Current user manual for the AVMS 2000 series
Contents
1. Backed Out Backed Out Line In Serial I O EPO Bypassed Out 1 PWR RS232 PWR 1 48 VDC me COM 1 RS232 9 Motor Fanout Panel Door 1 Door 2 Door 3 EPO Line In 12 VDC er VE Lamp Power E Lamp On Off 20 ma Camera LED DG VO Power Computer I O Block PWR 24 V Outputs m D 5 Computer 8 24 V Inputs Link a USB Ethernet AN W 58 USB Ethernet RJ45 RS232 T w RS232 s bag USB Touchscreen VGA Video VGA U RS232 Line In Serial O 23 M me PS2 Line In m PS2 D 5 tc UPS Battery Battery 2 Computer Connections T 89 serial cable connection to auxiliary hardware A DB9 serial cable connection to the SC106 system controller COM 1 S DB9 serial cable connection to the weight scale VGA DB15 cable connection to the touchscreen monitor Customer RJ45 ethernet cable connection for the network IEC 320 013 AC line input cord to a UPS battery backup outlet USB connectors M DB9 serial cable connection to the touchscreen monitor PS2 type keyboard and mouse connectors U DB9 serial cable connection to the UPS W RJ45 ethernet cable connection to the I O Block 3 SC106 System Controller Connections IEC 320 C13 AC line in2. 5 Internal Component Layout Refer to figures 3 and 4 for the layout and identification of the major system controller components Back panel Terminal SC22 3 safety 48 volt servo motor Front panel connectors block TB1 controller module SC1 power supply PS4 controls 24 VDC 60 W WO 12 VDC 30W lamp Lamp On Off Relay board power supply PS2 power supply PS3 relay K4 Fig 3 Internal Components Safety relay K1 Safety relay K2 24 VDC power LED2 Camera LED 24 VDC 40 W Safety controller current limiter R5 power supply PS1 regulator U1 Fig 4 Relay Board 6 Circuit Function Description Figures 5a 5b 5c and 5d show the complete system controller circuitry The Banner Engineering model SC22 3 safety controller labeled as SC1 in Fig 5c has outputs SO1A and SO1B wired to JCoil that drive force guide safety relay coils K1 and K2 respectively on the relay board shown in Fig 5a K1 and K2 each have 2 poles in a DPST configuration These contacts are wired in tandem from the AC line input at JACin to the JACmotors connector line output to power supply PS4 and to the JACIO connector line output to power supply PS2 Servo motor power from power supply PS4 and I O power from power supply PS2 will therefore only be enabled when both of K1 and K2 are activated Normally closed contacts from K1 and K2 are wired to SC1 pins S20 and S21 through JFault These contacts are monitored by SC1 to determine whether the K1 and K2 relays are functionin
3. Find Meniscus button This will start a search for the meniscus on the standard Once found the system will prompt the user to Save 7 Once completed press the Save Setup button From Left to Right 1 Convex meniscus too high remove some water 2 Flush meniscus OK 3 Concave meniscus too low add some water Verification To verify the calibration with a known height standard follow the above steps then proceed with the following 1 2 3 4 5 6 7 Create a new program called Height Check and assign it to a button In the Setup Set Up tab enter a bottle height equal to the height of the standard you will be verifying the system with Ensure that Overflow Fill Point and Volume Height checkboxes are all UNCHECKED Save the Part Exit to Main Place the height block at the filling position off to one side so the fill tube or sensor will not strike the block but the height pad will contact the block Press the Run Manually button When complete the height measurement will appear If this number is within 0 010 of the nominal height of the block the system is operating normally If the number falls outside the 0 010 threshold contact AVID for further support Calibration Volume AVID Corporation recommends an annual or semi annual calibration service be performed on the AVMS 2000 to ensure proper measurement and system function If a third party calibration is required
4. Slow Fill Speed Medium fill speed setting of the cylinder taken as s divisor of the maximum fill speed Motor Speed Length Motor speed and length settings Polarity Polarity settings for each motor Advanced Setup Controls Misc Conversions Cylinder Offset Offset value to account for system stiction within the main cylinder Set upon system delivery I O Controls Open Tank Opens the pneumatic controller to the tank Open Dispense Opens the pneumatic controller to the dispensing tube BackPressure On Off Toggles backpressure setting to the cylinder to prevent stiction Typically set to ON Feeder Controls Run Conveyor Botties I Reset wee DON Bottles Displays the number of bottles as LED dots currently to be run Yellow dots are unmeasured red have volumes that fall outside of tolerance ranges green have volumes that fall within tolerance ranges Probe Indicator Displays the sensor condition of the fill height sensor Red is tripped green is open Number of Bottles Displays the number of bottles to be run as a set on the conveyor Run Runs the total number of bottles entered into the Number of Bottles display Load CE Systems Allows bottles to be moved to the laser trip position without having to open the doors Reset Resets the system Exit Exits the feeder window back to the main screen System Elements Conveyor and Load Arm Conveyor AVMS u
5. Limit Switch Used to find the overall height of a container Deltron Slide Allows the filling head to float when finding the top of containers Filling Tube Tube through which water flows during filling Tube Clamp Holds fill tube and sensor at a set height Adjusting the position of the tubes will require a recalibration of the system Sensor Tube Tube housing the sensor fiber optic cables Handle with care Height Pad Allows the AVMS to find the overall height of a given container in order to properly measure volume Height can be changed by loosening set screw and adjusting position of height pad Adjusting the position of the pad will require a recalibration of the system Fill Tube Spout Water leave filling tube at this point A smaller draw cylinder within the spout wicks water away from the sensor during slow filling Water Sensor Detects the meniscus of the water at fill and overflow positions System Elements Reservoir and Filtration System if equipped Reservoir The reservoir holds 6 gallons 22 7L of water The reservoir is equipped with a capacitance sensor that will notify the user via the touchscreen if the water level is low less than 1 gallon 3 7L Water can be added via the recovery chute ensure that recovery door is closed or via the recovery funnel on the front of the AVMS AVID Corporation recommends using distilled water in the AVMS 2000 to prevent mineral deposits biological bu
6. change the value of the fill height Meniscus Offset to a small negative value generally between 0 050 and 0 150 This may require some experimentation to find the appropriate meniscus offset Guide Programming New Bottles for Measurement New part programming and modification should only be performed by system programmers trained at AVID Corporation This guide is a brief step by step instruction to refresh system programmers post training r s 0 CHANGE BOTTLE 1 Press the New Bottle Button 2 If you wish to create a bottle from scratch select Create If you wish to use an existing bottle file as a template similar features heights etc select Modify Create Modity Gat 3 If Create is selected give the bottle you are L lt programming a unique filename If Modify is selected first Open a part file to use as a template then Save with a unique filename when prompted 4 Assign to a part button if desired Place the correct bottle onto the conveyor 5 Press the Setup Button Press the Set Up tab 6 If measuring overflow brimfill volume check the box for Brim Volume and enter the target overflow brimfill volume in the Brim Volume display using the onscreen numerical entry tabulator If not measuring overflow brimfill volume uncheck the box for brim volume 7 If measuring overflow brimfill volume enter the tolerance for overflow brimfill volume in the Brim Volume Tol display us
7. contact AVID Corporation to schedule a calibration service However a basic calibration can be performed by a trained system user Using a calibrated weight scale calibrated thermometer and a large volume container a 2000mL Erlenmeyer flask or other large volume container works well follow the instructions below 8 In Setup go to the Adv Controls tab 9 Place the empty bottle on the weight scale and zero tare the scale 10 Place the empty bottle underneath the fill tube 11 In the Stages window lower the Spout Head until the filling tube is just above the sealing surface of the bottle 12 Under Dispense Controls enter a fixed volume to dispense 500mL is convenient place to start 13 Press the Dispense Fixed Volume button The fixed volume entered will be dispensed into the container 14 Record the temperature of the water now in the bottle 15 Weigh the filled container Using the weight with a water density temperature conversion chart determine the actual volume in the container 16 If the actual volume in the container is LESS than stated dispensed volume from the AVMS DECREASE the cylinder scale value and press Save Setup button If the actual volume in the container is MORE than stated dispensed volume from the AVMS INCREASE the cylinder scale value and press Save Setup button 17 Dispense the same volume again and repeat the conversion procedure When the value dispensed is within 0 3mL
