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BI2000 Board Inverter

Owner’s Manual

Revision F

WHERE

PRECISION

DRIVES

PRODUCTION

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2
3
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Summary of Contents for BI2000

Page 1: ...BI2000 Board Inverter Owner s Manual Revision F WHERE PRECISION DRIVES PRODUCTION ...

Page 2: ...lders of this document with respect to changes subsequently made Precision Valve and Automation Inc makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply This document including the...

Page 3: ...se Levels 9 Materials Chemicals 9 Transportation Operation and Storage 9 Handling and Transportation 9 Storage 9 Temperature and Humidity 10 Description of Components 10 Hazards Due to Contact 10 Setup 11 Installation 11 Air Pressure Regulator 12 Safety Devices and Guarding 13 Safety Circuit 13 Work Area Access 13 Door 13 Light Tower Operation 13 Interface Overview 14 Operation 15 Startup Procedur...

Page 4: ...cess 21 Board Flip 21 Board Second Flip 22 Conveyor Width 22 Profile Naming 23 Fault Recovery 24 Board Removal 24 Manual Board Removal 24 Conveyor Board Removal 24 Open Door or Emergency Stop Recovery Procedure 25 Recovery Procedure for Board Processing Failure 26 Recovery Procedure for a Rotation Error 26 Error Messages 27 Maintenance 28 Conveyor Belt Replacement 28 Board Sensor Adjustment 28 Boa...

Page 5: ...Revision F February 2020 Page 5 of 37 Rotary Adjustment 30 Rotation Angle 30 Soft Start Adjustment 31 Rotary Speed Adjustment 31 Width Adjustment 32 Main Air Regulator 33 Troubleshooting 34 Notes 35 Warranty 36 Table of Figures 37 ...

Page 6: ...net Email info pva net Technical Support Tel 1 844 734 0209 Email cs pva net Document History Revision Revision Date Reason for Changes REV F February 2020 SoftStart Initial Setup Updated REV E January 2020 Template updated REV D September 2017 Screens updated REV C July 2016 Maintenance updated REV B June 2016 Template update and chain conveyer added REV A January 2003 Initial release for Unitron...

Page 7: ...with the unit Never put hands or tools in areas with this symbol when the machine is in operation A dangerous condition may exist Read and understand the manuals provided with the unit before any repairs or maintenance is done Only a qualified individual should do service Use caution when there are pressurized vessels Find and repair any leaks immediately Always wear appropriate safety equipment w...

Page 8: ...to emphasize that hazardous voltages current temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with its use Only qualified personnel should enter areas designated with this symbol Laser light source present Do not stare directly into the beam Do not use in the presence of highly reflective surfaces Pinch hazard from moving parts Avoid co...

Page 9: ...otective Equipment Operators must use eye protection because material contents are under pressure Always wear gloves when handling materials and solvents Refer to MSDS sheets on the material being dispensed for other precautions Environmental Noise Levels The audible noise level of the board invertor is below 65 dBA Materials Chemicals There are no dangerous materials or chemicals used in the oper...

Page 10: ...designed to operate with PVA workcells The operator can control the system with the user interface The machine status and error messages are displayed on the LCD screen and the light tower optional Operators must be trained or have read the manual Any uses other than listed above could result in a dangerous condition and cannot be protected against by the safety features installed on the system Fi...

Page 11: ...n of the Operating Guide or the legend plate on the machine The electrical service should be correctly grounded and the power source clean If there is high power equipment operating off the same source a line conditioner may be necessary Machine errors can be caused by poor quality power WARNING Failure to comply with electrical specifications can damage the machine and injure personnel Electrical...

Page 12: ...e regulator knob so the orange ring can be seen Figure 4 Pull Up on the Regulator to Adjust 2 Turn the knob clockwise to increase the pressure or counterclockwise to decrease the pressure 3 Wait for the pressure to adjust as shown on the dial 4 Push the regulator knob down to lock the pressure at the current value Figure 5 Push Down to Lock ...

Page 13: ...e state of the Emergency Stop button and other safety mechanisms When one or more of the safety devices have opened the power is stopped Work Area Access The work area is enclosed with Lexan guarding or safety glass Door The top of the machine is protected by a door The door is monitored by a non defeatable limit switch The Door Bypass key is for maintenance access only Light Tower Operation Three...

