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This document contains information considered proprietary and confidential to Tecnar Automation Ltd 

40101-00024-00– Rev E 

Revision date: 2019-03-17 

Page 40 of 43 

 

User manual

   Accuraspray4.0 

 

6  TROUBLESHOOTING 

On  power-up  of the  controller,  once the  sensor  is  initialized  properly,  the 
back-plate LED will start blinking quickly (3 quick blinks every 5 seconds), it 
behaves the same way as a beacon light. This initial blinking indicates that 
the electronics components inside the sensor are up and running, and that 
the sensor is waiting for the software to connect. Note that the back-plate 
LED  button  is  not  available  during  this  initialization  sequence.  Once  the 
software is connected to the sensor, the LED will stop blinking immediately, 
and the back-plate button becomes enabled. Thus, it can now be used for 
alignment purposes. The startup time of the controller is usually as fast as 
the initialization of the sensor head. Depending on the startup time duration, 
the blinking might be hard to notice if the controller connects to the sensor 
as soon as it is initialized. 

In the event that the initialization sequence is not successful, the LED will 
not stop blinking. Instead, it will start blinking more slowly, indicating that the 
sensor is now in error state (the LED will be held ON for approximately 1.5 
seconds  instead  of  166  milliseconds,  maintaining  a  5  second  interval  in 
between the blinks). The back-plate button will remain disabled. Refer to the 
troubleshooting section for more information on the LED error codes.  

6.1 

S

ECTION TROUBLESHOOTING 

(LED

 ERROR CODES

) 

As mentioned in the operation section, in the case of hardware failure, the 
back-plate  LED  is  used  as  a  troubleshooting  tool  to  provide  more 
information on the system error state. Here is a list of all the possible codes, 
descriptions, and troubleshooting actions to be taken.  

Error code 

Description 

Actions 

2 blinks 

The  controller  did  not 
connect to the sensor within 
2 

minutes 

after 

the 

initialization 

Reboot the controller 

3 blinks 

Internal micro-switch error 

Contact  Tecnar  service 
team 

4 blinks 

Microcontroller error 

Contact  Tecnar  service 
team 

 

 

 

Содержание accuraspray 4.0

Страница 1: ......

Страница 2: ...tronic storage and retrieval or translation into a foreign language without prior agreement and written consent from Tecnar Automation Ltd MANUAL PART 40101 00024 00 The material contained in this document is provided as is and is subject to change without notice in future editions OVERVIEW Table of content at the beginning of the document Table of figures at the beginning of the document This man...

Страница 3: ...WARE 12 3 1 USER INTERFACE 12 3 2 NAVIGATION ICONS 12 3 3 LOGGING IN AS AN ADMINISTRATOR USER 22 3 4 MANAGING SETUPS 23 3 5 LOADING A SETUP 24 3 6 TECHNICAL SPECIFICATIONS 28 4 INSTALLATION 29 4 1 INSTALLING THE SENSOR HEAD 29 4 2 ACCESSING THE USER INTERFACE 34 4 3 SETTING UP THE ACCURASPRAY ON A NETWORK OPTIONAL 35 4 4 CONNECTING THE I OS OPTIONAL 35 5 MAINTENANCE 37 5 1 MAINTENANCE SCHEDULE 37 ...

Страница 4: ...CREEN 14 FIGURE 8 STRIPCHART SCREEN 17 FIGURE 9 LOGIN WINDOW 20 FIGURE 10 PASSWORD SCREEN 21 FIGURE 11 DIALS PROCESS CONTROL ZONES 22 FIGURE 13 SETUP SELECTION WINDOW 24 FIGURE 14 SETUP OVERRIDE WINDOW 25 FIGURE 15 POSITION OF THE SENSOR HEAD 30 FIGURE 16 SENSOR HEAD MONTING PLATE DIMENSIONS 30 FIGURE 17 M OUNTING THE SENSOR HEAD 31 FIGURE 18 SENSOR HEAD INTERFACE 31 FIGURE 19 CONTROLLER INTERFACE...

Страница 5: ...each spray run This ensures that the spray properties are within predetermined acceptance ranges for ideal coating and performance To help detect potential issues such as electrode wear partial clogging of the nozzle or in the powder injection system and instability of the powder feeder before the coating process the Accuraspray monitors Particle s temperature and velocity Plume profile and intens...

