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ALPS TURRET NGR ROTARY LEAK TESTER ADVANCED OPERATOR MANUAL

Air Logic Power Systems, LLC 2440 W Corporate Preserve Drive, Suite 600

Oak Creek, WI. 53154 Phone: 414-574-4151 Fax: 414-574-4152

24 Hour Service Hotline: 800-325-8717 www.alpsleak.com and [email protected]

Notices: Documentation Air Logic Power Systems, LLC; (ALPS), reserves the right to make changes or improvements to the standard NexGen Rotary (NGR) at any time. These changes may not be immediately reflected in the manual accompanying your system. If you notice any inaccuracies or oversights in the manual, please contact the ALPS Service Department. This manual is protected by U.S. federal copyright laws © 2012 Air Logic Power Systems LLC. However, limited permission is hereby granted to photocopy portions of this manual for training of company personnel only. No part of this manual may be duplicated or transcribed in any form, for any other purpose, except as stated above, without expressed written permission from Air Logic Power Systems LLC.

Software Installation of any new or modification of existing software in the NGR not approved by Air Logic Power Systems LLC may affect the operation or performance of the machine and possibly void the warranty and or service agreements. Please consult Air Logic Power Systems Service Department prior to installing or modifying existing software on this machine.

System Modifications Mechanical or electrical modifications not approved by Air Logic Power Systems LLC to the NGR system may also void the warranty and/or service agreements. Please contact the Air Logic Power Systems Sales or Service Department for approval or assistance with any machine modifications.

Trademark and Patent Acknowledgments All products or product names mentioned in the manual are trademarks of their respective companies. The NGR (NEXGEN) is protected under the United States patent laws.

Contact Information Sales and service department personnel at Air Logic Power Systems, LLC:

Service Manager, Ext. 199 Sales & Customer Service Support, Ext. 188 Sales Manager, Ext. 184

Air Logic Power Systems, LLC. Headquarters 1745 S.38th Street, Suite 100, Milwaukee, WI. 53215 Phone: 414-671-3332 Fax: 414-671-6645 24 Hour Service Hotline: 800-325-8717 Email: [email protected]

Copyright © 2012 by Air Logic Power Systems, LLC

AIR LOGIC POWER SYSTEMS (ALPS) SECTION GENERAL INFORMATION

NGR TURRET ADVANCED OPERATOR MANUAL i 04-20

General Information Introduction to the NGR The NexGen Rotary (NGR) feature higher speeds, better leak test sensitivity, quicker and easy changeovers, and comprehensive machine & test data. The NGR can run at for speeds up to the 1,200 BPM (72,000 BPH) range. The NGR uses a modular concept incorporating the test electronics, probe, cylinder, manifold and valves in a single quick-connect assembly called the Leak Test Controller LTC. This allows very fast and accurate response times to maximize the leak test performance. All LTC information is available for review through the standard color touch screen interface.

Warnings, Cautions, and Notes: Note: Notation messages provide additional information or helpful tips about a topic.

WARNING MESSAGES APPEAR BEFORE PROCEDURES AND ALERT YOU TO THE DANGER OF SLIGHT TO MODERATE PERSONAL INJURY IF A STEP OR PROCEDURE IS NOT FOLLOWED PROPERLY. EACH MESSAGE IS ACCOMPANIED BY THE APPROPRIATE SAFETY WARNING SYMBOL.

DANGER MESSAGES APPEAR BEFORE PROCEDURES AND ALERT YOU TO THE POTENTIAL OF SERIOUS PERSONAL INJURY OR DEATH IF A PROCEDURE IS NOT FOLLOWED PROPERLY. MESSAGES OF THIS TYPE ARE USED ONLY FOR EXTREME CASES. EACH MESSAGE IS ACCOMPANIED BY THE

THE NGR ROTARY SYSTEM USES 480 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.

CAUTION!

Caution messages can appear before procedures. Messages of this type indicate possible damage to the machine or loss of data if a step or procedure is not properly observed.

AIR LOGIC POWER SYSTEMS (ALPS) SECTION TABLE of CONTENTS

NGR TURRET ADVANCED OPERATOR MANUAL 1 04-20

Table of Contents Notices: ................................................................................................................................... i

Documentation .................................................................................................................. i Software ............................................................................................................................ i System Modifications ........................................................................................................ i Trademark and Patent Acknowledgments ........................................................................ i Contact Information ........................................................................................................... i Copyright © 2012 by Air Logic Power Systems, LLC ........................................................ i

General Information ................................................................................................................. i

Introduction to the NGR .................................................................................................... i Warnings, Cautions, and Notes ........................................................................................ i

NGR Safety ............................................................................................................................. i

Labeling on the NGR: ....................................................................................................... i

Glossary of Terms ................................................................................................................... i

NGR Advanced Operator ....................................................................................................... 1

Advanced Operator Introduction ..................................................................................... 1

Viewing and editing ......................................................................................................... 1

NGR Theory of Operation ...................................................................................................... 2

Leak Test Theory ............................................................................................................ 2

Tooling and Rotary Theory ............................................................................................. 3

Supervisor .............................................................................................................................. 4

User Administrator .......................................................................................................... 4

User Administration Table ............................................................................................... 5

Cam Settings .................................................................................................................. 7

Shut Down Procedure ..................................................................................................... 7

Additional Supervisor Menus .......................................................................................... 8

Set Date and Time .......................................................................................................... 8

Restore Default Settings ................................................................................................. 8

ALPS Technician ............................................................................................................ 8

Log Off ............................................................................................................................ 8

Reset Counts .................................................................................................................. 8

Language ........................................................................................................................ 8

AIR LOGIC POWER SYSTEMS (ALPS) SECTION TABLE OF CONTENTS

NGR TURRET ADVANCED OPERATOR MANUAL 2 TM2012-013 REV00 © 9/26/2012

Supervisor Navigation ..................................................................................................... 9

Cam Settings Navigation .............................................................................................. 10

Date and Time Navigation ............................................................................................ 10

Restore Default Navigation ........................................................................................... 11

ALPS Technician Navigation ........................................................................................ 11

Options Navigation ........................................................................................................ 11

Language Navigation .................................................................................................... 11

Reset Counts Navigation .............................................................................................. 11

Shut Down Navigation .................................................................................................. 12

Test Settings ........................................................................................................................ 13

Introduction Test settings .............................................................................................. 13

Test Settings Basic Navigation and Editing .................................................................. 13

Fill and Probe Pressure ................................................................................................ 14

Introduction Test Setting Advanced .............................................................................. 15

Test Settings Description Table .................................................................................... 15

...................................................................................................................................... 17

Leak Test Flow Chart .................................................................................................... 17

Test Settings Navigation and Editing ............................................................................ 18

Leak Testing and Settings, Related Problems and Solution Table ............................... 19

Recipes ................................................................................................................................ 22

Introduction to Recipes ................................................................................................. 22

Recipe Navigation and Advanced Procedures .............................................................. 23

Reject Device ....................................................................................................................... 24

Reject Verify Mode ........................................................................................................ 24

Bypass Reject Verify After Fault ................................................................................... 24

Bypass Reject Verify Count .......................................................................................... 24

Reject Chute Monitor .................................................................................................... 24

Reject Device navigation .............................................................................................. 25

Laser Height ......................................................................................................................... 26

Laser Height Navigation ................................................................................................ 26

Coding .................................................................................................................................. 27

Coding Navigation ......................................................................................................... 27

Test Results ......................................................................................................................... 28

AIR LOGIC POWER SYSTEMS (ALPS) SECTION TABLE OF CONTENTS


Test Result Explanation Table ...................................................................................... 28

MANUAL Test ............................................................................................................... 29