8. ethernet port 6 Computer Front Panel The two RAID 1 configured hard drives should only be removed with the computer powered off To remove a hard drive rotate the barrel key lock counter clockwise 1 4 turn on the drive drawer Then lift up on the drawer handle and pull the drive out To insert the drive push it in until it begins to engage and then lower the handle to complete the entry Only gentle force is required Then rotate the barrel key clockwise 1 4 turn on the drive drawer and remove the key Lower removable hard drive Upper removable hard drive bay Drive 1 in the RAID 1 bay Drive 0 in the RAID 1 array array USB connectors DVD ROM or R W drive 7 Parts List Description Mfr Part Mfr ty CE Data Source Computer Power supply FSP550 60PLG Sparkle Power Inc 1 Yes Data Sheet Motherboard DP43BF Intel 1 Yes Data Sheet Hard drive ST380815AS Seagate Yes Data Sheet DVD RAM drive SH 228L Samsung _ 1 Yes User Guide Serial 0 Board 4 port PCI QUATTRO PCI Lava Yes Data Sheet Ethernet board 10 100 PCI Yes User Manual Graphics board 5b12 P3 12134R 6 1 Yes ata Sheet Fan 12VDC 120 X 120 X 25 mm Yes Data Sheet UPS a ai p UPS SID Tp po Motors po xi Servo Motor 1 stack 2000 count SM2315D Animatics 9 Yes Catalog
9. lt 33mm should be expected to drain more slowly than bottles with large neck finishes gt 38mm Larger volume containers will also take longer to drain Experimentation with the draining time may be required to determine an appropriate draining time 17 CONVEYOR SETUP Press the Transport tab Ensure that the bottle is on the conveyor Press the Next Bottle button When the conveyor stops go to the Stages menu Select the Conveyor axis and advance the conveyor is placed in front of the loading jaw Press the Set button 19 Press the Load Pos Go button The load arm will move the bottle from the conveyor to a default position In the Stages menu select the load arm axis and adjust the position until the neck finish of the bottle is centered under the filling tube Press the Load Pos Set button Note if it is difficult to determine if the bottle is centered lower the Spout Head in the Stages menu until you can better determine if the centering 20 If the bottle is being moved too quickly slowly lower raise the Load Speed setting 21 Press the Eject Pos Go button The load arm will move the bottle from the loading plate to an ejection position In the Stages menu select the load arm axis and adjust the position until the bottle is dumped into the recovery chute Press the Eject Pos Set button 22 Save the bottle program by pressing Save Part ensuring that the proper program is highlighted and press Save Filling Tips Techni
10. fpd EN 1 Controller Base Adapter RifpdAVID h Controller Base R2 pd AVID h Controller Front R2fpd h Controller Laser Blank ROfpd AVID ft LH 9 DFi21225BM Dynatron as Data Sheet lt 2 L bB po B B Do EUER o B o 5 5 5 5 mt j B B EE h _ S e h P e NE L 558 5012 joc 1 Yes Data Sheet Ps5R SD24 Yes Data Sheet PFCS00W 48 Animatics ji Yes Data Sheet o p p j AN SC223 Bannet Nes instruction Manual _ Switch head short lever 2 pos Switch 3 position clip Switch contact block SPST NO Switch contact block SPST NO Switch head key 2 pos Switch 3 position clip Switch contact block SPST NO Switch contact block SPST NO Switch head round mom red Switch 3 position clip Switch contact block SPST NO Switch LED block red Switch head round mom blue Switch 3 position clip Switch contact block SPST NO Switch LED block blue Indicator LED 13mm green Indicator LED 18mm amber Wiring Wire duct slotted PVC 1 2 X 1 Screw clamp block 6mm
11. from filling tubes Air being pulled into cylinder from Check water level in reservoir reservoir Add water Air being pulled into cylinder from Attempt to locate loose other location connection If able tighten connection Foreign matter in filling line Contact AVID for assistance Other Contact AVID for assistance Sensor not System Controller OFF Check Emergency stop button glowing Press Green Blue button on System Controller Reset system Sensor disconnected from controller Trace sensor wires back to controller and check connection Water backwashing from reservoir out of recovery trapdoor Reservoir overfilled Drain water from reservoir to appropriate level Bottle not draining fully after drain cycle Insufficient drain time Increase drain time Short bottle Bottle landing on side in recovery chute Bottle must be run manually or water drained back into reservoir following testing Water discolored Foreign liquid matter in system If possible determine what fluid has been introduced Contact AVID for assistance Algae build up non distilled water systems Contact AVID for assistance Filter dirty discolored Filter requires replacement Replace filter Contact AVID for assistance Circulator pump making noise Air pocket formed in pump Unplug pump then plug pump in again Repeat process until all air bubbles exit
12. initiating Find Brim Find Standard and Find Brim should always be conducted after moving the height pad Probe State Displays the current state of the probe Green indicates that the sensor is not detecting water red indicated water Test Find Bottle Top Pressing this button starts a bottle height search Bottle must be placed under the fill tube Get Bottle Indexes the next bottle from the conveyor and loads it to the filling position on the loading plate Clear Data Clears all data from the data grid Set Bottle Top Sets the current position of the fill tube and height pad as the height of the bottle Fill Cylinder Refills cylinder Empty Cylinder Purges cylinder contents into main reservoir Setup Understanding Sensor Offset Set Screw Height Pad size varies Sensor Offset The sensor offset value can be increased or decreased by raising or lowering the height pad on the fill tube sensor tube In order to adjust the position of the height pad loosen the height pad set screw and move the pad to the desired position Raising the pad allows greater depths from the sealing surface to be reached for fill point and volume height measurements Be aware that increasing the sensor offset may prevent smaller bottles from being measured spout will strike bottle push up before height pad contacts the sealing surface 10 Setup Set Up Tab Controls Set Up Transport Specifications O
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14. leech from the fill tube to the sensor and cause the sensor to trip Water metal components and electricity don t mix Mop up spills quickly If water gets on stage components dry them off with a clean dry cloth then apply a light amount of WD 40 or other water repellent with a cloth to the components If performing a gauge repeatability study wet the bottles prior to starting as the AVMS does not completely dry the bottles post test The AVMS should never be placed in areas of high or heavy vibration or extreme temperature fluctuation as this will affect measurement accuracy and repeatability Troubleshooting Problem Possible Cause Solution During filling Water may be splashing up from the Reduce fill rate filling stops empty base up to the sensor abruptly Overflow Fill Point or Volume Check Overflow Fill Point Height volumes set too low and or Volume Height volume settings During filling Overflow Fill Point or Volume Check Overflow Fill Point water surges above sensor Height volumes set too high and or Volume Height volume settings Overflow or Fill Point tolerances too tight Check Overflow and or Fill Point tolerance settings Fill rate set too high causing pubbling Lower fill rate Water spurts Air bubbles forming in system after Run a 500 1000mL bottle twice during filling period of non use 10 hours to purge any bubbles
15. operator to select the desired motion device Spout Head Dispenser Main dispensing stage Spout Head Filling tube stage Push Arm Loading Arm Conveyor Conveyor Gnd LED Indicators If the stage is powered it will indicated m Serene n i qon with a green LED If the stage is unpowered due to an open door fault or problem with the individual motor Exit to Main the stage will be indicated red Move Stage Allows the positioning of the selected motion device within it travel limit Pressing the speed button in the center adjusts the speed the axis will move Position Box Displays the current position of the highlighted motion axis from the home limit switch If the box is clicked upon the numeric keypad will pop up and allow a value to be entered This allows the user to send the selected axis to a point in space if desired Reset All Resets the motor if a door was opened or the Emergency Stop button was pressed and released If this button is pressed the Home All button should also be pressed after power to the stages is restored LEDs turn green Reset All does NOT automatically home all stages Controls Go to Start Sends the selected motion device to its start position Set Park Sets the current position of the selected motion device as the park position Home Selected Homes the selected motion device Home All Homes all motion devices Should be pressed when
