Tài liệu THIẾT BỊ ĐIỆN CÔNG NGHIỆP ĐIỆN TỰ ĐỘNG HÓA ĐO LƯỜNG ĐIỀU KHIỂN PPT3000 Manual

100 - INTRODUCTION SYSTEM OVERVIEW The PPT3000™ Packaging Pressure Tester offers high-resolution, servo-controlled pressure and volume expansion testing capabilities for plastic contain

Packaging Pressure Tester

Telephone: (724) 482-2163 Technical Service: (724) 482-2138 Telefax: (724) 482-2767

Copyright  2006 Agr International, Inc PPT3-2-2-E

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105 Specifications 105-1 Environmental Requirements 105-1

Utility Requirements 105-2 Electrical Supply 105-2 Gas Supply 105-2 Water Supply 105-3 AGR Water Quality Recommendations for Laboratory Equipment 105-3 Drain 105-3

Physical Dimensions 105-4

110 Safety Information 110-1

Important Safety Notes 110-1 Safety Terms 110-1 Safety Symbols 110-2

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The Touch Screen 300-1 Types of On-Screen Controls 300-1 The Virtual Keyboard 300-2 Controls on the Virtual Keyboard 300-4 The Password Feature 300-5

305 The Main Screen 305-1

Introduction 305-1 Parts of the Main Screen 305-2 The Control Buttons 305-3 The Test Results Graph 305-4 The Test Results Report 305-7 The Water Temperature Display 305-8 The Job Parameters Display 305-8 The Mold Number Entry Buttons 305-9 The Status Bar 305-10 The Message Box 305-10 Differences after an M-RULE® Test 305-11

310 Operation 310-1

Introduction 310-1 Testing Plastic Containers 310-1 The Temperature Equalization Feature 310-6 Shutting Down the PPT3000 310-12 Insert Sizes (Table) 310-14

320 Using Job Configurations 320-1

Introduction 320-1 Using Job Configurations 320-1 Loading Jobs 320-3 Copying Jobs 320-4 Creating Jobs 320-6 Deleting Jobs 320-6 Importing Jobs 320-7 Exporting Jobs 320-8

330 System Setup 330-1

Introduction 330-1 Settings on the General Tab 330-3 Settings on the Maintenance Tab 330-4 Buttons on the Maintenance Tab 330-5

340 CSV Output 340-1

Introduction 340-1 Output Formats and Modes 340-1 Host System Requirements for COM Port Data 340-1 Host System Requirements for Network Port Data 340-1 Legacy Format 340-2 Profile Setup Information 340-2 Legacy Format - Profile Setup Information (Table) 340-2 Test Results 340-3 Legacy Format - Test Results (Table) 340-3 Regular Format 340-4 Profile Setup Information (Table) 340-4 Test Results (Table) 340-6 Verification Packet (Table) 340-8 CSV Setup 340-9

350 Verifying the Pressure, Volume, and Temperature Measurements 350-1

Introduction 350-1 Verifying the Pressure Measurement 350-1 Procedure 350-2 Using the Diagnostics Screen during Pressure Verification 350-9 Verifying the Volume Measurement 350-10 Procedure 350-10 Using the Diagnostics Screen during Volume Verification 350-17 Verifying the Temperature Measurement 350-18 Procedure 350-18 Using the Diagnostics Screen during Temperature Verification 350-25

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Section 6 - Maintenance

600 Maintenance 600-1

Routine Maintenance 600-1 Routine Maintenance Schedule (Table) 600-1 Cleaning the Fan Filter 600-2 Preparing the Machine for Storage or Shipment 600-3 Introduction 600-3 Flushing the System 600-4 Cleaning the Touch Screen 600-17

Section 7 - Troubleshooting

700 Troubleshooting 700-1

Responding to On-Screen Alarms (Table) 700-1 Symptoms and Solutions (Table) 700-2 Using the Diagnostics Screen 700-4 Introduction 700-4 The Status Tab 700-4 The Log Tab 700-6 The System Log Tab 700-6 The Alarm Log Tab 700-8 Using the Remote Access Feature 700-9

Addendum A – Buckle Testing Aluminum Bottles

A Buckle Testing Aluminum Bottles A-1

Introduction A-1 Mechanical A-1 The Main Screen A-2 Operation A-4 Job Setup A-7 CSV Output A-10

