current settings.

  • Page 41: Load Existing Recipe

    “Set0”. If the save button is pressed, the name of the product will be saved as Set0. Values can be changed on the save popup screen if necessary. Select the parameter on the popup screen and enter the new value. NOTE: The values on the save popup are for mechanical settings.
  • Page 42 Figure 35: Current Recipes Drop Down Menu www.alpsleak.com...

  • Page 43: Test Results Menu

    Figure 36: Loading a New Recipe Screen Additional settings can be viewed by pressing the page down button and pressing the page up button to return to the recipe screen. Figure 37: Additional Recipe Screens 12.2.1 Load Recipe from Memory Card to HMI To load a recipe from an external source, such as a thumb drive or wifi, use the import single or all button and follow the screen prompts.
  • Page 44 Figure 38: Test Results Screen To access the test results screen, press the home button. The last test results will be displayed on the test results screen. Figure 39: Last Test Results Screen 1 There are three windows associated with the test results screen. Each can be accessed by touching www.alpsleak.com...

  • Page 45: All Results, Individual Results, Timer Details And Recent Rejects Overview

    in the test results area of the screen. Figure 40: Last Test Results Screen 2 Figure 41: Last Test Results Screen 3 Test results is where comparative data on leak test results is viewable. This information can help an operator or supervisor make quality control decisions on current production runs. 13 All Results, Individual Results, Timer Details and Recent Rejects Overview The Test Results menus are designed to view real time for leak testing, and machine performance.

  • Page 46: How To Use All Results

    Table 14: Description Table Function Description All Results Provides the real-time test results from all the heads and the capability to perform self-tests The detailed leak test from each test head is selected. The user enters a test head station number, and the Individual Results leak test results are displayed.

  • Page 47: How To Use Individual Results

    Figure 43: Station Overview Menu The All Results screens provides the real-time test results and test details from all the heads. The Station Results button navigates to the Test Results, which provides detailed station results. Table 15: All Results Description Table All Results Display Description y Head Number, Test Result, Test 1 % Loss, and Test 2 % Loss is displayed for each test head...

  • Page 48: How To Use The Cycle Time Statistics

    Individual Results Display Description To use this function, stop production, and place a container under the proper test probe and Manual Test button push the manual test button. The leak test results will be displayed on the screen. 13.3 How to Use The Cycle Time Statistics From the navigation menu, select the Cycle Time Statistics screen.
  • Page 49 Timer details provide test cycle times, servo times, and test times for each test probe station number. The Cycle Time Statistics looks at the last one hundred cycle times and displays the last readings, minimal, average and maximum data points. The times can be analyzed by an advanced user to optimize the leak test recipe settings.
  • Page 50 Figure 48: Number of Samples for Calculation As with all screens, when a data box is white, press on the white box and the appropriate key pad will pop up to enter values. Note: that the keypad displays the Min Max values that can be entered. Table 17: Timer Details Description Table Description Test Results Display...

  • Page 51: Alarm Log & Counters Overview

    14 Alarm Log & Counters Overview The Alarm Counter will keep track of how many times the various alarms may have occurred. The Alarm Log will keep a record of all alarms that occurred and include time and date stamp. From any screen press the results icon and select Alarm Counters to access the alarm screen.

  • Page 52: How To Use Alarm Log

    Table 18: Alarm Counter Descriptions Function Description Alarm Counters Total counts (how many times they occurred) for every possible alarm. Alarm Log Alarm tracking time stamp details The user can Log-In as an Operator, Supervisor, or ALPS Technician. The user can Log Log In Out of the machine.
  • Page 53 Figure 52: Alarms Screen Access Figure 53: Alarms Screen There are four options icons use: 1. Alarm reset can be pressed when the cause of the alarm has been corrected. 2. Warning can be reset by may reactivate if there is an impending issue. 3.

  • Page 54: Manual Test Overview

    15 Manual Test Overview Manual Test and Manual Self-Test are essential tools for checking test settings accuracy. To access the Manual Test and Self Test screen which is the Station Overview as described earlier in the manual, press the results icon and select Station Overview from the drop-down menu. The Manual Test, allows for leak test settings verification and settings may be adjusted from this screen.

  • Page 55: How To Use Manual Test

    Part Description 2: Probe and Fill regulator Indicates what the probe and fill regulators are set at. gauge readings The Part Pressure gauge can be a very helpful tool for setting proper fill pressure. The gauge shows the actual pressure in the container. In addition, it shows if the container pressure was in the appropriate range of .5 and 25 IWC.