Self-Test Results ........................................................................................................... 30

Recent Rejects.............................................................................................................. 31

Total Machine Counts ................................................................................................... 31

Individual Station Counts .............................................................................................. 31

Test Results Navigation ................................................................................................ 32

Test results navigation continued ................................................................................. 32

Results overview navigation ......................................................................................... 32

Self-test result Navigation ............................................................................................. 33

Manual Test navigation ................................................................................................. 34

Recent Rejects navigation ............................................................................................ 34

Reject results navigation ............................................................................................... 34

Total Counts navigation ................................................................................................ 35

Total Counts navigation ................................................................................................ 35

NGR Operator Maintenance ................................................................................................. 36

Operator Maintenance Introduction and implementation .............................................. 36

LTC Diagnostics............................................................................................................ 36

LTC INFORMATION (DATA) ........................................................................................ 37

Timing (Machine Re-Timing) ......................................................................................... 37

Profibus Inputs .............................................................................................................. 38

Profibus Outputs ........................................................................................................... 38

VTPG I/O ...................................................................................................................... 39

Alarm Limits .................................................................................................................. 39

Alarms and Alarm Log .................................................................................................. 40

Container Change Over ....................................................................................................... 41

Change Over Introduction ............................................................................................. 41

Tooling Change Over .................................................................................................... 41

New Container Setup Guide ......................................................................................... 46

AIR LOGIC POWER SYSTEMS (ALPS) SAFETY


NGR Safety Labeling on the NGR: The NGR has three types of labels associated with safety, “DANGER”, “WARNING”, and “LOCK OUT HERE”. Labels with the word “DANGER” on them indicate the severity level is high and describe what the hazard is. “WARNING” indicates a moderate level of severity and describes the hazard. The label: “LOCK OUT HERE” indicates that a Lock Out/Tag Out point is present.

AIR LOGIC POWER SYSTEMS (ALPS) TERMS


Glossary of Terms TERM DESCRIPTION

Absolute Encoder Generates digital electronic pulses that represent to the NGR the position, speed and direction of motion. Of the various devices installed on the NGR.

Air Preparation Unit Cleans and regulates the incoming air supply, includes an air dump lockout valve, primary particulate filter, coalescing filter, reject supply regulator, and an NGR supply regulator.

ALPS Remote Access Screen

Allows the user to remotely control the NGR no differently than controlled at the machine. This is an excellent tool for engineering, maintenance, and for remote monitoring of machine performance information.

Audible Alarm This Alarm can be turned ON or OFF. The audible alarm is located atop the stack lights on a mast above the main operators’ control panel.

AUX 1 Mode Container is rejected for parameters defined under Auxiliary Test 1 conditions. AUX 2 Mode Container is rejected for parameters defined under Auxiliary Test 2 conditions.

Available Test Time The calculated maximum amount of time to perform the leak test. This calculation is based on the following factors: Max Fill Time, Test 1, Test 2, Probe-Retract and CPM (containers per minute).

Backlogging The accumulation of containers upstream of the timing screw. Back-pressure from accumulated containers is necessary to ensure proper feeding.

Bypass Reject Verify After Fault

This setting ignores the reject versify photo-eye after a fault. If containers are removed manually after they have been registered by the container present photo-eye, the NGR will not register a fault for reject verification. The number of containers bypassed is selectable via the HMI (Bypass Reject Verify Count).

Bypass Reject Verify Count

If Bypass Reject verify after Fault is enabled, this count value is for how many containers the NGR will ignore. This also represents the number of containers blown-off on power-up. The count value should equal the number of containers that can normally fit within the NGR enclosure.

CAM Settings CAM settings are defined as a group of Set Points which provide encoder location points to the VTPG.

CAN Bus Controller Area Network. The VTPG (Variable Trip-Point Generator) and LTC (Leak Test Controller) communicate via a CAN bus.

Center-guide Guides the containers on and off the turntable through the infeed and exit star-wheels. It is a part of the change-over tooling and maybe container specific.

Chute Monitor

This feature has two functions that work off of the reject verify photo-eye: 1)-if it is blocked when no container is being rejected, an alarm will be generated; 2)-to detect an blocked chute, misaligned photo eye or obstruction that could possibly keep rejected container from being removed from the conveyor

Coding Device Enabled A selected or enabled option. The optional coding device is activated.

Container Coding This option uses a laser or ink-writer to add coded data to each container. The coded data that is written is provided by the laser or ink-writer. This can be a lot-number (#) code, a date code, or some other form of data.

Container Present Photo-Eye

Detects containers that are present in the pockets of the infeed star-wheel. This information is used by the VTPG to initiate the test sequence when running LTC’s in the normal mode.

Container Present Sensor Use the preferred term: Container Present Photo-Eye

Container Too Short Error generated by laser height option indicating container is under the customers’ height specification.


NGR TURRET ADVANCED OPERATOR MANUAL ii TM2012-013 REV00 © 9/26/2012

TERM DESCRIPTION

Container Too Tall Error generated by laser height option indicating container is over the customers’ height specification.

CPH/CPM Containers Per Hour / Containers Per Minute

Crank Shaft Assembly

The assembly that allows users to raise and lower the probe disk. The probe disk is what the LTC assemblies and their supporting components are mounted on top of.

Dead-plate Center Guide Mount

Supports the base of containers as they transition between the tabletop conveyor and the turntable. Also serves as an attachment point for the container specific center-guide tooling.

Default (In reference to CAM Settings Set points)

The set point that ALPS established when the container was set up. The default serves as a quick check to see what settings may have been changed.

Disk Assembly Comprised of turntable disk that the base of the container rests on and probe disk which mounts and locates the LTC assemblies and their supporting components.

Distribution Panel LTC Power Distribution Boards. All LTC power cables meet at this hub for connection to the slip-ring assembly which ties to the stationary NGR controls.

Downstream Photo-Eye

This photo eye sends a signal to pause the operation of the NGR due to lack of space on the conveyor to discharge containers.

Encoder Counts Used in Cam settings the Encoder Counts show current position of a device.

ETOR End of Test Retreat

Alarm generated when the Peak Pressure exceeds the Peak Maximum value.

End of Fill Pressure A test result will display the pressure in the container after the target pressure has been reached and the fill valve turned OFF.

End of T1 Pressure Test result displays the pressure in the container at the end of Test 1.

End of T2 Pressure Test result displays the pressure in the container at the end of Test 2.

End of Test Delay (In Seconds)

Advanced Test limit entry that allows for the purge of the vacuum lines at the end of the test (not required if vacuum testing is not used).

Extend Probe Position

*The set point position where the probe will extend and the test sequence begins.

Fast Speed Photo-Eye

When blocked by a backlog of containers, the NGR will accelerate to Fast speed or decelerate to Normal speed when unblocked or when the backlog is cleared.

Fill Pressure The pressure used to fill the container. This pressure is set in PSI.


NGR TURRET ADVANCED OPERATOR MANUAL iii TM2012-013 REV00 © 9/26/2012

Fill Valve The Solenoid valve that controls the air used to pressurize the container.

HMI An acronym meaning: Human Machine Interface. This is also referenced as the Operator Touch Screen.

Reject Air Pressure Sensor

The sensor that monitors air pressure used to reject containers. The alarm limits are established with settings in the HMI.

Increase to Peak *Test result term that displays in PSI or in “inWC”-the difference between peak pressure and target pressure.

Infeed Star-Wheel Interfaces between the timing screw and turntable to maintain the degree of pitch and timing necessary to feed the containers onto the turntable.


