Packaging Pressure Tester
OPERATION MANUAL Serial # ________
IMPORTANT! READ THIS MANUAL THOROUGHLY BEFORE OPERATING THIS EQUIPMENT. IF THERE ARE ANY QUESTIONS, CONTACT:
Agr International 615 Whitestown Road Butler, PA 16001-8703 Telephone: (724) 482-2163 Technical Service: (724) 482-2138 Telefax: (724) 482-2767
Copyright 2006 Agr International, Inc. All Rights Reserved
PPT3-2-2-E Rev. P 10/2013
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PPT3000™ Packaging Pressure Tester Manual Table of Contents
Section 1 – Introduction, Specifications, and Safety 100
Introduction....................................................................................................... 100-1 System Overview .............................................................................................. 100-1 Test Modes........................................................................................................ 100-2 Fill-Ramp Mode.......................................................................................... 100-2 Burst Test Mode.......................................................................................... 100-2 Custom Mode.............................................................................................. 100-2 M-RULE® Mode........................................................................................ 100-3 Available Options ............................................................................................. 100-3 External Connections - Back ............................................................................ 100-4 External Connections - Side ............................................................................. 100-5
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
i
Section 3 - On-Screen Controls, Operation and Job Setup 300
Using the Touch Screen and Virtual Keyboard ................................................ 300-1 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
ii
Section 3 - On-Screen Controls, Operation and Job Setup (continued) 325
Job Setup ........................................................................................................... 325-1 Introduction ....................................................................................................... 325-1 Setting Up a Fill-Ramp Job............................................................................... 325-1 Setting Up a Burst Test Job .............................................................................. 325-8 Setting Up a Custom Test Job........................................................................... 325-15 Setting Up an M-RULE® Job........................................................................... 325-26 Introduction ................................................................................................. 325-26 Obtaining the M-RULE® Parameters......................................................... 325-26 Procedure .................................................................................................... 325-27 Using the Mold Number Sequence Tab ............................................................ 325-41
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
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Section 3 - On-Screen Controls, Operation and Job Setup (continued) 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
iv
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
vi
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
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100-1
100 - Introduction
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 segmentby-segment basis. As each segment is developed, it is graphically displayed on the user interface.
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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
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100-3
100 - Introduction
EXTERNAL CONNECTIONS - BACK
LOW PRESSURE
1
HIGH PRESSURE
2
3
4
5
Figure 100-3
EXTERNAL CONNECTIONS - BACK
100-4
#
Component
1 2 3 4 5
Dual Regulator Knob Manual Water Valve Air In Water In Drain
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100 - Introduction
EXTERNAL CONNECTIONS - SIDE
2
1
4
3
5 Figure 100-4
EXTERNAL CONNECTIONS - SIDE
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#
Component
1 2 3 4 5
Network Connector USB Connector Serial Connector Power Switch Power Cord Connector
100-5
100 - Introduction
END OF SECTION 100
100-6
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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).
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105-1
105 - Specifications
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.
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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 CaCO3
Total Dissolved Solids
Less than 290 ppm
Particulates
Under 5 microns
pH
6.5 - 8.5
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.
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105-3
105 - Specifications
PHYSICAL DIMENSIONS
Figure 105-1 shows the physical dimensions of the PPT3000™ system and the optional stand.
28.01" (711mm)
30" (762mm)
30.5" (777mm)
65.56" (1665mm)
27.25" (692mm)
22.13" (562mm)
FRONT
SIDE
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PPT3-E
Figure 105-1
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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.
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110 – Safety Information
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
High voltage.
DANGER - Conditions other
!
than high voltage. Example: a pinch point.
HOT SURFACE - This GROUND - Protective earth
1406
(ground) terminal.
symbol identifies surfaces that become hot to the touch during normal operation.
ENTANGLEMENT - This
CRUSH - This symbol
symbol identifies areas or components that may pose an entanglement hazard.
identifies areas or components that may pose a crush hazard.
FOOT CRUSH - This symbol
1393
1459
identifies areas or components that may pose a foot crush hazard. 1335
EYE - This symbol identifies
areas where eye protection should be worn.
FLUID INJECTION - This
symbol identifies areas or components that may pose a fluid injection hazard. 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.
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Section 3 ON-SCREEN CONTROLS, OPERATION & JOB SETUP
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300 - USING THE TOUCH SCREEN AND THE VIRTUAL KEYBOARD THE TOUCH SCREEN
The PPT3000™ system utilizes a touch screen and “virtual” keyboard to make selections and enter data while working in the test system. Different types of on-screen controls are shown in Figure 300-1.
1
5 2
3 4
ON-SCREEN CONTROLS Figure 300-1 TYPES OF ON-SCREEN CONTROLS #
Description
Purpose
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
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300-1
300 – The Touch Screen and Virtual Keyboard
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
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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
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300-3
300 – The Touch Screen and Virtual Keyboard
CONTROLS ON THE VIRTUAL KEYBOARD Control
Description The BACK Key – Touch this key to delete the character preceding the cursor in the entry field.
The HOME Key – Touch this key to move the cursor to the beginning of the entry field.
The CLEAR Key – Touch this key to delete all of the text and/or numerals in the entry field.
The Cursor Keys – Touch these keys to move the cursor left or right (one character for each touch) in the entry field.
The END Key – Touch this key to move the cursor to the end of the entry field.
The ENTER Key – Touch this key to confirm the text and/or numerals in the entry field.
The CANCEL Key – Touch this key to close the virtual keyboard without making an entry in the entry field.
The SHIFT Key – Touch this key to toggle between uppercase and lowercase characters.
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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
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300-5
300 – The Touch Screen and Virtual Keyboard
END OF SECTION 300
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305 - THE MAIN SCREEN INTRODUCTION
The Main Screen for the PPT3000™ system is illustrated in Figure 305-1. The onscreen controls can be accessed with the touch screen and modified with the virtual keyboard. Use these on-screen controls to adjust and run the software-controlled elements of this system (for more information on the touch screen and virtual keyboard, see Section 300). 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
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305-1
305 – The Main Screen
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.
TEST RESULTS GRAPH
WATER TEMPERATURE
CONTROL BUTTONS
ALARM MESSAGE BOX
STATUS BAR JOB PARAMETERS
MOLD NUMBER ENTRY BUTTONS
TEST RESULTS REPORT
PARTS OF THE MAIN SCREEN Figure 305-2
305-2
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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, Operation.
Touch this button to open the Diagnostic screen, which includes a graphical display of the system status, as well as the System Log and the Alarm Log. For more information, see Section 700, Troubleshooting.
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305-3
305 – The Main Screen
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
305-4
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305 – The Main Screen
TEST RESULTS GRAPH – CUSTOM MODE Figure 305-5
TEST RESULTS GRAPH – M-RULE® MODE Figure 305-6
TEST RESULTS GRAPH – OPTIONAL CUSTOM EXPANSION FEATURE Figure 305-7
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305-5
305 – The Main Screen
DEFAULT FILL-RAMP TEST RESULT (PRESSURE AND % VOLUME EXPANSION VS. TIME)
CORRESPONDING PRESSURE VS. VOLUME EXPANSION TEST RESULT GRAPH
GRAPH OPTIONS Figure 305-8
305-6
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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
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305-7
305 – The Main Screen
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.
305-8
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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
CURRENT MOLD NUMBER
PREVIOUS NUMBER
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ADVANCE TO NEXT NUMBER IN SEQUENCE
NEXT NUMBER
305-9
305 – The Main Screen
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.
305-10
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305 – The Main Screen
DIFFERENCES AFTER AN M-RULE® TEST
Figure 305-11 shows the Main Screen after a typical M-RULE® test. Note that the Job Parameters portion of the screen lists “M-RULE” as the Profile Test Type and includes the Shelf Life Limit and Material Utilization Limit. The Test Results Report includes the calculated M-RULE® Shelf Life and M-RULE® Material Utilization. For the container to pass, the calculated M-RULE® Shelf Life and MRULE® Material Utilization must meet or exceed the limits that were established during job setup.
TYPICAL MAIN SCREEN AFTER AN M-RULE® TEST Figure 305-11
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305-11
305 – The Main Screen
END OF SECTION 305
305-12
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310 - OPERATION INTRODUCTION
This section includes general instructions for testing plastic (PET) containers. TESTING PLASTIC CONTAINERS
1. If necessary, install the appropriate pair of inserts for the finish size of the container to be tested. A table, which lists finish sizes and insert sizes, is included at the end of this section. 2. If necessary, install the correct Seal (2, Figure 310-1) on the Test Head (3, Figure 310-1) based on the table below. SEAL SELECTION FOR ALUMINUM BOTTLES
Finish Height
Seal
1/8 – 3/8-inch
Large
3/8 – 3/4-inch
Medium
3/4 – 1-inch
Small
3. Make sure the water and air supplies are turned on. 4. Edit, create and/or load the Job Configuration for the container to be tested. See Section 320, Using Job Configurations, and/or Section 325, Job Setup, if necessary. 5. Make sure the water temperature is in the acceptable range. NOTE: If the water temperature is outside of the acceptable range, test results may fall outside of expected accuracy.
6. Check the settings on the General tab of the System Settings screen. See Section 330, System Setup, if necessary. 7. If CSV data is to be output, check the settings on the CSV tab of the System Settings screen. Establish a serial or network connection and check that the connection is functioning properly. See Section 340, CSV Output, if necessary. 8. If the Job Configuration includes a Mold Sequence, the mold number for the container to be tested will be displayed. Otherwise, manually enter the mold number, if desired. See Section 305, On-Screen Controls, and/or Section 325, Job Setup, if necessary.
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310-1
310 – Operation
9. Place the first container to be tested in the Inserts (1, Figure 310-1) of the Bottle Holder and close the door. • You do not need to fill the bottle; the PPT3000™ system will fill it. • There is a safety interlock on the door. If it is not fully closed, the PPT3000™ system will not test the bottle. 10. Touch the “Start Test” button on the Main Screen. The Test Head (2, Figure 310-1) will clamp down on and seal the finish of the bottle. The test can be stopped by touching the “Stop” button. Note that during a Ramp Test, an “Expansion at 13 Seconds” value will be recorded if the “Stop” button is touched after the test has run for 13 or more seconds. NOTE: After the container has been filled, it is normal for a small amount of water to be dispensed from the fitting in the back of the Test Chamber. It also is normal for a small amount of air and water to be dispensed from the fitting after the completion of a test (more so if the container bursts).
2
1
1
M159-E
Figure 310-1
310-2
11/16/2007
310 – Operation
11. If the container fails and the Failure Input Mode is enabled, the Failure Mode Input dialog box will appear (see Figure 310-2). • Touch the dropdown box and select a description of the failure (see Figure 310-3). Or, select “Other” and use the virtual keyboard to enter a description of the failure (up to 30 characters). • Touch the “Save” button on the Failure Mode Input dialog box to save the description with the test results, and to make the description the default failure description for subsequent failures. • Or, touch the “Back” button on the Failure Mode Input dialog box to save the failure description with the test results without changing the default description for subsequent failures.
FAILURE MODE INPUT DIALOG BOX Figure 310-2
FAILURE MODE INPUT DIALOG BOX WITH DROPDOWN LIST Figure 310-3
11/16/2007
310-3
310 – Operation
12. To see a graphical display of test results (including results for up to 10 previous tests), touch the “Statistics” button. The Statistics screen will be displayed (see Figure 310-4).
STATISTICS SCREEN Figure 310-4
13. To see a spreadsheet with additional test data, touch the “Spreadsheet” button at the bottom of the Statistics screen. The Test Results Spreadsheet will be displayed (see Figure 310-5). Or, touch the “Back” button to return to the Main Screen. 14. If there are more containers in the batch, remove the tested container and place the next container to be tested in the Bottle Holder. Close the door and repeat steps 9 through 12.
310-4
11/16/2007
310 – Operation
TEST RESULTS SPREADSHEET Figure 310-5
11/27/2006
310-5
310 – Operation
THE TEMPERATURE EQUALIZATION FEATURE
If the Temperature Equalization feature is enabled on the General tab of the System Setup screen (see Section 330), the system will prompt the operator to flush the supply water if: • the incoming supply water temperature is outside of the Alarm Limits (see Figure 3106). • after conducting a test, the system senses that the temperature of the fill water or the test water is outside of the Alarm Limits (see Figure 310-7).
Figure 310-6
Figure 310-7
310-6
11/6/2007
310 – Operation
Flush Supply Water –
If this button is touched, the screen shown in Figure 305-8 will be displayed.