16. or to recall System Controls program that is not assigned to a part button By pressing this button the user can 2 TI either create an entirely new part profile modify a pre existing part template and save X the values into a new part profile or call up Now Bottle Stages a saved part profile for use 3 Stages Pressing the Stages button will bring up a stage control window allowing control of Setup Manual each individual motion device Pressing this button also allows the operator to return all or selected motion devices to their individual home limit switches move a single axis or place a device at its start position Reset Re links and homes all stages Setup Password Protected if enabled Displays the menu for setup volume nominal and tolerance entry data setup and conveyor setup Manual Displays this manual in PDF Clear Data The clear data button will reset the bottle count to 0 and clear data from the system Run with Conveyor Displays conveyor control menu and associated feeder command buttons System is typically run by the operator through this menu Exit to Windows Exit will move the stages to home close the program properly and then shut down the bottle program To completely turn off power shut down the Windows operating system Press the power button on the uninterrupted power supply UPS after the system shuts down Run Manually The Run Manuall
17. pump Pump requires replacement Normal wear and tear item Contact AVID for assistance System groaning squeaking during filling Cylinder lead screw requires lubrication Contact AVID for instructions Cylinder requires replacement Normal wear and tear item Contact AVID for assistance Foreign matter in cylinder Contact AVID for assistance Meniscus forming incorrectly during measurement Calibration required Check calibration with standard Meniscus offset incorrect Check meniscus offset Contacting AVID When contact AVID for support please be prepared to provide as much information as possible SC106 System Controller Technical Guide This manual contains Complete information on using the SC106 System Controller as well as safety maintenance and troubleshooting information Revision 1 0 August 2010 Table of Contents 1 Overview 5 38 2 Operator Controls 39 2 1 E Stop Lamp 39 39 sees BOO 1 Door 2 Door 3 Lamps isa ecc I a aQ SR saa 2 2 Reset Button 39 2 3 2 4 Run Button 40 2 5 Bypass Key Switch 40 2 6 Power Switch 40 3 Operation 41 3 1 Normal System Startup41 3 2 Commissioning Periodic and Da
18. target volumes Bottle Height Displays the nominal height of container Draining Time Amount of time in seconds bottle requires to drain once dropped into the recovery chute Generally containers with larger finish bottles 238mm require less time to drain than small finishes 33mm Experiment to determine the appropriate drain time for a particular bottle Note short bottles may not drain completely if they land on their side in the chute Reset Resets system Exit To Main Returns user to main screen Save Setup Saves system settings green values Save Part Saves part specific settings yellow values 11 Setup Transport Tab ee e ee Ady Controls Set Up Transport System Data Setup Measured Data Exit to Main Conveyor Load Arm Eject Load Pos Next Bottie 67024 Set Go TIW Load Speed Open Eject meto Km mi ELM Go Home Conveyor Next Bottle Pressing this button will advance the next bottle until it reaches the electric eye laser Pressing this button will also call up the stage control window and automatically highlight the input conveyor The operator can then advance the bottle to the proper loading position Set Pressing this button sets the amount of movement required to move the bottle from the electric eye to the load arm Go Pressing this button will advance the next bottle until it reaches the electric eye then to the load
19. warnings and safety standard compliance declarations are available in the Banner Engineering Safety Controller Models SC22 3 and SC22 3E Instruction Manual Most any machine state or fault that might be unsafe is neutralized by removing power from the system motors and any attached I O hardware Lamp and camera power are not disabled as part of a safety shutdown WARNING All servicing of the System Controller is to be performed by Qualified Service Personnel only No user operator adjustments inside the System Controller are necessary or recommended by the manufacturer Modification of the System Controller can result in a loss of safety monitoring and serious hazards to operator personnel WARNING Always disconnect power from the System Controller and the guarded machine before making any connections or replacing any system component Use extreme caution to avoid electrical shock at all times Serious bodily injury or death could result WARNING The commissioning periodic and daily safety system checks see section 3 2 must be performed by appropriate personnel at the appropriate times in order to ensure that the safety system is operating as intended Failure to perform these checks may create a potentially dangerous situation which could lead to serious injury or death WARNING Verify that the guarded area is clear of personnel and unwanted materials such as tools before applying power to the guarded machine Failure to do so cou
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21. AVMS 2000 Automated Volume Measurement System System and Operation Manual AVID Corporation 222 International Drive Suite 105 Portsmouth NH 03801 603 559 9700 Copyright 2011 Starting System Up From a power off condition press and hold the power button on the uninterrupted power supply UPS until the UPS emits a single beep The computer and I O will automatically start The computer takes approximately 1 2 minutes to boot up from a cold state Login into Windows when prompted User privilege settings should be set at Power User or higher to avoid program issues Start the AVMS software by clicking on the shortcut on the desktop screen The AVMS will prompt the operator to press either the Green or Blue button on the system controller Do so You will notice in the taskbar that the System Controller I O connects to the computer via a network connection When the System Controller is connected click on the OK button If there is a problem with the air source the operator is presented with an Air Pressure message Check the air supply to the system to ensure the system is receiving air DAMAGE CAN OCCUR IF THE SYSTEM IS RUN WITHOUT AIR The system will check the position and home all stages and fill the main cylinder prior to displaying the main screen When starting the system up from a weekend or overnight of non use it is good practice to run a random bottle 500 1000mL once or twice to clear an
22. cessary 12 If measuring volume height s maximum of 5 ensure that all Fill Points are checked in each box for each Height you wish to measure Enter the Height for each volume height measurement 13 If measuring volume height s maximum of 5 enter the volume values to be dispensed in Volume Height Volume using the onscreen numerical entry tabulator Note 1 Volume Height volumes must be in ascending order of amount from smallest 1 to greatest 5 Note 2 Volume Height volumes cannot be set at volumes greater than 1 the volume of the container or 2 the volume of the cylinder 14 Enter the Dispensing Speed using the onscreen numerical entry tabulator 100 is full power AVID recommends a dispensing speed that does not create bubbles foaming or backsplash that could accidentally trigger the sensor during filling and result in false volume measurements Speeds should be set such that the bottle fills evenly and efficiently Experimentation may be necessary 15 Enter the nominal Bottle Height of the container using the onscreen numerical entry tabulator 16 Enter the Draining Time for the bottle using the onscreen numerical entry tabulator Draining time should be set to give the bottle adequate time to fully drain when dumped into the recovery chute Note 1 small bottles may only partly drain if they land on their sides in the recovery chute Some water loss should be expected Note 2 bottles with smaller neck finishes