NGR TURRET ADVANCED OPERATOR MANUAL iv TM2012-013 REV00 © 9/26/2012

TERM DESCRIPTION

InWC (iWC) Inches at water column. (One inch of water = 27.7 iWC = 1 PSI).

Laser Height Includes the Keyence controller/digital display module, receiver/emitter head, rigid mounting and slide for height adjustments. Container height inspection occurs as containers pass through the unit

Leak Test Controller (LTC)

Performs the leak test and communicates the results back to the VTPG. It is an interchangeable leak test assembly that controls the cylinder/probe assembly for an individual station. The LTC consists of a probe, cylinder, manifold, valves, transducer, and electronic controls.

LTC Disconnect Air and electrical connections for an LTC that allows for a quick-disconnect to facilitate fast and reliable LTC replacement.

LTC Modes

Normal: Probe extends when container is present and Probe Extend cam setting has been reached. Probe retracts at Probe Retract cam setting. Normal Retract at test end: Probe extends when container is present and Probe Extend set point has been reached. Probe retracts when leak testing has been completed or the container has failed any portion of the test. This means the probe may retract much sooner than it does on a successful test. Manual: Probe extends on every pitch at the Probe Extend set point and retracts at the Probe Retract set point. The probe will extend even if there is no container present. Manual retract at test end: Probe extends on every pitch at the Probe Extend set point and retracts when the leak testing has been completed or the container has failed any position of the test. This means the probe may retract much sooner that it does on a successful test. No Test: The probes will not extend any time when the NGR is running.

Zero Point Reference point for all set point locations on the NGR. The NGR is at zero point when the infeed star-wheel is tangent to station one.

Manual Mode Speed Mode where the NGR runs at a pre-set speed, regardless of the backlog or the presence of containers in front of the timing screw.

Max % Loss in (T1) This is a test result term referring to the maximum % pressure loss that occurred during Test 1.

Max % Loss in (T2) This is a test result term referring to the maximum % pressure loss that occurred during Test 2.

Max Fill Time Test setting entry that sets the maximum amount of time allowed to reach the target fill pressure.

Maximum Fill Failure Alarm generated when the pressure exceeds the factory set maximum pressure limit. This is used to prevent excessively high pressures that could damage the test circuit or container.

Maximum Peak Exceeded

Alarm generated when the pressure in the container has exceeded the limit set in the Test settings for Peak pressure.

Min % Loss During Test 1 See definition below.

Min % Loss During Test 2 See definition below.

Min % Loss in T2 The displayed Test Result of Minimum percentage loss during test 2. Minimum Conveyor Speed

The minimum required speed the conveyor must run to adequately supply containers to the timing screw.

Normal Photo Eye Changes NGR speed from normal to slow when containers have cleared the sensor field.

On-Demand Operation Uses the upstream Photo-Eyes for speed control and starting and stopping the NGR.

Exit Star-Wheel Provides means for container exit. Note that this star-wheel has a slightly enlarged pocket and anti-rotational pads.


NGR TURRET ADVANCED OPERATOR MANUAL v TM2012-013 REV00 © 9/26/2012

TERM DESCRIPTION PE Acronym for Photo-eye.

Peak Maximum (inWC) Test pressure setting entry that sets the upper limit for the peak pressure. Exceeding this value will cause an alarm.

Peak Minimum (inWC) The range between the target pressure and Peak Maximum. If this is left at “0”, the peak minimum would = the target pressure

Peak Pressure Test result displays the value of the peak pressure reached for the LTC chosen

Pitch A term used to describe distances from one center to the next. For instance, from station to station or container to container.

PLC An acronym for Programmable Logic Controller.

Pressure Settings

Consists of four settings: Test Minimum Target Pressure Peak Minimum Peak Maximum (These terms are defined separately)

Probe Assembly That part of the LTC that seals the container, and provides connections for the fill and sense lines.

Probe Pressure The pressure set on the electronic regulator or displayed on the manual gauge to extend the probe cylinder. This pressure is set in units of PSI (pounds per square inch).

Probe Retract Time (Probe Retract)

The maximum time allowed for the probe to retract, before a probe retract fault occurs.

Production Counts Data collection information displays the amount of containers process, passed and rejected.

Profibus Communication protocol between VFD, HMI, and the remote I/0.

Profibus Inputs Diagnostics HMI display that provides an indication of when a remote input is ON or OFF.

Profibus Outputs Diagnostics HMI display that provides an indication of when a remote output is ON or OFF.

Recipe A set of test setting values that can be saved and used for a particular container. Reject Device A solenoid that rejects a defective container located at the exit end of the NGR. Reject Verification/Chute Monitor Eye

Verifies that the rejected containers have left the production line. If this sensor is not blocked after a reject occurs, the NGR will shut down. An alarm condition called Reject Verification Failure is registered on the HMI.

Remote I/0 Input and Output connections, connected via a network cable to the main PLC. Retract Probe Position Encoder set point at which the probe will begin to retract. Run Mode There are two modes the NGR can run in: On Demand or Manual. See Run Modes.

Run Modes

On-Demand: Photo eyes on the infeed conveyor determine when the NGR will start, stop, and what speed (s) it will run to process containers. Manual: The NGR runs at one set speed regardless of the amount of containers present on the conveyor upstream of the timing screw.

Scaled Encoder Counts Displayed Encoder counts showing NGR current position.


NGR TURRET ADVANCED OPERATOR MANUAL vi TM2012-013 REV00 © 9/26/2012

TERM DESCRIPTION Secondary Air Reject Option to reject all containers after a reject verification fault; recommended if the conveyor

cannot be stopped in the event of a fault. Set Point A specific encoder count location used in the CAM settings.

Slip Rings There are (18) circuits in the slip rings to send power and signals from the stationary to the rotating partition of the NGR.

Slow Photo-Eye Shuts down the NGR when containers are not present within the sensor field.

Speed Compensation This feature is used to allow NGR devices to react to a set point position to compensate for solenoid reaction time and speed of the NGR.

Speed Compensation (Probe Extend)

Given the variations in machine speeds, this feature factors the compensation value to the current speed of the machine to react early or on time to the extend probe set point position allowing the probe to come down in the same relative physical position.

Speed Compensation (Reject Device)

Given the variations in machine speeds, this feature factors the compensation value to the current speed of the machine to react early or on time to the extend reject set point position allowing the probe to come down in the same relative physical position.

Speed Setting HMI entry where speeds are set for the different Run Modes. Manual mode has only one speed while the On-Demand mode has either two or three settings depending on the options purchased with the NGR.

Speed Settings

Slow Speed Setting: Value setting for running at slow speed in the On-Demand mode. Normal Speed Setting: Value setting for running at normal speed in the On-Demand mode. Fast Speed Setting: Value setting for running at fast speed in the On-Demand mode. Current Speed: Displays the actual running speed of the NGR.

Start of Test Delay (In Seconds)

Feature used with the Vacuum option to allow time for the purge of the vacuum lines at the start of the test.

Start Point Refers to the starting point in encoder counts used in the logic to look for an input like a container present signal, or start an action such as container present photo eye.

Station Refers to an LTC; order of positioning: (1-2-3-4-5-6-7-8-9-10), etc.

Stop Point Used in conjunction with start point where the logic will monitor an input within the encoder window but will ignore it outside of the window.

T1 Maximum An acronym for Test 1 which refers to the maximum allowed pressure percent loss during test one (T1).

T1 Minimum An acronym for Test 1 which refers to the minimum allowed pressure percent loss during Test one (T1).

T1 Pressure Loss An acronym for Test results for Test 1 which refers to the total pressure loss during Test one (T1).

T2 Maximum An acronym for Test results for Test 2 which refers to the maximum allowed pressure percent loss during test two (T2).