– If this button is touched, the General tab of the System Settings will be displayed (after the password is entered) and the Alarm Limits can be changed or the Temperature Equalization feature can be disabled (see Section 330). Change Settings
Cancel –
If this button is touched, the Temperature Equalization process will be halted but the Temperature Equalization feature will remain enabled.
Figure 310-8
– If this button is touched, the flushing phase of the equalization process will begin and the system will flush the supply line for the amount of time specified in the Flushing Time field. (The Flushing Time value can be changed on this screen, but it will not overwrite the default value established on the General tab of the System Setup screen.) If the Door is opened, the process will be cancelled but the Temperature Equalization feature will remain enabled. While the supply line is being flushed, the screen shown in Figure 310-9 will be displayed.
Start
Cancel –
If this button is touched, the Temperature Equalization process will be halted but the Temperature Equalization feature will remain enabled.
11/6/2007
310-7
310 – Operation
Figure 310-9
Stop –
If the Stop button is touched while the supply line is being flushed, the system will stop flushing and begin equalizing the temperature of the water in the tank (see Figure 310-10). The “Stop” button can be touched if the Current Temperature returns to an acceptable level before the Flushing Time runs its full course.
310-8
11/6/2007
310 – Operation
Figure 310-10
After the supply line has been flushed, the system will drain a portion of the water from the tank, refill the tank, and then compare the temperature of the water in the tank to the temperature of the incoming water (in an effort to equalize the water temperature between the supply line and the tank). This process will be repeated up to five times or until the two temperatures are within the acceptable range of 5°F. (The process will be cancelled if the Door is opened before the process completes.)
11/6/2007
310-9
310 – Operation
If the temperature of the water in the tank and the temperature of the supply water have returned to an acceptable range, the system will display the screen shown in Figure 310-11.
Figure 310-11
Touch this button to return to the Main Screen. The system is ready to test.
310-10
11/6/2007
310 – Operation
If the temperature of the water in the tank and the temperature of the supply water have not returned to an acceptable range after five cycles, the system will display the screen shown in Figure 310-12.
Figure 310-12
Touch this button to return to the Main Screen. The system is ready to test. (Note that the accuracy of the tests may be affected by the water temperature.) If the system continues to initiate the Temperature Equalization routine, it may be necessary to increase the acceptable temperature range or disable the Temperature Equalization feature on the General tab of the System Setup screen (see Section 330).
11/6/2007
310-11
310 – Operation
SHUTTING DOWN THE PPT3000
Do not remove power from the system without first closing the PPT3000 program. Use the following procedure to shut down the PPT3000: 1. Touch the “Diagnostics” button on the Main Screen (see Figure 310-13). • The Diagnostics screen will be displayed (see Figure 310-14).
MAIN SCREEN Figure 310-13
310-12
12/15/2008
310 – Operation
DIAGNOSTICS SCREEN Figure 310-14
2. Touch the “Exit to Windows” button at the bottom of the Diagnostics screen. • The dialog box shown in Figure 310-15 will be displayed. 3. Touch “Yes” to close the PPT3000 program. 4. After the program has closed and the Windows desktop is displayed, turn off the power to the PPT3000.
Figure 310-15
12/15/2008
310-13
310 – Operation
INSERT SIZES
An Insert Pair may be chosen depending on the outside diameter of the container as measured immediately below the finish. Available sizes are shown below. INSERT PAIR PART NO.
DIAMETER (INCHES)
DIAMETER (MM)
INSERT PAIR PART NO.
DIAMETER (INCHES)
DIAMETER (MM)
6017122A-01
0.937”
23.799
6017122A-29
1.299”
32.994
6017122A-02
0.953”
24.206
6017122A-30
1.515”
38.481
6017122A-03
0.970”
24.638
6017122A-31
1.889”
47.980
6017122A-04
1.000”
25.400
6017122A-32
1.250”
31.750
6017122A-05
1.040”
26.416
6017122A-33
0.980”
24.892
6017122A-06
1.390”
35.306
6017122A-34
1.010”
25.654
6017122A-07
0.924”
23.469
6017122A-35
1.406”
35.712
6017122A-08
0.930”
23.622
6017122A-36
1.055”
26.797
6017122A-09
0.950”
24.130
6017122A-37
0.935”
23.749
6017122A-10
0.955”
24.257
6017122A-38
0.540”
13.716
6017122A-11
0.960”
24.384
6017122A-39
0.945”
24.003
6017122A-12
0.968”
24.587
6017122A-40
1.142”
29.006
6017122A-13
0.973”
24.714
6017122A-41
0.690”
17.526
6017122A-14
0.987”
25.069
6017122A-42
1.430”
36.322
6017122A-15
0.990”
25.146
6017122A-43
1.260”
32.004
6017122A-16
1.050”
26.670
6017122A-44
1.530”
38.862
6017122A-17
1.100”
27.940
6017122A-45
1.062”
26.974
6017122A-18
1.125”
28.575
6017122A-46
0.600”
15.240
6017122A-19
1.156”
29.362
6017122A-47
0.520”
13.208
6017122A-20
1.240”
31.496
6017122A-48
1.359”
34.518
6017122A-21
1.375”
34.925
6017122A-49
0.896”
22.758
6017122A-22
1.500”
38.100
6017122A-50
1.093”
27.762
6017122A-23
0.450”
11.430
6017122A-51
0.904”
22.961
6017122A-24
0.665”
16.891
6017122A-52
1.135”
28.829
6017122A-25
1.110”
28.194
6017122A-53
1.634”
41.503
6017122A-26
1.023”
25.984
6017122A-54
1.359”
34.518
6017122A-27
1.180”
29.972
6017122A-55
1.560”
39.62
6017122A-28
1.220”
30.988
6017122A-56
1.450”
36.83
310-14
12/15/2008
320 - USING JOB CONFIGURATIONS INTRODUCTION
A Job Configuration is a set of test parameters for a specific container and/or test. Once a Job Configuration has been created, it can be stored and then reloaded when needed. Up to 100 Job Configurations can be stored on the PPT3000™ system. This section includes instructions for loading, copying, creating, deleting, importing, and exporting Job Configurations. For instructions on editing Job Configurations, see Section 325, Job Setup. USING JOB CONFIGURATIONS
To access the Job Menu and the Job Configuration controls, touch the Job Setup button on the Main Screen (see Figure 320-1). The Job Menu will be displayed (see Figure 320-2).
MAIN SCREEN Figure 320-1
11/28/2006
320-1
320 – Using Job Configurations
JOB MENU SCREEN Figure 320-2
320-2
12/1/2006
320 – Using Job Configurations
Loading Jobs
To switch to (load) a Job that has already been created for a different type of container or test: 1. Touch the “Job Setup” button on the Main Screen (see Figure 320-1). • The Job Menu screen will be displayed (see Figure 320-2). 2. Touch the Job that you want to use. • The Selected Job (displayed at the top of the Job Menu screen) will change to reflect the Job Configuration that has been selected. 3. Touch the “Load” button. • The Loaded Job (displayed at the top of the Job Menu screen) will change to reflect the Job Configuration that has been loaded. The Status report (displayed at the bottom of the Job Menu screen) will indicate that the job has been loaded.
11/28/2006
320-3
320 – Using Job Configurations
Copying Jobs
If a new job is needed and similar job already exists, it might be easier to copy the existing job and then edit the copy rather than to create a job from scratch. (For instructions on editing a job, see Section 325, Job Setup.) The maximum number of jobs that can be stored is 100. If you try to make a copy of a job after this capacity has been reached, the system will instruct you to delete a job first. NOTE: M-RULE® jobs cannot be copied.
To copy a job: 1. Touch the “Job Setup” button on the Main Screen (see Figure 320-1). • The Job Menu screen will be displayed (see Figure 320-2). 2. Touch the Job that you want to copy. • The Selected Job (displayed at the top of the Job Menu screen) will change to reflect the Job Configuration that has been selected. 3. Touch the “Copy” button. • The Virtual Keyboard will appear (see Figure 320-3). 4. Enter a name for the Job using any of the alphanumeric keys on the virtual keyboard – except the “.” (period), “:” (colon), or “/” (slash) – and then touch the “Enter” button. • The Job will appear on the list of Jobs. The Status report (displayed at the bottom of the Job Menu screen) will indicate that the job has been copied. NOTE: When you copy a job, the new job does not become the Current Job. You must touch the job and then touch the “Load” button to make it the Current Job.
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320 – Using Job Configurations
VIRTUAL KEYBOARD Figure 320-3
11/28/2006
320-5
320 – Using Job Configurations
Creating Jobs
The maximum number of jobs that can be stored is 100. If you try to create a new Job after this capacity has been reached, the system will instruct you to delete a job first. To create a job: 1. Touch the “Job Setup” button on the Main Screen (see Figure 320-1). • The Job Menu screen will be displayed (see Figure 320-2). 2. Touch the “Create” button. • The Virtual Keyboard will appear. 3. Enter a name for the Job using any of the alphanumeric keys on the virtual keyboard – except the “.” (period), “:” (colon), or “/” (slash) – and then touch the “Enter” button. • The new Job will appear on the list of Jobs. The Status report (displayed at the bottom of the Job Menu screen) will indicate that the job has been created. NOTE: When you create a job, the new job does not become the Current Job. You must touch the job and then touch the “Load” button to make it the Current Job.
Deleting Jobs NOTE: You may want to export a job (described later in this section) as a way of storing a backup copy of a job before deleting it.
To delete a job: 1. Touch the “Job Setup” button on the Main Screen (see Figure 320-1). • The Job Menu screen will be displayed (see Figure 320-2). 2. Touch the Job that you want to delete. • The Selected Job (displayed at the top of the Job Menu screen) will change to reflect the Job Configuration that has been selected. 3. Touch the “Delete” button. • The system will display a confirmation dialog box. 4. Touch “Yes” to delete the Job. (Or, touch “No” to abort the deletion). • The job will be removed from the list of jobs. The Status report (displayed at the bottom of the Job Menu screen) will indicate that the job has been deleted. NOTE: The Default Job and the Current Job cannot be deleted.
320-6
11/28/2006
320 – Using Job Configurations
Importing Jobs
To import a Job Configuration: 1. Connect a USB 2.0 Memory Device (see Figure 320-4) to the PPT3000™ system (see Figure 320-5). • The Memory Device must contain the Job Configurations to be imported in a folder named “PPTJobs” (without the quotation marks). 2. Touch the “Job Setup” button on the Main Screen (see Figure 320-1). • The Job Menu screen will be displayed (see Figure 320-2). 3. Touch the “Import” button. • A list of jobs will be displayed (see Figure 320-6). 4. Touch the Job that you want to import. 5. Touch the “Import” button at the bottom of the Import List screen. • If the Job to be imported already exists in the job list, the system will ask you to confirm that you want to overwrite the existing Job. • After the Job is successfully imported, the system will display the Job Menu screen. The imported job will appear in the list of Jobs on the Job Menu screen. The Status report (displayed at the bottom of the Job Menu screen) will indicate that the job has been imported.
11/28/2006
320-7
320 – Using Job Configurations
Exporting Jobs NOTE: M-RULE® jobs cannot be exported.
To export a Job Configuration: 1. Connect a USB 2.0 Memory Device (see Figure 320-4) to the PPT3000™ system (see Figure 320-5). • The Memory Device must contain a folder named “PPTJobs” (without the quotation marks). 2. Touch the “Job Setup” button on the Main Screen (see Figure 320-1). • The Job Menu screen will be displayed (see Figure 320-2). 3. Touch the Job that you want to export. • The Selected Job (displayed at the top of the Job Menu screen) will change to reflect the Job Configuration that has been selected. 4. Touch the “Export” button. • If the Job to be exported already exists in the “PPTJobs” folder, the system will ask you to confirm that you want to overwrite the existing Job. • The Status indicator at the bottom of the Job Menu screen will indicate that the Job has been exported successfully.
320-8
11/28/2006
320 – Using Job Configurations
TYPICAL USB STORAGE DEVICE Figure 320-4
11/28/2006
320-9
320 – Using Job Configurations
USB CONNECTOR ON THE PPT3000™ SYSTEM Figure 320-5
320-10
6/29/2012
320 – Using Job Configurations
IMPORT LIST Figure 320-6
12/1/2006
320-11
320 – Using Job Configurations
END OF SECTION 320
320-12
11/28/2006
325 - JOB SETUP INTRODUCTION
This section includes instructions for setting up a Fill Ramp job (see below), a Burst job (see Page 325-8), a Custom job (see Page 325-15), and an M-RULE® job (see Page 32526). Instructions for using the Mold Number Sequence tab, which functions the same for all four Test Modes, begin on Page 325-41. SETTING UP A FILL-RAMP JOB
1. To access the Job Menu and the Job Configuration controls, touch the Job Setup button on the Main Screen (see Figure 325-1). The Job Menu will be displayed (see Figure 3252).
