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User Manual 

Table of Contents 

QCL-MAN- CT2211-Aerosol-Leak-Detection-System-Rev F 

October 2015 

 

Table of Contents 

 

i 

Table of Contents 

Section 1:

 

Introduction ................................................................................................ 1

 

1.1

 

Qualified personnel ........................................................................................ 1

 

1.2

 

Safety  

......................................................................................................... 

1

 

1.3

 

Certifications and approvals ........................................................................... 2

 

1.4

 

System overview ............................................................................................ 2

 

1.5

 

Leak detector overview .................................................................................. 5

 

1.6

 

Detailed system specification ......................................................................... 6

 

1.7

 

Operators’ system pre startup checklist ......................................................... 7

 

Section 2:

 

System Connection ...................................................................................... 8

 

Section 3

:

 

System Startup .......................................................................................... 12

 

Section 4:

 

Shutdown .................................................................................................. 14

 

Section 5: Operation .................................................................................................. 15

 

5.1

 

Software screens .......................................................................................... 15

 

5.1.1

 

Home screen — aerosol leak detection system .............................. 15

 

5.1.2

 

User Login screen ........................................................................ 16

 

5.1.3

 

Program Page .............................................................................. 17

 

5.1.4

 

Error Status page ......................................................................... 18

 

5.1.5

 

CT2211 Main Screen .................................................................... 19

 

5.1.6

 

CT2211 Graphs Screen ................................................................ 20

 

5.1.7

 

Digital IO Status page .................................................................. 21

 

5.1.8

 

Optical Gates page ...................................................................... 22

 

5.1.9

 

Rejector page .............................................................................. 23

 

5.1.10

 

Line Speed page .......................................................................... 24

 

5.2

 

Errors  

....................................................................................................... 

24

 

5.2.1

 

Overall system healthy ................................................................. 24

 

5.2.2

 

Leak detector (CT2211) system healthy ....................................... 25

 

5.2.3

 

Leak detector (CT2211) laser healthy ........................................... 25

 

5.2.4

 

Can lost  ....................................................................................... 25

 

5.2.5

 

Can found .................................................................................... 25

 

5.2.6

 

Too many consecutive rejects ...................................................... 25

 

5.2.7

 

Reject verification ........................................................................ 26

 

5.2.8

 

Encoder  error ............................................................................... 26

 

5.2.9

 

Air sampling healthy .................................................................... 26

 

5.2.10

 

Bin full   ...................................................................................... 26

 

5.2.11

 

Mirror purge warning ................................................................... 26

 

5.2.12

 

Mirror purge error ........................................................................ 26

 

5.2.13

 

Repeatable reject error ................................................................ 27

 

5.2.14

 

Compressed air error ................................................................... 27

 

5.2.15

 

Error Flags 14/15 ......................................................................... 27

 

5.3

 

Line PLC communication .............................................................................. 27

 

5.3.1

 

Linestop (in) ................................................................... 28

 

5.3.2

 

System shutdown signal (in) ........................................... 28

 

5.3.3

 

Linestop 1 and linestop 2 (out) ........................................ 28

 

5.3.4

 

Heartbeat  signal  (out) ..................................................... 28

 

5.3.5

 

Reject counter pulse (out) .............................................. 28

 

5.4

 

Control system programs ............................................................................. 29

 

5.4.1

 

Add Programs ................................................................. 30

 

Section 6:

 

Maintenance .............................................................................................. 31

 

6.1

 

Schedule ...................................................................................................... 31

 

6.1.1

 

Daily ............................................................................... 31

 

6.1.2

 

Weekly ........................................................................... 31

 

Содержание CT2211

Страница 1: ...User Manual QCL MAN CT2211 Aerosol Leak Detection System Rev F October 2015 CT2211 Aerosol Leak Detection System ...

Страница 2: ...s prior written permission of the copyright holder Contact Details Cascade Technologies Limited Glendevon House Castle Business Park Stirling FK9 4TZ United Kingdom General inquiries about this or other Cascade Technologies products should be sent to qcl csc emerson com If you require technical assistance with this product that is not covered within this user manual then help can be requested from...

Страница 3: ... Digital IO Status page 21 5 1 8 Optical Gates page 22 5 1 9 Rejector page 23 5 1 10 Line Speed page 24 5 2 Errors 24 5 2 1 Overall system healthy 24 5 2 2 Leak detector CT2211 system healthy 25 5 2 3 Leak detector CT2211 laser healthy 25 5 2 4 Can lost 25 5 2 5 Can found 25 5 2 6 Too many consecutive rejects 25 5 2 7 Reject verification 26 5 2 8 Encoder error 26 5 2 9 Air sampling healthy 26 5 2 ...