T2 Pressure Loss An acronym for Test results for Test 2 which refers to the total pressure loss during test two (T2).

Tangent Point 1 (TP1) This is a physical position where by a station, turntable, and the infeed star-wheel are aligned to receive a container.

Tangent Point 2 (TP2) This is a physical position where by a station, turntable and the exit star-wheel are aligned to release a container.

Target Pressure (inWC) The desired pressure for a leak test. Once this pressure is reached, the fill valve will close.

Test 1 (T1) Time Test 1 function where the applied pressure must reach the target pressure for the test to begin. If target pressure is reached, the pressure loss must not exceed the minimum or maximum percentage amount allowed during the allotted time or the container will be rejected.

Test 2 (T2) Time Test 2 function begins when test 1 is completed and no rejects have occurred. During Test 2, the pressure loss must not exceed the minimum or maximum percentage amount allowed during the allotted time or the container will be rejected.

Test Leak Orifice When performing a self-test, the NGR allows the pressure to be bypassed through a test orifice. The orifice size can help determine the size of the leak that can be detected based on current test settings.


NGR TURRET ADVANCED OPERATOR MANUAL vii TM2012-013 REV00 © 9/26/2012

TERM DESCRIPTION

Test Minimum (inWC) The pressure setting where the value entered determines the minimum pressure that must be achieved to ensure a sealed probe.

Test Probe: End of Fill Pressure (inWC) Increase to peak (inWC) Peak Pressure (inWC) End of T1 Pressure (inWC) T1 Pressure Loss (%) End of t2 Pressure (inWC) T2 Pressure Loss (%)

Pressure (target pressure) recorded when the fill valve was told to close. Pressure difference from end of fill to peak pressure. Maximum pressure recorded during the test. Pressure recorded at the end of test 1. Pressure loss from peak pressure to the end of test 1. Pressure recorded at the end of test 2. Pressure lost from the end of test1 to the end of test 2.

Test Result Terms Loss from T1 to T2 (%) Loss from Peak to T1 (%)

Pressure lost from the end of test 1 to the end of test 2. Pressure loss from peak pressure to the end of test 1.

Three-Speed Operation Fast/Normal/Slow operation including additional upstream photo-eye. Requires that customer provide a leak tester dedicated conveyor with its’ own frequency drive to accept a 0-20 mA (Mille-Ampere) signal for speed control.

Timing Screw The timing screw is designed to control the special interval between containers as they transit through the machine synchronizing with the test probes as they arrive. Conveyor speed must be slightly (approximately 2%) faster than the time screw.

Timing Screw Gate Prevents random containers from being released into the timing screw infeed that may cause jams.

Top Load

Top Load has a drop-down box with two options: “Top Load” is a check to see if the container has collapsed during the probe extension. Not Used: The NGR does not have the top load option installed or the customer wants to turn off the option. Enable: Turn on the top load option. This will enable checking containers and rejecting those that fail the test.

Turntable Vacuum System Assists container handling and may enhance detection of smaller base leaks in flat based containers.

Vision System Turn Vision System ON or OFF. Vision systems are supplied by other vendors and when installed, it allows the NGR to reject containers identified as defective by the Vision System.

VTPG

An acronym that stands for: Virtual Trip Point Generator. The main controller in the system relative to leak testing. Using the CAN bus, it instructs each LTC in the system when to begin a leak test and when to end a leak test, and when to report its test results. The VTPG collects these test results and stores a summary of them in its memory so that one can access the latest test results through the HMI.

VTPG Inputs/outputs Graphic indication of when VTPG Inputs and Outputs are ON or OFF. VFD Variable Frequency Drive: Used to control the main motor speed

AIR LOGIC POWER SYSTEMS (ALPS) ADVANCED OPERATOR


NGR Advanced Operator Advanced Operator Introduction The advance operation manual will cover:

1. Theory of Operations

2. In-depth coverage on all the possible NGR Menu Selections (procedures, navigation and definition)

a.

b.

c.

Viewing and editing A password is not required for viewing any screen; however, editing or changing settings requires a supervisor level login. If not previously logged in, when attempting to edit or change settings a supervisor password login pop up box and keyboard will appear. The NGR ships with default user names and password.

AIR LOGIC POWER SYSTEMS (ALPS) THEORY of OPERATION

NGR TURRET ADVANCED OPERATOR MANUAL 2 04-2014 REV00 © 04/03/2014

NGR Theory of Operation Leak Test Theory

The NGR and LTC accomplish the task of leak testing by pressurizing containers with a very small amount of PSI and then monitoring the amount of pressure decay. More decay equals bad containers and less decay equals good containers. The task of leak detection begins when containers are conveyed onto to the turntable and under the LTC. Once a container is in place the LTC extends the probe assembly which seals the container for the applied air pressure. If the air pressure stabilizes and reaches a peak a pressure then two additional measurements are made. These measurements are called Test 1 (T1) and Test 2 (T2). T1 is designed and set up to detect large holes and stretch and distortion over a quick or short decay period (time). T2 is designed to detect smaller holes or leaks over a longer decay period (time)

AIR LOGIC POWER SYSTEMS (ALPS) SUPERVISOR


Tooling and Rotary Theory

1. Timing Screw: Not used for turret only applications

2. Infeed Star-wheel: Maintains bottle pitch through center guide 3. Center guide: Provides a guide rail into and out of machine. 4. Strippers and Base Locators: Provide a stable handling system for leak test. 5. Exit Star-wheel: Provides means for bottle exit. Note that exit star-wheel has a slightly opened up pocket and anti-rotation pads. 6. Radial Pitch: Radial pitch of bottles in turntable = Linear bottle pitch of bottles on conveyor. 7. Guide Rails: Guide rails are an extension of the tooling. 8. Tangent Point 1 (TP1): The point at which the infeed star-wheel is tangent to the turntable. 9. Tangent Point 2 (TP2): The point at which the exit star-wheel is tangent to the turntable.



Supervisor

The Supervisor Settings display is typically used for system setup or restoring lost parameters. Each function selected on the right side of the display generally fits this purpose. The Supervisor default username is “super”. Usernames and passwords maybe edited, deleted or added with Administrative permissions.

User Administrator

User Administer can change or add login, names, times and groups. Group selection establishes the limits or restrictions of given login in or USER. There are six different groups available: 1. Admin: can change user names passwords, logoff times and all settings and recipes. 2. Technician: Supervisor level. Can change all settings and recipes 3. Supervisor: Supervisor level. Can change all settings and recipes. 4. Operator: recipes only 5. Guest; viewable only no changes permitted. This is the default or when logoff time expires or

upon boot up. 6. Unauthorized: Same as guest

Logoff time user is automatically logged off a User off when time expires. Entering 0 means the User is permanently logged in. A User can be logged off at any time by a higher level login, pushing the log off button, or if a power down and re-boot occurs. The log off timer starts when there has been no activity on the HMI screen. Any activity (touching the HMI) resets the timer back to no time expired.



User Administration Table Group

Defaults: User &

Password

Authorizations

Administrators Defaults: 1. User: 1111

Pass: 1111

2. User: alps Pass: Not shown

3. User: admin Pass: Not shown

All displays and functions can be viewed, edited and engaged except ALPS technician

Technician User: maint Pass: Not shown

All displays and functions can be viewed, edited and engaged except user administration and ALPS technician



Supervisor Defaults: User: super Pass: super

Same as Technician

Operator Defaults: opera Pass: 1234

All applicable NGR displays are viewable. Recipe Management and Test Functions are fully functional

Guest Viewable only



Cam Settings

CAM Settings is where location set points are entered into the NGR. A set point is a location point for key devices based on encoder counts. For example the test probe has positions for extend and retract point. The Container present photo eye also has set point locations. These set Points are necessary for the NGR to monitor and track containers through the NGR.