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END OF TABLE OF CONTENTS

Section 1 INTRODUCTION, SPECIFICATIONS & SAFETY

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100 - INTRODUCTION

SYSTEM OVERVIEW

The PPT3000™ Packaging Pressure Tester offers high-resolution, servo-controlled pressure

and volume expansion testing capabilities for plastic containers with the versatility to

perform a number of industry-standard and custom test profiles

The PPT3000™ system can be used in the laboratory or along manufacturing lines to verify

that containers meet minimum pressure capabilities and/or to monitor the rate of volume

expansion throughout the testing cycle

Figure 100-1

TEST MODES

The PPT3000™ system offers four testing modes that allow operators to perform a variety of

industry-standard tests Tests also can be customized for unique applications

Fill-Ramp Mode

This test mode is designed to simulate the

conditions for PET container filling operations In

this mode of operation, the container is pressurized

quickly to an operator-specified level and held for

13 seconds The pressure is then ramped at a rate

of 10 psi per second until container failure or the

maximum level of pressure or volume expansion is

achieved Input parameters include: Initial

Pressure, Nominal Volume, and Expansion Limit

Burst Test Mode

In this mode of operation, the container is

pressurized quickly to a predefined pressure level

and held for a specific time Input parameters

include: Initial Pressure, Nominal Volume,

Expansion Limit, and Hold Time

Custom Test Mode

The custom test mode provides the capability of

creating unique profiles to meet special testing

requirements The custom profile editor lets

operators build custom test profiles on a

segment-by-segment basis As each segment is developed,

it is graphically displayed on the user interface

100 - Introduction

M-RULE® Mode (Optional)

The M-RULE® test mode is designed to provide

material utilization and predicted shelf-life data In

this mode, bottles are pressurized at a precise rate

up to 60 psi Pressure and expansion data is

captured then analyzed by the embedded version of

the M-RULE® Container Performance Model

software to ascertain material utilization Predicted

shelf-life for the bottle is presented based upon test

data and bottle attributes

The M-RULE® Container Performance Model is a proven, software-based predictive tool that operates by integrating the fundamentals of permeation with critically evaluated, physical data for the component materials and other pertinent data affecting the permeability of a container M-RULE® is a registered trademark of Container Science Inc

AVAILABLE OPTIONS

The following options are available for the PPT3000™ system:

• Floor stand

• Water-saver recirculation system

• Supply water filtration system

• Verification kit for calibration verification

• Additional M-RULE® profiles

• Buckle Test capability for aluminum bottles

1 Dual Regulator Knob

2 Manual Water Valve

4

END OF SECTION 100

105 - SPECIFICATIONS

SPECIFICATIONS

MACHINE SPECIFICATIONS

Item Range

Operating Pressure Range 0 bars to 20.7 bars (0 psi to 300 psi)

Pressure Measurement Accuracy

(based on calibration to a certified gauge)

±0.2 bars (±3 psi)

Pressure Units of Measure psi, kg/cm2, bars or MPa (user selectable)

Volume Expansion Units of Measure Milliliters, ounces, or cubic inches

(user selectable) Pressure Source Nitrogen gas recommended (not supplied)

Option: compressed air if properly filtered Ambient Operating Temperature 4 ºC to 50 ºC (40 ºF to 122 ºF)

Power Requirements 100 VAC, 120 VAC, 220 VAC or 230-240 VAC

@ 50/60 Hz Maximum Volume Expansion Capability 1.87L (63.23 fluid ounces)

Output Interface Standard serial link

with legacy CSV output and Ethernet

BOTTLE SPECIFICATIONS

Item Range

Volume Up to 3.0L (101.44 fluid ounces)

Finish Diameter 20 mm to 43 mm (0.79 inch to 1.69 inches)

ENVIRONMENTAL REQUIREMENTS

To meet and maintain the specifications, the machine should be operated within these

recommended ambient conditions:

• No continuous or shock vibration of the instrument standing base

• A stand or table capable of supporting approximately 102 kg (225 pounds)

105-2 11/9/2007

UTILITY REQUIREMENTS

Electrical Supply

Operating Voltages – 100 VAC, 120 VAC, 220 VAC, and 230-240 VAC, 50/60 Hz

Power Required - 230 volt-amperes (VA)