MAIN SCREEN Figure 325-1
10/15/2013
325-1
325 – Job Setup
2. Generally, it is easier to copy an existing job and edit the copy. Select an existing Fill Ramp job and touch the “Copy” button. 3. Enter a name for the new job on the virtual keyboard and touch the “Enter” key. 4. Select the new job on the Menu screen and touch the “Load” button. 5. Touch the “Edit” button. A screen similar to Figure 325-3 will be displayed.
JOB MENU SCREEN Figure 325-2
325-2
12/1/2006
325 – Job Setup
Figure 325-3
11/30/2006
325-3
325 – Job Setup
6. Adjust the following fields and settings: Profile Description – Use the virtual keyboard to enter a brief (up to 30 characters)
description of the test profile, such as “ramp after 100 psi.” Profile Test Type – If the new job is a copy of a previous Fill Ramp job, the “Fill Ramp”
radio button will be selected by default. If the new job was created, make sure the “Fill Ramp” radio button is selected. Failure Mode Input – When this feature is enabled, a dialog box will appear after a
container breaks to allow the operator to enter information about the breakage such as the location or severity. This information will be included in the CSV output. Initial Pressure – Enter the initial pressure. This pressure will be applied for 13 seconds.
After 13 seconds, pressure will be increased at a rate of 10 psi per second until the test is completed (the timeout is reached, the ramp pressure limit is reached, the container breaks or the expansion limit is reached) or terminated (the “Stop” button is pressed or the door is opened). NOTE: The unit of measure for pressure cannot be changed during Job Setup. To change the unit of measure for pressure, access the System Settings screen (see Section 330). Nominal Volume – Enter the nominal volume. The unit of measure can be changed by
touching the “Units” cell in the “Nominal Volume” row. Options include ounces, milliliters, and cubic inches. NOTE: 1.6 liters must be entered as 1600 milliliters; 2 liters must be entered as 2000 milliliters, etc. Expansion Limit – Enter the expansion limit. The unit of measure can be changed by
touching the “Units” cell in the “Expansion Limit” row. Options include percent, milliliters, and none. 7. Touch the “Save” button at the bottom of the screen to save the new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Job Menu screen.
325-4
11/30/2006
325 – Job Setup
8. Touch the Graph tab to bring it to the front. A screen similar to Figure 325-4 will be displayed.
Figure 325-4
9. Visually confirm that the graph displays the intended test profile. 10. Touch the Mold Number Sequence tab to bring it to the front. A screen similar to Figure 325-5 will be displayed.
11/30/2006
325-5
325 – Job Setup
Figure 325-5
11. See Using the Mold Number Sequence Tab at the end of this section.
325-6
11/30/2006
325 – Job Setup
12. After the settings on the Mold Number Sequence tab have been adjusted, touch the “Save” button at the bottom of the screen to save the new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Job Menu screen. 13. Once the new settings have been saved, touch the “Back” button at the bottom of the screen to return to the Job Menu screen. 14. Touch the “Back” button at the bottom of the screen to return to the Main Screen. The system is ready to test containers with the new job (see Section 310, Operation).
11/30/2006
325-7
325 – Job Setup
SETTING UP A BURST TEST JOB
1. To access the Job Menu and the Job Configuration controls, touch the Job Setup button on the Main Screen (see Figure 325-6). The Job Menu will be displayed (see Figure 3257).
MAIN SCREEN Figure 325-6
325-8
11/30/2006
325 – Job Setup
2. Generally, it is easier to copy an existing job and edit the copy. Select an existing Burst job and touch the “Copy” button. 3. Enter a name for the new job on the virtual keyboard and touch the “Enter” key. 4. Select the new job on the Menu screen and touch the “Load” button. 5. Touch the “Edit” button. A screen similar to Figure 325-8 will be displayed.
JOB MENU SCREEN Figure 325-7
12/1/2006
325-9
325 – Job Setup
Figure 325-8
325-10
11/30/2006
325 – Job Setup
6. Adjust the following fields and settings: Profile Description – Use the virtual keyboard to enter a brief (up to 30 characters)
description of the test profile, such as “20-ounce at 50 psi.” Profile Test Type – If the new job is a copy of a previous Burst job, the “Burst” radio
button will be selected by default. If the new job was created, make sure the “Burst” radio button is selected. Failure Mode Input – When this feature is enabled, a dialog box will appear after a
container breaks to allow the operator to enter information about the breakage such as its location or severity. This information will be included in the CSV output. Initial Pressure – Enter the initial pressure. This pressure will be applied for the duration
of the Hold Time, or until the test is completed (the timeout is reached, the container breaks or the expansion limit is reached) or terminated (the “Stop” button is pressed or the door is opened). NOTE: The unit of measure for pressure cannot be changed during Job Setup. To change the unit of measure for pressure, access the System Settings screen (see Section 330). Nominal Volume – Enter the nominal volume. The unit of measure can be changed by
touching the “Units” cell in the “Nominal Volume” row. Options include ounces, milliliters, and cubic inches. NOTE: 1.6 liters must be entered as 1600 milliliters; 2 liters must be entered as 2000 milliliters, etc. Expansion Limit – Enter the expansion limit. The unit of measure can be changed by
touching the “Units” cell in the “Expansion Limit” row. Options include percent, milliliters, and none. Hold Time – Enter the amount of time that the Initial Pressure will be applied. After the
Hold Time expires, pressure will be removed. Hold Forever – When this feature is activated, the Initial Pressure will be held
indefinitely, or until the test is completed (the container breaks or the expansion limit is reached) or terminated (the “Stop” button is pressed or the door is opened). Note that the pressure graph will stop updating after 10 minutes. NOTE: When the Hold Forever feature is activated, the Hold Time value will be displayed as 600 seconds (the maximum amount of time that the graph will update) even though the test may continue longer.
11/30/2006
325-11
325 – Job Setup
7. Touch the “Save” button at the bottom of the screen to save the new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Job Menu screen. 8. Touch the Graph tab to bring it to the front. A screen similar to Figure 325-9 will be displayed.
Figure 325-9
9. Visually confirm that the graph displays the intended test profile. 10. Touch the Mold Number Sequence tab to bring it to the front. A screen similar to Figure 325-10 will be displayed.
325-12
11/30/2006
325 – Job Setup
Figure 325-10
11. See Using the Mold Number Sequence Tab at the end of this section.
11/30/2006
325-13
325 – Job Setup
12. After the settings on the Mold Number Sequence tab have been adjusted, touch the “Save” button at the bottom of the screen to save the new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Job Menu screen. 13. Once the new settings have been saved, touch the “Back” button at the bottom of the screen to return to the Job Menu screen. 14. Touch the “Back” button at the bottom of the screen to return to the Main Screen. The system is ready to test containers with the new job (see Section 310, Operation).
325-14
11/30/2006
325 – Job Setup
SETTING UP A CUSTOM TEST JOB
1. To access the Job Menu and the Job Configuration controls, touch the Job Setup button on the Main Screen (see Figure 325-11). The Job Menu will be displayed (see Figure 325-12).
MAIN SCREEN Figure 325-11
11/30/2006
325-15
325 – Job Setup
2. Generally, it is easier to copy an existing job and edit the copy. Select an existing Custom job and touch the “Copy” button. 3. Enter a name for the new job on the virtual keyboard and touch the “Enter” key. 4. Select the new job on the Menu screen and touch the “Load” button. 5. Touch the “Edit” button. A screen similar to Figure 325-13 will be displayed.
JOB MENU SCREEN Figure 325-12
325-16
12/1/2006
325 – Job Setup
Figure 325-13
11/30/2006
325-17
325 – Job Setup
6. Adjust the following fields and settings: – Use the virtual keyboard to enter a brief (up to 30 characters) description of the test profile, such as “sawtooth profile.”
Profile Description
– If the new job is a copy of a previous Custom job, the “Custom” radio button will be selected by default. If the new job was created, make sure the “Custom” radio button is selected.
Profile Test Type
Failure Mode Input –
When this feature is enabled, a dialog box will appear after a container breaks to allow the operator to enter information about the breakage such as the location or severity. This information will be included in the CSV output. – Enter the initial pressure. This pressure will be applied at the beginning of the custom test. Additional pressures and hold times can be added on the Graph tab.
Initial Pressure
NOTE: The unit of measure for pressure cannot be changed during Job Setup. To change the unit of measure for pressure, access the System Settings screen (see Section 330).
– Enter the nominal volume. The unit of measure can be changed by touching the “Units” cell in the “Nominal Volume” row. Options include ounces, milliliters, and cubic inches.
Nominal Volume
NOTE: When the Hold Forever feature is activated, the Hold Time value will be displayed as 600 seconds (the maximum amount of time that the graph will update) even though the test may continue longer.
– Enter the expansion limit. The unit of measure can be changed by touching the “Units” cell in the “Expansion Limit” row. Options include percent, milliliters, and none.
Expansion Limit
% Expansion at –
If the system includes the optional Custom Expansion feature, an additional parameter will be available as shown in Figure 325-14. Enter the amount of time into the test that the system will report the % Expansion. This value must be greater than zero and less than the duration of the test.
7. Touch the “Save” button at the bottom of the screen to save the new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Job Menu screen.
325-18
10/15/2013
325 – Job Setup
Figure 325-14
10/15/2013
325-19
325 – Job Setup
8. Touch the Graph tab to bring it to the front. A screen similar to Figure 325-15 will be displayed.
Figure 325-15
9. To modify the Start Pressure, Duration, and/or End Pressure, touch the desired cell and use the virtual keyboard to enter a different number. 10. Touch the “Add” button and continue to enter additional Start Pressures, Durations and End Pressures (see Figure 325-16). The graph will update to reflect the additions. Note that the system’s maximum ramp pressure rate of 10 psi per second cannot be exceeded. • To delete a row, select the row and touch the “Delete” button. • To clear all of the added rows, touch the “Clear All” button.
325-20
10/15/2013
325 – Job Setup
Figure 325-16
10/15/2013
325-21
325 – Job Setup
Creating Steps in a Custom Test
To create steps in a Custom test as shown in Figure 325-17: A. Create a row with matching Start and End pressures with a Duration greater than 0. B. On the next row, use the End pressure from the previous row as the Start pressure. Enter a Duration greater than 0. Enter an End pressure that is greater than the Start pressure. C. Touch the Duration cell on the last row and change the value to 0. D. Repeat the above three instructions to continue building steps.
Figure 325-17
325-22
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325 – Job Setup
11. Touch the “Save” button at the bottom of the screen to save the new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Job Menu screen. 12. Touch the Mold Number Sequence tab to bring it to the front. A screen similar to Figure 325-18 will be displayed.
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325 – Job Setup
Figure 325-18
13. See Using the Mold Number Sequence Tab at the end of this section.
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325 – Job Setup
14. After the settings on the Mold Number Sequence tab have been adjusted, touch the “Save” button at the bottom of the screen to save the new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Job Menu screen. 15. Once the new settings have been saved, touch the “Back” button at the bottom of the screen to return to the Job Menu screen. 16. Touch the “Back” button at the bottom of the screen to return to the Main Screen. The system is ready to test containers with the new job (see Section 310, Operation).
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325 – Job Setup
SETTING UP AN M-RULE® JOB
Introduction
The M-RULE® feature forecasts each container’s Shelf Life and Material Utilization based on container characteristics. Shelf Life is defined as the amount of time, in days, before product quality is affected by the container’s permeability to air and light. Material Utilization is defined as how well the material in the container is distributed to optimize the container’s shelf life, measured as a percentage of optimal utilization. Obtaining the M-RULE® Parameters File
Before an M-RULE job can be created, an M-RULE® Parameters file must be generated. This file is created by Agr based on customer-provided information about the container to be tested. Agr provides an M-RULE® Questionnaire to collect the necessary information. The questionnaire must be completed in its entirety to successfully create the profile. Once the M-RULE® Parameters file has been generated, it must be imported into the job as part of Job Setup. This typically is done by an Agr Service Technician during installation. However, instructions for importing an M-RULE® Parameters file are provided on the following pages.