  • Page 56: Inputs And Outputs Overview

    1. If necessary, stop production flow of containers into the FlexPitch. 2. To ensure the FlexPitch is not in production push the stop. 3. Status should say: System Stopped: Waiting for Run Button. 4. Place a container under test probe for station selected 5.

  • Page 57: Analog Inputs

    16.1 Analog Inputs Figure 54: Menu to Access I/O Status Screen Figure 55: I/O Status Screen www.alpsleak.com...

  • Page 58: Digital Inputs

    16.2 Digital Inputs Figure 56: Digital Inputs The Digital Inputs provide real time status of the digital inputs to the FlexPitch. These screens are useful to verify the correct functionality of the devices on the FlexPitch machine 16.3 Analog Inputs The Analog Inputs use an electronic device called a transducer to examine and contrast air pressures used to leak test each container.

  • Page 59: Digital Outputs

    16.4 Digital Outputs Figure 58: Digital Output 16.4.1 Analog Outputs The Analog Outputs provide a view of the raw values of the analog outputs of the FlexPitch. Figure 59: Digital Analog Outputs 16.5 I/O Forcing, and Maintenance To access the digital outputs I/O Forcing Screen, press the Maintenance icon and select I/O Forcing from the dropdown menu.
  • Page 60 Figure 60: Navigation to I/O Forcing Screen The Digital Outputs screens provide access to manually test the digital outputs of the FlexPitch. While the machine is stopped, individual outputs may be turned on to diagnose problems. See the FlexPitch Maintenance Manual for more information. The maintenance menu contains the I/O diagnostics, system information, and analog calibration screens.

  • Page 61: Interface I/O Screen

    Figure 61: I/O Forcing Screen For Maintenance or troubleshooting stop the machine and select any item that needs changed Figure 62: I/O Forcing Station Select Each station can be accessed by entering the station number into the station select box. 16.6 Interface I/O Screen Additional information can be accessed.

  • Page 62: How To Use Inputs And Outputs

    Figure 64: Interface I/O Selection Using the dropdown menu return to the digital output screen. 17 How to Use Inputs and Outputs Figure 65: I/O Forcing Screen For Maintenance or troubleshooting stop the machine and select any item that needs changed www.alpsleak.com...

  • Page 63: How To Use Analog Inputs

    CAUTION Attempting to calibrate analog inputs without proper knowledge will adversely affect leak test results. 17.1 How to Use Analog Inputs Viewing Analog Inputs and scaled values during production can be useful to determine if the transducers are functioning properly. The values should increase with test probe down on container, and conversely the value should decrease rapidly as pressure drops and the probe is going up.

  • Page 64: How To Use Station Diagnostic

    19 How to use Station Diagnostic Figure 66: I/O Forcing Screen 1. If necessary, stop production flow of containers into the FlexPitch. 2. To ensure the FlexPitch is not in production push the stop. 3. Status should say: System Stopped: Waiting for Run Button. 4.

  • Page 65: Analog Calibration Overview And Use

    20 Analog Calibration Overview and Use CAUTION Attempting to calibrate analog inputs without proper knowledge will adversely affect leak test results. The calibration screen is used for general maintenance and when a transducer or item that needs calibrated is replaced. Press the maintenance icon and select calibration from the drop-down menu to enter the calibration screen.
  • Page 66 Figure 68: Diagnostics Screen Figure 69: Diagnostics Screen Generate Report To save externally, select either export to usb or view report and save. www.alpsleak.com...
  • Page 67 Figure 70: Generate Report The following is a sample diagnostics report. Figure 71: Diagnostic Report www.alpsleak.com...
  • Page 68 Figure 72: Diagnostics Report Page Sample Figure 73: Diagnostics Report Page Sample 2 www.alpsleak.com...

  • Page 69: Supervisor Menu Introduction

    22 Supervisor Menu Introduction The supervisor settings allow for turning on and off various functions and options. 22.1 System Options Overview and Interface I/O To access the system options overview screen press the supervisor icon. From the drop down menu select options.

  • Page 70: Auxiliary Test Overview

    Option Description Secondary Reject Used to reject a container for purposes other than leak testing Analog Conveyor Output Enables PLC analog (speed following) output to conveyor drive Alarm Siren Siren will sound off in the event of an Alarm stopping production. When upstream production cannot be stopped blow off valve will eject all containers until jam is Blow Off Downstream Jam cleared.