Page 14: ... OFF In Cycle OFF OFF ON OFF Machine Error FLASH OFF OFF FLASH Figure 6 Light Tower Buzzer Status Interface Overview The operator interface terminal OIT has touch screen icons and buttons on the display that are related to the shown icons A keyboard or keypad will be shown when a related value or text field is selected Figure 7 Pump Components ...

Page 15: ... Shutdown Do not shut down the machine down with parts in it 1 Wait for all boards to clear the module 2 Press ESC on the OIT Wait for the Cycle Stop screen to appear 3 Engage the Emergency Stop button CAUTION If maintenance will be done lockout and tagout the machine Cycle Stop This is the default machine state All other modes are accessed from this screen To shut down the machine or select a dif...

Page 16: ...oards in the inverter when the ESC button is pushed 3 To change the settings shown in Auto Cycle go to Setup Mode 4 The Profile is shown above the screen name Go to Setup mode to change the profile 5 The current conveyor speed is shown 6 The text field shows information about board handling and processing 7 The SMEMA indicators show the signals being sent and received Output from the system are in...

Page 17: ...Red X or the Green Checkmark button to toggle the conveyor On or Off 2 Select the Direction button to toggle between L to R left to right or R to L Right to Left The default direction is downstream Board Stops To manually extend or retract the board stops select the Red X or the Green Checkmark button Figure 11 Manual Mode Board Stop ...

Page 18: ...creen The arrow direction shows the current position o When the arrow is Up the cage is in the home position 0 degrees o When the arrow is Down the cage is in the flip position 180 degrees SMEMA You can view the status of the SMEMA input from the machine selected To toggle the SMEMA output on and off push the related light on the screen Figure 13 Manual Mode SMEMA ...

Page 19: ...s View the status of the part in place PIP input from the machine Figure 14 Manual Mode PIP Status Shutters This screen only applies to systems with shutters To manually open or close the shutters select the Green Checkmark or Red X Closed shutter Open shutter Figure 15 Shutters ...

Page 20: ...tor can set the options for the PVA board inverter The profile name is shown at the top of the screen You will make changes to the profile shown 1 Select the Setup icon or the ESC button from Cycle Stop 2 Use the Use the Page icons or the F2 and F4 keys to scroll through the profiles The profile name is shown at the top of the screen You can have a maximum of 30 profiles 3 Use the Left and Right a...

Page 21: ...oard In arrow will be shown so when the Board In Left arrow is shown the Board In Right arrow will be hidden 2 Select the Board Out arrow bottom to switch between Board Out Left and Board Out Right Only the selected Board Out arrow will be shown so when the Board Out Left arrow is shown the Board Out Right arrow will be hidden Board Flip Select the square flip icon in the center of the screen to s...

Page 22: ...or the F1 and ESC button to scroll to the Setup Conveyor Width screen 2 Select the indicator to toggle this feature on and off Figure 19 Conveyor Width 3 Put the board on the conveyor 4 Select Auto Width Adjust icon to auto adjust the conveyor 5 Use the Manual Width Adjust handle to make any necessary changes 6 Select Save to keep and use the new value 7 Use the Use the Page icons or the F2 and F4...

Page 23: ...l to the Setup Rename Profile screen 2 Use the Page icons or the F2 and F4 keys to scroll through the profile names You can have a maximum of 30 profiles Figure 20 Rename Profile 3 Select the name you want to change 4 The keyboard will be shown type the new name and select enter The new name will be saved Profile names are limited to 15 characters ...

Page 24: ... disengage the Emergency Stop button Shutdown the system and have qualified personnel repair the machine Board Removal After a fault if there is a board in the inverter it must be removed There are two ways to remove a board Manual Board Removal 1 Engage the Emergency Stop Button 2 Open the Door 3 Use your hand to rotate the roll cage if necessary 4 Slide the board out of the conveyer Conveyor Boa...

Page 25: ...rror do this procedure Do not continue if the Emergency Stop was engaged because of a system failure instead shutdown the system and have it repaired by qualified personnel 1 Disengage the Emergency Stop button or close the doors as necessary Figure 21 Emergency Stop 2 Follow the on screen display push the POWER ON button to restore control power 3 Operate the system as normal ...