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325 – Job Setup
Procedure
1. Once the M-RULE® Parameters file has been returned by Agr Technical Services, save the file on a supported portable USB Memory Device in a folder named “MruleImport” (capital M, capital I, no spaces, without quotation marks). 2. To access the Job Menu and the Job Configuration controls, touch the Job Setup button on the Main Screen (see Figure 325-19). The Job Menu will be displayed (see Figure 32520).
MAIN SCREEN Figure 325-19
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325-27
325 – Job Setup
3. Touch the “Create” button. NOTE: M-RULE® jobs cannot be copied.
4. Enter a name for the new job on the virtual keyboard and touch the “Enter” key. 5. Select the new job on the Menu screen and touch the “Load” button. 6. Touch the “Edit” button. A screen similar to Figure 325-21 will be displayed.
JOB MENU SCREEN Figure 325-20
325-28
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325 – Job Setup
Figure 325-21
7. Touch the “M-RULE®” radio button. The M-RULE Parameters tab will become visible as shown in Figure 325-22.
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325-29
325 – Job Setup
Figure 325-22
8. Touch the M-RULE Parameters tab to bring it to the front. A screen similar to Figure 325-23 will be displayed.
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325 – Job Setup
Figure 325-23
9. Connect the USB Memory Device to the system that contains the M-RULE® Parameters file for the container to be tested. Once the USB Memory Device has been connected, a list of M-RULE® Parameters files will be displayed (see Figure 325-24). NOTE: It may take the system a few seconds to recognize the USB Memory Device.
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325-31
325 – Job Setup
Figure 325-24
10. Touch the description of the M-RULE® Parameters file that will be used for the Job. The “Import” button will activate. 11. Touch the “Import” button. The M-RULE® Parameters will be imported and the “Verify M-RULE® job” button will appear (see Figure 325-25).
325-32
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325 – Job Setup
Figure 325-25
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325-33
325 – Job Setup
Figure 325-26
12. Touch the “Verify M-RULE® job” button. 13. Place the container for which the M-RULE job was created in the PPT3000 and close the door. 14. Touch the “Start” button. • The system will pressurize the container five times.
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325 – Job Setup
Figure 325-27
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325-35
325 – Job Setup
Figure 325-28
15. At the completion of the verification process, touch the General Parameters tab to bring it to the front. A screen similar to Figure 325-29 will be displayed.
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325 – Job Setup
Figure 325-29
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325-37
325 – Job Setup
16. Adjust and/or note the following fields and settings (only the Shelf Life Limit and Material Utilization Limit can be modified): – The Profile Description will be imported with the M-RULE® Parameters file and cannot be changed.
Profile Description
– After the M-RULE® Parameters file has been imported, the Profile Test Type cannot be changed.
Profile Test Type
Failure Mode Input –
When this feature is enabled, a dialog box will appear after a container breaks to allow the operator to enter information about the breakage such as the location or severity. This information will be included in the CSV output.
– For M-RULE® tests, the initial pressure cannot be changed. The system applies 30 psi for 10 seconds, then increases pressure at a rate of 1 psi per second for an additional 30 seconds.
Initial Pressure
– The Nominal Volume will be imported with the M-RULE® Parameters file and cannot be changed.
Nominal Volume Expansion Limit Shelf Life Limit
– The Expansion Limit is not used in M-RULE® jobs.
– Enter the minimum acceptable shelf life of the container as a number of
days. – Enter the minimum acceptable utilization of the material in the container as a percentage of the optimum utilization.
Material Utilization Limit
17. Touch the “Save” button at the bottom of the screen to save the new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Job Menu screen.
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325 – Job Setup
18. Touch the Graph tab to bring it to the front. A screen similar to Figure 325-30 will be displayed.
Figure 325-30
19. Visually confirm that the graph displays the intended test profile. 20. Touch the Mold Number Sequence tab to bring it to the front. A screen similar to Figure 325-31 will be displayed.
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325 – Job Setup
Figure 325-31
21. See Using the Mold Number Sequence Tab at the end of this section.
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325 – Job Setup
USING THE MOLD NUMBER SEQUENCE TAB
The Mold Number Sequence tab (see Figure 325-32) functions the same in all four Test Modes. Since adjusting the settings on the Mold Number Sequence tab is the final part of Job Setup, this subsection also includes instructions for saving and closing the Job Configuration. 1. To adjust the settings on the Mold Number Sequence tab and save and close the Job Configuration: Manual
– Select the “Manual” radio button to manually enter a mold number before each test. – Select the “Using Sequence” radio button if containers are to be tested in a predetermined sequence based on their mold numbers. A screen similar to 325-33 will be displayed. Enter the mold sequence (1-999) using the virtual keyboard and the buttons on the screen. During testing, the system will automatically display the mold number of the container to be tested.
Using Sequence
NOTE: A sequence can contain a maximum of 100 mold numbers.
Figure 325-32
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325 – Job Setup
Figure 325-33 NOTE: The function of each button is explained on the next page.
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325 – Job Setup
Select a row and touch this button to move the mold number up one row in the sequence. Select a row and touch this button to insert a new row above the selected row. Select a row and touch this button to insert a new row below the selected row. Select a row and touch this button to move the mold number down one row in the sequence.
Select a row and touch this button to delete the row.
Touch this button to delete all of the entries.
Touch this button to undo any changes that have been made since the “Save” button was last touched.
2. Touch the “Save” button at the bottom of the screen to save the new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Job Menu screen. 3. Once the new settings have been saved, touch the “Back” button at the bottom of the screen to return to the Job Menu screen. 4. Touch the “Back” button at the bottom of the Job Menu screen to return to the Main Screen. The system is ready to test containers with the new job (see Section 310, Operation).
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325 – Job Setup
END OF SECTION 325
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330 - SYSTEM SETUP INTRODUCTION
The System Setup screen includes the General tab, the CSV tab, the Verification tab and the Maintenance tab. This section includes instructions for adjusting settings on the General tab and on the Maintenance tab. For information on the CSV tab, see Section 340, CSV Output. For information on the Verification tab, see Section 350, Verifying the Pressure, Volume and Temperature Measurements.
To access the System Setup screen: 1. Touch the “System Settings” button on the Main Screen (see Figure 330-2). The virtual keyboard will be displayed.
MAIN SCREEN Figure 330-1
2. Enter the password. The General tab of the System Setup screen will be displayed (see Figure 330-2).
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330 – System Setup
SYSTEM SETUP SCREEN – GENERAL TAB Figure 330-2
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330 – System Setup
SETTINGS ON THE GENERAL TAB
1. If necessary, adjust the Unit settings: 2 Pressure – Select psi, kg/cm , bar, or MPa. Temperature – Select °F or °C. 2. If necessary, adjust the Language setting: Language – Select English, French, German, Italian, or Spanish. 3. If necessary, adjust the Alarm Limits settings: Min. Temperature – Enter the minimum acceptable water temperature. The minimum allowable value is 4.4 °C (40 °F). The “Min. Temperature” value cannot be greater than the “Max. Temperature” value. Max. Temperature – Enter the maximum acceptable water temperature. The maximum allowable value is 48.9 °C (120 °F). The “Max. Temperature” value cannot be less than the “Min. Temperature” value. 4. If desired, enable the Temperature Equalization feature. Supply water flushing time – When the Temperature Equalization feature is enabled, this is the amount of time that the system will flush water through the incoming supply line and is dependent on the length of the incoming supply line and the water flow rate. 5. Touch the “Save” button at the bottom of the screen to save any new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Main Screen. The “Remote Access” Button
The “Remote Access” button can be used to open a secure connection with an AGR service technician so that assistance can be provided remotely. Once connected, an AGR technician can remotely operate the PPT3000™, transfer files, execute commands, and view log files. For more information, see “Using the Remote Access Feature” in Section 700, Troubleshooting.
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330 – System Setup
SETTINGS ON THE MAINTENANCE TAB
1. From the System Settings screen, touch the Maintenance tab to bring it to the front. The Maintenance tab will be displayed (see Figure 330-3).
SYSTEM SETUP SCREEN – MAINTENANCE TAB Figure 330-3
For each item in the Category column, the system will display a reminder on the Main Screen when maintenance is scheduled. Figure 330-3 shows typical values. However, you may want to modify these values as experience with the system yields a better understanding of your maintenance requirements (which can be affected by your water quality, operating environment, hours of usage, etc.). 2. If necessary, touch a value in the Maintenance Schedule column and use the virtual keyboard to adjust the number of days for an item in the Category column. 3. Touch the “Save” button at the bottom of the screen to save any new settings. Or, touch the “Back” button at the bottom of the screen and select “No” on the “Do you want to save changes?” dialog box to abort any changes (since the “Save” button was last touched) and return to the Main Screen.
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330 – System Setup
Buttons on the Maintenance Tab Cold Flush – The “Cold Flush” button is used to purge water from the system. See
Preparing the Machine for Storage or Shipment in Section 600. Touch Screen Calibration – After installation, the Touch Screen should not need to be
calibrated unless the Touch Screen, Display, or Compact Flash Memory Card is replaced. Replaced Particulate Filter – Touch this button after the Particulate Filter has been
replaced to reset the on-screen alarm for replacing the Particulate Filter. Replaced Ionization Filter – Touch this button after the Ionization Filter has been replaced
to reset the on-screen alarm for replacing the Ionization Filter. Backup Jobs – Touch this button to save all Job Configurations and the System
Configuration to a non-removable secondary memory location. Restore Jobs – Touch this button to restore Job Configurations and/or the System
Configuration from the non-removable secondary memory location. A dialog box will appear to individually confirm that the System Configuration and/or each Job Configuration is to be restored.
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330 – System Setup
END OF SECTION 330
330-6
11/20/2006
340 – CSV OUTPUT INTRODUCTION Output Formats and Modes
The PPT3000™ system supports two CSV output formats: Legacy Format and Regular Format. Both formats are described later in this section. The CSV data can be output two ways: through a COM Port (as serial data) or through the Network port (using the UDP protocol). CSV Port Details Port #
COM2
Baud Rate
9600
Stop Bits
1
Hand Shake
None
Host System Requirements for COM Port Data
To receive data through a COM Port, the host system must: • include a PC or Laptop with at least 1 COM Port, with a supported baud rate of 9600. • be running HyperTerminal or a similar application to receive the data Host System Requirements for Network Port Data
To receive data through a Network Port, the host system must: • include a Network port • have TCP/IP protocol installed on it • have an application to listen to the UDP mode socket in the network port of that machine, to collect the data
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340 – CSV Output
LEGACY FORMAT
This format is provided for backward compatibility. The packet formats available in this mode are the same as those output by the original PPT system. Therefore, customers with data collection systems for the original PPT can continue to use these collection systems with the PPT3000™ system without making changes. Two packets are available in the Legacy format: a Profile Setup Information packet, and a Test Results packet. Profile Setup Information
When the system determines that the setup information needs to be updated, it waits until the next test occurs and sends the Profile Setup Information packet just before it sends the Test Results packet. The format of the Profile Setup Information Packet in the Legacy Mode is shown below: LEGACY OUTPUT – PROFILE SETUP INFORMATION #
Item
Max. Size (bytes)
Range
1
Type Designator
5
<99999>
2 3
Delimiter Date (MM/DD/YY)
1 8
<,> MM (01-12) DD (01-31) YY (00-99)
4 5
Delimiter Time (HH:MM)
1 5
<,> HH (00-23) <:> MM (00-59)
6 7
Delimiter Profile Number
1 2
<,> <00>
8 9
Delimiter Profile name
1 255
<,> Text
10 11
Delimiter Nominal Volume
1 8
<,> <0.00 – 9999.9999>
12 13
Delimiter Nominal Volume Units
1 10
<,> Text
14 15
Delimiter Expansion Limit
1 8
<,> <0.00 – 999.9999>
16 17
Delimiter Expansion volume limit type
1 10
<,> Text
18 19
Delimiter Initial Pressure
1 8
<,> <0.00 – 999.9999>
20 21
Delimiter Pressure Units
1 10
<,> Text
22 23
Delimiter Hold Time (mm:ss)
1 5
<,> mm (00-59) <:> ss (00-59)
24
End of Packet
1
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340 – CSV Output
Test Results
The test results are output one packet per test as shown below: LEGACY OUTPUT – TEST RESULTS #
Item
Max. Size (bytes)
Range
1 2
Sequence Number Delimiter
5 1
<00001 – 99998> <,>
3 4 5
Date (MM/DD/YY) Delimiter Time (HH:MM)
8 1 5
MM (01-12) DD (01-31) YY (00-99) <,> HH (00-23) <:> MM (00-59)
6 7
Delimiter Max Pressure
1 8
<,> <0.00 – 999.9999>
8 9
Delimiter End Pressure
1 8
<,> <0.00 – 999.9999>
10 11
Delimiter Expanded Volume
1 8
<,> <0.00 – 999.9999>
12 13
Delimiter %Expansion
1 6
<,> <0.00 – 9999.9999>
14 15
Delimiter Test Time (mm:ss)
1 5
<,> mm (00-59) <:> ss (00-59)
16 17
Delimiter 2 Test Status Code
1 3
<,> <006 – 014>
18
End of Packet
1
2
Status Code 006 007 008 009 013 014
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Test Status Message Test Completed: Timeout Reached Test Terminated: Stop Button Pressed Test Completed: Bottle Broke Completed: Ramp Pressure Limit Reached Test Completed: Expansion Limit Reached Test Terminated: Door Opened
340-3
340 – CSV Output
REGULAR FORMAT
This is the format for the PPT3000™ system following CSV guidelines and supporting multiple delimiters. This format offers additional information in comparison to the Legacy format. Three packets are available in the Regular format: a Profile Setup Information packet, a Test Results Packet, and a Verification packet. The Profile Setup Information packet is output when the user changes any job setup related information. The Test Results packet is output at the end of every test (with information about all the parameters at the end of the test). The Verification packet is output at the end of every verification operation indicating what verification was performed and whether it was successful or not. NOTE: The following tables reflect output based on the system’s default Region setting (US Regional), which can be changed on the CSV Settings tab of the System Setup screen (explained later in this section). If Local is selected, the CSV output will vary depending on the Windows regional settings. For example, the Date Format and the decimal symbol may differ from the following examples.
