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VeriFast

TM

LVDT – User Manual – FDP-VFA-LVD-UM-EL-1.15-0918

41

Troubleshooting Quick Guide

Important Safety Information

Please review the

Safety Information

section starting on page 9 and

Personal Protective

section starting on page 10.

Follow all plant safety procedures and guidelines, as well as all
safety instructions given in this manual before performing any
troubleshooting procedures. Only certified personnel should perform
any troubleshooting tasks on the machinery.

Troubleshooting Instructions

Lockout Equipment

•

Before starting to troubleshoot the VeriFast LVDT, ensure that the

equipment is disconnected from all sources of power and is in the
lockout state.

•

Before turning ON the equipment, make sure all components are

assembled properly.

To troubleshoot the VeriFast LVDT unit, please refer to Table 4 that follows.

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Содержание VeriFast LVDT

Страница 1: ...connecting needs with capabilities VeriFast TM LVDT User Manual Ver 1 15 September 2018 FDP VFA LVD UM EL 1 15 0918 ...

Страница 2: ...orton Drive Windsor ON N9J 3T9 Canada CAN 519 734 8464 CenterLine SE USA 3409 Lorna Lane Hoover AL 35216 USA U S 734 260 2845 CenterLine De Mexico S de R L de C V Av La Noria 110 Parque Industrial Querétaro Santiago de Querétaro Qro Mexico CP 76220 MX 52 442 240 9255 CenterLine Brazil Solda e Automação Ltda Rod BR 280 KM 43 n 501 Bairro Poço Grande Cidade de Guaramirim Santa Catarina Brazil P O Bo...

Страница 3: ...r special direct indirect incidental consequential or compensatory directly or indirectly resulting from the publication use of or reliance on this document and also from the use of the equipment described herein In issuing and making this document available CenterLine Windsor Limited is not undertaking to render professional or other services for or on behalf of any person or entity Nor is Center...

Страница 4: ...This page is left blank intentionally ...

Страница 5: ... 10 Equipment and Process Overview 11 Intended Use of Equipment 11 VeriFast LVDT Main Components 12 VeriFast LVDT Configurations 13 Base Mount Styles Except SXZR 13 SYVR Extended Base Mount Style 14 SXZR Base Mount Style 14 Tapered and Threaded Mount Styles 15 Clamp Mount Style 15 Part Ordering Information 16 Required Services 17 Control Requirements 17 Electrical Requirements 17 Pneumatic Supply ...

Страница 6: ...pplicable to Clamp Mount Assemblies 27 Pneumatic Connection Diagram for LVDT Weld Bodies with Non Retractable Pin Not applicable to Clamp Mount Assemblies 27 Pneumatic Connection Diagram for LVDT Clamp Mount Weld Bodies with Retractable Pin 28 Pneumatic Connection Diagram for LVDT Clamp Mount Weld Bodies with Non Retractable Pin 28 Maintenance 29 Important Safety Information 29 Special Caution 29 ...

Страница 7: ...d in its entirety prior to installation operation or maintenance of any VeriFast LVDT While every effort has been made to ensure that the product descriptions procedures and installation requirements included in this publication are accurate at the time of printing CenterLine reserves the right to make product changes that might not be reflected in this document Should you require additional infor...

Страница 8: ...ion and understanding of the product This symbol indicates that serious hazards can occur due to pinch points This symbol indicates that you should read and understand the User Manual and all other applicable instructions before operating the equipment This symbol indicates that the equipment must be disconnected from all sources of power and put in the lockout state This symbol indicates that eye...

Страница 9: ...ought to CenterLine s immediate attention for clarification Equipment is not to be modified adapted or changed without consulting the relevant sections of this manual or the manufacturer please refer to the inside front cover of this manual for CenterLine contact information Before any installation maintenance or repair work is started all sources of energy should be removed from the equipment usi...

Страница 10: ...n the welding equipment ensure that the equipment is disconnected from all sources of power and is in the lockout state Before turning ON the equipment make sure all components are assembled properly Before removing the VeriFast from the welding equipment make sure the equipment is turned OFF and is in the lockout state Personal Protective Equipment When handling installing and operating VeriFast ...

Страница 11: ... can trigger either an interruption in the cycle or a warning message indicating that the process has fallen outside the set value These occurrences can indicate a potential part quality issue The set point values may indicate Weld Pin Extended Position System ready to load part and fastener Weld Proceed Presence and Correct Fastener Orientation Weld Complete Nut Welded Nut is Upside Down No Faste...

Страница 12: ...e 1 Nut Detection and Orientation VeriFast LVDT Main Components The VeriFast LVDT has a robust construction that allows for fast and easy component changes A standard configuration of VeriFast LVDT is illustrated in Figure 2 below Figure 2 VeriFast LVDT Configuration ...