Ground Fault Circuit Interrupter - For added safety, we recommend that a ground fault circuit interrupter be used on the plant circuit supplying the PPT3000™ system

Gas Supply

The PPT3000™ system requires a gas supply in the 2068 kPa to 2413 kPa (300 psi to 350 psi) range We recommend that you use bottled nitrogen as the gas supply You can use a plant air supply if necessary However, if you use plant air, you must filter the air with a 20 micron filter to prevent damage to components The gas supply regulator must be able to maintain the pressure to the PPT3000™ system within the 2068 kPa to 2413 kPa (300 psi to

350 psi) range Gas supply connection to the PPT3000™ system is by way of 6 mm (1/4 inch) outer diameter tubing that is supplied with the PPT3000™ system You will need to provide a compression fitting for the tubing on the supply end

105 - Specifications

Water Supply

The PPT3000™ system requires a water supply having a pressure in the range of 138 to 414

kPa (20 psi to 60 psi) Water supply connection to the PPT3000™ system is by way of 13

mm (1/2 inch) outer diameter tubing that is supplied with the PPT3000™ system You will

need to provide a compression fitting for the tubing on the supply end The temperature of

the water supply must be in the 15º C to 26 º C (60 ºF to 80 ºF) range

Agr Recommendations for Laboratory Equipment

The components in Agr equipment have been selected to have the highest possible resistance

to damage by water However, some parts may be prematurely damaged by poor quality

water The following table includes water quality recommendations to maximize the life of

the components used in Agr equipment

WATER QUALITY

Property Limit

Water Temperature 15 C - 26 C (60 F - 80 F) Hardness Less than 180 ppm as CaCO 3

Total Dissolved Solids Less than 290 ppm Particulates Under 5 microns

If you have concerns about your local water quality, or experience a reduced lifetime of these

components, Agr recommends that you contact a reputable water conditioning company in

your area Local companies are often familiar with problems unique to the local water

chemistry and should be able to perform tests to determine if your water exceeds the

recommendations listed above They also may be able to suggest specific solutions for

filtering and treating your water

Drain

The PPT3000™ system requires a drain for water runoff from the bottom of the enclosure

Drain connection to the PPT3000™ system is by way of a 3/4 inch (19 mm) inside diameter

hose supplied with the PPT3000™ system You will need to provide a suitable connector for

the drain end of the hose

6/29/2012 110-1

110 - SAFETY INFORMATION

IMPORTANT SAFETY NOTES

 Do not use the PPT3000™ system to test glass bottles, or for any purpose other than its

intended use

 For the safety of the operator and to maintain the machine’s warranty, use only Agr

replacement parts

 Connect the PPT3000™ system to a Ground Fault Interrupt (GFI) protected outlet The

user is responsible for assuring the AC power conforms to all local safety standards

 High voltage is present inside the Enclosure Do not remove the Cover unless instructed

to do so by Agr personnel

 Turn off the high-pressure air or gas supply before servicing any mechanical items

Always relieve system pressure before servicing equipment Trigger all dispensing

devices and bleed off system pressure

 While the noise level at bottle burst may not mandate ear protection under your local

safety regulations, it is suggested that ear protection be worn while operating the

PPT3000™ system

 Always wear protective glasses when operating the PPT3000™ system

 Always wear protective glasses and gloves when removing debris from the Test

Chamber

 The floor around the PPT3000™ system may become wet and slippery during the course

of normal operation It is recommended that a perforated rubber mat be provided for the

operator to stand on

 The incoming air line should be secured to a secondary fixture

SAFETY TERMS

The following is a list of the typical safety related terms that Agr uses in this

Operation Manual:

 CAUTION - These statements typically identify conditions or actions that you need to

guard against because they could result in damage to the equipment

 WARNING - These statements typically indicate conditions or actions that you need to

guard against because they could result in personal injury

110-2 6/29/2012

SAFETY SYMBOLS

The following is a list of the typical safety related symbols that Agr uses to indicate

hazards and warnings All of these symbols may not be used on this product

DANGER

Example: a pinch point

GROUND - Protective earth (ground) terminal

HOT SURFACE - This symbol identifies surfaces that become hot to the touch during normal operation

