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Alps Electric SPEEDGLIDER, Operator'S Manual

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Alps Electric SPEEDGLIDER Operator'S Manual Download Page 19

AIR LOGIC POWER SYSTEMS (ALPS) 

  

THEORY of OPERATIONS

 

SPEEDGLIDER 

 ADVANCED OPERATOR MANUAL 

 18 

 TM 2012-005 REV02 © 03/19/2013 

Theory of Operations  

Leak Test Operations 

Untested Containers are transferred from line conveyor to the 
SpeedGlider  through  the timing screw. When  1 to 4  container(s)

 

are 

detected by the speed glider photo eye the probes will extend and fill 
valves will execute simultaneously.  At this time pressurization of the 
containers  occurs. During this process the containers are 
electronically monitored to insure the sealed container reaches the 
specified 

Peak Pressure. 

If  any one of the containers  fails to reach 

peak pressure, that  container will be rejected for a fill failure. A fill 
failure usually occurs if there is a large hole or defect in the container.

 

If the container  reaches target pressure then the SpeedGlider  
performs Test 1. 

 
TEST 1 (T1)-(Stabilize Test) 

T1 is considered a pressure stabilization period. T1 is the time allowed 
for pressure curve to flatten out. (See the graph below) Test 1 will 
reject the container if Maximum % percent value for is exceeded. If 
Maximum % value is not exceeded test 2 is performed. 

Test 2 (T2)-(Leak Test) 

Unlike test 1, test 2 is normally performed over a longer period time. (1 to 2 second range) This is done so that 
smaller leaks can be detected. The graph below shows how time is relative to pressure loss in both good and bad 
containers. Notice the pressure loss is more uniform or steady in T2 in relation to T1. In test 2 the container will be 
rejected if the maximum % percent value is exceeded.  If the T2 maximum % is not exceeded the container is 
considered good.  At the end of the test cycle the test probe is lifted and a probe retract timer begins. At the end 
of this time period, the probe is considered to be retracted and the test cycle is completed. 

Pressure Decay Values and Percentages 

Unless otherwise specified the pressure values in the HMI displays are usually shown in Inches of Water Column 
(iWC). This is done for scaling and calibration purposes as iWC units are on a much finer scale then PSI. For 
general purpose and knowledge it should be known that one inch of water = 27.7 iWC = 1 PSI. 
 

 

 

Summary of Contents for SPEEDGLIDER

Page 1: ...C 1745 S 38 th Street Suite 100 Milwaukee WI 53215 1732 Phone 414 671 3332 Fax 414 671 6645 24 Hour Service Hotline 800 325 8717 www alpsleak com and info alpsleak com ALPS SPEEDGLIDER LINEAR LEAK TESTER ADVANCED OPERATOR MANUAL ...

Page 2: ...tion 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 SpeedGlider system may also void the warranty and or service agreements ...

Page 3: ...the machine 12 Glossary of Terms 13 SpeedGlider Advanced Operator 14 Advanced Operator Introduction 14 SpeedGlider Main Features 15 Viewing and editing HMI Displays 16 Password Protected Options and Settings 16 Creating and changing On Screen Variables Values and Settings 16 Changing settings and values using the TENKEY screen 16 This Advanced Operator Manual Overview 17 Theory of Operations 18 Le...

Page 4: ...ble 33 Machine Speed Navigation and Information help Screens 34 Photo Eye Settings Introduction 36 Photo Eye Settings Navigation 36 Test Results Menu 37 Test Results Introduction 37 Test Result Descritption Table 37 Last Test Detail Navigation 39 Last Detail Timers Navigation 39 Counters Navigation 39 Recent Rejects Navigation 40 Alarms Counters Navigation 40 Alarm Log Navigation 40 Maintenance Me...

Page 5: ... containers are captured and fed into the test area by a timing screw located adjacent to the line conveyor The timing screw conveyer and test probes are synchronized so that a smooth transition occurs from test cycle to test cycle After the test is complete good containers pass on and defective containers are ejected off of the conveyor line A single electrical cabinet is installed on the backsid...

Page 6: ...aque affixed to the inside door surface of the High Voltage control enclosure as shown below Along with it are the 24 Hour service hotline phone number and the UL Panel Rating plate LABEL 1 ALPS 24 hour service hotline phone number 2 UL Panel Rating Label 3 Identification and serial number plaque 4 UL Certification Sticker 5 UL Panel and Rating Label 4 5 3 1 2 4 5 ...