PROFILE SETUP INFORMATION #
Max. Size (bytes)
Item
Range
1
Type Designator
1
<1>
2 3
Delimiter Date (MM/DD/YYYY)
1 8
<,> or or or <;> MM (01-12) DD (01-31) YYYY (0000-9999)
4 5
Delimiter Time (HH:MM:SS)
1 8
<,> or or or <;> HH (00-23) <:> MM (00-59) <:> SS (00-59)
6 7
Delimiter Profile Name
1 255
<,> or or or <;> Text
8 9
Delimiter Profile Description
1 255
<,> or or or <;> Text
10
Delimiter
1
<,> or or or <;>
- CONTINUED ON NEXT PAGE -
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340 – CSV Output
- CONTINUED FROM PREVIOUS PAGE #
Item
Max. Size (bytes)
Range
11 12
Profile Type Delimiter
1 1
<0 – 3> <,> or or or <;>
13 14
Nominal Volume Delimiter
8 1
<0.00 – 9999.9999> <,> or or or <;>
15 16
Nominal Volume Units Delimiter
10 1
Text <,> or or or <;>
17 18
Expansion Limit Delimiter
8 1
<0.00 – 999.9999> <,> or or or <;>
19 20
Expansion volume limit type Delimiter
10 1
Text <,> or or or <;>
21 22
Initial Pressure Delimiter
8 1
<0.00– 999.9999> <,> or or or <;>
23 24
Pressure Units Delimiter
10 1
Text <,> or or or <;>
25 26 27
Hold Time (hh:mm:ss) Delimiter 5 Temperature Units
5 1 1
hh (0-23) <:> mm (00-59) <:> ss (00-59) <,> or or or <;> or
28 29
Delimiter Reserved for Buckle Test
1 0
<,> or or or <;> <0>
30 31
Delimiter Empty (Reserved for Buckle Test) Delimiter
1
<,> or or or <;>
0
<>
1
<,> or or or <;>
0
<>
1
<,> or or or <;>
8 1
<0.0-999.9>
32 33 34 35 36
3
6
4
Empty (Reserved for Buckle Test) Delimiter % Expansion at End of Packet
7
4
Only valid for Burst Test jobs, otherwise this value is empty Only valid if an Expansion Limit has been specified in the job, otherwise this value is empty 7 Only valid if system includes the optional Custom Expansion feature, otherwise this value is empty 6
3
0 1 2 3
Profile Type Code Description Fill Ramp Burst Custom M-RULE®
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5
Temperature Units Code Description C Celsius F Fahrenheit
340-5
340 – CSV Output
TEST RESULTS #
Max Size (bytes)
Item
Range
1
Type Designator
1
<2>
2 3
Delimiter Date (MM/DD/YYYY)
1 8
<,> or or or <;> MM (01-12) DD (01-31) YYYY (0000-9999)
4 5
Delimiter Time (HH:MM:SS)
1 8
<,> or or or <;> HH (00-23) <:> MM (00-59) <:> SS (00-59)
6 7 8
Delimiter Mold # Delimiter
1 3 1
<,> or or or <;> <000 – 999> <,> or or or <;>
9 10
Expansion in Current Units Delimiter
8 1
<0.00 – 999.9999> <,> or or or <;>
11 12
%Expansion Delimiter
6 1
<0.00 – 999.9999> <,> or or or <;>
13 14
%Exp at 13 Seconds Delimiter
6 1
<0.00 – 999.9999> <,> or or or <;>
15 16
Max Pressure Delimiter
8 1
<0.00 – 999.9999> <,> or or or <;>
17 18
End Pressure Delimiter
8 1
<0.00 – 999.9999> <,> or or or <;>
19 20
Temp Fill Delimiter
5 1
<00.0 – 999.0> <,> or or or <;>
21 22
Temp Test Delimiter
5 1
<00.0 – 999.0> <,> or or or <;>
23 24
Test Time (HH:MM:SS) Delimiter
8 1
HH (00-23) <:> MM (00-59) <:> SS (00-59) <,> or or or <;>
25
Test Ended
26
or or or or or or
26
Delimiter
1
<,> or or or <;>
6
- CONTINUED ON NEXT PAGE -
340-6
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340 – CSV Output
- CONTINUED FROM PREVIOUS PAGE #
Item
Max Size (bytes)
Range
27 28
Test Status Code Delimiter
3 1
<006 – 014> <,> or or or <;>
29 30
Bottle Fail Mode Delimiter
30 1
Text <,> or or or <;>
31 32
Shelf Life Delimiter
4 1
<00.0 – 99.9> <,> or or or <;>
33 34
Material Utilization Delimiter
5 1
<0.0 – 100.0> <,> or or or <;>
35
Empty (Reserved for Buckle Test) Delimiter
0
<>
1
<,> or or or <;>
0
<>
36
6 7 8
2
7
7
37
Empty (Reserved for Buckle Test)
38 39
Delimiter Empty (Reserved for Buckle Test)
1
<,> or or or <;>
0
<>
40 41
Delimiter % Expansion at user8 specified time
1
<,> or or or <;>
8
<<0.00-999.9999>>
42
End of Packet
1
Only valid for Fill-Ramp jobs, otherwise this value is empty Only valid for M-RULE® jobs, otherwise this value is empty Only valid if system includes the optional Custom Expansion feature, otherwise this value is empty
2
Status Code 006 007 008 009 013 014
10/15/2013
Test Status Message Test Completed: Timeout Reached Test Terminated: Stop Button Pressed Test Completed: Bottle Broke Completed: Ramp Pressure Limit Reached Test Completed: Expansion Limit Reached Test Terminated: Door Opened
340-7
340 – CSV Output
VERIFICATION PACKET #
Max. Size (bytes)
Item
Range
1 2
Type Designator Delimiter
1 1
<3> <,> or or or <;>
3 4
Date (MM/DD/YYYY) Delimiter
8 1
MM (01-12) DD (01-31) YYYY (0000-9999) <,> or or or <;>
5 6
Time (HH:MM:SS) Delimiter
8 1
HH (00-23) <:> MM (00-59) <:> SS (00-59) <,> or or or <;>
7 8
Verification Type Delimiter
1 1
<0 – 2> <,> or or or <;>
9 10
Verification Status Delimiter
1 1
<0 – 1> <,> or or or <;>
11 10
Verification Details End of Packet
255 1
Text
8
9
8
Verification Type Code Description 0 Pressure 1 Volume Expansion 2 Temperature
340-8
9
Verification Status Code Description 0 Fail 1 Pass
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340 – CSV Output
CSV SETUP
To access and modify the system’s CSV settings: 1. Touch the “System Settings” button on the Main Screen (see Figure 340-1). The virtual keyboard will be displayed.
MAIN SCREEN Figure 340-1
2. Enter the password. The General tab of the System Setup screen will be displayed (see Figure 340-2).
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340 – CSV Output
SYSTEM SETUP SCREEN – GENERAL TAB Figure 340-2
3. Touch the CSV tab to bring it to the front. The CSV tab will be displayed (see Figure 340-3).
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340 – CSV Output
SYSTEM SETUP SCREEN – CSV TAB Figure 340-3
4. If the “CSV” checkbox is not selected, touch the checkbox to enable CSV output and display the CSV settings. 5. To change the Output Format, touch the “Format” dropdown box and select either “Legacy” or “Regular.” 6. If “Regular” is selected as the Output Format, the number and date formats of the CSV output can be changed by touching the “Region” dropdown box and selecting either “Local” or “Default.” • If “Local” is selected, the system will use the number and date formats that are displayed on the screens. (For example, if the comma is used as the decimal point on the screens, it also will be used as a decimal point in the CSV output.) • If “Default” is selected, US Regional settings will be used. (A period will be used as the decimal point and the date format will be MM/DD/YYYY.) 7. If “Regular” is selected as the Output Format, the separator (field delimiter) for the CSV output can be changed by touching the “Separator” dropdown box and selecting either “,” (comma), “tab,” “space,” or “;” (semicolon). • Do not select “,” as the separator if your data collection software will recognize the comma as a decimal point, or if (based on the Region setting) the comma already is being used as a decimal point.
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340 – CSV Output
8. To change the Output Port, touch the “Serial” radio button or the “Network” radio button. • When “Network” is selected, the Host Address and Port will appear on the CSV tab (see Figure 340-4).
Figure 340-4
9. To establish an output connection, touch the “Connect” button.
10. To send a test packet, touch the “Send” button. 11. Touch the “Save” button at the bottom of the screen to save the new settings.
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350 - VERIFYING THE PRESSURE, VOLUME AND TEMPERATURE MEASUREMENTS INTRODUCTION
This section includes instructions for verifying the accuracy of the system’s pressure, temperature, and volume measurements. The accuracy of each measurement should be verified according to your Standard Operating Procedure. If any of these measurement verifications yield a result outside of acceptable operating specifications, that measurement should be calibrated by Agr personnel. Instructions for verifying the pressure measurement begin on Page 350-2. Instructions for verifying the temperature measurement begin on Page 350-10. Instructions for verifying the volume measurement begin on Page 350-18. A Verification Kit (see Figure 350-1) supplied by Agr includes the necessary components for verifying the three measurements: a Pressure Gauge, a Volumetric Flask, and a Thermometer.
VERIFICATION KIT Figure 350-1
6/29/2012
350-1
350 – Verifying the Pressure, Volume and Temperature Measurements
VERIFYING THE PRESSURE MEASUREMENT Procedure
To verify the pressure measurement: 1. Touch the “System Settings” button on the Main Screen (see Figure 350-2). The virtual keyboard will be displayed.
MAIN SCREEN Figure 350-2
2. Enter the password. The General tab of the System Setup screen will be displayed (see Figure 350-3).
350-2
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – GENERAL TAB Figure 350-3
3. The system will use the Pressure unit of measure that is selected and saved on the General tab. If desired, change and save the Pressure unit of measure. 4. Touch the Verification tab to bring it to the front. The Verification tab will be displayed (see Figure 350-4).
11/28/2006
350-3
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-4
5. Touch the “Pressure” cell in the “Category” column. The “Verify” button will activate. 6. Touch the “Verify” button. A screen similar to Figure 350-5 will be displayed.
350-4
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-5
7. Follow the on-screen instructions. • Modify the Verification Pressure, if desired. • • •
NOTE: The optimal verification pressure is at the bottle burst pressure, or the pressure used as the initial pressure of the ramp tests or burst tests they perform. Place the Pressure Gauge in the Container Holder as shown in Figure 350-6. Make sure the volumetric flask is not in the Container Holder. Applying pressure to the flask could damage the flask and create a hazard.
Close the door. Touch the “Start” button. The bottle clamp will seal and the PPT3000™ system will apply the user-defined pressure to the Test Gauge Fixture. When the verification process completes, a screen similar to Figure 350-7 will be displayed.