1406

ENTANGLEMENT - This symbol identifies areas or components that may pose

CRUSH - This symbol identifies areas or components that may pose a crush hazard

FOOT CRUSH - This symbol identifies areas or

components that may pose a foot crush hazard

1459 FLUID INJECTION - This

symbol identifies areas or components that may pose a fluid injection hazard

1335

EYE - This symbol identifies areas where eye protection should be worn

1336

EAR - This symbol identifies areas where ear protection should be worn

ELECTROSTATIC SENSITIVE DEVICES - Components in this equipment are

subject to electrostatic damage Components with this symbol should be serviced by personnel who are familiar with proper handling precautions

Section 3 ON-SCREEN CONTROLS, OPERATION & JOB SETUP

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300 - USING THE TOUCH SCREEN AND THE VIRTUAL KEYBOARD

THE TOUCH SCREEN

selections and enter data while working in the test system Different types of on-screen controls are shown in Figure 300-1

1 Tabs Used to display different sets of controls and/or settings

2 Drop-down boxes Used to select an option from a list of options

3 On-Screen Buttons Used to make a selection or open other controls

4 Radio Buttons Used to choose between options or features

5 Checkbox Used to enable or disable a feature

11/27/2006 300-1

THE VIRTUAL KEYBOARD

To use the virtual keyboard to enter text or numerals, touch a textbox or parameter on the screen For example, to modify the Initial Pressure value on the Job Setup screen, touch the value (see Figure 300-2) and the virtual keyboard will appear (see Figure 300-3)

NOTE: The keys on the virtual keyboard will remain in English regardless of the Language selection

on the System Settings screen

INITIAL PRESSURE VALUE ON THE JOB SETUP SCREEN

Figure 300-2

300 – The Touch Screen and Virtual Keyboard

As you touch the on-screen keyboard keys, your entry will appear in the text field at the top of the virtual keyboard When the text field is complete, you must touch the “Enter” key on the virtual keyboard to enter the text or numerals

THE VIRTUAL KEYBOARD Figure 300-3

CONTROLS ON THE VIRTUAL KEYBOARD

300 – The Touch Screen and Virtual Keyboard

THE PASSWORD FEATURE

A password is used to protect system-level settings Once the password is entered, all password-protected settings can be modified and all password-protected features can be accessed When the Enter Password screen appears (see Figure 300-4), enter the password and touch the Enter key on the virtual keyboard

NOTE: The software is "case sensitive” for passwords The system accepts and "remembers"

uppercase and lowercase letters as part of the password If you use uppercase and/or lowercase characters for your password, you must use the same combination when you login If not, the software rejects your password at login

NOTE: The keys on the virtual keyboard will remain in English regardless of the Language selection

on the System Settings screen

ENTER PASSWORD SCREEN

Figure 300-4

END OF SECTION 300

on-There are differences in the appearance of the Main Screen when the system is

conducting an M-RULE® test These differences are explained at the end of this section

THE MAIN SCREEN Figure 305-1

305-2 10/15/2013

PARTS OF THE MAIN SCREEN

The primary components of the Main Screen are identified in Figure 305-2 Each of these components is described on the following pages

PARTS OF THE MAIN SCREEN

TEST RESULTS GRAPH

JOB PARAMETERS MOLD NUMBER

ENTRY BUTTONS

WATER TEMPERATURE

305 – The Main Screen

The Control Buttons

The following buttons control the test system or open controls to other functions

Touch this button to initiate a test For more information, see Section 325, Job

Setup, and/or Section 310, Operation

Touch this button to open the Job Setup screen where you can edit, load, copy, create, delete, import, and export Job Configurations For more information,

see Section 325, Job Setup

Touch this button to open the System Setup screen, where General, CSV, Verification and Maintenance settings can be viewed and/or modified Note that the password must be entered to access this screen For more information, see

Section 330, System Setup

Touch this button to display the Statistics screen, which displays graphical results for up to 10 previous tests For more information, see Section 310,

305-4 10/15/2013

The Test Results Graph

The appearance of the Test Results Graph will vary depending on the Test Mode By default, the system plots Bottle Pressure (cyan line) and Volume Expansion (red line) vs Time (see figures 305-3 through -7) over the Pressure Profile (blue line) that was created during Job Setup To display a graph of Bottle Pressure vs Volume Expansion, touch the graph after the completion of a test The background of the graph will change from white to yellow (see Figure 305-8) To return to the Bottle Pressure and Volume Expansion vs Time display, touch the graph again