Page 7: ...y if caution is not observed Refer to section 2 of the service and maintenance manual for procedures relating to the transit of this machine to a new location The SpeedGlider Linear Leak Tester should be mounted on firm and level floor space This machine comes with various height settings Verify that contact is solid and the machine is level at all four corners Adjust all four feet as shown to lev...

Page 8: ...f the High Voltage Control enclosure Do not open to explore or attempt to affect repairs in this area In case of breakdown initiate Lock Out Tag Out procedures to secure the machine Notify authorized personnel WARNING LOW VOLTAGE CONTROL ENCLOSURE This label is displayed on the outside of the Low Voltage Control enclosure This area controls power to all electronic modules on the machine A potentia...

Page 9: ...trol cabinet at the rear of the machine Lock out and tag out procedures are covered in the service and maintenance manual WARNING WATCH YOUR HANDS AND FINGERS This warning is seen on the front of the discharge chute Do not thrust your hand up this chute while the machine is operating Contact with moving container material poses a slight to moderate threat of injury ...

Page 10: ...o attempt to operate this machine without a plexiglass guard panel in place The potential for severe injury exists while the machine is operating Please keep hands long hair low hanging jewelry and loose clothing away from the moving parts DANGER STARTS AUTOMATICALLY This warning is displayed on all plexiglass doors as a warning that the machine starts and stops automatically as a function of its ...

Page 11: ...EFEAT THE SAFETY FEATURES OF THIS EQUIPMENT TO GAIN ACCESS TO INTERNAL VOLTAGES VOLTAGE HAZARD WARNING WARNING DO NOT WEAR LOOSE CLOTHING LOW HANGNING JEWELRY OR ANYTHING THAT CAN BECOME ENTANGLED IN THE MOVING CONVEYOR WOMEN ARE CAUTIONED TO PIN UP LONG HAIR THE POTENTIAL FOR SLIGHT TO MODERATE PERSONAL INJURY EXISTS DANGER NEVER ATTEMPT TO SERVICE THIS MACHINE WITHOUT FIRST DISCONNECTING ELECTRI...

Page 12: ...stop on HMI touch screen panel 2 Guard Assembly Protects personnel during operation from moving components that are located inside the enclosure Plexiglass doors and panels are designed to limit access to the machine during operation The doors have safety interlocks which will stop the machine if a door is opened while the machine is running Both doors must be closed before the machine can be rest...

Page 13: ...the machine TABLE 2 HMI Status LED Color Code Indicates Running Status COLOR STATUS CONDITION Green Normal operating status Yellow Machine in bypass Mode or in Pause Condition Red Machine stopped door ajar or waiting for operator to press START The circuit is open interrupted e stop has been pressed or a fault has occurred ...

Page 14: ...Mode where the SpeedGlider runs at a pre set speed regardless of the backlog or the presence of containers PE Acronym for Photo eye An electronic sensor for container status communication to the PLC PLC An acronym for Programmable Logic Controller Recipe A set of test setting values that can be saved and used for a particular container T1 Maximum An acronym for Test 1 which refers to the maximum a...

Page 15: ...chscreen HMI The HMI touchscreen includes controls for starting and stopping the machine guided or manual setup and displays machine status counter alarms and fault conditions Contains the ON OFF and e stop palm buttons 2 Reject Chute Area where discarded containers are channeled 3 Emergency Stop E Stop palm button 4 ON OFF Switches Controls ON OFF operation of the machine 5 LED Pictorial Display ...

Page 16: ...nt where testing takes place 2 Sense Line Outgoing air line for pressure results 3 Fill Line Incoming air line for pressurized inflation 4 Timing Screw Advances synchronizes and spaces the containers for test sequence 5 Electrical Enclosure Contains essential electronics to run the machine 6 Airflow Shut Off and Filter System Airflow pressure control and filtration 7 Main Power Switch Controls inc...

Page 17: ... Select an option from the HOME SCREEN 2 A password prompt screen appears Touch the white area 3 Enter your PASSWORD and touch ENTER ENT on the keypad screen at right 4 Press OK Creating and changing On Screen Variables Values and Settings There are screen values and settings that can be changed from time to time Changing settings and values using the TENKEY screen Steps 1 Press on any grayed out ...

Page 18: ...is Advanced Operator Manual Overview 1 Theory of Operations 2 In depth coverage on all the possible SpeedGlider Menu Sections procedures navigation and definition a Settings Menu b Test Results Menu c Maintenance Menu d Supervisor Menu 3 Change Over and Setup 1 16 inch gap Horizontal Adjustment Vertical Adjustment ...

