Alps Electric FlexPitch User manual

ALPS
FLEX PITCH LEAK TESTER
FIELD INSTALLATION
MANUAL
Air Logic Power Systems, LLC
2440 W Corporate Preserve Drive Unit 600
Oak Creek, WI 53154 - USA
Phone: [phone] Fax: [phone]
24 Hour Service Hotline: [phone]
www.alpsleak.com and [e-mail]

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch
FLEX PITCH INSTALLATION MANUAL i TM 2017-014 REV01 © 8/2/2017
Notices:
Documentation
Air Logic Power Systems LLC (ALPS), reserves the right to make changes or improvements to the
standard Flex Pitch™at any time. These changes may not be immediately reflected in the manual
accompanying your system. If you notice any inaccuracies or oversights in the manual, please contact the
ALPS Service Department.
This manual is protected by U.S. federal copyright laws © 2017 Air Logic Power Systems LLC.
However, limited permission is hereby granted to photocopy portions of this manual for training of company
personnel only. No part of this manual may be duplicated or transcribed in any form, for any other purpose,
except as stated above, without expressed written permission from Air Logic Power Systems LLC.
Software
Installation of any new or modification of existing software in the FLEX PITCH not approved by Air Logic
Power Systems LLC may affect the operation or performance of the machine and possibly void the
warranty and or service agreements. Please consult Air Logic Power Systems Service Department
prior to installing or modifying existing software on this machine.
System Modifications
Mechanical or electrical modifications not approved by Air Logic Power Systems LLC to the Flex
Pitch™system may also void the warranty and/or service agreements. Please contact the Air Logic
Power Systems Sales or Service Department for approval or assistance with any machine modifications.
Trademark and Patent Acknowledgments
All products or product names mentioned in the manual are trademarks of their respective companies. The
name Flex Pitch™ is protected under copyright laws of the United States. Flex Pitch™ is a registered patent
and is protected by US patent laws.
Contact Information
Service Department 24 Hour Hotline (US): 1-800-325-8717 (International): 1-414-574-4151
Service Manager, Ext. 22180
Sales & Customer Service Support, Ext. 22181
Sales Manager, Ext. 184
Air Logic Power Systems LLC, Headquarters
2440 W Corporate Preserve Drive Unit 600 Oak Creek, WI 53154 - USA
Phone: [phone] Fax: [phone]
Email: www.alpsleak.com and [e-mail]
Copyright © 2017 by Air Logic Power Systems LLC

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch
FLEX PITCH INSTALLATION MANUAL ii TM 2017-014 REV01 © 8/2/2017
Table of Contents
Notices: i
Documentation........................................................................................................................................................i
Software..................................................................................................................................................................i
System Modifications..............................................................................................................................................i
Trademark and Patent Acknowledgments .............................................................................................................i
Contact Information ................................................................................................................................................i
Copyright © 2017 by Air Logic Power Systems LLC..............................................................................................i
General Information 1
Introduction............................................................................................................................................................1
Warnings and Cautions .........................................................................................................................................1
ALPS Flex Pitch Multi-Moving Head Leak Tester .................................................................................................2
General Information................................................................................................................................. 2
Linear Dimensions (Top View) ................................................................................................................ 2
Linear Dimensions of the Flex Pitch machine .......................................................................................................3
Section 1: Location Site and Installation Requirements 4
Location .................................................................................................................................................................4
Electrical Power Requirements .............................................................................................................................4
Air Supply ..............................................................................................................................................................4
Section 2: Components Inventory 5
Common Components shipped with the Flex Pitch...............................................................................................6
Common components boxed separately with shipment.......................................................................... 6
Tunnel Shielding...................................................................................................................................... 6
Set of Legs............................................................................................................................................... 6
Common Components...........................................................................................................................................7
Photo-Eyes and Photo-Eye brackets ...................................................................................................... 7
Section 3: Installation to Conveyor System 8
Vertical Adjustment for Probe Carriage.............................................................................................................. 18
Section 4: Installing Peripheral Devices 20
Photo-Eyes and support brackets ...................................................................................................................... 20
1. Photo-Eyes and Photo-Eye brackets ............................................................................................. 20
2. Photo-Eyes: Placement and Positioning ........................................................................................20
3. Photo-Eyes: Mounting and Positioning on Conveyor.....................................................................21
Tuning Container Present and Reject Photo-Eyes............................................................................................. 21
Banner Q4X Laser Sensor Tuning and Adjustment..............................................................................21
Tuning Downstream Jam and Reject Verification Photo-Eyes........................................................................... 21
OPTEX DR-Q150TCN Sensor tuning and adjustment..........................................................................21
Change Mode Button Options...............................................................................................................22
Installing the Encoder to the Conveyor .............................................................................................................. 24