Страница 6: ...raspray 4 0 from damage you must Connect it to an unloaded properly grounded power line 50 60 Hz 100 240VAC 50 60Hz 1 5 A We also recommend using an additional power line filter to filter out any power surges or bursts Use it at an ambient temperature between 4 and 45 C Supply 30 LPM 2CFM of cooling cleaning air at 1 7 2 7 bar 25 40 psi to the sensor head AT ALL TIMES while the unit is powered on ...

Страница 7: ...er manual Accuraspray4 0 2 DESCRIPTION The Accuraspray 4 0 system includes the following elements 1 A sensor head 2 A controller 3 A substrate pyrometer optional 4 Air hoses and filter 5 Controller power cable 6 Sensor head power and communication cable Each elements are described in details on the following pages FIGURE 1 SCHEMATICAL DESCRIPTION OF THE SYSTEM ...

Страница 8: ...date 2019 03 17 Page 8 of 43 User manual Accuraspray4 0 2 1 CONTROLLER The controller must be kept in a ventilated area to reduce the risk of overheating The controller receives readings from the sensor head It processes the data and broadcasts the results to the user interface s FIGURE 2 CONTROLLER FRONT FIGURE 3 CONTROLLER BACK ...

Страница 9: ...cess the Accuraspray user interface through a wireless network connection The Wi Fi connection acts as a Hotspot It can be disabled but not reconfigured 3 Sensor head port Used to power and communicate with the sensor head 4 Power switch Used to active the unit 5 User interface port Used to interface the Accuraspray to the user s spray controller via digital I Os 6 Ethernet Used to access the Accu...

Страница 10: ...4 00 Rev E Revision date 2019 03 17 Page 10 of 43 User manual Accuraspray4 0 2 2 SENSOR HEAD The sensor head measures the following particles and spray plume properties Particles velocity Particles temperature Spray plume geometry width position and intensity FIGURE 4 SENSOR HEAD FRONT FIGURE 5 SENSOR HEAD BACK ...

Страница 11: ...m switch Activation switch for the alignment beam 6 Substrate pyrometer port Used to power and communicate with the optional substrate pyrometer sensor 7 Communication port Used to power the sensor head and communicate with the controller 2 3 CABLES HOSES AND ANTENNAS The Accuraspray 4 0 is delivered with several cables hoses and antennas which are described in the following table Cables Hoses Ant...

Страница 12: ...TERFACE The user interface can be accessed with most internet browsers It connects to the controller via an Ethernet cable or Wi Fi network 3 2 NAVIGATION ICONS Different icons are displayed at the top of the Accuraspray user interface in order to navigate between the different screens The following table describes those icons Icons Description Access the main measurement screen FIGURE 6 ACCURASPR...

Страница 13: ...00 Rev E Revision date 2019 03 17 Page 13 of 43 User manual Accuraspray4 0 Access the charts screen Access the setup screen Only when logged in as Operator or Administrator Access the menu to change user s passwords Take control and access the configuration screen Operators and Administrators only Log in Log out ...

Страница 14: ...in the acceptance range is shown in green a measurement just barely within the acceptance range is shown in yellow and a measurement outside the acceptance range is shown in red Corrective actions should be taken to ensure that all measurements are within the acceptance range and displayed in green In the middle of the screen in the camera view an orange bullseye represents the position where the ...

Страница 15: ...rate on which the coating is applied Plume deviation Deviation of the plume position against the bullseye Plume width Width of the spray plume 3 2 1 1 Zoom in out It is possible to zoom in on the center of the image where the bullseye is located To do so click on the magnifying glass icon This will enlarge the image so that the sampling line the dotted vertical line overlaid on the camera image ta...

Страница 16: ...ce To open a saved sequence click on the folder icon select the sequence that you want to replay As mentioned previously the video sequences are not stored on the Accursaspray controller You will find them on your computer in your default download directory or wherever you have stored them When replaying a sequence an X icon will appear It is used to exit replay mode and return back to live mode I...

Страница 17: ...ng one measurement It s possible to select which measurement to display from the table located to the right of the graphs 3 2 2 1 Adjusting the time display The time duration displayed on the strip charts can be adjusted using the text box at the top of the page The charts can display up to 60 minutes of measurements The last 60 minutes are stored in the database and can be recalled at any time 3 ...

Страница 18: ...rs select Save the data contained in the strip charts and a screen shot of the camera screen will be copied into a pdf and csv files The production reports are stored on the Accuraspray controller s hard drive The directory where the files are stored is accessible by clicking on the Open icon It also contains all the strip charts The duration of the strip charts in the production report is the sam...