Notice: CAM settings (set points) are performed by the factory technicians before shipment and are rarely accessed in the field. The setup procedure for CAM settings is described in the Maintenance Manual.

Shut Down Procedure

Ideally the NGR should never be shut down just by turning the main disconnect OFF. If the NGR is not shut down properly it is possible for data to be lost and as a result a system restore must be done. If a system restore is required please refer to the NGR software manual. Select the “SHUTDOWN PROCEDURE” button and follow procedure to shut down NGR. The navigation procedure is explained further on page 8.



Additional Supervisor Menus

Set Date and Time

This syncs the time viewable on HMI to PLC.

Restore Default Settings

In the event system configuration is lost using this function will restore the factory defaults.

ALPS Technician

Technician access to PLC diagnostics and some setup options for the NGR.

Log Off

The Log Off button allows the user to log off before the allotted auto log off time.

Reset Counts

The reset button will reset all production and data collection counts to zero.

Language

Changes displays to desired language.



Supervisor Navigation To navigate to the supervisor display: SELECT

Select to open User Administration display.

Select the applicable box to change a user name, password or logoff time. A box will pop up, to enter the new information. Changes will not take place until the auto logoff has taken place. To change the group select from the pull down menu.

Notice: Please use care when changing passwords and users as ALPS does not keep a record of any password changes made in the field.



Cam Settings Navigation

Select to open Cam Settings Display

Select the arrows to navigate between the CAM settings screens. Select the appropriate box enter the new value. Please refer to the NGR Maintenance Manual for cam setting procedures.

Date and Time Navigation

Select to navigate to the Date and Time

1. Enter the time in 24 hour format (on a keypad) and the date in mm/dd/yyyy format the HMI / Panel Date and Time

2. Select synchronize button. This button synchronizes the PLC time reading at right to the HMI time just entered at left.

Changing Cam Settings Set Points may result in equipment damage!



Restore Default Navigation Select to navigate to the Restore Default Settings display.

Select Restore Default Settings to restore the cam settings and machine zero setting. Select Restore Default Passwords to restore the passwords and logins.

ALPS Technician Navigation Accessible with a password from ALPS and contains settings that should only be accessed when working with ALPS personnel.

Options Navigation Select the desired pull down box to turn option on or off.

Language Navigation Select to change desired language.

Reset Counts Navigation

Select to reset production counts to zero



Shut Down Navigation Select SHUTDOWN PROCEDURE, Shutdown WinAC MP, Exit WinCC Flexible, and Shut off main disconnect.

AIR LOGIC POWER SYSTEMS (ALPS) TEST SETTINGS

NGR TURRET ADVANCED OPERATOR MANUAL 13 04-2014 REV00 © 04/03/2014

Test Settings Introduction Test settings Detecting pressure losses that will indicate leaks in containers involves managing and creating test settings. The test settings have a direct correlation to how well the NGR will perform leak testing. Test settings for all original containers are factory set by ALPS technicians. Factors such as temperature and atmospheric conditions located in the production facility may warrant changes to test settings from time to time. Included in this section is a helpful trouble shooting guide on alarms and faults that can occur, based on how the test settings are set. For adding new containers to the NGR see the change over and new container setup guide section.

Notice: Adjustments to test settings require some understanding of NGR leak test operations. For this reason any changes made to these settings require a supervisor or above login. For additional clarification on terms used in this manual and by the NGR please refer to the glossary of terms.

Test Settings Basic Navigation and Editing

Select then select from

On the TEST SETTINGS – BASIC display there are four test settings that maybe adjusted or viewed. These are Max % loss in T2, Test 2 (T2) Time, Fill pressure, and Probe Pressure.

Max % Loss in T2, and Test 2 (T2) Time

Adjustments can be made by selecting the appropriate box



Fill and Probe Pressure The NGR can have one of two different types of regulators installed, manual or electronic (digital). NGRs equipped with electronic regulators have the ability to change the value and pressure delivered from the HMI. Manual regulators must be adjusted by hand and the display functions as a place to record and view the settings.

Manual regulators

Electronic regulator

Fill and probe regulators are physically located in the center of the NGR and about level with the top of the Leak Test Controllers or LTC’s.



Introduction Test Setting Advanced TEST SETTTINGS ADVANCED displays all of the test parameters that can be entered or edited for a leak test. These test parameters are located on two displays called Test Settings and Test Limits. The Test Settings display interprets the time available to perform the leak test and the Test Limits display determines the allowable pressure percentages. During production these test settings are used by the Leak Test Controller (LTC). The LTCs are responsible for leak testing the containers on the NGR. The LTC will perform 3 tests, fill, test 1 (T1) and Test 2 (T2). The fill test requires minimal time to insure the container is pressurized and reaches the target pressure. T1 requires minimal time to check for large leaks and allows the container pressure to stabilize before T2 begins. T2 requires the most time to check for smaller leaks and rim defects in the container. All of the test settings are described in the Test Setting Description table.

Test Settings Description Table

= Test pressure must exceed this amount for leak test to begin.

= Pressure point where the fill valve will shut off and leak test 1 will begin. Note: ALPS Leak Testing is usually done with very small amount of pressure. Point of fact 1 PSI = 27.689 IWC there for 6 IWC = 0.216 PSI.

= Time allowed for container to reach target pressure. The standard time entry is: 0.300 seconds for most containers. Larger container = more fill time. Smaller

container = less fill time Minimum fill failures could mean, no seal, fill valve is not coming on, the allowed time to fill the container is to short, or there is a large hole in the container.

Machines with the Top Load option to turn the feature on (enable) and off (not used).



Test Settings Description Table continued

Time allowed for Test 1 (T1). The optimal time is 0.300 seconds for most containers. Larger or more flexible containers may require more T1 time for pressure stabilization.

The maximum % pressure loss allowed during Test 1. The optimal range is 25% to 45%.

The minimum % pressure loss required during Test 1. The optimal entry is 0.00% to (–) 1.00. Note 1: T1 min to T1 max entries together create an acceptable window. In the entries shown the window is a 0% to 41% pressure loss the container is good. A negative 1 value will keep the container from rejecting if there happens to be a slight increase in pressure (above target). Note 2: If there is a + value entered in T1 Min then that amount of pressure loss or greater must occur or the container will be rejected. Some items checked on NGR’s must have leaks, like filters and pressure valves, and no leakage is an indication of failure.

T1 failure: Max % loss could mean bad seal, rim defect, large hole, or % loss set to low.

Time allowed for Test 2 (T2). The optimal time entry is to use as much of the available.

Use the available test time and test time used to factor the proper time. This example shows 1 second could be added to T2 time. Available test time is the sum of max fill, test 1, test 2 and probe retract times. If the user enters parameters whose sum is greater than the available test time the NGR will create a warning message as well as turn the test time used field red to alert the user to shorten the time(s) entered

The maximum % pressure loss allowed during Test 2. The optimal range is 15 to 20%.

The minimum % pressure loss/gain allowed. The optimum entry is 0% to -20.00%.

Note 1: T2 min to T2 max entries together create an acceptable window. In the entries shown the acceptable window is a (-) 20% pressure gain to 41% pressure loss the container is good.

Time allowed for the probe to retract. The standard setting is: 0.100 seconds. If using specialty probes, that increase the travel distance that probe has to retract, the probe retract time may be increased. Probe retract faults could mean probe is not coming up or allowed time is to short.