  • Page 71: How To Use Auxiliary Test

    Table 21: Aux Test Overview Function Description Aux Test OFF/ON Turn ON or OFF Aux at Start of Test Checks probe position at start of leak test Aux During Test Checks probe position during leak test Aux at End of Test Checks probe position at end of leak test 24 How to use Auxiliary Test To turn on function select where test should occur.

  • Page 72: How To Use Reject Alarm

    26 How to Use Reject Alarm Figure 77: Options Overview Screen Reject Alarm Follow Step Below: 1. Turn ON Consecutive Reject alarm turns Yellow 2. Turn OFF Consecutive Reject alarm turns Gray 3. Alarm Mode: Warning Turns Yellow 4. Alarm Mode: Alarm turns Red 5.

  • Page 73: System Bypass Overview And Use

    28 Set Up New Bottle Use the following procedure to set up a new bottle: 1. Ensure that the Flex Pitch DUO is not operational. 2. Ensure that the conveyor remains running. 3. Navigate to the “Change Bottle Size” screen on the HMI.
  • Page 74 Figure 79: Bottle Size Change 1 4. Press the Change Bottle Size button “6”. A - Neck Diameter B - Bottle Volume C - Bottle Width Figure 80: Bottle Parameters www.alpsleak.com...
  • Page 75 Figure 81: Bottle Size Change 2 5. Enter the bottle width in inches “C” in box “8”. 6. Enter the Neck Diameter “A” in box “9”. 7. Enter the bottle volume “B” in box “10”. 8. Enter the hole size into box “11”. (the maximum hole size of a possible leak) 9.

  • Page 76: Auto Self-Test Overview

    NOTE: All values entered into the HMI are in inches 29 Auto Self-Test Overview Figure 83: Options Overview Screen Auto Self Test Section Auto Self-Test allows the FlexPitch to automatically perform a Self-Test during production. How often it’s performed is programmed by the number of containers transitioning through the FlexPitch. The Auto Self-Test can help ensure the test settings and recipe used for production are indeed detecting defective containers in accordance with the required hole size.

  • Page 77: Laser Height Quick Reference Procedure (Ib-1500)

    30 Laser Height Quick Reference Procedure (IB-1500) Focus: Keyence IB-1500 Laser Height Sensor Quick-Start Setup procedure. Part 1: Changeover/Setup New Container Part 2: Flex Pitch DUO Container Height Calibration Part 3: To Access Initial Setup Screens Part 4: Laser Controller – Initial Setup...

  • Page 78: Part One Changeover/Setup New Container

    Item Description Item Description Sub-Display Check Indicator HIGH Tolerance Indicator LED Timing Input Indicator 31 Part One Changeover/Setup New Container: 31.1 Left: Zeros will appear in the sub-display. Press the Zero-shift button. 31.1.1 Part 1: Setting the Display High/Low NOTE: The FlexPitch uses the raw analog value for comparison. The HI/GO/LO lights are to be used for informational purposes only.

  • Page 79: Part Three Flexpitch Container Height Calibration

    sensor mount: Adjust the designated calibration container inside the sensor field. Have the neck portion centered directly in the path of the laser. Steps: 1. Press once the ZERO-SHIFT button (lower left). This will set the zero point for the sensor without container being present.
  • Page 80 2. Navigate to the Laser Height Calibration Screen. NOTE: This will require at least Maintenance level log-in. 3. Take a container of known good height and insert it through the Laser Height detector. Enter this known height into the “KNOWN HEIGHT Container” field. 4.

  • Page 81: Part 4: Access Initial Setup Screens

    6. Return to the Laser Height Results screen. Enter in the Min and Max height for the container. These are the reject limits for the Laser Height. Anything shorter than the minimum, or taller than the maximum, will be rejected. 31.4 Part 4: Access Initial Setup Screens: 31.4.1 Keypad Layout: Press the MODE button for (2) seconds to access the settings level command.

  • Page 82: Reference Light Registration-Gain Adjust

    4. Hold ZERO-SHIFT button (lower left) and the MODE button (lower right) in unison. 5. UNITS will be displayed in the main digital display area above. 6. Press the UP/DOWN buttons ( ) until (inch) is displayed in the sub-menu. 7.