Страница 19: ... or wireless Another user can be viewing saved files from previous runs in the QC department When accessing the Accuraspray interface users are in viewer mode and can only visualize the sensor s readings like the engineer or QC person discussed earlier In order to actually use the sensor and record sequences it is necessary to log in by clicking the designated icon Users can Log in either as Opera...

Страница 20: ...idered proprietary and confidential to Tecnar Automation Ltd 40101 00024 00 Rev E Revision date 2019 03 17 Page 20 of 43 User manual Accuraspray4 0 To log in click to display the login window and enter your credentials FIGURE 9 LOGIN WINDOW ...

Страница 21: ...Page 21 of 43 User manual Accuraspray4 0 3 2 4 MODIFYING USER S PASSWORD To modify user s password click on the lock icon at the top of the screen Once on the Password page enter a new password and click Change Password to apply it Note that you will have to login either as Operator or Administrator to access this screen FIGURE 10 PASSWORD SCREEN ...

Страница 22: ...tains the green and yellow zones The green value represents 60 of the full range between the min and max while the yellow regions warns the operators that the measurement is approaching the red zone The yellow zones are located 20 from the min and max values of the process 3 3 LOGGING IN AS AN ADMINISTRATOR USER When the user interface is accessed the home screen is displayed with Viewer user acce...

Страница 23: ...nfidential to Tecnar Automation Ltd 40101 00024 00 Rev E Revision date 2019 03 17 Page 23 of 43 User manual Accuraspray4 0 3 4 MANAGING SETUPS The Setup screen is where the different parameters of the sensor head are managed Click to access the configuration screen ...

Страница 24: ...DING A SETUP On the Setup screen click This displays the list of setups Select the setup and click Open The new setup is automatically applied 3 5 1 SAVING A SETUP Once you have modified any parameter on the configuration screen you can save them as a new setup or overwrite the existing setup On the configuration screen click This displays the following window FIGURE 12 SETUP SELECTION WINDOW ...

Страница 25: ...ve 3 5 2 SETUPS IMPORT AND EXPORT Setups can be exported from one Accuraspray units and imported to another When clicking on the Export button a setup file will be downloaded on your computer To import a setup simply click on the Import button and select the setup file that you wish to import from your computer This enables you to ensure that multiples sensors are using the same setting That is es...

Страница 26: ... along which the intensity profile is measured It is normally set to about four times the regular plume width Process type This value indicates to the sensor if the process brightness is high or low Typically SPS Arc spray and SSPS are considered high brightness processes while HVOF and HVAF are considered low brightness Reaction Time Length of the rolling average used by the sensor to display mea...

Страница 27: ...reference for future measurement Execute Autoset This feature automatically adjusts the exposure time for the camera and the signal amplification for the particle s velocity and temperature measurments These settings can be modified manually but it is easier via the AUTO SET However before this can be accomplished the spray plume has to be centered on the bullseyes and the following data acquisiti...

Страница 28: ...gun axis 200 mm 7 87 in Particle temperature measurement range 1 000 C 1 832 F and higher at 3 accuracy Particle velocity measurement range 5 1 200 m s at 3 accuracy Plume relative intensity measurement 2 precision Plume geometry measurement 0 1 mm 0 004 in accuracy Camera field of view 400 mm 15 75 in Particle s measurement volume 3 2 mm x 10 mm x 25 mm 0 13 in x 0 39 in x 0 98 in 3 6 2 CONTROLLE...

Страница 29: ... INSTALLATION 4 1 INSTALLING THE SENSOR HEAD 4 1 1 UNPACKING THE PARTS Carefully open the box remove the content and set it on a work surface The box should contain the following items 1 Sensor head 2 Controller 3 Substrate pyrometer and its support bracket optional 4 Air filter and hoses 5 Controller power cable 6 Communication cable between the head and controller 1 2 1 3 1 4 1 5 1 6 1 ...

Страница 30: ... to install Install the sensor head in the spray booth at a location easily reachable by the robot spray gun Also ensure that the sensor head does not interfere with normal spraying operations FIGURE 14 POSITION OF THE SENSOR HEAD Install the sensor head on a sturdy mounting that does not vibrate or move during spraying Refer to the following schematic of the Accuraspray mounting plate FIGURE 15 S...

Страница 31: ...nsor head mounting plate to your support bracket using the 4 mounting holes FIGURE 16 M OUNTING THE SENSOR HEAD Connect compressed air supply and communication cable to the sensor head Pull the other end of the communication cable out of the spray booth Connect the air hoses to the booth air supply FIGURE 17 SENSOR HEAD INTERFACE Air supply Communication cable Supplied with the Accuraspray 4 0 Sup...