Страница 13: ...VeriFast TM LVDT User Manual FDP VFA LVD UM EL 1 15 0918 13 VeriFast LVDT Configurations Base Mount Styles Except SXZR ...

Страница 14: ...14 VeriFast TM LVDT User Manual FDP VFA LVD UM EL 1 15 0918 SYVR Extended Base Mount Style SXZR Base Mount Style ...

Страница 15: ...VeriFast TM LVDT User Manual FDP VFA LVD UM EL 1 15 0918 15 Tapered and Threaded Mount Styles Clamp Mount Style ...

Страница 16: ...bout your specific configuration When ordering a replacement component please check your own equipment and have that specific part number readily available If you need to order other components please refer to the detailed VeriFast LVDT Part Ordering Instructions brochure available from CenterLine For optimal equipment performance and full warranty support CenterLine consumables must be used ...

Страница 17: ...efer to Determining Effective Resolution on page 24 Electrical Requirements The VeriFast LVDT power supply requirements are as follows Volts 24 VDC Amps 90 mA For more electrical specifications please see the values listed in the Appendix A Signal Conditioner Specifications section starting on page 44 Pneumatic Supply Requirements The operating performance of the VeriFast LVDT is closely tied to t...

Страница 18: ... water are as follows Water Temperature Water temperatures between 24 C to 30 C 75 F to 85 F are recommended The water temperature should not exceed 30 C 85 F after the load since high water temperatures will prevent the equipment from being adequately cooled In the event that the water temperature exceeds 30 C 85 F the equipment should be operated at a reduced duty cycle to prevent damage to the ...

Страница 19: ...holes would be drilled too close to the existing ones Base Mount LVDT weld bodies are approximately 1 2 taller than legacy bodies Threaded and Tapered mounted LVDT bodies are approximately 1 3 4 taller than legacy bodies If replacing older legacy or Smart Electrode bodies ensure that the air water and electrical connections of the new LVDT weld bodies will work with the existing equipment Please c...

Страница 20: ...s are cleaned the copper components should be installed immediately to prevent surface oxidation which will cause a poor connection As long as the connection remains tight there should be no concern for heat buildup or loss of current at the connection If however during routine service it is discovered that the joint is loose then it should be completely disassembled cleaned and reassembled To mou...

Страница 21: ...ing the VeriFast LVDT and Signal Conditioner Use a 5 pin shielded cable to establish the connection between the VeriFast LVDT Electrode and Signal Conditioner see Figure 3 below Use separate wiring not shown to connect the Signal Conditioner to the PLC Figure 3 Wiring the VeriFast LVDT and Signal Conditioner VeriFast LVDT Electrode any configuration Signal Conditioner Micro 12 mm 5 pin shielded fe...

Страница 22: ...DT Signal Conditioners must be synchronized with each other Synchronization of VeriFast LVDT Signal Conditioners is accomplished by connecting the SYNC I O terminals of each unit into a daisy chain terminal 1 One unit will automatically assume Master Mode when connected properly with other units Once one unit becomes Master all other units enter Slave Mode If the current Master ceases to function ...

Страница 23: ... indicators LED Name Function LED Color During Operation Status Description OPER CAL Module Status Red Lit Normal operation Flashing Calibration mode Core Position LEDs Yellow Lit Indicates core is above null position during calibration Flashing Indicates open Primary circuit NULL Green NULL Lit Indicates core is at null position when in calibration mode Indicates that the calibration is complete ...

Страница 24: ... extended position and press the B button Wait for the Position LEDs to stop blinking 4 Move the Pin to its retracted position and press the A button The unit will exit Calibration Mode and operate with its new calibration The OPER LED will be steady ON Figure 5 LVDT Sensor Display and Operating Elements Calibration mode can be cancelled by pressing the two buttons simultaneously for 3 seconds Det...

Страница 25: ...information This is accomplished using an Analog to Digital Converter ADC An ADC accepts the analog signal and assigns a discrete digital value to a defined signal value For example a 15 bit ADC can represent a 0 10 V signal as any one of 32 768 numbers 215 32 768 Using the above example 22 mm 32 768 0 0006713 mm 0 866 32 768 0 0000264 Important Note that in the above example the limitation as a r...

Страница 26: ...e valve to ensure continuous air blow off in all pin positions While referring to the diagram in Figure 6 please consider the following In home load position the solenoid extending the pin should be energized to facilitate loading and locating the stamping and or location of fastener After a weld complete signal is received the solenoid extending the pin must be de energized and the solenoid to re...