  • Page 83: Perform Basic Settings In This Order

    31.7 Perform basic settings in this order: The Dimensional Mode has been selected. Right: This table shows dimension mode for IB10 models. 31.7.1 Basic Settings (1.Fnc) 1. Press the MODE button (at lower right) and hold for (2) seconds. 2. The first function to be displayed is (1.Fnc). This is a percentage / dimension mode. 3.

  • Page 84: Averaging/High-Pass Filter

    31.9 Averaging/High-Pass Filter 31.9.1 Auto-Adjust function enabled: (3. AvE) Set the average or high-pass filter for the data retrieved at the sampling rate. 31.10 Averaging: (AvE) For ALPS purposes alone: 1. The default setting is “64”. Leave this setting alone. 2.

  • Page 85: Output Mode

    1. Press the right arrow key ( ) to advance to the next setting or exit 2. Initially, you must press the DOWN arrow key ( ), when the End is displayed, to go to the advanced settings for the first time. 31.12 Output Mode 31.12.1 Advanced Settings Mode (PRO)

  • Page 86: Maintenance Menu

    3. Press the UP/DOWN arrow keys ( ) until (TG.Lu) is equal to (0.0050) 4. (Press the RIGHT arrow key ( ) to accept. 5. Press the RIGHT arrow key ( ) multiple times until (END) to exit this setting mode. 32 Maintenance Menu The maintenance menu contains the manual test function, I/O diagnostics, and analog calibration screens.

  • Page 87: Flex Pitch Routine Maintenance Schedule

    32.1 Flex Pitch Routine Maintenance Schedule NOTE: The Flex Pitch bearing blocks are “Perma Lubed” and will not need additional lubrication Table 24: Flex Pitch Maintenance Schedule System Component Service Required Weekly Maintenance Air Filters Drain filters by pressing manual petcocks. Container Sensors/PE’s Use clean, filtered shop air (50psi max) to remove dust.

  • Page 88: Hmi Reference Tables

    Product labels can be assigned to each recipe making change-out features easy to find and assign. This manual will walk through each screen and define the interfaces available for a Flex Pitch DUO machine but may be applied to various ALPS products. 33.1 Software...

  • Page 89: Screen Navigation

    This manual will use an existing machine setup to illustrate typical machine HMI navigation. Each screen illustrated may or may not be applicable to each installation. Each HMI is identified with an ID and Serial Number that can be accessed on the home screen along with the current firmware version.

  • Page 90: Home Screen

    Figure 86: HMI Navigation Flowchart 34.2 Home Screen Figure 87: Home Screen Label Counters Title All Station Counters This is just a header or title for that block. Total Total containers tested on machine, does not include the self test Accepted Total containers accepted on machine, does not include the self test Rejected...
  • Page 91 Label Peak Current value of Peak Pressure (inches of H20) for the previous test End T1 Current value of T1 End Pressure for the previous test. Test t Current value of test time for the previous test. Ext Time Current value of cylinder extend time for the previous test. Head Accepts Rejects Levels Total accept or reject per head Machine Information...
  • Page 92 Figure 88: Home Screen Duo 2 Figure 89: Home Screen Duo 3 www.alpsleak.com...

  • Page 93: Information

    Label Hourly Totals Title Total Accepts Per Hour Total Rejects Per Hours Reject % Per Hour 34.3 Information The alarms screen will display current alarms /warnings and inactive alarms/warnings along with an alarm history. www.alpsleak.com...

  • Page 94: Alarm Screen

    34.4 Alarm Screen Figure 90: Alarms Screen Label Alarm Reset Home Screen / Reset the active alarms Name Alarm name Time Time the alarm occurred Description Description of posted alarm From: - To: Time period of alarm history Alarms History Title of this block Duration Time period alarm history...

  • Page 95: Event History

    34.5 Event History Figure 91: Event History From: - To: Time period of event history Event History Title of this block Duration Time period of the search Refresh Refresh the search Column Filter Select a filter to near the search Record ID Record number Time Stamp...

  • Page 96: Reports

    34.6 Reports Figure 92: Reports Label Shift Setup Title Shift Enable Select to enable shift report End Time Time period of when the report will end Report Duration Time period of report Production Report Title Days Select which day to generate a report Custom Report Custom report based on this time period Duration...

  • Page 97: Documentation

    34.7 Documentation Figure 93: Documentation Label Hardware Manuals List of pertinent PDF hardware information. User Manuals List of pertinent PDF user manuals Drawings List of pertinent PDF drawings Tutorials Coming Soon! www.alpsleak.com...