23. creen DO NOT POUR OTHER LIQUIDS INTO THE RESERVOIR Purging the System Removing Contaminants Only flat tap water or distilled water should be added to the system NO SOAP OR CLEANING SOLUTION SHOULD EVER BE ADDED TO THE RESERVOIR Should foreign liquids of any kind be introduced to the system the reservoir and cylinder should be purged 1 2 3 4 5 6 7 8 9 In Setup Adv Controls tab press the Empty Cylinder button Once completed exit to Windows Turn off the AVMS and unplug the system from the electrical supply Remove the lower panels of the system to reveal the main reservoir tank and filtration system Most systems have a release valve on the reservoir to assist draining Drain the fluid into a container Unscrew the filter base from the filter head and dispose of water in the filter Dispose of the filter If necessary rinse clean all foreign liquids from the reservoir and filtration system The pump powering the filtration system can be plugged into a standard 110V outlet to cycle water into and out of the filter component When cleaned add fresh distilled or tap water to the reservoir Insert a new filter into the filtration system Turn the AVMS back on and start the volume software Place a large capacity container at the filling position Lower the spout head into the container 10 Enter a large fixed volume to dispense 1000mL is good and press the Dispense Fixed Vo
24. e USB 2 1 ft A male B male USB2HAB1 StarTech h Motor Connector Board avion AVID BG p Jackscrews 4 40 3 16 thd length TB Connector PC D sub 9 pin female IMD9F3S600X 929 7 pPosironics P Catalog Connector PC D sub mixed female CBD7W2F35S600X Positronics 2 05 09 Terminal block 2 pin 1714955 Phoenix h DataSheet Power Entry module 4303 0001 Schurter 1 Data Sheet Fuse drawer 4303 2401 Schurer J Datta Sheet Fuse 5A 250V 5X20mm fast act 217005H LittleFuse 2 Data Sheet System Components Configuration Guide This manual contains Information on the major System Components as well as connection and identification information Revision 1 0 August 2010 Table of Contents 1 System Block DiagramError Bookmark nc 2 Computer Connections 75 3 SC106 System Controller Connections 76 4 Motor Fanout Panel Connections 77 5 VO Block Connections 78 6 Computer Front Panel 79 7 Parts USt 80 1 System Block Diagram Motors Guard Door 1 Switch Guard Door 2 Switch Guard Door 3 Switch E Stop Switch Halogen Lamp IR Controller Lamp On Off Camera LED Solenoid valves Sensors etc Camera Network Auxiliary Gauge Weight Scale IR Controller Keyboard Mouse AC Line Power Rack Safety Switch
25. e AVBIS to recognize Windows menu and font size settings Note enabling this feature can change formatting in the AVMS control menus and make certain buttons disappear or make text difficult to read Metric Toggles all measurements readings and settings into metric requires software restart Manual Save Data Toggles Save Data button on an off Light Stack Allows system to use a lightstack if equipped Clear Parts Clears all part buttons Does not delete programs only removes the button names I O Settings Allows setting of the outputs from the controller to external devices Values should not be changed by the customer unless instructed to do so by AVID Input Allows setting of the air inputs Values should not be changed by the customer unless instructed to do so by AVID Advanced Setup Controls Stage Settings ainixi System Options Stage Settings Misc Mtr Assignment Motor Speed Length Polarity Spout B Offset 14 1252 1 1 g Load Arm 2 2 E lt gt m mos RIR Bg Canas paac Travet KEEN MEIN ELM a j HE Mec Fal Speed 88 7388 85 88 s Save see re speca METENE oo Motor Assignment Allows assignment of motors Max Travel Stroke length of the fill cylinder Charge Speed Charge speed of fill cylinder Med Fill Speed Medium fill speed setting of the cylinder taken as s divisor of the maximum fill speed
26. e system further If there appears to be a problem non emergency try to note as many details as possible regarding the issue press the Stop button and contact the certified AVMS system programmer or supervisor to address the problem After the last bottle is measured the system will refill the main cylinder charging Remove the emptied bottles from the bin beneath the system If there is any water remaining in the bottles return the water through the recover funnel at the front of the system to reduce wasted water Main Control Screen The control screen displayed at system start up is divided into three regions JEE xi Overflow Height FillPt VHeight System 1 Controls 28 J Ay ainara Hoca Gta Dus ffe sp mes 5 d r netur save N mata er tart 1 8 TOY ane System Controls top right Permits access to setup and data screens and controls for frequently used functions Data Grid top left Displays the measurements made on the last series of parts Part Buttons bottom The Part Buttons section allows quick selection of commonly measured parts and displays the part file currently active Main Screen System Controls New Part 112 AVID Volume Measurement Ver AVLO005 S N A3 A0OL 7 15 x The new part button is used when a new 8 8 Mw Tet Hip part is to be programmed
27. e to be determined for data output Send Header Allows header information to be sent along with data Exit To Main Returns user to main screen Save Setup Saves system settings green values Save Part Saves part specific settings yellow values 14 Setup Measured Data Tab Adv Controls Set Up Transport System Dota setup Measured Data Exit to Main Fill Point Volume Vol Height Fill Point Volume Displays extra volume measurements for the first 5 fill point tests Vol Height Displays height measurements for the first 5 volume height tests Note Due to limited space in the data display grid only the first fill height volumes and volume height measurements are shown Additional fill height or volume height measurements will appear in Excel or the Data Output but will not appear in the grid display Advanced Setup Controls System Options System Options Stage Settings Misc Setup Options WO Settings Main Air 224 Dump 5 Redlight B EM Valve Air Cylinder Yellow Light A WW o lt gt Password Tank 5 zx Pressure 2 22 Green Light 8 ig lt Windows File Geer Parts r Metric A YY r Manual Save Data Inout Light Stack Pressure Save DrainTank 8 r NC Setup Options Data Status Toggles flagging of out of tolerance data Password Toggles password protection prevents access to the Setup controls of the AVMS Windows File Allows th
28. f the container when filled to a specified height Height Displays the nominal height position from the sealing surface for fill point volume measurements Fill Point Checkbox If checked AVMS will measure fill point volume at the indicated height Volume Nominal fill point volume at the displayed height position F Meniscus Offset Position of the fill sensor from the nominal fill point heights within the bottle This position can be altered if the body of the container creates a different meniscus than the calibration artifact Positive fill meniscus values are above the nominal fill point and allow greater meniscuses than the calibrated meniscus to form negative values are below the nominal fill point and allow smaller meniscuses than the calibrated meniscus to form Fill Volume Tol Tolerance of the fill point volume nominal For example if a bottle has fill point tolerance of 5 0mL the fill volume tolerance should be set at 5 0 Volume Height Volume height measurement allows the AVMS to measure the fill height of a container when filled with a known volume Note Volume Height cannot be run while Fill Points are enabled and vice versa Volume If selected with the checkbox system will dispense the indicated amounts then measure the fill height for each volume Dispense Speed Speed at which water will be dispensed into the container 100 is full speed Speed will automatically slow when nearing
29. f the relay board Contact opening disables motor power with a much faster decay than the sole removal of line input power by K1 and K2 U1 of the relay board provides optional 12 VDC power for the system fan at JFan One of JP24V or JP12V are shorted to select 24 VDC or 12 VDC respectively for power to the fan Camera LED power is output at JCam line power input for the halogen lamp power supply PS3 is at JACLamp and front panel control 24 VDC power is at JFP24V Relay K4 switches line power to PS3 on and off by means of a 3 32 volt DC control signal from the rear panel Lamp On Off connector Relay board LEDs LED3 and LED4 show the on off state of K1 and K2 respectively LED 1 is lit when AC line power is at JACin and LED2 monitors onboard 24 VDC power from power supply PS1 Figures 6a through 6d show a pictorial representation of all internal point to point wiring according to subsets of function and wire gauge Figure 7 was generated from the Banner Engineering Safety Controller PC Interface program which is installed on the system computer It shows a simplified schematic of the system controller connections to the SC22 3 safety module Different labels are used in that diagram for some of the controls and outputs Use the SC22 3 pin number names as a correspondence guide Figure 8 provides a summary of the detailed functionality that has been programmed into the SC22 3 safety module This was also generated from the Banner Engineerin