Страница 4: ...r 2015 QCL MAN CT2211 Aerosol Leak Detection System Rev F Table of Contents ii 6 1 3 Monthly 31 6 2 Analysis system 31 6 3 Venturi 32 6 4 Replacement parts 32 Section 7 Troubleshooting and Diagnostics 33 7 1 Warning and error messages 33 ...

Страница 5: ...ak Detection System Rev F October 2015 List of Tables iii List of Tables Table 1 1 Leak detection system specifications 7 Table 5 1 IO lines 28 Table 6 1 Aerosol leak detection system replacement parts list 32 Table 7 1 Possible problems and solutions 33 ...

Страница 6: ...te 10 Figure 2 4 Left Sensor head Right Air extraction arch assembly 11 Figure 3 1 Isolation switch 12 Figure 3 2 Control system display 13 Figure 5 1 Control system Home screen 15 Figure 5 2 User login screen 16 Figure 5 3 Program Page screen 17 Figure 5 4 Error Status screen 18 Figure 5 5 CT2211 Main Screen 19 Figure 5 6 CT2211 Graphs Screen 20 Figure 5 7 Digital IO Status screen 21 Figure 5 8 O...

Страница 7: ...tallation and Service Manual Additional help can also be requested from Cascade Technical Support qcl csc emerson com or Cascade Technologies distribution partners 1 1 Qualified personnel These operating instructions have been prepared for technically qualified personnel who have been specially trained or who possess appropriate knowledge in the field of instrumentation and control Knowledge of th...

Страница 8: ...tions according to USA 21 CFR 1040 10 1 3 Certifications and approvals All in zone parts comply with the ATEX directive 94 9 EC This leak detector complies with USA 21 CFR 1040 10 It is also designed and manufactured under an approved quality management system to ISO 9001 2008 1 4 System overview The aerosol leak detector is used on aerosol production lines in conjunction with a control and reject...

Страница 9: ... A HMI M Input gate signal B Leak Detection System1 N Compressed air supply min 5 BAR max 10 BAR customer supplied C AC supply voltage 110V 220V AC 50 60 Hz 13A customer supplied O Encoder D Line status signals to customer communications running waiting error P Output gate E Encoder signal Q Reject F Rejected can signal R Micro leak detector G Output gate signal S Air status air control H Reject s...

Страница 10: ... T Air status air control I CT2211 communications cat5 U Input gate J CT2211 I O and power V ATEX zone 2 disconnect switch K Mirror cleaning signal W ATEX zone 2 rated blower L Air status signal X Rejected can gate Y Reject bin customer supplied 2 The leak detection system components are DC power supplies 12V 24V system controlling PC with Microsoft Windows operating system micro leak and control ...

Страница 11: ...n a conveyer A Air extraction arch draws the air from around the aerosol can into the sample handling system B Air filter for the removal of air particles and leaked contents of the aerosol cans C Sample cell laser light is directed through the air extracted from around the cans and back into the sensor head D Sensor head contains the lasers and laser light detector It is ATEX Category 3 rated for...

Страница 12: ...n arch The Venturi air status pressure switch not shown signals a third party controller if the air pressure drops below that required by the Venturi Gas concentrations are measured using mid infrared optical absorption spectroscopy The light sources are quantum cascade lasers which are operated to produce wavelength sweeps that cover the absorption lines of the gases The lasers are mounted in the...

Страница 13: ... out n a Analog signal in n a Digital signal out 3 X normally closed contact Digital signal in 10 100 Base T ethernet Inlet gas port connector in BSPT Exhaust gas port connector in BSPT Power supply 120 VAC 60 Hz 240 VAC 50 Hz 200 W A Control console size 1 200 x 600 x 560 mm H x W x D Control console weight 70 kg Sensor head size 590 x 330 x 330 mm H x W x D sensor only Sensor head weight 20 kg s...

Страница 14: ... OUT 0 OUT 1 OUT 4 OUT 3 Status lamps Encoder O IN 14 IN 13 IN 11 IN 12 IN 10 OUT 13 OUT 7b OUT 10 OUT 9 OUT 8 CASCADE OPTO BOX CT2211 DC power Interface Air status 9 way dtype plug 9 way dtype socket 15 way dtype plug 15 way dtype socket Connects to 9 way socket Cascade opto box power Connects to 15 way socket Cascade CT2210 sensor Connects to 15 way dplug see above Connects to 9 way dsocket Casc...