Страница 27: ...ld Body Used in Welding Ring Projections or Clinching Applications Not applicable to Clamp Mount Assembly Pneumatic Connection Diagram for LVDT Weld Bodies with Non Retractable Pin Not applicable to Clamp Mount Assemblies For proper operation the AIR UP Regulator must be set at a higher pressure than the AIR DOWN Regulator Figure 8 Pneumatic Connection Diagram for LVDT Weld Body with Non Retractab...

Страница 28: ...eld Bodies with Retractable Pin Figure 9 Pneumatic Connection Diagram for LVDT Clamp Mount Weld Body Only with Retractable Pin Pneumatic Connection Diagram for LVDT Clamp Mount Weld Bodies with Non Retractable Pin Figure 10 Pneumatic Connection Diagram for LVDT Clamp Mount Weld Body Only with Non Retractable Pin ...

Страница 29: ...t LVDT Electrode Damage to the equipment will occur Servicing the LVDT Electrode Assembly for Base Except SXZR Extended Base Tapered and Threaded Mount Styles Important For SXZR and Clamp Mount styles please see the sections that follow Although the VeriFast LVDT unit is a sealed low maintenance device the Weld Pin and the Electrode Head need to be replaced at regular intervals In addition by foll...

Страница 30: ...upside down in a vise see picture on the right Continue with Step 4 below Otherwise If the Weld Pin and Connecting Rod Assembly are being replaced as a whole assembly skip directly to Step 10 on page 32 Step 4 Use the Spanner Tool provided with your equipment and a wrench to loosen the Pin Lock from the used Weld Pin Step 5 Remove the Connecting Rod Assembly and Pin Lock and set them aside for fut...

Страница 31: ...reads Step 8 Using the Spanner Tool thread the Connecting Rod Assembly and Pin Lock onto the new Weld Pin Step 9 Use a torque wrench and a 17 mm deep socket to tighten the Pin Lock and Connecting Rod Assembly Note Do not over tighten Maximum 30 in lbs 3 4 Nm Very Important After tightening ensure that the Connecting Rod Assembly is tight and cannot move or rotate relative to the Weld Pin New Weld ...

Страница 32: ... Pin Note Magnalube G grease is recommended Step 11 Remove the Weld Pin from the vise and discard the Protective Wrap Insert the new Pin Connecting Rod Assembly into the Electrode Body Carefully allow the Core and inner bore of the Electrode Body to guide the insertion Step 12 Thread on the Electrode Head and tighten O ring ...

Страница 33: ...nts can be inspected and or replaced as needed Step 1 Remove the air and water services from the system Step 2 Unthread and remove the Weld Head Step 3 Gently remove the used Weld Pin from the Weld Body altogether with the complete LVDT Cable Assembly that is attached at the bottom of the weld pin Slightly twisting the weld pin while pulling may help the cable find its way out Step 4 Inspect the C...

Страница 34: ...ing replaced as a whole assembly skip directly to Step 13 on page 36 Step 6 Position the Spanner Tool provided with your equipment on top of the Pin Lock and fit its pegs into the holes of the Pin Lock 1 Unthread the Pin Lock from the bottom of the old Weld Pin 2 Remove the LVDT Cable Assembly and Pin Lock and set them aside for future use Discard the used Weld Pin Step 7 Place the new Weld Pin up...

Страница 35: ... E Clip Disk stays seated into the sunken area of the Pin Lock Then apply Loctite 243 to the threads of the Pin Lock Step 11 Position the Spanner Tool on top of the Pin Lock so that the pegs of the Spanner Tool fit into the holes of the Pin Lock Note To keep all the components in place keep the cable under tension by gently pulling its other end with your other hand Pin Lock Sunken Area on Pin Loc...

Страница 36: ...move the Weld Pin from the vise Continue with the next step Step 13 Use Magnalube G grease to lubricate the O ring on the new Weld Pin Step 14 Gently insert and fully slide the LVDT Cable Assembly through the hole in the bottom center of the Weld Body until the Weld Pin will properly sit inside the Weld Body During this process slightly twisting the cable or using needle nose pliers may help to ge...

Страница 37: ...d at regular intervals In addition by following the procedure illustrated below other internal components can be inspected and or replaced as needed Step 1 Remove the water service from the system Retract the weld pin to remove force internally on the weld head Step 2 Remove the weld head Step 3 Extend the weld pin to service position exposing the flats of the piston rod above the weld body Then r...

Страница 38: ...l a new Pin and Head skip directly to Step 9 on page 39 then finish by reversing the steps performed to this point Step 4 to Step 1 If other internal components need to be inspected replaced continue with Step 5 below Step 5 Remove the LVDT insert from the base of the assembly Step 6 Manually push the piston rod from above and it will pass through the bottom of the adapter LVDT Insert ...