Page 19: ... flatten out See the graph below Test 1 will reject the container if Maximum percent value for is exceeded If Maximum value is not exceeded test 2 is performed Test 2 T2 Leak Test Unlike test 1 test 2 is normally performed over a longer period time 1 to 2 second range This is done so that smaller leaks can be detected The graph below shows how time is relative to pressure loss in both good and bad...

Page 20: ...peed when the volume of containers has thinned out or cleared the sensor field 4 Fast Speed Photo Eye Accelerates the machine into fast speed when the sensor field is obstructed or broken 5 Downstream Jam Photo Eye Temporarily pauses the machine when the sensor field is broken It automatically restarts the machine when the sensor field is clear 6 Reject Verification Chute Monitor Photo Eye Verifie...

Page 21: ...ner will be rejected for a Max Fill Failure if the pressure does not reach the required amount in the time given The normal setting is approximately 150 seconds Test 1 Time Range 005 to 10 seconds Time allowed for test 1 container stabilization time The normal setting for test 1 is around 1 seconds for smaller container and 2 for larger more flexible containers The test 1 time works in conjunction...

Page 22: ...ainer will be rejected The normal setting for minimum percentage is 0 The normal setting maximum percentage is 10 15 above a good bottle result Minimum test 2 percent Maximum test 2 percent Range 75 to 75 Test percent values create an acceptable pressure loss range for the container being leak tested The Minimum and Maximum percentage entries for test 2 create an acceptable pass fail window If the...

Page 23: ...ect One of Three Navigation between all screens is accomplished by pressing the arrow button To enter values in a setting select the appropriate box The TENKEY box will appear Enter a value by typing it in on number pad The new value will show up on the input pane Select to enter the new value or the key to cancel the entry Select the Information button to Access helpful information on the current...

Page 24: ...g the test probes on the container This process is used to fine tune the test probes or for a container change over where the timing screw is changed out to accommodate a different size container Notice The adjustment displays and procedure for aligning the test probes for a 3 or 4 heads SpeedGlider will be different than a 2 head SpeedGlider 3 and 4 head Adjustment Display 2 head Adjustment Displ...

Page 25: ...ainer at test is in the proper position Container at test Photo Eye Alignment When the Current Encoder Position and the Probe Take Off encoder values are equal the container must be aligned with the Container at Test Photo Eye To check 1 Place a container in the timing screw slot near the Container at Test Photo Eye 2 Rotate the timing screw until the Probe Take Off value and the Current Encoder P...

Page 26: ...0 The window should turn ON GREEN 4 Place a container in the timing screw pocket near the Container At Test photo eye 5 By hand advance the timing screw to 1600 The Container At Test indication should start to come ON GREEN as you advance the timing screw 6 If the Container at Test does not turn ON GREEN adjust the photo eye towards the leading edge of the container until the indicator turns ON 7 ...

Page 27: ...n ON GREEN adjust the photo eye towards the leading edge of the container until the indicator comes 13 Tighten the photo eye into place 8 Adjust timing screw using a 4 mm Allen wrench a Loosen both set screws b Using one hand hold on to the shaft S c With the other hand rotate the timing screw T i For situation A rotate backwards opposite the flow direction ii For situation B rotate forward with f...

Page 28: ...Deleting Existing Recipes This button will open a password screen Recipe settings are password protected After selecting and entering password reselect and the DELETE CURRENT RECIPES SCREEN appears Steps 1 Press the SAVE icon to save your changes This permanently sets the changes made to the recipe 2 Select the number of the recipe in the left hand column only Press the DELETE icon This permanentl...

Page 29: ...only display your name in addition to the text already in place 3 Enter recipe name 24 oz STOCK and touch the ENTER key New name will appear on the NAME RECIPE SCREEN below left the SAVE RECIPE SCREEN appears Select the number corresponding to the new recipe left column and progress through steps 1 2 3 as they are shown Note select a recipe number only do not select in the text field at right Othe...

Page 30: ...Note select a recipe number only do not select in the text field at right 3 Click on the bar LOAD RECIPE to MEMORY CARD The Load Recipe to Memory Card screen appears From the left hand column ONLY select a recipe among the recipes shown Note select a recipe number only do not select in the text field at right 4 Click on the download icon below 5 All selected recipe s will be downloaded automatical...