The graphs include an auto-scaling feature At the beginning of a test, the graph will display a 60-second range for time and a 50-percent range for volume expansion As the test progresses, the time range will increase in 60-second increments and the volume expansion range will double if necessary

TEST RESULTS GRAPH – BURST MODE

Figure 305-3

TEST RESULTS GRAPH – FILL RAMP MODE

Figure 305-4

305 – The Main Screen

305-6 10/15/2013

DEFAULT FILL-RAMP TEST RESULT (PRESSURE AND % VOLUME EXPANSION VS TIME)

CORRESPONDING PRESSURE VS VOLUME EXPANSION

TEST RESULT GRAPH

GRAPH OPTIONS Figure 305-8

305 – The Main Screen

The Test Results Report

A text-based report is generated at the completion of each test This report will not update until the completion of the next test

Test Comments can be added if the Failure Mode Input feature is enabled For

information on enabling the Failure Mode Input feature, see Section 325, Job Setup For information on entering Test Comments, see Section 310, Operation

TEST RESULTS REPORT Figure 305-9

If the system includes the optional Custom Expansion feature, the Test Results Report will appear as shown in Figure 305-10 The report will include an additional result for the % Expansion at the user-defined time (established during Job Setup)

TEST RESULTS REPORT – OPTIONAL CUSTOM EXPANSION FEATURE

Figure 305-10

305-8 10/15/2013

The Water Temperature Display

The water temperature is updated every second The temperature unit (Fahrenheit or Celsius) can be changed and minimum and maximum temperature limits can be set on the

General tab of the System Setup screen (see Section 330, System Setup)

The temperature will be displayed in blue if the temperature is within the user-defined limits The temperature will be displayed in red if it falls outside of the user-defined limits

The Job Parameters Display

The parameters that were entered during job setup are shown in the Job Parameters Display The Initial Pressure, Nominal Volume, Expansion Limit, and Hold Time (Burst tests only), as well as the M-RULE® Shelf Life and M-RULE® Material Utilization (M-RULE tests only) settings can be modified by touching the desired cell on the Main Screen

However, any change made on the Main Screen will not be saved to the Job Configuration Once the settings have been changed on the Main Screen, they will not revert to those

established during Job Setup unless the job is reloaded or power is cycled

305 – The Main Screen

The Mold Number Entry Buttons

The Mold Number Entry Buttons can be used to record the mold number of each container that is tested During Job Setup, the system can be set to record mold numbers manually or using a user-defined sequence

In the Manual Mode, touch the Current Mold Number field and use the virtual

keyboard to enter a mold number before initiating a test When the test completes, the mold number will be displayed on the Test Results Report The “Next” button can be used to increment the Current Mold Number and the “Previous” button can be used to decrement the Current Mold Number Touch the Current Mold Number and use the virtual keyboard to enter any number

In the Sequence Mode, the Current Mold Number field will display the mold number

of the next container to be tested When the test completes, the mold number will be

displayed on the Test Results Report The system will then display the next mold number in the sequence The “Advance” button can be used to advance through the sequence and the

“Back Up” button can be used to back up through the sequence The “Next” button can be used to increment the Current Mold Number and the “Previous” button can be used to

decrement the Current Mold Number Touch the Current Mold Number and use the virtual keyboard to enter any number Once any of these buttons have been used, the system will resume following the predefined sequence

BACK UP

TO PREVIOUS NUMBER

IN SEQUENCE

PREVIOUS NUMBER

CURRENT MOLD NUMBER

NEXT NUMBER

ADVANCE TO NEXT NUMBER

IN SEQUENCE

305-10 10/15/2013

The Status Bar

The Status Bar displays the current system status, the name of the job that is loaded, and the current date and time

The Alarm Message Box

The Alarm Message Box displays alarms as well as reminders for Pressure

Calibration, Volume Expansion Calibration, Temperature Calibration, changing the Water Filter, and changing the Water Conditioner The amount of time between these reminders is set on the Maintenance tab of the System Setup screen For more information, see Section

330, System Setup

Touch the Alarm Message Box to display the Alarm Log on the System Setup screen and to clear the alarm from the Message Box