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch
FLEX PITCH INSTALLATION MANUAL iii TM 2017-014 REV01 © 8/2/2017
Installing Intake Tunnel Guard............................................................................................................................ 25
........................................................................................................ 25
Install Exit Tunnel Guard.................................................................................................................................... 26
Section 5: Power up 27
Main Electrical Power Switch ............................................................................................................................. 27
Airflow Control .................................................................................................................................................... 28
Air intake pressure gauge...................................................................................................................... 28
Lockout-Tag Out....................................................................................................................................28

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch GENERAL INFORMATION
FLEX PITCH INSTALLATION MANUAL 1 TM 2017-014 REV01 © 8/2/2017
General Information
Introduction
This manual is a guide on how to install the ALPS Flex Pitch Multi-Moving Head Leak Tester. A complementary
listing of the standard components shipped with the unit is also provided.
Warnings and Cautions:
BURN HAZARD
THE DETECTOR CONNECTED TO THE MOLDER ASSEMBLY MAY REACH A TEMPERATURE
SUFFICIENT TO CAUSE SECOND DEGREE BURNS. AVOID CONTACT WITH THESE
COMPONENTS DURING OPERATION OF THE SYSTEM.
DANGER!
NEVER ATTEMPT TO SERVICE THIS MACHINE WITHOUT FIRST DISCONNECTING ELECTRICAL
AND PNEUMATIC POWER AND PERFORMING LOCK-OUT / TAG-OUT PROCEDURES. THE
POTENTIAL OF SERIOUS PERSONAL OR FATAL BODILY INJURY EXISTS!
WARNING!
WARNING! DO NOT WEAR LOOSE CLOTHING, LOW-HANGING JEWELRY, OR ANYTHING THAT
CAN BECOME ENTANGLED IN THE MOVING CONVEYOR. EVERYONE IS CAUTIONED TO PIN UP
LONG HAIR. THE POTENTIAL FOR SLIGHT TO MODERATE PERSONAL INJURY EXISTS.
WARNING
BEFORE POWER-UP, MAKE SURE THAT THIS MACHINERY IS PROPERLY GROUNDED TO
AVOID SERIOUS INJURY DUE TO ELECTRICAL SHOCK HAZARD!

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch GENERAL INFORMATION
FLEX PITCH INSTALLATION MANUAL 2 TM 2017-014 REV01 © 8/2/2017
ALPS Flex Pitch Multi-Moving Head Leak Tester
General Information
The ALPS Flex Pitch Multi-Moving Head Leak Tester provides high speed leak testing of a wide range of
bottle types including shingling, reverse-taper, and small bottles which are traditionally difficult to test. The
Flex Pitch has a smaller footprint to perform leak testing on an existing conveyor line, requiring no conveyor
line modifications. The Flex Pitch has built in flexibility with 2-4 test heads for a variety of container sizes up
to 350oz.
The Flex Pitch uses servo motors and linear slide combination coupled with an encoder (mounted to the top
of the conveyor) to track the conveyor movement and speed. As molded bottles enter the machine, the
Multi-Moving test heads locate and leak test each bottle. After the test is completed, good bottles pass
through machine, and defective bottles are ejected off the conveyor line with a reason displayed on the
HMI.
A single electrical cabinet is installed on the backside of the machine containing the AC power circuits,
servo motor drives, DC power supplies, power contactors, and main disconnect. The control system
features a multi-channel PLC and color touch screen interface with an intuitive, icon-based menu structure.
Standard features include an integrated Self-Test feature for each station.
Linear Dimensions (Top View)