Page 31: ...the box temporarily 2 From the left hand column ONLY select a recipe to upload among the recipes shown Note select a recipe number only do not select in the text field at right 3 Inserting the memory card into the HMI memory card can be corrupted 4 Select LOAD from Memory Card DO NOT SELECT IN THE TEXT AREA AT RIGHT RECIPES IN THIS FIELD CAN BE MISTAKENLY CORRUPTED IF CARE IS NOT EXERCISED HERE 3 ...

Page 32: ...1 You will be prompted to select a source or cancel 6 After the selection is made press Step 2 save options to HMI and complete the transfer right 7 Re open the control enclosure and remove the memory card Secure the enclosure Step One Step Two Note It is vitally important that both steps be followed in order 2 Do NOT select from the recipe name area at right Select Recipe number in left column on...

Page 33: ...ctive container When making changes to these setting it is very important to test and verify that the failed leak test container is being rejected and not good containers Follow the on screen instructions for setting the reject timing Reject Timing Navigation From the Home Screen select the Setting Menu then select Reject Timing Select Reject Start to enter the current encoder value Reject end is ...

Page 34: ... single container has passed the PE Primed Back LOG The Primed Backlog Mode PBL requires the use of one Speed PE input and if setup properly will run base on a backlog of containers For proper operation of the PBL the PE must be setup for proper delays The PE on delay must be set long enough to where at least a back log of container can occur before the SpeedGlider begins to run In other words one...

Page 35: ...AIR LOGIC POWER SYSTEMS ALPS THE SETTINGS MENU SPEEDGLIDER ADVANCED OPERATOR MANUAL 34 TM 2012 005 REV00 10 25 2012 Machine Speed Navigation and Information help Screens Next Page ...

Page 36: ...AIR LOGIC POWER SYSTEMS ALPS THE SETTINGS MENU SPEEDGLIDER ADVANCED OPERATOR MANUAL 35 TM 2012 005 REV00 10 25 2012 Machine Speed Navigation and Information help Screens continued ...

Page 37: ...he delays are set on the photo eyes themselves not HMI and usually accomplished by an ALPS Technician at installation However on occasion there may be need for adjustments When the status indicator is Green that Photo Eye is sending the signal to the SpeedGlider PLC Remember because of the delays the ON or OFF signal may not occur when initially blocking the Photo Eye Refer to the Photo Eye D seri...

Page 38: ...s the key is to have Spare Time at Start and End to avoid Servo timing Alarms See information help screens on SpeedGlider HMI on how to use spare time Test Times The Cycle Extend Fill Time Test 1 Test 2 and Cycle Retract Time shows the current time settings for easy comparison to the cycle time These times combined should not exceed the cycle time however in using all available test time it should...

Page 39: ...AIR LOGIC POWER SYSTEMS ALPS THE RESULTS MENU SPEEDGLIDER ADVANCED OPERATOR MANUAL 38 TM 2012 005 REV00 10 25 2012 Available Help Screens for TEST RESULTS Test Result Display Help Screens ...

Page 40: ...ails to navigate to the Last Test Details screen Selecting any station will navigate to that station number Last Detail Timers Navigation Select Test Result Menu then Detail Timers to navigate to the Detail Timers screen Counters Navigation Select Test Result Menu then or or Then the Arrow buttons will naviagte between all three displays Select Reset Counters to zero out all counters ...

Page 41: ... Test Result Menu then Counters Alarm to navigate to the Counters Alarm up down arrows moves to display to view other alarms on the list Vertical Arrows moves display for more information about the alarms not visble on the current display There are four options icons across the bottom of this screen 1 To select individually listed values touch the SELECT icon and select the value above Selected va...

Page 42: ...r which has not run on the SpeedGlider See the new container setup guide in this manual for leak testing a new container A manual test menu has two basic functions the Manual Test and the Manual Self test The Manual Test functions just as a normal leak test does except it cannot be used during production To use this function place a container under the proper test probe and push the manual test bu...

Page 43: ...ill pressure and larger containers more fill pressure For more on this see new container setup procedures Notice that the PART PRESSURE gauge values do not have gray entry boxes associated with them This is because the values are hard coded at 0 5 and 25 percent and cannot be changed by the operator The current analog to digital value for PART PRESSURE gauge is shown in the black This digital read...

Page 44: ...iated gray box Part 5 and 6 Test 1 and 2 Result The TEST 1 and 2 RESULT gauge shows the values entered in test settings for test 1 and 2 minimum and maximum percentage loss allowed The values can be changed or updated by selecting one of the gray boxes These values may also be changed in the test setting display The analog to digital read out is a reflection of the last manual test performed and w...