30. g Safety Controller PC Interface program Symbol names are matched to those in figure 7 1 jo p 8 Beg 91096179 eres pueog PE Tax 21 1041103 ue4shs peyeuoduoouy 1 0 1 21882 3 in u J9 2031 Z USv2 0v2U3l 4 v S 28 Abe Aba en ie 1 6525 punoug stsseuj 2 50061 5006 4 9 ea 2a MI pem z mol IsA mot 3 sa 131 ean ES US29 US29 Te 2 e Di Abe lt t 1 9 8 1 MI 3661 psa 1037 Td 2 27 aac yinede Fig 5a Relay Board schematic rgo 1 abeg LEER SMU 81 DneD au m 4 nezag Jemog 4e 043u0j u qshs pena here pueog A OMY 51 pel 9923393 p q3eJoduooSul l ued 3 6 4 OMY pI 10619 40394 entia 48 31 eswed 48 we c da ve4c 88 S4030ujUC 88 morr9A ueaJ5S ania 3 99 Seius id qndul da MOT 1 9 8 4 70 0 due dg 931uM pa3 AOE TIPSY 4emog due gg due315UC 88 835 050 Ria OIOUC 83 Fig 5b Power distribution schematic 1 JO 1 Beg ewe ewes S ene SM 81 ebneb autm 520 4 10473409 wa yshs pueog fe az peyeuoduoouy 15 4 eg euey 4u044 10 20 0 bO OMY 22 360 MY 22 unoug SMO 52 2194 3819 2
31. g properly with undamaged contacts If not then SC1 will remove power from both the K1 and K2 coils SC1 will then light the front panel Reset button with an output from pin O6 Pressing the Reset button will then activate SC1 pin SR and SC1 will recheck to see if the malfunction has been cleared SC1 also monitors up to three system guard door switches at pins S5 through S13 that are connected directly to the back panel door switch connectors These are 3 wire connections to allow for a normally closed and normally open contact in each switch to be monitored In a similar way pins S1 to S4 monitor the system DPST normally closed contacts of the E Stop switch by direct wiring to the back panel E Stop connector Activating any of these switches causes K1 and K2 to deactivate and outputs at SC1 pins O1 through O4 will light the appropriate status indicator lamp on the front panel When all safety switches have been subsequently deactivated SC1 will light the front panel Run pushbutton with the output pin O5 Pressing the Run button will signal SC1 at pin S22 to reactivate K1 and K2 The front panel DPST normally open contacts of Bypass keyswitch are connected to SC1 pins S14 to S17 to monitor the selected bypass state SC1 is powered by 24 VDC power supply PS1 on the relay board with a connection to JSC24V Additional normally open contacts on K1 and K2 are wired in series between the RC and RCG shutdown pins of motor power supply PS4 by means of JRC o
32. her pin of JFault on the relay board to R5 on the end closest to JCoil LED3 and LED4 should extinguish Relays K1 and K2 should deactivate The power LEDs on PS2 and PS4 should also extinguish The red Reset pushbutton on the front panel should light and stay lit Press the Reset button and its lamp should extinguish Repeat the previous with the other pin of JFault jumped to R5 8 Parts List Description Chassis Cabinet rack mount 4U Panel back Panel base adapter Panel base Panel front Panel laser blank Fan guard 60mm DIN rail 35mm 1M long Fan 12VDC 120 X 120 X 25 mm Screw flat head M3 X 6mm SS Screw flat head M4 X 6mm SS Screw flat head M4 X 20mm SS Screw flat head 8 32 5 16 SS Screw socket 1 4 20 5 16 SS Screw socket 8 32 1 4 oxide Screw socket 8 32 5 8 oxide Screw phil 6 32 3 8 SS Screw phil 6 32 3 8 SS oxide Screw phil 8 32 3 8 SS Screw phil 8 32 3 4 SS Bracket 11 16 x1 x1 2 steel Standoff 8 32 F F 1 2 3 8 hex Washer 10 thick oxide Washer 10 SS Washer M4 SS Washer split lock M4 SS Nut hex M4 SS Nut hex 6 tooth washer SS Nut hex 10 tooth washer SS Power Supplies Power supply 12 VDC 2 5 A 30W Power supply 24 VDC 2 5 A 60W Power supply 48VDC 10A Safety Controller Safety Controller Front panel controls Mfr Part Mfr Qty CE Data Source SL CASE R4U SuperLogics Controler Back_R2
33. ildup from forming within system components Filtration System The reservoir features a cycling filter system that continuously filters water within the reservoir This filtering removes plastic particles or debris entering the fill tube or valves that could affect measurements or damage the system If a replacement filter is required the filter is a commercially available component available through most supply companies or hardware stores Contact AVID Corporation for the part number Adding Water to the System Internal Reservoir System System being supplied by local plant plumbing and sewer do not need to add water to the system Despite the recovery chute and water recycling system some water loss will occur with every bottle measured and is normal Therefore the system must occasionally be replenished with water The system will indicate to the user if water is required by displaying a water sensor message in the system control menu as seen below While tap water may be used AVID recommends using distilled water to fill the internal reservoir in order to prevent mineral deposits or biological buildup on internal system components If prompted to do so add 1 gallon of distilled water via the recovery funnel on the front of the system After filling give the system a moment to check the capacity of the reservoir If filled the indicator will turn off If more water is required the indicator will remain on s
34. ily Safety System Check seen 41 4 Connections 43 4 1 AC Input 43 4 2 PWR 1 COM 1 PWR 2 COM 2 u aa ei 43 4 3 Computer 43 4 4 eue 43 4 5 Door 1 Door 2 Door 343 4 6 VO Power 44 4 7 Lamp Power 44 4 8 Lamp On Off 44 4 9 Camera LED 44 5 Internal Component Layout45 B Circuit Function Description caeco aa a ke 47 EA Career nia bei ie owes cess sass ULPPE 68 69 Paris List 8 1 Overview The model SC106 System Controller controls power distribution to the system servo motors on all motorized stages to the attached I O block device used to operate hardware such as solenoid valves and sensors and to the halogen lamp in infrared measurement equipped systems Internal power supplies provide 48 volts DC for the motors 24 volts DC for the I O hardware and 12 volts DC to the halogen lamp An additional 24 volt DC power supply is dedicated to the internal safety control circuits and is also used for powering an illumination LED on imaging equipped systems Additionally the System Controller incorporates a Banner Engineering SC22 3 safety controller module to monitor an emergency stop button and one to three safety door switches A full description of the SC22 3 module and all relevant safety
35. ing the onscreen numerical entry tabulator 8 If the brim meniscus offset value is known enter the positive or negative brim meniscus offset in the Brim Meniscus display using the onscreen numerical entry tabulator If the value is unknown observe the brim fill measurement when the bottle is run and adjust the offset if necessary STEPS 9 11 are for fill point volume measurements If performing volume height measurements skip to Step 12 9a If measuring a single fill point volume check the box for 1 fill point and enter the target fill point Height for 1 and the target fill point Volume for 1 9b If measuring multiple fill point volumes maximum of 5 check the box for each fill point and enter the target fill point Height and Volume for each point Note 1 fill points must be in descending order of depth from deepest least volume 1 to shallowest greatest volume 5 Note 2 fill points cannot be set at depths greater than the sensor offset value see Adv Control tab to note Sensor offset value 10 If measuring any fill point volume s enter the fill point tolerance in the Fill Volume Tol display using the onscreen numerical entry tabulator 11 If the fill meniscus offset value is known enter the positive or negative fill meniscus offset in the Fill Meniscus display using the onscreen numerical entry tabulator If the value is unknown observe the fill point measurement when the bottle is run and adjust the offset if ne
36. ld result in serious bodily injury or death 2 Operator Controls Fig 1 Front Panel Controls 2 1 E Stop Lamp Amber colored and when illuminated indicates that the emergency stop button has been activated Power to the motors and I O hardware is removed 2 2 Door 1 Door 2 Door 3 Lamps Green colored and when illuminated indicate that a corresponding guard door 1 2 or 3 is open Power to the motors and I O hardware is removed 2 3 Reset Button Red colored illuminated pushbutton Resets the safety controller module This will only light in the event of a serious internal malfunction such as welded or stuck safety relay contacts or failure of the safety controller module itself A soft error may correct itself by actuating the button If the red Reset button light stays on the system must not be used and the Power Switch should be rotated to the Off position Alert the Safety Officer of the situation 2 4 Run Button Blue colored illuminated pushbutton When lit indicates that the system controller is ready to be activated Then pressing the button will enable the motor and I O hardware power outputs WARNING When performing the system run operation it is the user s responsibility to make sure that all potential hazards are clear and free of people and unwanted materials such as tools that could be exposed to the hazard Failure to do so could result in serious bodily injury or death 2 5 Bypass Key Switch Key ope