Leak Test Flow Chart

Start: LTC receives a container. Fill Test time begins Container reaches target pressure

No Yes LTC begins T1 Time Container exceeds or

in the allotted time Yes No T2 begins. Container

exceeds or in the allotted time Yes No Good Container. Finish

When container is present (from photo-eye) the test probe will extend at cam set point and retracts at retract cam set point

When container is present (from photo-eye) the test probe will extend at cam set point and retract when leak testing has been completed. Note: If the container has failed any portion of the test the probe may retract much sooner than it does on a successful test. This mode can be useful to help visualize available test area.

Regardless of container present photo eye the test probe will extend for every station at the probe extend set point and retract at the probe retract set point. This mode can be useful in determine if the probe extend solenoid or the container present photo eye is functioning properly versus.

Regardless of container present photo eye the test probe will extend for every station at the probe extend set point and retract when leak testing has been completed

The probes will not extend any time when the NGR is running



Test Settings Navigation and Editing

Select then to navigate to TEST SETTINGS – BASIC. Then select to navigate to Test Settings Advanced

To enter test setting parameters select the appropriate box. For example select to change T1 time.



Leak Testing and Settings, Related Problems and Solution Table Problem Root Cause/Checks Solutions Machine rejects known good containers

Carefully inspect container rims for parallelism, short shots or other defects

Make sure that containers are good

Check the container walls for thickness, and plastic distribution Look for contamination, pin holes or split seams Check if one or more LTC’s are rejecting containers

Replace LTC’s as necessary

Check seals for wear Readjust Reject Device Reject device is ejecting wrong container. it may be mis-adjusted enough so that it is reacting to an empty station next to the container

Confirm that correct recipe is loaded

Test settings are wrong Adjust Probe Pressure Probe Pressure Low Adjust Probe Alignment Infeed Starwheel not aligning container to probe

Adjust Infeed Starwheel

Containers colliding with centerguide, not lining up to probe.

Centerguide too loose at the infeed

Adjust Centerguide

Machine not rejecting defective containers.

Check whether one or all stations are involved

Confirm that the recipe loaded is the correct recipe.

Only one LTC is not rejecting containers.

All LTC settings are the same. Replace the LTC and return the faulty one to the factory

All stations are not rejecting

Reject Cylinder not activating, flow control may be off

Check adjustment

LTC settings may be off. Confirm that correct recipe is loaded Minimum Fill Failure The container did not reach the

Target Pressure within the Max Fill time. This generally indicates a gross leak in the container or the test circuit. Or if the container has a larger volume, the Fill Pressure Regulator and/or Max Fill time may be set too low

Analyze rejected containers to determine if there are gross leaks or seal surface defects. If containers are not defective, check the condition of the probe seals and that at all fittings and air lines on the specific station are air tight. The LTC can be changed out with a spare or swapped with another station. If a problem persists on a specific LTC, it can be returned to ALPS for analysis and repair



Problem Root Cause/Check Solutions Minimum Peak Failure

The Peak Pressure measured in the container did not exceed the Peak Minimum value. The factory setting for the Peak Minimum is zero (0)

If you do not wish to reject for a low Peak Pressure, set the Peak Minimum to 0" W.C. If the Peak Minimum is set to 0 and there are still failures, consult factory

Min% Loss In Test 1

The percentage of pressure drop during Test 1 was lower than the T1 Minimum limit during the T1 (Test 1) Time.

The factory setting for this value is 0%. If the T1 Minimum limit is set to 0% a failure indicates negative pressure drop (pressure rise) in the container during T1. Examine container handling throughout the machine to determine if there is a pinch point potentially causing a pressure rise in the container. If the containers exhibit a high surface temperature, consider cooling prior to leak testing

Max% Loss In Test 1

The percentage of pressure drop during Test 1 exceeded the T1 Maximum limit during the T1 (Test 1) Time. This generally indicates a medium size leak in the container or test circuit that caused a rapid loss of pressure after the Peak Pressure was reached.

Analyze rejected containers to determine if there are 'medium' size leaks or seal surface defects. If containers are not defective, check the condition of the probe seals and that at all fit-tings and air lines on the specific station are air-tight. The LTC can be changed out with a spare or swapped with another station. If a problem persists on a specific LTC, it can be returned to ALPS for analysis and repair

Maximum Fill Failure

The pressure measured in the container exceeded the factory-set maximum pressure limit. This is used to prevent excessively high pressures that could damage the test circuit or container.

Assuming the issue is isolated to one station, remove and replace the LTC. Check operation of the Fill Valve on the LTC and/or send the LTC back to ALPS for analysis and repair

Height-Too Tall or to Short

The container height as measured by the Laser Height option exceeded the upper limit

Measure the heights of containers that are rejected for this reason, making sure to take multiple measurements around the circumference. Note that the Laser height option takes an average of readings as the container moves through the sensor. If container heights are well within specification and the reject limits, analyze container handling through the sensor. If containers are not traveling smoothly through the sensor, check the leveling of the conveyor-to-deadplate-to-turntable transitions. Adjust the "pocket tighteners" on the center guide as necessary



Problem Root Cause/Check Solutions

Test Too Long The leak test was not completed prior to receiving its signal to raise the probe (Trip

Point 2)

If the problem occurs on multiple stations, the time needed to fill the containers to Peak

Pressure may be borderline based on the total test time allowed. Keep in mind that fill times

are allowed to be as long as the Maximum Fill time setting. Reduce the test time (typically T2

if all else is set correctly) if needed. If it becomes necessary to increase the Max Fill

time, it may be possible that there are sluggish Fill Valves, which should be replaced.

AIR LOGIC POWER SYSTEMS (ALPS) RECIPES


Recipes Introduction to Recipes A recipe is the saved test settings for a particular container. Recipes can be saved locally in the HMI and on a separate USB memory. Recipes may also be down loaded from the USB memory, as well as deleted and saved. For example: if a test setting has changed to make a those changes can be saved in the current recipe or a newly created one. Please refer to the quick start manual for simple recipe import.

.

AIR LOGIC POWER SYSTEMS (ALPS) RECIPES


Recipe Navigation and Advanced Procedures

Select, then select from .

Select to export (backup) to USB Answer yes/no to proceed.

Select to import recipes from USB Answer yes/no or cancel to proceed.

Select to Save As To do a Save As click on the The

will appear. Type the new name in or save it to the existing name to proceed.

Select to delete the select recipe in the pull down menu Select

yes/no to proceed

AIR LOGIC POWER SYSTEMS (ALPS) REJECT DEVICE


Reject Device

Reject Verify Mode

The Reject Verify confirms a defective container has been rejected when the reject verification photo eye is triggered by the defective container being ejected off of the production line. After a reject occurs if the reject verification photo eye is not triggered before the Reject Verify Limit is reached the NGR will go into a fault condition.

In the event the NGR is changing speeds at the time a container is rejected the Speed Compensation setting helps adjust for this variant.

Bypass Reject Verify After Fault In the event a container must be manually removed from the NGR as a result of a fault or jam the NGR will ignore the reject photo-eye and not cause the machine to go into a reject verify fault.

Bypass Reject Verify Count If bypass reject verify after fault is enabled this value is how many containers the NGR will ignore. This also represents the number of containers that will be blown off on power up. The value entered should equal the number of containers that can normally fit within the machine enclosure.

Reject Chute Monitor If this option is enabled the NGR will fault and stop production in the event the reject photo eye is triggered without an actual reject occurring.

AIR LOGIC POWER SYSTEMS (ALPS) REJECT DEVICE


Reject Device navigation

Select, then select from .

Use the Pull down menu to enter or change options.