11/28/2006
350-5
350 – Verifying the Pressure, Volume and Temperature Measurements
PRESSURE GAUGE IN CONTAINER HOLDER Figure 350-6
350-6
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-7
8. If the system-measured pressure is within ±0.2 bars (±3 psi) of the value on the Pressure Gauge, touch the “Yes” button. A screen similar to Figure 350-8 will be displayed. Remove and dry the gauge and store it properly. If the system-measured pressure is not within ±0.2 bars (±3 psi) of the value on the Pressure Gauge, touch the “No” button. A screen similar to Figure 350-9 will be displayed. Remove and dry the gauge and store it properly. Contact Agr Technical Services to have the Pressure Measurement calibrated.
6/29/2012
350-7
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-8
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-9
350-8
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
Using the Diagnostics Screen during Pressure Verification
During the Pressure Verification, the Diagnostics screen can be accessed by touching the “Diagnostics” button on the Maintenance tab.
DIAGNOSTICS SCREEN – STATUS TAB Figure 350-10
During the Pressure Verification, the system will display the “Voltage” from the Water Pressure Transducer – identified as “0 (WP)” in the Channel column – along with its calculated output “Value” (based on the current calibration). Before pressure is applied, Channel 0 should report -5 volts and 0 psi. As pressure builds, the “Voltage” value and the pressure “Value” should increase. At 300 psi, the “Voltage” value should be approximately +5 volts.
11/28/2006
350-9
350 – Verifying the Pressure, Volume and Temperature Measurements
VERIFYING THE VOLUME MEASUREMENT Procedure
To verify the volume measurement: IMPORTANT: The system will use the Volume unit of measure in the currently loaded Job Configuration to conduct the Volume Verification. To change the unit of measure for the Volume Verification, edit the Job Configuration and change the Volume unit, then save the Job Configuration. Or, load a job with the desired Volume unit of measure. Normally, the Volume Verification is done in milliliters since the Volumetric Flask provided by Agr is graduated in milliliters.
1. Touch the “System Settings” button on the Main Screen (see Figure 350-11). The virtual keyboard will be displayed.
MAIN SCREEN Figure 350-11
2. Enter the password. The General tab of the System Setup screen will be displayed (see Figure 350-12).
350-10
6/29/2012
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – GENERAL TAB Figure 350-12
3. Touch the Verification tab to bring it to the front. The Verification tab will be displayed (see Figure 350-13).
11/28/2006
350-11
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-13
4. Touch the “Volume Expansion” cell in the “Category” column. The “Verify” button will activate. 5. Touch the “Verify” button. A screen similar to Figure 350-14 will be displayed.
350-12
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-14
6. Follow the on-screen instructions. Modify the Verification Volume, if desired. NOTE: The Volumetric Flask supplied by Agr is marked for 1000 milliliters.
Place the Volumetric Flask in the Container Holder as shown in Figure 350-15. Make sure that the inside of the flask is clean and dry. Make sure that the scale on the flask is visible. Close the door. (Although you are asked to close the door, no pressure will be generated in the flask. The Bottle Clamp will not be lowered to seal the surface.) Touch the “Start” button. The PPT3000™ system will dispense the user-specified amount of water into the flask. The filling is done by applying a low pressure to the Cylinder. As the flask fills, the software will display the volume of water the sensor indicates has gone into the flask. If you touch the “Stop” button during this process, the flow of water will stop. When the verification process completes, a screen similar to Figure 350-16 will be displayed.
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350-13
350 – Verifying the Pressure, Volume and Temperature Measurements
VOLUMETRIC FLASK IN CONTAINER HOLDER Figure 350-15
350-14
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-16
7. If the system-measured volume is within ±25mm of the marked line on the Agr-supplied flask, touch the “Yes” button. A screen similar to Figure 350-17 will be displayed. Remove and dry the flask and store it properly. If the system-measured volume is not within ±25 mm of the marked line of the Agrsupplied flask, touch the “No” button. A screen similar to Figure 350-18 will be displayed. Remove and dry the flask and store it properly. Contact Agr Technical Services to have the Volume Measurement calibrated.
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350-15
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-17
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-18
350-16
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
Using the Diagnostics Screen during Volume Expansion Verification
During the Volume Verification, the Diagnostics screen can be accessed by touching the “Diagnostics” button on the Maintenance tab.
DIAGNOSTICS SCREEN – STATUS TAB Figure 350-19
During the Volume Verification, the system will display the “Voltage” from the Cylinder Transducer – identified as “2 (VE)” in the Channel column – along with its calculated output “Value” (based on the current calibration). Before the Volume Verification begins, the Cylinder should be full. The Channel 2 “Voltage” value should be near its low range of -5 volts and the Channel 2 output “Value” should report approximately 2150 ml. As water is moved from the Cylinder to the Volumetric Flask, the “Voltage” value should increase and the output “Value” should decrease. When the Volume Verification completes, the “Voltage” value should decrease and the output “Value” should increase as the Cylinder refills.
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350-17
350 – Verifying the Pressure, Volume and Temperature Measurements
VERIFYING THE TEMPERATURE MEASUREMENT Procedure
To verify the temperature measurement: 1. Touch the “System Settings” button on the Main Screen (see Figure 350-20). The virtual keyboard will be displayed.
MAIN SCREEN Figure 350-20
2. Enter the password. The General tab of the System Setup screen will be displayed (see Figure 350-21).
350-18
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – GENERAL TAB Figure 350-21
3. Touch the Verification tab to bring it to the front. The Verification tab will be displayed (see Figure 350-22). 4. Select the Temperature unit to match your thermometer.
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350-19
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-22
5. Touch the “Temperature” cell in the “Category” column. The “Verify” button will activate. 6. Touch the “Verify” button. A screen similar to Figure 350-23 will be displayed.
350-20
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-23
7. Follow the on-screen instructions. • Modify the Flask Volume, if desired. • Place the Volumetric Flask in the Container Holder as shown in Figure 350-24. • Close the door. (Although you are asked to close the door, no pressure will be applied to the flask. The Bottle Clamp will not be lowered to seal the surface.) • Touch the “Start” button. The PPT3000™ system will dispense the user-specified amount of water into the flask. The filling is done by applying a low pressure to the Cylinder. As the flask fills, the software will display the volume of water the sensor indicates has gone into the flask. If you touch the “Stop” button during this process, the flow of water will stop. When the verification process completes, a screen similar to Figure 350-25 will be displayed.
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350-21
350 – Verifying the Pressure, Volume and Temperature Measurements
VOLUMETRIC FLASK IN CONTAINER HOLDER Figure 350-24
350-22
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-25
8. Immediately open the door, remove the flask, and use the Thermometer to measure the water temperature. 9. If the system-measured temperature is within ±1 °C (±2 °F) of the temperature measured with the Thermometer, touch the “Yes” button. A screen similar to Figure 350-26 will be displayed. Remove and dry the flask and store it properly. If the system-measured temperature is not within ±1 °C (±2 °F) of the temperature measured with the Thermometer, touch the “No” button. A screen similar to Figure 35027 will be displayed. Dry the flask and thermometer and store them properly. Contact Agr Technical Services to have the Temperature Measurement calibrated.
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350-23
350 – Verifying the Pressure, Volume and Temperature Measurements
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-26
SYSTEM SETUP SCREEN – VERIFICATION TAB Figure 350-27
350-24
11/28/2006
350 – Verifying the Pressure, Volume and Temperature Measurements
Using the Diagnostics Screen during Temperature Verification
During the Temperature Verification, the Diagnostics screen can be accessed by touching the “Diagnostics” button on the Maintenance tab.
DIAGNOSTICS SCREEN – STATUS TAB Figure 350-28
During the Temperature Verification, the system will display the “Voltage” from the Water Temperature Transducer – identified as “1 (WT)” in the Channel column – along with its calculated output “Value” (based on the current calibration). Since the water temperature should be relatively stable, there should not be any dramatic changes in the “Voltage” value or the output “Value.”
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350-25
350 – Verifying the Pressure, Volume and Temperature Measurements
END OF SECTION 350
350-26
11/28/2006
Section 6 MAINTENANCE
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600 - MAINTENANCE
ROUTINE MAINTENANCE
This table lists some routine maintenance tasks and suggests a frequency for each item. The required frequency will vary from user to user. For example, the table recommends replacing the water particulate filter monthly. You may find that your water conditions may require more or less frequent changes.
ROUTINE MAINTENANCE SCHEDULE TASK
1
FREQUENCY
REQUIRED ACTION
Check the Bottle Seal for cuts or wear.
Weekly
Replace seal if damaged.
Check inserts for wear or damage.
Weekly
Replace inserts if damaged.
Check the Fan Filter.
Monthly
Remove and clean.
Replace the Filter Element in the Air Filter.
Monthly
Install new filter element (Part No. 1 2013184).
Clean the Test Chamber Door.
As needed
Clean door using warm water and soap or a commercial cleaner for plastics. Never use a solvent for cleaning the door!
Clean the Touch Screen.
As needed
See Cleaning the Touch Screen on Page 600-17.
Replace the Particulate Filter in optional Water Filtration System.
Monthly
Install new filter.
1
Replace the Ionization Filter in optional Water Filtration System.
Every three months
Install new filter.
1
Depending on your operating conditions, you made need to change the filter more frequently.
12/11/2007
600-1
600 - Maintenance
CLEANING THE FAN FILTER
1. The ventilation fan (1, Figure 600-1) is located on the right side panel. 2. Remove the filter holder from the fan housing. The holder clips onto the outside of the housing. 3. Clean the filter element. You can usually remove accumulated dust by tapping the holder gently. 4. Re-install the holder on the fan housing.
1
Figure 600-1
600-2
6/29/2012
600 - Maintenance
PREPARING THE MACHINE FOR STORAGE OR SHIPMENT Introduction
Using the Cold Flush feature, you can flush all of the water from the PPT3000™ system. You should use this procedure to remove the water before shipping the PPT3000™ system, particularly if the PPT3000™ system will experience freezing temperatures during shipment. It is also a good idea to remove water from the system if the PPT3000™ system will not be used for an extended period of time. Once you start the procedure, a series of screens will guide you through the procedure. The actual system flushing process is automated. However, you will be prompted to perform actions at certain points in the procedure. During the procedure, touch the “Next” button to acknowledge that you have performed the requested action and move on to the next instruction. You can stop the procedure at any time by touching the “Cancel” button on any screen where this option appears. If you touch the “Cancel” button, the display will return to the System Settings screen. IMPORTANT: Once the Cold Flush procedure is complete, the system must be shut down.
11/8/2007
600-3
600 - Maintenance
Flushing the System CAUTION: Do not attempt to remove or service any components during – or after – this procedure unless instructed to do so.
1. If the PPT3000 is equipped with a Dual Pressure Regulator, make sure the regulator is switched to its High Pressure position (see Figure 600-2). • Turn the knob so that the pointer on the knob is down. 2. From the Main Screen, touch the “System Settings” button. After the password is entered, the System Settings screen will be displayed. 3. Touch the Maintenance tab on the System Settings screen. A screen similar to Figure 600-3 will be displayed.
LOW PRESSURE
HIGH PRESSURE
DUAL REGULATOR KNOB (SHOWN IN HIGH PRESSURE POSITION) Figure 600-2
600-4
11/8/2007
600 - Maintenance
Figure 600-3
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600-5
600 - Maintenance
4. Touch the “Cold Flush” button. The screen shown in Figure 600-4 will be displayed.
Figure 600-4
5. Close the Main Water Inlet Valve, then touch the “Next” button. The screen shown in Figure 600-5 will be displayed.
600-6
11/8/2007
600 - Maintenance
1 Figure 600-5
6. Turn off the water supply to the PPT3000™ system. If a Recirculator is being used to supply water to the system, turn off the Recirculator. 7. Disconnect the water supply from the external fitting on the PPT3000™ system (1, Figure 600-5), then touch the “Next” button. The screen shown in Figure 600-6 will be displayed.
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600-7
600 - Maintenance
Figure 600-6
8. Remove the PPT3000™ system Cover and open the Flush Valve (turn the handle on the valve so that it is parallel to the fitting), then touch the “Next” button. The screen shown in Figure 600-7 will be displayed. • To remove the Cover: Unscrew and remove the panel from the back of the PPT3000™ system. Unscrew the Cover from the Base. Tilt the Cover forward and carefully lift the Cover up and off of the PPT3000™ system.
600-8
11/8/2007
600 - Maintenance
Figure 600-7
9. Place a container in the Test Chamber and close the door, then touch the “Next” button. The screen shown in Figure 600-8 will be displayed.
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600-9
600 - Maintenance
Figure 600-8
10. A blue bar at the bottom of the screen will monitor progress as the system flushes water from the system. During this time, the PPT3000™ system is flushing the water from the main inlet water path and the line that contains the pressure transducer. When this process is complete, the screen shown in Figure 600-9 will be displayed.