Страница 32: ...OLLER 4 1 3 1 Where to install Install the controller outside the spray booth ideally close to the booth control equipment 4 1 3 2 Installation procedure Connect the sensor head communication cable Connect the power cable to the controller and into a power socket FIGURE 18 CONTROLLER INTERFACE Flip the Accuraspray controller power switch to ON Wait until the LED turns green FIGURE 19 CONTROLLER ST...

Страница 33: ... the back of the sensor FIGURE 20 SENSOR HEAD ALIGNEMENT BUTTON Bring the spray gun near the sensor head as shown on the schematic below The sensor measurement point is normally set to your standard process spray distance The distance between the front of the sensor head and the spray torch axis should be adjusted to 200mm FIGURE 21 SENSOR HEAD WORKING DISTANCE Save the new position as Sensor Home...

Страница 34: ...HE USER INTERFACE Connect your computer or tablet to the controller network using the ethernet port at the back of the controller FIGURE 22 CONTROLLER ETHERNET PORT Change your computer IP address to 192 168 101 20 using 255 255 255 0 for the mask Open any browser and enter the URL 192 168 101 150 8004 to connect to the Accuraspray user interface Ethernet port FIGURE 23 ACCURASPRAY 4 0 USER INTERF...

Страница 35: ...G UP THE ACCURASPRAY ON A NETWORK OPTIONAL To connect the Accuraspray to your local network you must connect the controller to the network with an Ethernet cable wi fi connection is not possible 4 4 CONNECTING THE I OS OPTIONAL You may remotely control the Accuraspray using the I Os connections To use the I Os connections please refer to the following schematic and descriptions FIGURE 24 I O PORT ...

Страница 36: ...he sensor is acquiring its initial data buffer Once the buffer is filled this output will fall Logic rising edge Acquiring initial buffer Logic falling edge Initial buffer acquired 5 OUT 2 Measurement valid Following the acquisition of the first buffer this output 1 will be raised when measurements are valid If the measurements are invalid error messages will be displayed in the user interface and...

Страница 37: ...3 User manual Accuraspray4 0 5 MAINTENANCE 5 1 MAINTENANCE SCHEDULE Components Actions Frequency Sensor head Cleaning the sensor head windows Daily Replacing the sensor head windows assembly When damaged Sensor head calibration Annually Compressed air filter cartridge Replacing the filter cartridge Periodically see visual indicator on the cartridge assembly ...

Страница 38: ...s the window in a single motion instead of rubbing back and forth If any marks remain clean the windows with lens paper and a small amount of isopropanol Wipe the paper across the window in a single motion instead of rubbing back and forth If any marks remain replace the sensor head window assembly see next section 5 2 2 REPLACING THE SENSOR HEAD WINDOW ASSEMBLY We recommend you use latex or nitri...

Страница 39: ...before being shipped to the end users To ensure accurate measurements sensor calibration should be verified every year so that their calibration is NIST traceable You must send the sensor heads to Tecnar Automation Ltd every year for calibration contact service tecnar com There is no need to send the cables and controller 5 3 RECOMMENDED SPARE PARTS Components Part number Compressed air filter car...

Страница 40: ...ation the blinking might be hard to notice if the controller connects to the sensor as soon as it is initialized In the event that the initialization sequence is not successful the LED will not stop blinking Instead it will start blinking more slowly indicating that the sensor is now in error state the LED will be held ON for approximately 1 5 seconds instead of 166 milliseconds maintaining a 5 se...

Страница 41: ... contains information considered proprietary and confidential to Tecnar Automation Ltd 40101 00024 00 Rev E Revision date 2019 03 17 Page 41 of 43 User manual Accuraspray4 0 6 2 ERROR REPORTING IN THE USER INTERFACE ...

Страница 42: ...s Signal level too low The sensor head is aimed at the spray plume The proper setup has been selected Powder is injected into the spray plume The sensor head windows are clean SIGNAL AMPLIFICATION is set adequately for your process Invalid velocity temperature measurements Saturated signal The proper setup has been selected SIGNAL AMPLIFICATION is set adequately for your process Invalid plume widt...

Страница 43: ...This document contains information considered proprietary and confidential to Tecnar Automation Ltd 40101 00024 00 Rev E Revision date 2019 03 17 Page 43 of 43 User manual Accuraspray4 0 ...

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