Страница 39: ...of O rings and piston rod shaft Step 9 Inspect all components for wear and replace as needed Assemble all components in reverse order manually lowering the pin to ensure that the connecting rod properly aligns inserts into the LVDT coil Note Loctite 243 Blue is recommended when re attaching the weld pin to the piston rod assembly Allow sufficient curing time for the Loctite before resuming product...

Страница 40: ...e VeriFast LVDT must be frequently inspected for contamination and buildup and should be kept as clean as possible The operating performance of the LVDT in the sensing process is highly dependent on the cleanliness and good maintenance of the equipment Excessive contamination and buildup reduce the performance accuracy and service life of the VeriFast A routine examination of the VeriFast LVDT sho...

Страница 41: ... instructions given in this manual before performing any troubleshooting procedures Only certified personnel should perform any troubleshooting tasks on the machinery Troubleshooting Instructions Lockout Equipment Before starting to troubleshoot the VeriFast LVDT ensure that the equipment is disconnected from all sources of power and is in the lockout state Before turning ON the equipment make sur...

Страница 42: ...ting cable is fastened completely and firmly Is the Weld Pin correct Verify that the LVDT connecting rod and core is present and firmly attached to the Weld Pin Measurement Value will not respond to Pin movement Is the VeriFast LVDT unit connected wired calibrated properly Confirm wiring of the field connector See Table 2 on page 22 Confirm proper wiring of the signal conditioner See Table 1 on pa...

Страница 43: ...t LVDT from service Disconnect the VeriFast LVDT system from the external supplies electrical air and identify the connections to facilitate a future installation The storage location must be clean dry and not expose the VeriFast LVDT system to mechanical or thermal damage If the VeriFast will be covered there should be some air circulation to prevent condensation ...

Страница 44: ... Used for remote calibration only Terminals 5 11 and 15 are internally connected Signal Conditioner Specifications Parameter Value Power Input Voltage Current 9 30 VDC 90 mA max 24 VDC Signal Output Voltage Output 0 10 VDC Frequency Response 100 Hz Max Output Voltage Ripple 1 mVRMS max Output Non Linearity 0 05 of FSO Digital I O Input Current Sink High True I 3 0 mA Max V 30 VDC Max Output Open C...

Страница 45: ...FA LVD UM EL 1 15 0918 45 Should you have any questions after reading this User s Manual please feel free to contact your CenterLine representative Please refer to the inside front cover of this manual for CenterLine contact information ...

Страница 46: ...46 VeriFast TM LVDT User Manual FDP VFA LVD UM EL 1 15 0918 This page is left blank intentionally ...

Страница 47: ...8 Pneumatic for LVDT Clamp Mount Weld Bodies with Retractable Pin 28 Pneumatic for LVDT Weld Bodies with Non Retractable Pin 27 Pneumatic for LVDT Weld Bodies with Retractable Pin 26 Pneumatic for Weld Ring Projections Applications 27 Control Requirements 17 D Decommissioning 43 E Effective Resolution Determining the 24 Factors Affecting Analog Resolution 24 Input Resolution 25 Noise 24 Electrical...

Страница 48: ...tion 19 Mounting the Base Mount Electrode 20 Mounting the Signal Conditioner 21 Pneumatic Service Connection 25 Pre Installation Requirements 19 Pre Installation Tips 19 Wiring the Signal Conditioner 21 Wiring the VeriFast LVDT 21 Instructions Safety 9 L LED Operation 23 LVDT Electrode See Electrode M Maintenance 29 Cleaning Equipment 40 Servicing the LVDT Electrode Assembly 29 33 37 Working Area ...

Страница 49: ...3 the Tapered Mount LVDT Electrode 29 the Threaded Mount LVDT Electrode 29 Set Point Values No Fastener Detected 11 No Part Detected 11 Nut is Upside Down 11 Weld Complete 11 Weld Pin Extended Position 11 Weld Pin Retracted Position 11 Weld Proceed 11 Signal Conditioner Complete Electrical Connections 44 Core Position LEDs 23 Learning About 23 Module Status 23 Mounting 21 Operation of LED Indicato...

Страница 50: ...R Extended Base Mount Style 14 Tapered Style 15 Threaded Style 15 Wiring 21 Wiring the Electrode to 5 pin Shielded Cable Connector 22 W Water Flow 18 Pressure 18 Supply Requirements 18 Temperature 18 Weld Body 12 Complete 11 Head 12 Pin 12 Pin Extended Position 11 Pin Retracted Position 11 Proceed 11 Wiring 5 pin Shielded Cable Connector to VeriFast LVDT Electrode 22 Signal Conditioner to 5 pin Sh...

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