37. lume button Contaminated water from the upper lines will now flow into the container about 200mL followed by now clean water from the reservoir 11 Dispose of the contaminated line water and cycle another into the container Repeat two or three times or until water exiting fill tube is clean 12 When the water appears clear and uncontaminated replenish the reservoir with clean distilled or tap water Soaps oils and other viscous substances may take longer to cycle out of the system Blood urine and any other bodily fluid found in the system voids warranty and will terminate further support and service contracts without refund Calibration Height Sensor Offsets If the position of the height pad is adjusted it is recommended that a height calibration be performed 1 In Setup go to the Adv Controls tab 2 Place the provided artifact under the filling tube such that height pad will contact the sealing surface 3 Press the Find Standard button This will start a search for the artifact Once found the system will prompt the user to Save 4 Flip the artifact over and fill it to a proper brimfill position generally flush with sealing surface of the artifact however this position is different among different manufacturers and customers Use a syringe to achieve a desired meniscus 5 Place the now filled artifact under the filling tube such that the sensor will contact the meniscus 6 Press the
38. of actual press the Save Setup button Dispense larger or smaller volumes and check the amount against a conversion chart If there is a discrepancy with larger or smaller volumes contact AVID for assistance Discussion AVMS 2000 vs Fill Height Syringe Measurement The AVMS 2000 is able to measure fill height volume by first locating the sealing surface of the container and then offsetting the fluid level sensor on the fill tube from the sealing surface a known distance to the actual fill height The AVMS then dispenses water until the fluid trips the sensor Therefore the fluid will actually reach the fill height level Fill height volume measurements made using a fill height syringe will often not agree with the AVMS 2000 fill height volume measurements However the variation is generally constant This is because fill height syringes pull water from beneath their stated height due to the vacuum forces of the devices This can be proven by using a fill height syringe removing water from a container to the fill height remove and dry the syringe and then place syringe back in the bottle A gap will appear between the tip of the syringe and meniscus of the water The fluid level in the bottle is therefore NOT at the stated fill height of the syringe However forcing the numbers to agree is simple if the customer requires the AVMS to reflect numbers that the fill height syringe produces In the Set Up tab of the Setup menu
39. op switch Verify that the front panel E Stop indicator lamp is lit Verify that motor power is removed by checking that both LED s on each system servo motor are extinguished Verify that I O power is removed by checking that all LED s on the system I O block are extinguished Deactivate the system E Stop switch Verify that the front panel E Stop indicator lamp is extinguished The blue Run button should light Press the Run button momentarily The blue Run button light should extinguish and verify that power is applied to the motors and I O hardware Repeat steps 2 and 3 using in turn each guard door switch and corresponding front panel door indicator instead of and identically to the E Stop switch and E Stop front panel indicator Commissioning Checkout A Qualified Person must perform the safety system commissioning procedure above before the safeguarded machine application is placed into service and after the internal Safety Controller module configuration is created or modified Periodic Semi Annual Checkout A Qualified Person must also perform a safety system re commissioning semiannually every 6 months or at periodic intervals based on the appropriate local or national regulations Daily Operational Checks A Designated Person must also check the effectiveness of the protective devices each day that the safeguarded machine is in service WARNING The commissioning periodic and daily safety system checks must be performed b
40. position Load Arm Load Pos Set Go Allows the user to set the loading position of the loading arm i e pushes the bottle from the load point on the conveyor until it is centered under the fill tube on the loading plate Eject Pos Set Go Allows the operator to set the ejecting position of the loading arm i e pushes the bottle from the loading plate into the recovery chute Go Home Pressing this button sends the load arm back to the start position Load Speed Loading speed for the particular bottle program Unstable bottles generally require a slower load speed to avoid being knocked over by the load arm Open Eject Opens the pneumatic drain door under the system allowing any bottles in the chute to fall out Exit To Main Returns user to main screen Save Setup Saves system settings green values Save Part Saves part specific settings yellow values 12 Setup System Tab Adv Controis Set Up meet System pas Setup Measured Data Touch Screen Files Miscellaneous Format 862288 Touchscreen Allows recalibration of the touchscreen monitor Pressing the crosshair will launch the calibration routine Follow onscreen instructions Files Bottle File Shows current bottle file selected Miscellaneous Format Displays the number of decimal places data and settings will be read out to Password Reset Resets the password protection if enabled Allows the system to be password pro
41. put cord to a UPS non battery backup outlet 3 pin female M8 cable connection to the camera illumination LED 7 pin female mixed Dsub cable connection to the motor fanout panel PWR input connector DB9 female serial cable connection to the computer A DB9 connector USB B cable connection to any computer USB port Three female 4 pin M8 cable connections to the system guard door switches 3 pin male M8 cable connection to the IR Controller Lamp On Off 4 pin dual key female M12 cable connection to the IR system halogen lamp 4 5 pin female single key M12 cable connection to the E Stop switch 5 pin female 7 8 mini cable connection to the I O block 24 VDC power input 4 Motor Fanout Panel Connections 7 pin male mixed Dsub cable Unused connection to the SC106 COM System Controller at PWR 1 connector Nine 7 pin female mixed Dsub cable connections to the servo motors 7 pin male mixed Dsub cable connection to one of nine motor fanout panel connectors 5 I O Block Connections 7 8 mini male cable power input connection to the System Controller power output at I O Power Eight 4 pin female M12 cable connections for 8 input and 8 output 24 VDC general purpose I O ports a i 8 Two 4 pin female M12 ethernet cable connectors connect either one to the computer W RJ45
42. que and Troubleshooting Always perform a manual test Run Manually after the bottle has been initially setup and observe how the bottle fills before running with the conveyor Most measurement errors or problems during filling are attributable to filling speeds that are too high If the bottle fills too violently excessive splashing foaming bubbling problems can occur during the measurement routine and cause errors or poor measurement repeatability If this is the case lower the filling speed GOOD even smooth fill NOT GOOD fill too fast Always select a bottle fill speed that fills both swiftly and without undue turbulence If a bottle starts filling then stops quickly before fill height or overflow are reached and the filling head retracts the sensor may have been tripped by a drop of water splashing upwards Try lowering the filling speed Ensure that the overflow meniscus offset yields a desirable meniscus on the bottle when completely filled Adjust if necessary by changing the Overflow Meniscus Offset Ensure that the load position presents the bottle perfectly centered under the fill tube and sensor tube particularly when programming small finish bottles Set the height pad position at a height appropriate to measure the majority of your bottles Frequent adjustment of the height pad is not recommended due to the chance for errors A small gap must exist between the fill tube and the sensor or water will
43. r portion of this combination AC input module with a compatible power cord A removable fuse drawer is just above the connector containing two 5 amp 250 volt 5 X 20 mm fast acting fuses Littlefuse 217005H or equivalent The power source must be 100 240 VAC single phase at 50 or 60 Hz with ground pin 4 2 PWR 1 COM 1 PWR 2 COM 2 PWR 1 is a female 7 pin combination D Dub connector that is connected to the PWR connector on the Motor Fanout Panel 48 volt DC power is supplied to the system servo motors on the 2 large pins This power is removed during safety shutdowns Three small pins are jumped to the COM 1 connector to provide bidirectional serial RS232 communications to the motors as well The COM 1 female 9 pin D Sub connector is in turn cabled to the Com 1 port of the system computer An optional second bank of motors may be implemented with another Motor Fanout Panel and using the similar PWR 2 and COM 2 connectors 4 3 Computer This is a female B type USB connector used with a standard USB 2 0 compatible cable to connect the internal safety controller module to the system computer Support software on the computer can be used to configure the safety controller module and to monitor it s operating state 4 4 EPO This female 4 pin M12 connector connects the external emergency stop switch to the internal safety controller module The switch must have 2 poles of normally closed contact pairs 4 5 Door 1 Door 2 Door 3 The