Page 45: ...10 25 2012 Manual Test Navigation From the Home screen select the maintenance button Then select the manual test button From the manual test index select the station number to test Stop production and place a container underneath proper test probe Select Manual Test or Manual Self Test to leak test container ...

Page 46: ...ify inputs are on off or present For example if it is suspected that a test probe transducer has failed the analog input can be monitored in the analog input diagnostics display Input Diagnostics Navigation From the home screen select maintenance and then desired diagnostics display Use the to navigate between screen 1 and 2 About For information on the ALPS software versions and the machine seria...

Page 47: ... Manual Mode ON will bypass the container present photo eye and will make the test probes come down on every stroke Turns Siren on off 2 System Bypass Turns System Bypass function on off In system bypass containers will pass through the SpeedGlider untested 3 Aux Test settings These functions turn on various auxiliary outputs based on certain functions 4 Enable Auto Self Test Not shown above This ...

Page 48: ...012 005 REV00 10 25 2012 Supervisor Screen Flow and Navigation The following supervisor menus flow in the order shown Selecting the navigation arrow will prompt the next supervisor option display Supervisor Information Help Screens Reject Verification Manual Mode Secondary Reject System Bypass ...

Page 49: ...iage can be raised or lowered to accommodate most container heights by using the worm gear crank that can only be accessed from the front Turn clockwise to raise counter clockwise to lower C Place the container that will run on the SpeedGlider underneath a test probe Raise or lower the probe carriage to a level just inch above the top of the container opening Fine tuning can be controlled by viewi...

Page 50: ...lace the container on the conveyor belt and loosen the cross clamps and corresponding thumb screws With the container up against the timing screw pocket surface move the railing to create a 1 16 inch gap between rail and container surface 3 Replace Timing Screw Note Timing screws are made for specific size containers Depending upon the size variances in containers timing screw replacement may not ...

Page 51: ...vement Forward and backward adjustment is achieved by turning the knurled adjustment screw Distance is scaled in millimeters mm After adjustments are complete twist the locking lever clockwise to close to secure the pedestal F Vertical height settings are graduated in millimeters mm as shown by the scale at each end Vertical Adjustment Left and Right Ends The timing screw is raised and lowered usi...

Page 52: ...otor and or drive Potentiometer Adjustments Speed Is not used no adjustment is necessary S R Acceleration Set this so bottles accelerate smoothly Do not set excessively long If the SpeedGlider is not controlling conveyor speed it very important to reduce this timer to a minimum S S Deceleration Set this so bottles stop smoothly Do not set excessively long If the SpeedGlider is not controlling conv...

Page 53: ...nal peak pressure obtained during the leak test The goal for an accurate leak test is to fill the container in a very short amount of time as well as the same amount of time regardless of the container size To accomplish this the pressure flow rate Fill PSI must be set according to the container size Typically the larger the container the higher the higher the fill pressure will need to be The sma...

Page 54: ... allowed pressure value but below the minimum peak value Notice that the gauge is in the red zone Increase the Fill Regulator until the Minimum Peak Failure is no longer present after performing a manual test There is also the option of changing the minimum value by selecting the box and changing the value 8 Max Peak Failure Maximum peak failure occurs when the pressure in the container exceeds th...

Page 55: ...e a longer test time will more likely detect a smaller hole B For now the test time entered do not matter The machine speed along with the use of the Detail Timers menu will help determined to the appropriate test times 11 Enter the CPM Enter the appropriate CPM The CPM range for the SpeedGlider is 50 to 275 12 Run a few containers Watch the Spare Time At End field This will be the time we can use...

Page 56: ...eak pressure How long it takes to reach peak pressure also depends on the container size A good practice is to start from 02 and work up until there is no alarm 5 Enter Probe Retract Time This value is the time allowed for the probes to retract Start low 1 if a probe retract failure alarm condition occurs add more time Note about Test 2 Depending upon the container there may not be enough time in ...

Page 57: ...gauges Set the Max percentage approximately 10 percentage points above the maximum values reported on the gauges for both Test 1 and if Test 2 If Test 2 is being used C Check for consistency by performing several Manual Tests to ensure the percentage readings fall within the ranges entered 17 Perfom a Manual Self Test Performing a Manual Self Test on the same known good container This will open a ...

Page 58: ...AIR LOGIC POWER SYSTEMS ALPS CONTAINER CHANGE OVER SPEEDGLIDER ADVANCED OPERATOR MANUAL 57 TM 2012 005 REV00 10 25 2012 This concludes the Advanced Operator Manual ...

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