Changing reject options or setpoint(s) can result in bad containers not being

AIR LOGIC POWER SYSTEMS (ALPS) Laser Height & Coding


Laser Height

Laser Height is an available option in the NGR and is a standalone height detection system for containers. The NGR integrates to the laser height system to allow bad containers to be rejected by the NGR. The set point position for the laser height is factory set and usually not changed in the field. The set up and installation of the laser height is accomplished by the factory technicians. In the event setup or adjustment is needed for the Keyence Laser Height System please refer to the NGR maintenance manual.

Laser Height Navigation Pull down YES/NO to enable option

Select Start or Stop box to enter set point based on proper encoder position

AIR LOGIC POWER SYSTEMS (ALPS) CODING


Coding

Coding is an available option on the NGR and is used for a laser coder or ink jet coder that would be installed inside the enclosure of the NGR. This option will let the Coder know if a container is present. The set point position for the Coding device is factory set and usually not changed in the field. If setpoints need to be changed or updated refer to the NGR Maintenance Manual. Notice: Placing the coding device in the beginning of the NGR cycle will allow for more available test time. Placing the coder in towards the end of the cycle will shorten the available test time considerably.

Coding Navigation Pull down OFF if there is no coder on the NGR. PER CONTIANER FEEDBACK to enable a Domino coder installed on the NGR GENERAL FEEDBACK to enable a Videojet coder install on the NGR

Select Start or Stop box to enter set point based on proper encoder position

CAUTION!

Where the coding device start & stop is placed will affect the available test time.

AIR LOGIC POWER SYSTEMS (ALPS) TEST RESULTS


Test Results

Test results are where leaks tests results monitored. For the advanced operator a test result assessment can help determine what adjustments, if any, to make to test settings. The Basic screen shows test results and test limits. Remember Test Limits were established in the “Test Settings” menus. Both basic and advanced test result screens have a panel on the left hand side of the screen that allows for viewing of test results and performing a manual test.

Test Result Explanation Table Test Result Explanation and Use

Represented in IWC the peak pressure reached.

Pressure loss percentage results for T2. This could be

helpful in determining between bad and good containers or where the % limits are for T2.

Refers to the allowable percentage losses for T2. This serves as

a reminder of where the test setting limits currently are.

Represented in IWC the pressure value after the fill valve has been shut off. This value should closely follow the target pressure setting and may be helpful in determining if the fill time is set correctly. This result can be used to access the operation of the fill valve, associated components and test settings.

Represented in IWC this is the difference between the

peak pressure and end of fill pressure. This can also be helpful in determining fill time.

The pressure represented in IWC at the end of test 1.



Test Result Explanation and Use

The loss in pressure from peak pressure to end of T1

pressure. This could be helpful in determining T1 % limits.

The measured pressure represented in IWC at the end of test 2 f. This could be helpful in determining T2 % limits which determines good and bad containers.

This result is expressed in % loss from the end of T1 to

T2. It uses the results expressed in InWC for T1 and T2 to calculate the result.

Indicates test results for container at selected .station. For example if the container

failed to reach the max fill limit the Result will indicate “max fill failure”.

MANUAL Test

Manual test is the same leak test done during normal production but is performed when the NGR is in a stopped condition. Performing manual tests can help insure the test settings are still true and accurate. In addition to this manual tests are also a great way to troubleshoot suspected issues with an LTC or Station.

To use manual test, place a container under an LTC probe, ensure the corresponding station number is selected and select the “ ” button. A manual test will be performed and the results will be displayed on the basic and advanced test results screens.

Notice: The manual test will not function unless all access doors are closed



Self-Test Results

A Self-test is a leak test that uses an orifice installed in the LTC to create a leak path of an exact size that will cause a leak in the container. The orifice sizes can range from .004 to .040 inches. Performing self tests help insure that potential bad containers will be rejected based on the current test settings.



Recent Rejects

Test results and recent rejects are almost the same except for the right side of the display shows the last nine rejects, and the reason for the reject.

Total Machine Counts

Displays the total reject counts, for all stations and for any reason a container can be rejected. Self-test rejects are not added into the total reject counts.

Individual Station Counts

Displays the station rejects count by reject category.



Test Results Navigation

Select Then select Then Select to navigate to advance and to navigate back to basic.

Test results navigation continued

Results overview navigation

Select then or from the test results display select to navigate to the test results overview screen.



Self-test result Navigation

Select or to naviagte to the self test screen. Slecting will naviagte to the self test results overview screen

When the NGR is in a stopped condition selecting will perform a self-test on the

station indicated. The station number can be changed by selecting and entering

the desired station number. Selecting will start station number scroll and

will stop the scroll. Have no functionality unless the

NGR is moving (in production). Selecting any of one these functions

during production will result in a self-test being performed for the function chosen.



Manual Test navigation Select Manual to perform manual test (when NGR is in a stopped condition). Results

can be view in Test Results (Basic or Advanced) after manual test.

Recent Rejects navigation

Select then

Reject results navigation

Select then . Select to view graphical representation of total reject



Total Counts navigation

Select then. . Select to toggle between self-test counts and total

machine counts

Total Counts navigation

Select then.

AIR LOGIC POWER SYSTEMS (ALPS) OPERATOR MAINTENANCE


NGR Operator Maintenance Operator Maintenance Introduction and implementation

Select then select up to nine Maintenance screens available for advanced operations. These screens are available to aid the advanced operator in trouble shooting NGR.

LTC Diagnostics All the outputs shown can be forced on and off. This is a good way to check if the LTC leak test valves are functioning properly. In the event the LTC’s may have stopped responding they can be reset from this screen as well.

Note: A standard NGR only uses the Probe Valve, Fill Valve and Self-Test Valve. The Clamp and Purge Valves are optional. Outputs 1 through 3 are reserved for special designs that may require the use of additional valves and will be custom applications.

To force a output on select LTC station then select the out to force on . To reset

a particuler station or to rest all station select the aporitate reset button . Note: To force outputs on NGR must be in a ready to run condition where the access doors are closed and no e-stops are active.



LTC INFORMATION (DATA) The LTC Data screen displays the Serial Number and Firmware Version for the selected LTC. This LTC Data screen should be used when ever changing out a LTC to ensure the versions match. It can also help determine if the HMI PLC is communicating with the LTC (s).

To view the serial and firmware of a LTC select the station number and then select update station record.

Timing (Machine Re-Timing)

The timing menu is where the “set zero” point is set. The zero point is the reference point used for timing and tracking container through the NGR. The zero point is factory set and may never require setting in the field. Setting the zero point requires a Supervisor level log in. For trouble shooting purposes the timing menu can be used to see if the encoder is functioning properly.

To insure the encoder is function properly watch the window will go from 0 to 4096. To view this properly the NGR should be at JOG speed.

Selecting “Set Zero” can result in damage to NGR and should only be performed by appropriate personnel. Do not set zero without following specific guidelines referenced in the NGR maintenance manual.



Profibus Inputs

These screens display the Profibus inputs and can be used as an aid in troubleshooting suspected problems. Programmable Inputs: Selecting the down bottle input in the maintenance menu on one of the spare inputs will enable the DOWN BOTTLE count on the Home Screen

Profibus Outputs This screen displays the digital outputs. Green means active and white means not active. Viewing these outputs can be used to troubleshoot suspected problems with a device.

Q1.0 to Q1.3 has programmable selections and may be change to select one of the following: 1. Machine Faulted 2. Machine running 3. Machine Ready 4. Machine Paused



VTPG I/O This display allows the viewer to monitor VTPG inputs and outputs and can be helpful in trouble shooting the NGR.

Alarm Limits This function takes measurements for main air and vacuum, then compares them to their alarm set points. Main air is the air that is supplied to the reject system. There are upper and lower alarms for both Main air and vacuum. Vacuum entries will not be viewable unless the vacuum option is enabled and installed.