Страница 15: ...ction System Rev F October 2015 System Connection 9 The air arch is connected to the leak detector using the attached quick fit connector Figure 2 2 Filter assembly and archway quick connector A Filter assembly B Air arch C Leak detector quick fit connector A C B ...

Страница 16: ...ol Leak Detection System Rev F System Connection 10 The filter regulator pressure switch and valve shown below are mounted onto the leak detector pedestal stand Figure 2 3 Air preparation plate A Filter regulator B Pressure switch C Valve D Water separator A B C D ...

Страница 17: ...2211 Aerosol Leak Detection System Rev F October 2015 System Connection 11 The leak detector is comprised of the following components Figure 2 4 Left Sensor head Right Air extraction arch assembly A Sensor head unit B Air extraction arch B A ...

Страница 18: ...omponents on the production line are correctly mounted The control console must also be securely mounted with clear access around The shutdown signal from the line PLC must be set to not switch the system off otherwise the system will begin to shutdown straight after booting The system is activated by turning the isolation switch shown below to the ON position The system must have been off for at ...

Страница 19: ... two minutes after power is applied Figure 3 2 Control system display The message box at the bottom of the screen indicates any errors or warnings detected during the boot sequence If the system has successfully booted the traffic light indicator in the bottom right of the screen goes green For a full explanation of the control system software see Section 5 of this manual ...

Страница 20: ...t panel Failure to shut down the system using the correct procedure may damage the system Only use the isolation switch on its own to shut down the system in an emergency as a last resort to remove power from the system Once activated the first two safe shutdown methods follow the same sequence The screen shows the shutdown of the system and goes blank Once the screen has gone blank wait thirty se...

Страница 21: ...l system Home screen A Power button used to turn the system off safely generates a prompt to confirm the switch is off H Title bar displays the title of the current page B Home button allows navigation back to this screen from any screen I Main Screen button changes the center section of the screen to the main control page for the leak detector C User login button changes the central section of th...

Страница 22: ...n system requires that some functionality is restricted to authorized users only The different user login options are available through the User Login screen which is shown in Figure 5 2 below Figure 5 2 User login screen A User Selector allows the operator to select and log in to the different user levels of the control system B User Description describes the access options available to the curre...

Страница 23: ... operator to select from all the programs stored on the control system B Config backup this allows the operator to create a backup of the configuration file on an external USB drive C Program Description this describes the program and when it should be used This information is entered by the user during the program creation process D Add program button allows the user to add a new program using th...

Страница 24: ...ignals must be acknowledged by pressing the reset errors button Figure 5 4 below shows the Error Status screen Figure 5 4 Error Status screen A Error Status shows the status of all the configured error checks For all status flags green is OK orange is warning and red is error B Reset errors button is used to reset the errors in the control system If an error persists then it cannot be reset and wi...

Страница 25: ...rchway used to sample gas into the leak detector from the conveyor G Output Gate position is the position relative to the main input gate of the control system of the output gate from the leak detector which is typically located after the air archway used to sample gas into the leak detector from the conveyor H Purge Frequency is the time duration in hours between the required mirror purge cleanin...

Страница 26: ... displays a laser pulse from the last second of running B Laser Threshold is the voltage that the laser pulse must be above to ensure the laser healthy status signal is OK C Concentration Graph is the output from the concentration calculations on the Leak Detector A rejected can will show as a spike on this graph above the thresholds D Noise shows the overall noise level of the concentration data ...

Страница 27: ...or some signals that are rapidly changing the signal change on screen may be too quick to observe Figure 5 7 below shows the Digital IO Status screen Figure 5 7 Digital IO Status screen A Digital inputs displays the current status of the digital inputs to the control system Green is active and grey is inactive B Digital outputs displays the current status of the digital outputs from the control sy...

Страница 28: ... mm of the input gate of the system This is always 0 B Output Gate Position displays the position in mm of the output gate of the system relative to the input gate C Bin Full Time is the time in seconds that the reject verification gate must be blocked for the bin full error to be displayed D Last Output monitors the canister position as it exits the leak detection system E Position Summary Chart ...