  • Page 98: Diagnostics

    34.8 Diagnostics Figure 94: Diagnostics Generate Report Label PLC Information Title PLC Error Code Error code produced by the PLC EtherCat Error Code Error code produced by ethercat network NX IO Bus Error Code Error code produced by NX I/O BUS Motion Control Error Code Error code produced by motion control Ethernet I/P Error Code...
  • Page 99 Label 10 a Servo 1 Fault Code Fault code produced by servo #1 Servo 2 Fault Code Fault code produced by servo #2 Servo 1 Position Current position of servo #1 Servo 2 Position Current position of servo #2 HMI Information Title Available System Memory Available HMI Memory...

  • Page 100: Options

    34.9 Options Figure 95: Options NOTE: All options, Green is ON and Gray is OFF Label Reject Verification Turns ON/OFF the Reject Verification Option Secondary Reject Turns ON/OFF the Secondary Reject Option Conveyor Analog Turns ON/OFF the Conveyor Analog Out Option; This is for control of an alternate conveyor Alarm Siren Turns ON/OFF the Alarm Siren Option Blow On Down-...
  • Page 101 Label Downstream Jam Turns ON/OFF Downstream Jam Delay Option Delay Reject Verify Alarm Turns ON/OFF Reject Verify Alarm Bypass Option Bypass Spacing Wheel Turns ON/OFF the Spacing Wheel Option Auto Height Reject Percent Turns ON/OFF Reject Percent Alarm Option Alarm Reject Percent Reject Percent Alarm Mode toggles between Alarm and Warning Alarm Mode...

  • Page 102: Interface I/O

    34.10 Interface I/O Figure 96: Interface I/O Label AUX 1 Title AUX 2 Title Selectable Input 1 Various selectable inputs, Customer Pause, Blow On Input, SW Slow Speed Down Stream Jam Selectable Input 2 Various selectable inputs, Customer Pause, Blow On Input, SW Slow Speed Down Stream Jam Selectable Input 3 Various selectable inputs, Customer Pause, Blow On Input, SW Slow Speed Down Stream Jam Selectable Input 4...

  • Page 103: Calibration

    34.11 Calibration Figure 97: Calibration Label Analog Calibration - Container Title Pressure Station Select Selection between head 1-2 Raw Value Container pressure in engineering units Scaled Value Scaled value of the container pressure in inches of H20 Calibration Values Title Raw Zero Container pressure at zero pressure in engineering units Slope...

  • Page 104: I/O Status

    Label Raw Zero Reference only; Electronic regulator feedback signal at 0 psi Reference only; Multiplication factor for converting engineering units to scaled Slope units Analog Calibration Title Station Title Station_Min ADC Low Input; Minimum Analog/ DC Low limit for all head container pressure transducer Station_Min ADC Hi Input;...
  • Page 105 Label Digital Inputs Title Safety OK Safety circuit is working Start PB Start push button Stop PB Stop push button Reject Verify Photoeye Detect a rejected container Downstream Jam Photoeye Detect a conveyor jam after the tester. Down Container Photoeye Detects a down container Reject Bin Full Photoeye Detect when the reject bin is full.
  • Page 106 Label Spare Spare Digital Outputs Title Head 1 Probe Valve Displays Head 1 Probe Valve Status Head 1 Fill Valve Displays Head 1 Fill Valve Status Head 1 Self Test Valve Displays Head 1 Self Test Valve Status Head 2 Probe Valve Displays Head 2 Probe Valve Status Head 2 Fill Valve Displays Head 2 Fill Valve Status...

  • Page 107: I/O Forcing

    Label Probe Pressure Reference Only: Probe Pressure showing PLC Engineering Units on a scale of 0-8000 Fill Pressure Reference Only: Fill Pressure showing PLC Engineering Units on a scale of 0-8000 Conveyor Setpoint Reference only: display the engineering units of the conveyor speed Spare 34.13 I/O Forcing Figure 99: I/O Forcing...

  • Page 108: Large Values

    34.14 Large Values Figure 100: Large Values Label Probe (psi) Probe Pressure Indicator Fill (psi) Fill Pressure Indicator Speed ( FPM) Conveyor Speed Indicator www.alpsleak.com...