44. rated bypass switch that allows unrestricted guard door operation for testing and maintenance purposes by Qualified Service Personnel only for up to a maximum of 30 minutes Doors may be opened without loss of power to the motors and I O hardware The emergency stop button remains fully operational After 30 minutes if any guard door has been previously opened power to the motors and I O hardware will be removed Normal full safety monitoring is enabled The switch should normally be in the Off position at all times The switch keys should be kept in the sole possession of the responsible Safety Officer 2 6 Power Switch Powers the system controller On and Off When rotated to Off all power outputs are shut down 3 Operation 3 1 Normal System Startup 1 6 To turn on the system the operator should first check that all guard doors are closed and that the emergency stop button is not actuated Then rotate the Power switch to the On position Wait for the blue Run button to light No other indicator should be lit Observe all warnings cited in section 2 Press the Run button momentarily The blue Run button light should extinguish and power will be applied to the motors and I O hardware To turn off the system controller rotate the Power switch to the Off position at any time 3 2 Commissioning Periodic and Daily Safety System Check 1 2 Turn on the system as described in section 3 1 above Activate the system E St
45. se female 4 pin M8 connectors attach to the system guard door switches Magnetically coded switches are used each with a normally closed and a normally open pair of coordinated reed switch contacts 4 6 I O Power This female 5 pin 7 8 inch connector provides 24 volt DC power at up to 60 watts to attached general purpose input output hardware An intelligent I O block with compatible connector is normally used which communicates with the system computer over an Ethernet link using the Modbus TCP protocol This module is then attached to various product specific control components as needed such as air or water solenoid valves relays sensors etc This power is removed during safety shutdowns 4 7 Lamp Power This female 4 pin M12 connector connects to an external halogen lamp in infrared measurement equipped systems 12 volt DC power at up to 30 watts is provided on two separate wire pairs 4 8 Lamp On Off This male 3 pin M8 connector is normally attached to an IR controller in infrared measurement equipped systems Only 2 of the 3 pins are used to apply a 3 to 32 volt DC control signal to a solid state relay in the system controller that connects and disconnects power to the Lamp Power connector 4 9 Camera LED This female 3 pin M8 connector is normally attached to an illumination LED on imaging equipped systems Only 2 of the 3 pins are used to apply 24 volt DC power to the LED through an included 1K ohm current limiting resistor
46. ses a conveyor to index bottles into position for testing Bottles should be set onto the conveyor against the rear conveyor rail unless otherwise instructed Recovery Chute Filled bottles fall neck first into the recovery chute where they are drained After a set time to drain bottom of recovery chute opens to release emptied bottles Load Arm Moves empty bottles from conveyor to filling position Moves filled bottles from filling position to recovery chute Laser Sensor Banner Used as a switch to inform system that a bottle has been detected See information below Recovery Funnel Allows water to be added to the system Banner Laser Sensor Toggle Switch Cycles laser detection settings between dark opaque containers semi transparent bottles and transparent clear bottles Clear is the most sensitive setting Signal Indicators The leftmost signal light box indicates unobstructed signal from the reflector Any signal in the right two boxes indicates an object is present and will act as a trigger Setting up Laser Sensor Ensure that the laser sensor has an unobstructed view of the reflector before setting up the laser sensor Press and hold the side of the toggle switch until all lights go out Release the toggle switch The switch will perform a self calibration for the reflector The laser beam may grow brighter during the test System Elements Filling Head Assembly
47. system is RESET or when a fault occurs NOTE MOVING STAGES MANUALLY IN STAGE CONTROL DISABLES MOST FAILSAFES PAY ATTENTION TO STAGE POSITIONS WHEN MOVING STAGES Main Screen Data Display The data display screen is scroll based window that allows the user to see the past series of measurements from within the AVMS interface Overflow Displays the overflow brimfill volume measured on a particular bottle Volumes falling outside the tolerance value are indicated in red text Height Displays the overall height measured on a particular bottle Fill Pt Displays the fill point volume measured on a particular bottle if enabled V Height Displays the volume height measurement on a particular bottle if enabled BEE Overflow Height Fill Pt V Height 285 0 5 390 260 2 268 8 5 386 243 5 Setup Adv Controls Tab TET WEG a TE Dispense Controls Calibrate Std Height Lower 5735 Find Standard Ptatiorm 88 kaan Prem to Active ees 16767 Z Sermat Out Dispone Fixed Hod Rer Volume EL Volume Cylinder Scale WIN Exit to Main Test Find Bente Top Set Hottie Top Get Benin Fill Cytindes Clear Data Empty Cy amp ador Cylinder Volume Depe met Velume The Advanced Controls Tab allows the user to test calibrate and perform advanced tests Dispense Controls Lower Tube Raise Tube Lowers the dispensing tube to the nominal heigh
48. t of the part program selected Raises the dispensing tube back to the starting position Press to Active Dispense Pressing this button causes the system to dispense water through the tube as long as the button remains pressed Releasing the button stops the dispensing action Dispense Fixed Volume Dispenses a fixed volume of water from the tube amount set by Volume display Volume Display Allows user to set the fixed volume to be dispensed Calibrate Std Height Displays the height of the standard to be calibrated against Platform Offset Displays the distance between the height pad and the surface of the loading plate Sensor Offset Displays the distance between the sensor and the height pad affixed to the tube Indicates the maximum depth from the sealing surface of the bottle that the fill point can be measured Cylinder Scale Displays the conversion factor for measuring accurately in mL Factor is used to calibrate the system This value should not be changed unless advised to do so by AVID Find Standard Height Starts a slow search for the calibration standard artifact using the Std Height value as a basis Following the search the Platform Offset value will be updated Find Meniscus Starts a slow search for the calibration standard now brim filled as per customer specification Following the search the Sensor Offset value will be updated Note Find Standard should be completed before
49. te Switch Complementary Contact switch Manual reset logic Terminals 85 S6 S7 Mapped to 501 Simultaneous Closed open debounce time 6 ms Open closed debounce time 50 ms Startup test disabled O3 Door 2 O4 Door 3 Q5 Out Reset Track GS02 Track 5523 501 reset needed OV dc Run OV de Run 24V dc Reset needed Configuration Summary Configuration CFG1 By S Sama Date 02 20 2010 File name 3 Door csc 24V dc Reset needed Fig 8 Safety controller configuration summary 7 Internal Calibration and Checks 1 Remove the chassis top cover by removing the 4 topmost screws on the side rails 2 on each side Then pull the cover to the rear about 1 2 inch and then up and away Refer to figures 3 and 4 for the layout and identification of the internal system controller components Power up the controller in the normal run mode as per section 3 Adjust the DC output voltage of power supply PS4 to 46 0 volts down from the nominal 48 0 volts Activate Lamp On Off relay K4 Adjust the DC output voltage of power supply PS3 to 11 0 volts down from the nominal 12 0 volts Adjust the DC output voltage of power supply PS2 to 24 0 volts Confirm that all 4 LEDs are illuminated on the relay board Check for 24 0 5 volts DC at JSC24V on the relay board With JP12V jumpered and JP24V open on the relay board check for 12 0 5 volts DC at JFan Move the jumper to JP24V if the fan is 24 volt Momentarily jump eit