Страница 29: ... the main input gate of the rejector C Rejector Timing is the length of time the rejector is active for each faulty container D Rejector Type shows a picture of the particular rejector in use E Number of Consecutive Rejects is the number of consecutive canister rejects required to trigger the Too many consecutive rejects alarm F Check mark is to apply changes made to Number of Consecutive Rejects ...

Страница 30: ...There are a number of errors that the control system monitors for that may occur during the normal operation of the system If the error status indicator in the bottom right hand side of the screen or if the traffic light indicators change from green then the control system has detected an error Most errors are easily reset from the Error Status screen of the control system The errors that are acti...

Страница 31: ...s are slipping on the production line Someone has removed a can from the line inside the system A can in the system has fallen The height of the gate output is wrong causing the gate not to trigger when cans go through The output gate is not working or disconnected In order to reset this error all the cans in the system must be removed and the can buffer must be reset using the can buffer reset bu...

Страница 32: ...ject bin begins to fill The reject verification gate is used to detect when the bin is overflowing and trigger the bin full error 5 2 11 Mirror purge warning The leak detector requires a mirror purge cleaning at regular intervals to maintain the performance of the sensor The control system has a timer that is used to ensure that this cleaning purge is performed Once the timer reaches 0 the warning...

Страница 33: ...ompressed air error The compressed air error reports when insufficient pressure on the Venturi reject purge air is detected Insufficient air pressure results in decreased performance of the CT2211 aerosol leak detection system 5 2 15 Error flags 14 15 These error flags are currently unassigned 5 3 Line PLC communication The aerosol leak detection system communicates to the line PLC via digital IO ...

Страница 34: ...king within its operational parameters A 0 0V signals the line is stopped 5 3 2 System shutdown signal in The system shutdown signal allows the control system to be deactivated remotely If the signal is high the control system continues to function If the signal is low the control system switches off 5 3 3 Linestop 1 and linestop 2 out The control system provides two output signals to stop the pro...

Страница 35: ...ter 6 Bin full time 7 Maximum consecutive rejects line stoppable 8 Maximum repeatable rejects line stoppable Use of an incorrect program may lead to degraded performance of the control system and the wrong cans may be rejected Use the Program Page Program Selector to change or load a Control System program A login security level of Power User or higher is required for an operator to save changes t...

Страница 36: ...p to a maximum of twenty five To add a program press the Add programs button on the Program Page Figure 5 13 below shows the Add programs screen There is a description of the program on the Add programs screen that helps inform you about your selection Figure 5 13 Add programs screen The values on the right of the Add Programs screen come from the currently loaded program You can enter the program...

Страница 37: ...ld be performed once per week Inspect and clean the optical gates and reflectors Check the pressure settings on the filter regulators Inspect the rejector and ensure it is operating correctly Inspect the encoder to ensure the coupling to the line is solid 6 1 3 Monthly These are the activities that should be performed once per month Inspect and clean the air arch filter Verify that the compressed ...

Страница 38: ...0328a Yes Optical reflector Zone 2 P 5000 0328b Yes Encoder Zone 2 P 5000 0327 Yes Sample flow filters Zone 2 M 1000 1840 Yes Sample flow filter housing Zone 2 P 5000 0060 Yes Venturi Zone 2 P 5000 0117 Yes Pressure switch Zone 2 P 5000 0615 Yes Power supply 12 V Zone 2 P 5000 0331 Yes Power supply 24 V Zone 2 P 5000 0392 Yes Leak generator valve Zone 2 P 5000 0587 Yes Filter regulator Zone 2 P 50...

Страница 39: ...ected to the network switch in the control console and the network cable to the PC must be installed into the same switch The leak detection system is not powered See the leak detection systems manual for trouble shooting Ensure that the indicator lights are flashing on the network switch for both cables See Figure 7 1 Check the LED on the 12V PSU in the control console See Figure 7 2 Cannot updat...

Страница 40: ...nd Diagnostics User Manual October 2015 QCL MAN CT2211 Aerosol Leak Detection System Rev F Troubleshooting and Diagnostics 34 Figure 7 1 Network status Figure 7 2 12V PSU status Network status lamps 12V PSU status lamp ...

Страница 41: ...User Manual Troubleshooting and Diagnostics QCL MAN CT2211 Aerosol Leak Detection System Rev F October 2015 Troubleshooting and Diagnostics 35 Figure 7 3 Circuit breaker Circuit breaker ...

Страница 42: ...erson logo is a trademark and service mark of Emerson Electric Co All other marks are property of their respective owners The contents of this publication are presented for information purposes only and while effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or a...

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