  • Page 109: Systems

    34.15 Systems Figure 101: Systems Label Network Setup Title WIFI Enable Step 1: Enable Wifi button Update List Step 2: Update available SSID’s Select SSID Step 3: Select network names or Wifi names Password Step 4: Network Password Join Step 5: Join the network Cancel Cancel the network connection Not Connected...
  • Page 110 Label Email Setup Title SMTP Server Setting the SMTP Server Server Port Setting the server port Authentication / SSL Enable Authentication Username Enter user name Password Enter password “From” Enter Machine name or number Recipient 1 Email Recipient #1 Recipient 2 Email Recipient #2 Recipient 3 Email Recipient #3...

  • Page 111: Station Overview

    Label VNC Service Title Start Push button; Start the (VNC) Virtual Network Computing Stop Push button; Stop the (VNC) Virtual Network Computing Restart Push button; Restart the (VNC) Virtual Network Computing Connected Indicator; Status the Corvia Cloud Service Running Indicator; Status the VNC Service 34.16 Station Overview Figure 102: Station Overview Label...

  • Page 112: Pressure Curves

    Label Self Test All Runs a pressure test on all units Note: T2 percent will display data when used. 34.17 Pressure Curves Figure 103: Pressure Curves Label Visible Enable button Graph Selection Options: Head accept, rejects, and self tests Color Code Color associated with specific graph Test Result Test result code...

  • Page 113: Test Statistics

    Label Graph Line Graph 34.18 Test Statistics Label Visible Operator Selectable; Displays the desired Heads Y Axis Zoom H1:Head 1, H2:Head 2, H3:Head 3, H4:Head 4 Average Average rating for the desired graph. Minimum rating for the desired graph. Maximum rating for the desired graph. Y Axis Zoom Zoom on the graph based on the Y-Axis.
  • Page 114 Label Number of Samples The allotted size of the Array. Label Station Selection; Station Selection Start Pushbutton; Capture a continuous cycles of sample of data for 11 seconds Single Trace Pushbutton; Capture a single cycle of sample data History View historic data. Maximum of (4) samples Refresh Pushbutton;...
  • Page 115 Label Station # Graph Results; Station number of the latest container of the historic data. T1% Loss Graph Results; T1% Loss Result of the latest container of the historic data Spare at Start (s) Graph Results; Spare Time at Start of cycle of the latest container of the historic data. Time in Seconds Max Conveyor Vel.

  • Page 116: Main Counters

    34.19 Main Counters Figure 104: Main Counters Label Main Counters Title Total Tested Total containers tested Total Accepted Total containers accepted Total Rejected Total containers rejected Reject Percentage Total containers rejected percentage Cycle Count Total containers tested, not resettable Head 1 Total Total containers test on head #1 Head 1 Rejects Total containers rejected on head #1...
  • Page 117 Label T1 Min Pressure Drop T1 Minimum peak pressure drop error counter for specific station T1 Max Pressure Drop T1 Maximum peak pressure drop error counter for specific station Over Pressure Failure Over pressure failure error counter for specific station Minimum Test Pressure Minimum test pressure error counter for specific station Aborted Tests...

  • Page 118: Alarm Counters

    34.20 Alarm Counters Figure 105: Alarm Counters Label Alarm Counters Title Total Alarm Count Total alarm counter Loss of Air Air loss counter Servo HW Alarm Servo Hardware alarm counter Auto Self-Test Alarm Auto self-test alarm counter Min Pres Exceeded Minimum pressure exceeded counter Reject Verification Reject verification alarm counter...

  • Page 119: Settings Main

    Label Alarm Counters Title Conveyor VFD Conveyor VFD alarm counter Total Percent Reject Total percent reject alarm counter Head 1 Percent Reject Head 1 percent reject alarm counter Head 2 Percent Reject Head 2 percent reject alarm counter Head 3 Percent Reject Head 3 percent reject alarm counter Head 4 Percent Reject Head 4 percent reject alarm counter...
  • Page 120 Label Test Times Title Fill Time(s) Amount of time the Fill Valve will remain ON after the Start Fill Time Pressure is achieved Test Time 1 (s) Amount of time the TEST TIME #1 is active after the FILL TIME is achieved Test Time 2 (s) Amount of time the TEST TIME 2 is active after the TEST Time#1 is achieved Max Fill Time(s)

  • Page 121: Settings Options 1

    34.22 Settings Options 1 Figure 107: Settings - Options 1 Label Downstream Jam Timer Title Downstream Jam PE Delay The amount of time (seconds) before the tester goes to pause Downstream Jam PE Off The amount of time (seconds) before the tester goes to pause Delay Downstream Jam PE Input Reference Only;...
  • Page 122 Label Last Reject Verification Time Reference Only; Time lapse of the Last Reject Verification Chute Intrusion Alarm Selectable Option for Chute Intrusion Alarm. Secondary Blow Length Secondary Blow Off Length define in Inches Automatic Rail Guides Title Rail Guide Position Alterable, defining the width of the container in Inches.