Changing Alarm Limits require a Supervisor log in. To change alarm limit select the appropriate box and enter the new value



Alarms and Alarm Log

Displays list of active alarms.

Displays a log of alarm history and includes a date and time stamp.

AIR LOGIC POWER SYSTEMS (ALPS) CONTAINER CHANGEOVER


Container Change Over Change Over Introduction The NGR is versatile leak test machine that can easily change over, from job to job, to accommodate a wide variety of container sizes and shapes. The tasks usually involved in a changeover are changing out tooling and setting up test perimeters for a new container or loading a recipe for an existing container. (Container that has ran on the NGR before and was saved as a recipe). The steps involved for a changeover are:

1. Tooling Change Over

Note: The NGR tooling is made to fit a specific container and designed to be removed and replaced very quickly.

2. Container Test Setting Setup or Load Recipe

Tooling Change Over Step Action 1 Raise Probe Plate: Attach the extension bar (from the backside of the machine),

then use an electric drill to rotate the bar CCW. (Smaller machines have an extended bar with an attached crank).

Note: NGR with 18 LTC,s or more will require the use of a cordless drill at the end of the bar to raise the Disk Assembly 1-1/2” to 2” (10 to 50mm). Rotate the drill in a CCW direction to raise the disk assembly. WARNING-do not let the drill hang from the bar unassisted!

Note: The bar extension is stored (secured)

inside of the machine guard



2 Remove the Star-wheels. The Star Wheels are located on each side of the Center Guide. Remove both the in-feed and exit star-wheels.

Unlock the Star Wheels by turning each center knob counter-clockwise, about a

one-eighth turn. Lift out the Star Wheels

3 Remove Center Guide. Turn the Center Guide knob counter-clockwise, so that the Stepped Locators clear the Center Guide slots.

4 Remove the Strippers. Push the plate release buttons (2 for each section) on the guide posts.

Pull down on each plae section to remove.



5 Remove outer guides Access the Outer Guides by opening the rear doors of the machine Plexiglas enclosure. Depress the push-button on the guide posts (Outer Guide), and then lift each section of the guide up and out of each post base. Repeat the post and guide removal for each section.

6 Remove Base Locators: (If equipped with the Base Locator option) Pull up on the plungers, and then remove the base locators from the shoulder screws attached to the surface of the turntable.

7 Remove the timing screw. Unclamp and replace the Timing Screw.

Hold the Timing Screw stationary with one hand while opening the clamp with your

other hand. Remove the Timing Screw by lifting it out of the track. Replace the timing screw.



8 Install the Strippers: Push the plate release buttons (2 for each plate section) on the guide posts.

Push up to lock each stripper plate into place.

9 Install the Guide Post Receivers (outer guides). Push down and lock the guide posts into place on the post base receivers, ensuring the pushbuttons snap outward into position

Repeat the post and guide installation for each section

10 Install Center Guide Turn the Center Guide knob clockwise so that the Stepped Locators lock down the Center Guide.



11 Install the Star-wheels. Ensure that the locator pins and holes align. Note that one pin is larger than the others. Align the star-wheel locator holes and then turn locking knob 1/8th turn clockwise to secure it into position.



New Container Setup Guide Steps:

1. Open, Home Screen>Settings Button. Navigator to the Basic Test Settings screen (below, right).

2. Set the Fill Pressure (1) to approximately 5 PSI.

3. Set the Probe Pressure (2) to approximately 15 PSI



4. Place a known good container into an empty test station. 5. Select the arrow icon (upper right hand corner), to open the Advanced Test Limits Screen

(left). 6. Ensure that test time is adequate for machine speed e.g., (“Test Too Long” message is not

displayed) 7. Test Minimum value (3) should be set to .50 to 1.00 PSI. 8. Target Pressure value (4) should be at 6.00 (IWC). Navigate over to the Advanced Test

Limits screen.

9. T1 Minimum (5) should be set to -1.00%. 10. T1 Maximum (6) and T2 maximum should be 20.00%.

11. T2 Minimum (7) should be set to -20.00%. 12. T2 Maximum (8) should be set to 20.0 13. Navigate to the Basic Test Results screen. Navigate to the Advance Test Results

screen.

14. Ensure that (9) Station # is set to review the correct station. 15. Set your selected LTC station to match the station number of the test container (10). 16. Initiate a manual test by pressing the Manual push button (11) on the right side of the

screen. 17. See that the container has passed the leak inspection (RESULT: ACCEPT, (12), bottom

left. 18. Check your peak pressure value-a good target is between 6 and 8 inWC. The concern here

is that the container must be filled quickly enough so a minimum fill failure does not occur. If this occurs it means that the fill target pressure was never attained. Checks fill time, probe pressure, fill pressure to resolve.

3 4

5 6

7 8

9

10

11

12



19. Probe pressure can also be a concern if the container is not passing the leak inspection. To check for proper pressure reduce the probe pressure until containers no longer pass the leak inspection. Then slightly increase the probe pressure until the leak inspection again passes. The probe pressure is properly set when using the minimum pressure to seal the container and pass a leak inspection. Too much probe pressure can influence the test adversely by creating a spike upon sealing which can throw off the test results.

20. Once the Probe and Fill pressures are set, and the container passes leak inspection, the recipe is considered to be partially complete. The next step would be to run the machine, and test the containers at speed.

21. With the machine at speed, ensure that the containers are passing. If you begin to see minimum pressure problems, you may need to increase your probe pressure. This could also be indicative of improperly set guide rails, and /or tooling. If a container is not being fed properly into the tooling, it will be moving and not steady as the test heads come down, this will throw off the test results. Ensure that bottle handling is smooth as the containers transition into the machine. If the container handling is suspected, jog the containers into the machine; watching closely that the containers are not moving in/out or up and down as they transition from the conveyor into the test station.

22. Once the machine is running smoothly, and passing containers, the next step is to dial-in machine sensitivity.

23. While still viewing the Advanced Test Results screen, set your Station # to (16) Scroll All 24. As the machine is running, watch and make note of the average Loss from T1 to (%) T2

value (17). 25. This will be the normal value for “good containers”. 26. With the value known, you can now go back to your test settings screen and reduce the

Maximum T2%loss from 20.0% to your noted value (+10.0%). Essentially, this value translates as “sensitivity”; the closer this number gets to your known “good value”, the more sensitive the test, but this can increase false rejects.

27. With this new test setting loaded, navigate back to the Basic Test Results screen ( ). 28. Watch that your containers continue to pass the leak inspection. 29. If everything is looking good, the next step would be to confirm the container can pass a

self-test. 30. Press the “SELF TEST RESULTS” push button to navigate to the self-test screen. 31. Watch that your containers continue to pass the leak inspection



32. With the machine running, press the “SELF TEST SINGLE” push button. 33. The machine will perform a self-test on the selected container and you should see the

following message: **SELF TEST COMPLETE** Machine rejected container for MAX% Loss in Test 2.

34. If the container did not pass the self-test, there are a few considerations to check: a. Self-test orifice size for container. b. Is the test time long enough? (Maximize the test time). c. Machine speed is too fast to get adequate test time to achieve test hole? d. Difference between good test T2% loss and maximum T2% loss not gross

enough. 35. If all of the variables seem OK, then perform another self-test on a different test station the

self-test should pass. Re-check the original station to ensure there is not an issue with the LTC itself.

36. If everything tests OK, navigate to the Settings>Recipes screen (below) and save the recipe with a new name for the container you configured by pressing. Self- Test Results screen. Save Button

This concludes the NGR Advanced Operator Manual

alps turret ngr rotary leak tester advanced ......alps turret ngr rotary leak tester advanced...

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