Page 26: ...lear the fault 2 Remove the board Figure 22 Board Processing Failure 3 When the Cycle Stop screen is shown operate normally Recovery Procedure for a Rotation Error When the roll cage cannot do a complete rotation 180 there is a Rotation Error This can be caused by low air pressure 1 Push the circular arrow to clear the fault 2 Remove the board 3 When the Cycle Stop screen is shown operate normally...

Page 27: ...age Emergency Stop 0a Close Door If Door Bypass Off 1 Rotate 0 Failure Remove Board 2 Rotate 180 Failure Remove Board 3 Board Stop Did Not Extend 4 Board Stop Did Not Retract 5 Board Failed to Reach Stops 6 Inlet Shutter Failed to Open 7 Inlet Shutter Failed to Close 8 Outlet Shutter Failed to Open 9 Outlet Shutter Failed to Close 10 Conveyor Adjust Drive Fault Figure 24 Error Messages ...

Page 28: ...Replacement Note Not all systems have conveyor belts some have chains 1 Lockout the power supply 2 Remove the old conveyor belt from the pulley wheels 3 Install the belt on the pulley wheels farthest from the motor Note Make sure there are no twists in the belt 4 Install the belt around the large pulley wheel then around the other wheels 5 Rotate the pulley wheels several turns by hand to make sur...

Page 29: ...te Make sure you know the current orientation of the roll cage so that you can adjust the chain correctly Note Adjust both sides of the conveyer evenly 1 Engage the Emergency Stop button 2 Turn the main air pressure to Off 3 Loosen the four shoulder bolts at the end of the turnbuckle There are four bolts at each end of the conveyor and each end is adjusted independently Figure 26 Loosen the Bolts ...

Page 30: ...that locate the roll cage One shock is used at each position 0 degrees and 180 degree both shock absorbers are at the back of the machine 1 Engage the Emergency Stop button 2 Turn the main air pressure to Off 3 To decrease the angle of rotation turn shock absorbers clockwise To increase the angle of rotation turn the shock absorbers counterclockwise 4 Lock the shock absorbers with the hex locking ...

Page 31: ...ew clockwise until it is completely closed 4 Turn the set screw counterclockwise no more than 1 16th of a turn from the closed position Figure 30 Soft Start Adjustment Note The soft start should always be adjusted before the rotary speed is set Rotary Speed Adjustment Both ports on the rotary actuator have a quick exhaust flow control to adjust the rotary speed 1 To adjust the speed of the rotary ...

Page 32: ... do not have automatic width adjust 1 Engage the Emergency Stop button 2 Turn the main air pressure to Off 3 Turn the adjustment lock counterclockwise to loosen it Figure 31 Adjustment Lock 4 Turn the adjustment handle counterclockwise to increase the width or clockwise to decrease the width of the of the conveyor Figure 32 Width Adjustment Handle 5 When the necessary width is achieved turn the ad...

Page 33: ...BI2000 Board Inverter Manual Revision F February 2020 Page 33 of 37 Main Air Regulator Make sure there is no water in the bottom drain as necessary Figure 33 Main Air Regulator ...

Page 34: ...itioned incorrectly The sensor is out of adjustment Examine the cable connections and tighten loose connections Move the sensor Adjust the sensor Conveyor does not operate or communication error Conveyor belt stuck to rails Chain does not operate smoothly Cable is loose or not connected Control relay not on or Power On light not on A fuse is blown Clean or replace belt Apply lubricant to the chain...

Page 35: ...BI2000 Board Inverter Manual Revision F February 2020 Page 35 of 37 Notes ...

Page 36: ...from PVA or from factory authorized dealers will void all warranties All PVA warranties extend only to the original purchaser Third party warranty claims will not be honored at any time Prior to returning a product for a warranty claim a return authorization must be obtained from PVA s Technical Support department Authorization will be issued either via the telephone facsimile or in writing upon y...

Page 37: ... Mode Rotate 18 Figure 13 Manual Mode SMEMA 18 Figure 14 Manual Mode PIP Status 19 Figure 15 Shutters 19 Figure 16 Conveyor Width 20 Figure 17 Flip Roll Cage 21 Figure 18 Board Flip Icons 21 Figure 19 Conveyor Width 22 Figure 20 Rename Profile 23 Figure 21 Emergency Stop 25 Figure 22 Board Processing Failure 26 Figure 23 Rotation Errors 26 Figure 24 Error Messages 27 Figure 25 Board Sensor Adjustm...

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