50. tected preventing unauthorized access to setup parameters of the programmed files 13 Setup Data Setup Tab Adv Controls Set Up Transport Data Setup Upper Left Cell Row NEN 868 Excel Worksheet File Allows users to designate a specific Excel worksheet to use in conjunction with a bottle program If selected whenever the part file is opened for use the Excel sheet will automatically open and minimize itself Upper Left Cell Row Starting row cell for data output to an Excel worksheet Column Starting column cell for data output to an Excel worksheet Excel Worksheet File Allows users to designate a specific Excel worksheet to use in conjunction with a bottle program If selected whenever the part file is opened for use the Excel sheet will automatically open and minimize itself Excel Macro Names Allows certain Macros to be executed in Excel when data is sent Enable for Data Input Allows user to turn on off data exportation to the selected Excel file Excel Macro Names on B o cons B Exit to Main Data File 9 Auto Clear Data Area Allows system to automatically wipe data from Excel sheet Macro required Data File Allows output for the part program to be sent to remote data file example csv dat txt Data Delimiter Allows delimiter to be selected usually comma Data File Allows a particular destination fil
51. verflow Volume FW Point m Height ELEME ELM Overfiow Tol s 65 88 NL NM zy xm O Meniscus Offset System Data Setup S Measured Data Exit to Main Volume Height Dispense Speed Volume M ss eco 2 MEN ULLA EN ENIM The Set Up Tab allows the operator to modify the height volume limit settings and testing settings for the bottle volume test Specifications Overflow Volume Overflow volume nominal or target for the bottle Overflow volume is also known as brim volume Overflow Volume Checkbox If checked AVMS will measure brim volume overflow volume of the container based on the brim volume nominal Overflow Tol Tolerance of the overflow volume nominal For example if a bottle has overflow tolerance of 5 0mL the overflow volume tolerance should be set at 5 0 Note Larger brim volume tolerances will result in longer brim fill times O Meniscus Offset Position of the fill sensor from the nominal height of the bottle This position can be altered if the neck finish of the container creates a different filled meniscus than the calibration artifact Positive brim meniscus values are above the sealing surface and allow greater meniscuses than the calibrated meniscus to form negative values are below the sealing surface and allow smaller meniscuses than the calibrated meniscus to form Fill Point Fill point volume measurement allows the AVMS to measure the volume o
52. y air pockets that may have formed during the non use period You may wish to setup a simple program for this purpose Standard Operating Procedure Non CE Systems 1 Using the touchscreen click the part button associated with the bottle you wish to run If you do not see 2 3 4 5 8 9 the bottle you wish to run click on the New Bottle button CHANGE BOTTLE 3 6 mem The above window will appear Click on the Get button Select and Open the bottle from the file list Assign the bottle to an unused part button If a message pop up appears read the instructions within the pop up and click on OK when you have followed them Load bottles onto the conveyor If you must open the doors to load the bottles do so no If the message pop up suggested a specific orientation of the bottles onto the conveyor or a specific staggering be certain to follow these instructions Close Press the Run With Conveyor button In the feeder window enter the number of bottles placed on the conveyor by clicking on the Number of Bottles display box and entering the number on the touchscreen keypad Run Corweyar Ext Spee Staten Press the Run button It is generally good practice but not required to observe the first bottle run to ensure that proper filling speeds and settings have not been accidentally altered If the system appears to be measuring and handling properly you do not need to observe th
53. y appropriate personnel at the appropriate times as described above in order to ensure that the safety system is operating as intended Failure to perform these checks may create a potentially dangerous situation which could lead to serious injury or death WARNING If all of these checks cannot be verified do not attempt to use the safety system that includes the System Controller and the guarded machine until the defect or problem has been corrected Attempts to use the guarded machine under such conditions could result in serious bodily injury or death WARNING Verify that the guarded area is clear of personnel and unwanted materials such as tools before applying power the guarded machine Failure to do so could result in serious bodily injury or death 1 Designated Person 2 Qualified Person A person or persons identified and designated in writing by the employer as being appropriately trained and qualified to perform a specified checkout procedure A person who by possession of a recognized degree or certificate of professional training or who by extensive knowledge training and experience has successfully demonstrated the ability to solve problems relating to the subject matter and work 4 Connections PWR 2 COM 2 Computer Fig 2 Back Panel Connectors 4 1 AC Input Unlabelled and located to the extreme lower left on the back panel as shown in Fig 2 Mains power is applied to the male IEC320 C13 connecto
54. y button will execute the measurement program for the part highlighted in the part buttons area Note the bottle MUST be present on measurement platform before pressing this button Water Level Sensor If present AVMS requires additional water Add roughly 1 gallon of distilled or purified water via the front funnel Main Screen Part Buttons The Part Buttons area of the Control Screen permits the selection of different part inspection routines with the press of a single button This simplifies system operation when it is used by plant operators who might be unfamiliar with system setup When a button is selected it will turn green and the associated part template file and setup parameters including conveyor and data output setups will be automatically loaded To clear a button of its assigned part profile right click on it and erase the part number To overwrite a button assign a new part profile to the desired button Overwriting the button does not overwrite the part profile it is linked to Therefore it is possible to have many more bottle profiles than buttons Main Screen Stage Control stage contrat x Motion Axis Move Stage The Stage Control window allows the operator to control all motion devices from one central menu location Note only those motion axis included on the system will be displayed Dispenser e C Sm up o Motion Axis A Pressing a motion axis button allows the Conveyor o
55. yellow Screw clamp block 6mm black End section gray End stop Cable USB 2 0 3 ft Relays Relay SSR SPST 10A 280VAC Relay Board Relay Board PC board Relay 4PST 6A 24VDC coil Socket relay PCB mount Power supply 24 VDC 40W Terminal block 2 pin Terminal header 2 pin Terminal block 3 pin Terminal header 3 pin Resistor carbon film 1K 5 2W Resistor carb film 100K 5 1W Regulator 12V 1 A SIP Capacitor 10uf 20V tantalum Capacitor 47uf 35V tantalum Diode 600V 1A L21KA03 BACO Oontrols 1 Yes Catalog 333E 0 Controls Yes Catalog 33810 BACO Controls 1 Yes Catalog 33E10 amp 8600 Controls Yes Catalog L21LA00 pACOContols 1 Yes Catalog 333E BACO Controls fi Yes Catalog 33E10 amp 8600 Controls 1 Yes Catalog 33E10 BACO Controls Yes Catalog L21AH10 0 Controls Yes Catalog 333E 0 Controls i es Catalog 33810 BACO Controls fi Yes Catalog 33EARL 8800 Controls Yes Catalog L21aH60 BACO Controls Yes Catalog 333E Controls Yes Catalog 33E10 amp 88600 Controls Yes Catalog G3sEABL BACO Controls Yes Catalog 3SBLG24ST 13GNF 22 C3Contols B Yes Data Sheet s Sheet 1 Mae Entree h FF o Enee h BAM2 Entrelec 3 USB2HAB3 starten h TEE EEE Pp B61SSR210 DC 1 Magnecat
56. ys ae sioqui S 856 ve 82 v 8L vi us EOS 505 LOS 559 ICS OCS 615 815 LIS 915 SIS PIS EIS ZIS LIS OLS 6S BS 4S 9S SS S ES cS LS Asaunoy Addng Jamad 9p AO 5 4 2 Ajddags amo dg Sp Ape Fig 7 Safety controller simplified schematic Normal power up mode Mule on power up disabled Terminals S1 S2 S3 54 Mapped to SO1 Simultaneous Ciosed open debounco time 6 ms Open closed debounce time 50 ma EDMC1 External Device Monitoring Dual channel Contact switch Terminals S29 521 Mapped to 1 Ciosed open debounce time 50 ms Oper dosed debouncs time 50 ms Non Safety Input Devices Terminals 22 Mapped to SO1 Closed open debounce time 6 ms Oper clased cebounce time 50 ms Monitored reset 5561 10ms GS0t 10ms GS02 10ms GSO Gate Switch Complementary Contact switch Manual reset logic Terminals 511 12 513 Mapped to 501 Simultaneous Closed open debounce time 8 ms Onen clased debounce time 50 ms Starup test disabled BPO1 Bypass Switch Dual channel Contact switch Terminals 14 515 515 517 Mapped to GS01 GS02 53 Simultaneous Closed opan debounce time 6 ms Open closed debounce time 50 ms Bypass time limit 30 minutes 6502 Gate Switch Complementary Contact switch Manual reset logic Terminals 58 9 10 Mapped to 1 Simultaneous Closed open debounce time 6 ms Open ciosed debounce time 50 ma Startup test disabled 2593 Ga
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