600-10
11/8/2007
600 - Maintenance
Figure 600-9
11. Open the door, remove the container, and close the door. Then, touch the “Next” button. The screen shown in Figure 600-10 will be displayed.
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600-11
600 - Maintenance
Figure 600-10
12. A blue bar at the bottom of the screen will monitor progress as the system flushes water from the cylinder. During this time, the PPT3000™ system is flushing all water out of the cylinder and any associated valves in this path. When this process is complete, the screen shown in Figure 600-11 will be displayed.
600-12
11/8/2007
600 - Maintenance
1 Figure 600-11
CAUTION – Trapped water may be under high pressure. Safety glasses must be worn for the next step.
13. Hold a rag over the inlet fitting of the Main Water Inlet Valve (1, Figure 600-11) to catch any water that is exhausted when you open the valve. When you have the rag in place, slowly open the Main Water Inlet Valve. Then, touch the “Next” button. The screen shown in Figure 600-12 will be displayed.
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600-13
600 - Maintenance
Figure 600-12
14. Close the Flush Valve (turn the handle on the valve so that it is perpendicular to the fitting), then touch the “Next” button. The screen shown in Figure 600-13 will be displayed.
600-14
11/8/2007
600 - Maintenance
Figure 600-13
15. Close the Main Water Inlet Valve, then touch the “Next” button. The screen shown in Figure 600-14 will be displayed.
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600-15
600 - Maintenance
Figure 600-14
16. Remove the pressure transducer and drain any remaining water. Re-install the pressure transducer after it has been drained. 17. The Cold Flush procedure is complete. Turn off the PPT3000™ system power switch. IMPORTANT: Once the Cold Flush procedure is complete, all of the onscreen controls will be disabled. The system must be turned off.
18. Re-install the Cover. 19. Turn off the air supply to the PPT3000™. 20. Disconnect the air line from the PPT3000™. 21. Disconnect the drain hose from the PPT3000™.
600-16
11/8/2007
600 - Maintenance
CLEANING THE TOUCH SCREEN
To temporarily disable the Touch Screen so it can be cleaned: 1. From the Main Screen, touch the “Diagnostics” button (see Figure 600-15). The Diagnostics screen will be displayed (see Figure 600-16).
MAIN SCREEN Figure 600-15
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600-17
600 - Maintenance
2. On the Diagnostics screen, touch the “Clean Screen” button (see Figure 600-16). • The Touch Screen will be disabled for 30 seconds. A countdown box will appear, indicating how long the screen can be safely cleaned (see Figure 600-17). 3. Apply glass cleaner or a mild detergent to a soft cloth or soft paper towel and wipe the Touch Screen.
DIAGNOSTICS SCREEN Figure 600-16
600-18
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600 - Maintenance
SAFE-TO-CLEAN SCREEN Figure 600-17
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600-19
600 - Maintenance
END OF SECTION 600
600-20
11/8/2007
Section 7 TROUBLESHOOTING
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700 - TROUBLESHOOTING
!
CAUTION! Do not remove the Cover of the PPT3000™ system unless instructed to do so by Agr personnel.
RESPONDING TO ON-SCREEN ALARMS On-Screen Alarm Air trapped in bottle during test.
Cause and Possible Solution 1. The container may have expanded too rapidly because of container properties and triggered a false alarm. 2. The Nominal Volume value, which determines how much fill water is pumped into the container before the test, may be too small. Correct the Nominal Volume value, if necessary. 3. The Seal on the Test Head or the container itself may have leaked. Repeat the test and watch for leaks. If necessary, replace the Seal in the Test Head.
Failed to communicate with servo.
1. This alarm can occur at start-up as the system sends, then waits to receive, a signal from the Servo Valve while other system processes are occurring. 2. If this alarm is triggered outside of the start-up routine, contact Agr Technical Services.
Temperature out of range.
1. If the water temperature is outside of the acceptable range, test results may fall outside of expected accuracy. Verify that an external condition is not affecting the incoming water temperature. 2. The temperature limits on the General tab of the System Settings screen may be too tight. Check and, if necessary, adjust the limits. 3. Conduct a Temperature Verification to make sure the Temperature Sensor is functioning properly.
Flushing tank.
6/29/2012
1. The allowable volume of water in the Cylinder was exceeded and the system flushed the excess water. If this alarm appears frequently, a valve may be leaking. Contact Agr Technical Services.
700-1
700 - Troubleshooting
SYMPTOMS AND SOLUTIONS
!
CAUTION! Do not remove the Cover of the PPT3000™ system unless instructed to do so by Agr personnel. SYMPTOMS AND SOLUTIONS
Problem
Check this
The Front Panel Display is off, and the PPT3000™ system will not start a test.
1. Check to make sure line cord is plugged in.
The Test Head does not come down when you touch the “Start Test” button.
1. Check to make sure gas supply is turned on.
The Test Head comes down, but the PPT3000™ system does not fill the bottle.
1. Check to make sure there are no problems with the water supply to the PPT3000™ system and that the system’s manual valve is turned on.
The PPT3000™ system does not fill the container completely.
1. Contact Agr Technical Services.
The PPT3000™ system fills the bottle, but does not build pressure.
1. Contact Agr Technical Services.
700-2
2. Make sure the lamp in the main power switch is "ON". If it is OFF, toggle the power switch off and on. If the switch lamp lights, the circuit breaker in the power switch may have tripped.
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700 - Troubleshooting
SYMPTOMS AND SOLUTIONS Problem
Check this
The PPT3000™ system will build pressure in the bottle but not to the desired test level.
1. Conduct a Pressure Verification (see Section 350)
The bottle expands during a test, but the volume expansion readout does not indicate it.
1. Contact Agr Technical Services.
The PPT3000™ system is out of specification for volume.
1. Contact Agr Technical Services.
The PPT3000™ system is out of specification for pressure. (Machine calibration of the pressure does not bring the machine back into calibration, back into specification, or it is out of range.)
1. Contact Agr Technical Services.
The PPT3000™ system is out of specification for temperature.
1. Contact Agr Technical Services.
The “Stop Test” button appears and the “Start Test” button will not reappear to indicate the system is ready to test.
1. Check the system status bar at the bottom of the Main Screen for an explanation.
2. Check gas supply to make sure it is set to 310 psi (2137 kPa).
2. Check the water supply. 3. Check the air supply.
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700-3
700 - Troubleshooting
USING THE DIAGNOSTICS SCREEN Introduction
The Diagnostic screen contains a Status tab and a Log tab. Additionally, the Log tab contains a System Log tab and an Alarm Log tab. All of these tabs are explained on the following pages.
Figure 700-1
The Status Tab
The Status tab includes a Diagnostic Illustration, a Valve Function table, and Channel Voltage and Value table. The box around the illustration is green when the system is ready to conduct a test. The box is red when the system is not ready to conduct a test (for example, if the Door for the Test Chamber is open). Each valve in the illustration turns green when it is open and red when it is closed. Note that the Cylinder Fill Valve (V5) functions in both directions. Refer to the table on the next page for an explanation of the Status tab during a test. Information on using the Status tab during Pressure, Volume and Temperature verification is included in Section 350.
700-4
12/15/2008
700 - Troubleshooting
V2 - Main Fill
Open
Closed
V3 - Air Dump
Closed
V4 - Pri. Bottle Fill
Open
V5 - Cylinder Fill
Closed
V6 - Sec. Bottle Fill V7 - Head Down V8 - Presence3
Closed
Closed
Closed
Closed
Open
Open
Closed
Closed
Closed
Open
Closed
Closed
Closed
Closed
Open
Closed
Closed
Open
Closed
Open
Closed
Closed
Closed
Open
Open
Open
Open
Open
Closed
Open
Open
Open
Closed Open
Open
Recovery Completion Ready for Next Bottle
Closed
Servo Valve
Closed
Cylinder Fill
Recovery Sequence
Bottle Passes or Fails Vent Pressure
Pressurize Bottle
Test Sequence
Pre-Charge Cylinder
Bottle Fill
Bottle Full
Fill Sequence
Closed
Open
Closed
Closed
Closed
Closed
Open
Active During Test Voltage
Static
Increases or decreases2
Decreases to -5 volts
Static
Value
0 psi
Shows pressure in bottle1
Decreases to 0 psi
Static
0(WP)
Voltage 1(WT)
Value
Voltage 2(VE)
1
2 3
Value
Follows value Static
Shows temperature of water from Main Water Inlet
Shows temp. of water in cylinder
Static
Increase
Decreases
Static
Shows volume of water in cylinder
Shows volume of water into bottle
Increases
Static
The dynamic range for each transducer is from -5 volts to +5 volts, although these extremes will rarely be seen. The pressure voltage and value may increase or decrease based on the Test Profile. The Water Presence Reservoir Dump Valve (V8) is not shown on the Diagnostic screen.
7/2/2012
700-5
700 - Troubleshooting
The Log Tab
The Log tab contains a System Log tab and an Alarm Log tab.
The System Log Tab
Figure 700-2
700-6
2/7/2007
700 - Troubleshooting
• • • • • • • • •
The System Log lists the date and time of the following events: A job is edited or loaded A job is deleted A job is created A Pressure Verification is conducted A Volume Expansion Verification is conducted A Temperature Verification is conducted A pressure Calibration is conducted A Volume Expansion Calibration is conducted A Temperature Calibration is conducted
The capacity of the System Log is 100 entries, after which the system begins overwriting the oldest entry. The System Log cannot be cleared. The System Log tab includes a “Clean Screen” button. See Cleaning the Touch Screen in Section 600.
2/7/2007
700-7
700 - Troubleshooting
The Alarm Log Tab
Figure 700-3
• • • •
The Alarm Log lists the date and time of the following events: Air trapped in bottle during test Failed to communicate with the servo Flush tank Temperature out of limit (Appears only on the Alarm Log, not on the Main Screen)
The capacity of the Alarm Log is 100 entries, after which the system begins overwriting the oldest entry. The Alarm Log cannot be cleared.
700-8
2/7/2007
700 - Troubleshooting
USING THE REMOTE ACCESS FEATURE Introduction
The system includes a remote access feature that can be used to open a secure connection with an AGR service technician so that assistance can be provided remotely. Once connected, an AGR technician can remotely operate the PPT3000™, transfer files, execute commands, and view log files. An internet connection is required for this feature. Before connecting, contact AGR Technical Services to receive a Support ID number. This number must be entered on the Remote Support screen. Procedure
1. Contact AGR Technical Services to receive a Support ID number. 2. Touch the System Settings button on the Main Screen. After entering the System Password, the System Setup screen will be displayed (see Figure 700-4).
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700-9
700 - Troubleshooting
Figure 700-4
3. Touch the “Remote Access” button on the General tab of the System Setup screen (see Figure 700-4). The Remote Access screen will be displayed (see Figure 700-5).
700-10
11/6/2007
700 - Troubleshooting
4. Enter the hostname and port number in the “Connect To” field. The default value is butler.agrintl.com:24816. 5. Enter the Support ID that was provided by AGR Technical Services. 6. Touch the “Connect” button. 7. Verify the connection status. • The text on the “Connect” button will change to “Disconnect.” • The information in the “Connection Status” box will indicate that the system is connected, and the VNC, File Transfer, Telnet and HTML ports are enabled. 8. Contact AGR Technical Services to report that a connection has been successfully established.
Figure 700-5
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700-11
700 - Troubleshooting
END OF SECTION 700
700-12
11/6/2007
Addendum A BUCKLE TESTING ALUMINUM BOTTLES
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ADDENDUM A – BUCKLE TESTING ALUMINUM BOTTLES
INTRODUCTION
The system can be factory-configured to identify and report the buckle point pressure (also known as the “doming” point) of aluminum bottles. A Buckle Test also identifies and reports the volume expansion percentage at the Buckle Point and the volume expansion change after the container has buckled. The PPT3000 will function the same as described in the earlier sections of this manual, except for the differences described in this addendum. MECHANICAL
Systems that have been factory-configured with the Buckle Test option also will include a Dual Pressure Regulator, three Seals and special Inserts. The adjustment and use of these parts are described later in this addendum.
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A-1
ADDENDUM A – BUCKLE TESTING
THE MAIN SCREEN
Figure A-1 shows the Main Screen after a typical Buckle test. Note that the Job Parameters portion of the screen lists “Custom” as the Profile Test Type and indicates that Buckle Detection is enabled (in the Units column). The graph and the additional report entries are explained in Figure A-2.