  • Page 123: Setting Option 2

    34.23 Setting Option 2 Figure 108: Setting Options 2 Label Diverter Title Parts Before Diverting Parts prior to diverting; Counts up to target Current Diverter Counter Reference only: Current diverter counter Counter Reset Reset the diverter counter pushbutton Photoeye Re-arm Delay(s) Time before the Photo-Eye is active again Diverter Eye Input Diverter Photo-Eye input indicator...

  • Page 124: Change Container

    Label % Of Bottle To check for Percent of container to be seen at exit photo-eye Reject PE Down Bottle PE 34.24 Change Container Figure 109: Change Bottle 1 www.alpsleak.com...
  • Page 125 Figure 110: Change Bottle 2 Figure 111: Change Bottle 3 www.alpsleak.com...
  • Page 126 Label Current Settings Title Bottle Size (inches) Reference ONLY: Displays the current container’s physical size Crash (inches) Reference ONLY: Crash protection is automatically set to 80% of the Bottle Size Stroke (inches) Total Head Stroke length Depending on container (Bottle) size, the Mode will automatically change to Reduced, Series, or Nest- Mode ed.

  • Page 127: Recipes

    34.25 Recipes Figure 112: Recipes Label Recipe Control Title Select a Recipe Selection of recipe Delete Deletes the selected recipe Export All Exports all recipe Export Current Export selected recipe Create New Recipe Name entry for new recipe Create Create new recipe with the above name Import All Import from USB thumb drive all recipes Import Single...
  • Page 128 Label Max Peak Pressure Selected recipe Maximum peak pressure time Start Fill Time Selected recipe start fill pressure time Pressure T1 Min Loss Percent Selected recipe T1 minimum loss percentage T1 Max Loss Per- Selected recipe T1 maximum loss percentage cent T2 Min Loss Percent Selected recipe T2 minimum loss percentage...

  • Page 129: Settings

    34.26 Settings Figure 113: Settings Main Label Test Settings Title Test Times Title Fill Time(s) Amount of time the Fill Valve will remain ON after the Start Fill Time Pressure is achieved Test Time 1 (s) Amount of time the TEST TIME #1 is active after the FILL TIME is achieved Max Fill Time(s) Maximum time allowed for the START FILL TIME PRESSURE to be achieved Probe Retract(s)

  • Page 130: Counters

    Label Actual Speed(FPM) Actual Conveyor Speed (Feet per minute) Potential Throughput Container per Minute based on Actual conveyor speed (CPM) Reject Timing Title Encoder Reject Position Distance from the Entrance Photo-Eye at which the Reject will occur, in INCHES (inches) Reject Eye To Reject Distance from the Reject (Exit) Photo-Eye to the Reject Cylinder in INCHES Cylinder (inches)
  • Page 131 Label Rejected Total number of containers that Failed the Leak Test. Reject % Total percentage of Rejected containers. (Rejected / Total) *100 Alarm Count Total number of occurred alarms. Self Test Counters Title Total Total number of attempted Self Tests Passed Total number of Passed Self Tests.
  • Page 132 Label Rejected Total number of containers that Failed the Leak Test. Reject % Total percentage of Rejected containers. (Rejected / Total) *100 Alarm Count Total number of occurred alarms. Self Test Counters Title Total Total number of attempted self tests Passed Total number of Passed Self Tests.
  • Page 133 Label The graph fills in from right to left starting at hour zero, then after 60 minutes, increments to the Total Rejects % Per Hour next hour of Rejected Percentage Rejects Title Reject Listing of the last (4) rejects. Head Listing of the last (4) rejects and the head to which it is associated with the reject.
  • Page 134 Label Cycle Time (s) The Cycle Times are given as “LAST, MIN, AVG, and MAX” for each head or station number. The Cylinder Extend Times are given as “LAST, MIN, AVG, and MAX” for each head or station Cylinder Ext (s) number.
  • Page 135 NOTES: _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ______________ ______________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ___________________ _________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _____________________________________________________________________________________________________________...

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