TYPICAL MAIN SCREEN AFTER A BUCKLE TEST Figure A-1
A-2
11/6/2007
ADDENDUM A – BUCKLE TESTING
BUCKLE POINT
FAILURE POINT
}
BV
BUCKLE POINT PRESSURE (REPORTED AS BPP) VOLUME EXPANSION AT BUCKLE POINT (REPORTED AS BPV)
VOLUME EXPANSION AFTER BUCKLE POINT (USED TO CALCULATE BV)
BUCKLE VOLUME (BV) (DIFFERENCE BETWEEN VOLUME EXPANSION AT BUCKLE POINT AND AFTER BUCKLE POINT) NOTE: IF THE CONTAINER BUCKLES AND THEN BREAKS BEFORE THE TEST CONCLUDES, THE TEST RESULT WILL BE “FAIL.” IF THE CONTAINER BUCKLES AND THE TEST CONCLUDES, THE TEST RESULT WILL BE “BUCKLED.” BUCKLING TEST GRAPH AND REPORT Figure A-2
11/6/2007
A-3
ADDENDUM A – BUCKLE TESTING
OPERATION
Operation is the same as described in Section 310 except for the following:
WARNING!
!
If you are testing aluminum bottles, sharp edges may be present on the bottles, especially if the bottle has ruptured. Use caution when removing bottles from the Bottle Holder.
1. If necessary, adjust the Dual Pressure Regulator based on the table below. • The Back Cover of the PPT3000 must be removed to access the Dual Pressure Regulator. SEALING PRESSURE SELECTION FOR ALUMINUM BOTTLES
Mouth Diameter
Pressure Setting
38 mm
High
28 mm
Low
2. If necessary, install the correct Seal (2, Figure A-3) on the Test Head (3, Figure A-3) based on the table below. SEAL SELECTION FOR ALUMINUM BOTTLES
A-4
Finish Height
Seal
1/8 – 3/8-inch
Large
3/8 – 3/4-inch
Medium
3/4 – 1-inch
Small
11/16/2007
ADDENDUM A – BUCKLE TESTING
3. If necessary, install the correct pair of Inserts in the Insert Holders (1, Figure A-3) based on the table on the next page. Insert Pair sizes are based on the outside diameter of the container as measured immediately below the finish. 4. Continue operating the PPT3000 as described in Section 310.
3 2
1
1
M159-E
Figure A-3
11/6/2007
A-5
ADDENDUM A – BUCKLE TESTING
INSERT PAIR PART NO.
DIAMETER (INCHES)
DIAMETER (MM)
INSERT PAIR PART NO.
DIAMETER (INCHES)
DIAMETER (MM)
PPT3-3-47-000
0.000
0
PPT3-3-47-301
1.185
30.1
PPT3-3-47-220
0.866
22.0
PPT3-3-47-304
1.197
30.4
PPT3-3-47-223
0.878
22.3
PPT3-3-47-307
1.209
30.7
PPT3-3-47-226
0.890
22.6
PPT3-3-47-310
1.220
31.0
PPT3-3-47-229
0.902
22.9
PPT3-3-47-313
1.232
31.3
PPT3-3-47-232
0.913
23.2
PPT3-3-47-316
1.244
31.6
PPT3-3-47-235
0.925
23.5
PPT3-3-47-319
1.256
31.9
PPT3-3-47-238
0.937
23.8
PPT3-3-47-322
1.268
32.2
PPT3-3-47-241
0.949
24.1
PPT3-3-47-325
1.280
32.5
PPT3-3-47-244
0.961
24.4
PPT3-3-47-328
1.291
32.8
PPT3-3-47-247
0.972
24.7
PPT3-3-47-331
1.303
33.1
PPT3-3-47-250
0.984
25.0
PPT3-3-47-334
1.315
33.4
PPT3-3-47-253
0.996
25.3
PPT3-3-47-337
1.327
33.7
PPT3-3-47-256
1.008
25.6
PPT3-3-47-340
1.339
34.0
PPT3-3-47-259
1.020
25.9
PPT3-3-47-343
1.350
34.3
PPT3-3-47-262
1.031
26.2
PPT3-3-47-346
1.362
34.6
PPT3-3-47-265
1.043
26.5
PPT3-3-47-349
1.374
34.9
PPT3-3-47-268
1.055
26.8
PPT3-3-47-352
1.386
35.2
PPT3-3-47-271
1.067
27.1
PPT3-3-47-355
1.398
35.5
PPT3-3-47-274
1.079
27.4
PPT3-3-47-358
1.409
35.8
PPT3-3-47-277
1.090
27.7
PPT3-3-47-361
1.421
36.1
PPT3-3-47-280
1.102
28.0
PPT3-3-47-364
1.433
36.4
PPT3-3-47-283
1.114
28.3
PPT3-3-47-367
1.445
36.7
PPT3-3-47-286
1.126
28.6
PPT3-3-47-370
1.457
37.0
PPT3-3-47-289
1.138
28.9
PPT3-3-47-373
1.468
37.3
PPT3-3-47-292
1.150
29.2
PPT3-3-47-376
1.480
37.6
PPT3-3-47-295
1.161
29.5
PPT3-3-47-379
1.492
37.9
PPT3-3-47-298
1.173
29.8
--
--
--
A-6
11/6/2007
ADDENDUM A – BUCKLE TESTING
JOB SETUP
1. Copy or create a job with “Custom” as the Profile Type (as described in Section 325), then make the following adjustments on the General Parameters tab (refer to Figure A-4). 2. Enable the Buckle Test feature by touching the “Buckle Detection” checkbox. • The feature is enabled when a checkmark appears in the checkbox. • The “Buckle Duration” and “Stop test after buckling” settings will not be displayed until the Buckling Detection feature is enabled. 3. Adjust the Buckle Duration time. • This is the amount of time after the system detects a Buckle Point that the Volume Expansion will be recorded for the Buckle Volume report. • A typical time is 0.5 seconds. 4. Enable the “Stop test after buckle” feature, if desired. • If this feature is not enabled, the system will continue to apply pressure for the duration of the test or until the bottle fails, regardless of when or whether the system detects a buckle point. • If this feature is enabled, the system will stop applying pressure and conclude the test when the system detects the buckle point. 5. Adjust the Nominal Volume and Expansion Limit values, if desired.
11/6/2007
A-7
ADDENDUM A – BUCKLE TESTING
Figure A-4
6. Touch the Graph tab to bring it to the front. A screen similar to Figure A-5 will be displayed.
A-8
11/6/2007
ADDENDUM A – BUCKLE TESTING
Figure A-5
7. Define the pressure profile. • A typical Buckle Test profile starts at 0.0 psi and over 8 seconds increases to 80 psi, then applies pressure at 1 psi per second for 95 seconds to 175 psi.
11/6/2007
A-9
ADDENDUM A – BUCKLE TESTING
CSV OUTPUT
When the system is configured for Buckle Testing, the Profile Setup Information packet will be output as shown below. NOTE: The following tables reflect Regular output (not Legacy output) based on the system’s default Region setting (US Regional), which can be changed on the CSV Settings tab of the System Setup screen (explained in Section 340). If Local is selected, the CSV output will vary depending on the Windows regional settings. For example, the Date Format and the decimal symbol may differ from the following examples.
PROFILE SETUP INFORMATION # 1 2 3 4 5 6 7 8 9
Max. Size (bytes)
Item Type Designator Delimiter Date (MM/DD/YYYY) Delimiter Time (HH:MM:SS) Delimiter Profile Name Delimiter
Profile Description
1 1 8 1 8 1 255 1 255
<1> <,> or or or <\> or <;> MM (01-12) DD (01-31) YYYY (0000-9999) <,> or or or <\> or <;> HH (00-23) <:> MM (00-59) <:> SS (00-59) <,> or or or <\> or <;> Text <,> or or or <\> or <;> Text
1 1 1 8
<,> or or or <\> or <;> <0 – 3> <,> or or or <\> or <;> <0.00 – 999.9999> <,> or or or <\> or <;> Text <,> or or or <\> or <;> <0.00 – 9999.9999> <,> or or or <\> or <;> Text <,> or or or <\> or <;> <0.00– 999.9999> <,> or or or <\> or <;> Text <,> or or or <\> or <;>
10 11 12 13
Delimiter 3 Profile Type Delimiter
14 15
Delimiter
Nominal Volume Units
1 10
16 17 18 19 20 21 22 23 24
Delimiter Expansion Limit Delimiter Expansion volume limit type Delimiter Initial Pressure Delimiter Pressure Units Delimiter
1 8 1 10 1 8 1 10 1
Nominal Volume
Range
- CONTINUED ON NEXT PAGE -
A-10
11/6/2007
ADDENDUM A – BUCKLE TESTING
- CONTINUED FROM PREVIOUS PAGE #
Item
25
Empty (reserved for Hold Time) Delimiter 5 Temperature Units Delimiter Buckle On or Off Delimiter 1 Buckle Duration (seconds) Delimiter 1 Stop Test after Buckle End of Packet
26 27 28 29 30 31 32 33 34 1
Max. Size (bytes)
Range
0
<>
1 1 1 1 1 3 1 1 1
<,> or or or <\> or <;> or <,> or or or <\> or <;> <0> (Off) or <1> (On) <,> or or or <\> or <;> <0 – 600> <,> or or or <\> or <;> <0> (Do not stop) or <1> (Stop)
Only valid for if Buckle option is On, otherwise this value is empty
11/6/2007
A-11
ADDENDUM A – BUCKLE TESTING
When the system is configured for Buckle Testing, the Test Results packet will be output as shown below. TEST RESULTS # 1 2 3 4 5 6 7 8 9 10 11 12 13
Item
Max Size (bytes)
Range
1 1 8 1 8 1 3 1 8 1 6 1
<2> <,> or or or <\> or <;> MM (01-12) DD (01-31) YYYY (0000-9999) <,> or or or <\> or <;> HH (00-23) <:> MM (00-59) <:> SS (00-59) <,> or or or <\> or <;> <000 – 999> <,> or or or <\> or <;> <0.00 – 999.9999> <,> or or or <\> or <;> <0.00 – 999.9999> <,> or or or <\> or <;>
0
<>
14 15 16 17 18 19 20 21 22 23 24 25
Type Designator Delimiter Date (MM/DD/YYYY) Delimiter Time (HH:MM:SS) Delimiter Mold # Delimiter Expansion in Current Units Delimiter %Expansion Delimiter Empty (Reserved for %Exp at 13 Seconds) Delimiter Max Pressure Delimiter End Pressure Delimiter Temp Fill Delimiter Temp Test Delimiter Test Time (HH:MM:SS) Delimiter Test Ended
1 8 1 8 1 5 1 5 1 8 1 26
<,> or or or <\> or <;> <0.00 – 999.9999> <,> or or or <\> or <;> <0.00 – 999.9999> <,> or or or <\> or <;> <00.0 – 999.0> <,> or or or <\> or <;> <00.0 – 999.0> <,> or or or <\> or <;> HH (00-23) <:> MM (00-59) <:> SS (00-59) <,> or or or <\> or <;>
26
Delimiter
1
or or or or or or or <,> or or or <\> or <;>
- CONTINUED ON NEXT PAGE -
A-12
11/6/2007
ADDENDUM A – BUCKLE TESTING
- CONTINUED FROM PREVIOUS PAGE #
Item
27
Test Status Code
28 29 30 31
Delimiter Bottle Fail Mode Delimiter Empty (Reserved for Shelf Life) Delimiter Empty (Reserved for Material Utilization) Delimiter BPP Delimiter BPV (%) Delimiter BE (%) End of Packet
32 33 34 35 36 37 38 39 40
2
Max Size (bytes) 3
Range
1 30 1
<,> or or or <\> or <;> Text <,> or or or <\> or <;>
0
<>
1
<,> or or or <\> or <;>
0
<>
1 8 1 5 1 5 1
<,> or or or <\> or <;> <0.00 – 999.9999> <,> or or or <\> or <;> <0.00 – 999.9999> <,> or or or <\> or <;> <0.00 – 999.9999>
<006 – 014>
2
Status Code 000 006 007 008 009 013 014
11/6/2007
Test Status Message Test Completed: Buckled Test Completed: Timeout Reached Test Terminated: Stop Button Pressed Test Completed: Bottle Broke Completed: Ramp Pressure Limit Reached Test Completed: Expansion Limit Reached Test Terminated: Door Opened
A-13
ADDENDUM A – BUCKLE TESTING
END OF ADDENDUM A
A-14
11/6/2007