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch GENERAL INFORMATION
FLEX PITCH INSTALLATION MANUAL 3 TM 2017-014 REV01 © 8/2/2017
Linear Dimensions of the Flex Pitch machine

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch INSTALLATION SITE
FLEX PITCH INSTALLATION MANUAL 4 TM 2017-014 REV01 © 8/2/2017
Section 1: Location Site and Installation
Requirements
Location :
It is recommended that you:
1. Position the machine on a stable, flat surface.
2. Locate in a cooler area where the containers will remain at a lower temperature where the probe seal
will not stick. This over time results in more consistency in test results.
3. Avoid locating this machine anywhere near a blow molder or other heat source that could adversely
affect the temperature of container stock prior to test run. Test results can also be adversely affected.
Electrical Power Requirements :US: 240 VAC, 3Ø, 25A isolated circuit
Air Supply : A maximum of 80 PSI steady output is required. (Actual pressure may vary).
Conventional air regulator and filtration system
CAUTION
AIR SUPPLY MUST BE DRY AND NON-POLLUTED. CHECK TO SEE THAT THE AIRFLOW IS
FREE OF ANY FOREIGN SUBSTANCES; I.E. MOISTURE, OR ANY LIGHT LUBRICATING FLUIDS,
OR OTHER FOREIGN MATTER.
Plug in air
hose here.
Primary
Particulate
Filter
Coalescing
Air Filter
Incoming Air
Regulator and
Pressure Gauge
Adjustment
knob

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch COMPONENTS INVENTORY
FLEX PITCH INSTALLATION MANUAL 5 TM 2017-014 REV01 © 8/2/2017
Section 2: Components Inventory
A standardized inventory of normal components shipped and installed with standard Flex Pitch machines (2
listings). Verify that all components are present on-site.
REF
STANDARD COMPONENTS
DESCRIPTION
1 Flex Pitch (With devices installed)
2 Tunnel Guards
Set of (2) Plexiglass guards for entry and exit point of Flex
Pitch
3 Hardware for Tunnel Guards (1 Bag) Set of (8) M8 screws, set of (8) M8 hex nuts.
4 Legs Set of (4)
5 Encoder Wheel To be mounted to conveyor
6 Installation Manual Installation Guide
7 Basic/Advanced Operations Manual Operational Guide
8 Service Manual/Electrical Schematics Maintenance Guide
REF
OPTIONAL COMPONENTS
DESCRIPTION
9 Downstream Jam Photo-Eye * Optional installation and placement is required
10 Keyence IB-1500 Laser-Height Unit *Optional electronic laser-height verification module: setup
11 DB-100 Downed Bottle Detector
*Optional electronic sensor to identify downed containers along
the conveyor line.

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch COMPONENTS INVENTORY
FLEX PITCH INSTALLATION MANUAL 6 TM 2017-014 REV01 © 8/2/2017
Common Components shipped with the Flex Pitch
Common components boxed separately with shipment.
The following pages show a series of photos of commonly boxed and assembled components that should
come with a typical crated Flex Pitch shipment.
Tunnel Shielding:These come as a set, unboxed with the shipment. Two hardware bags contained within
come with this installation. There are (8) M5 x 20mm Allen-Head Capscrews and (8) 80/20 Anchors. Use a
5mm Allen wrench for Capscrews.
Tunnel Shielding:-Qty. 2 (One set) and 2 hardware bags
Set of Legs :These come secured to the pallet complete with their own mounting hardware. The hardware here is
used as a mounting device. Raise the unit from the back side with a fork lift to install legs.
Set of (4) Legs; bolted to pallet

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch COMPONENTS INVENTORY
FLEX PITCH INSTALLATION MANUAL 7 TM 2017-014 REV01 © 8/2/2017
Common Components
Photo-Eyes and Photo-Eye brackets
Shown here is the pre-assembled photo-eye emitter reflector. See section 4 for installation and positioning.
This photo-eye is the downstream jam photo-eye just after the exit.
Left: Photo-Eye bracket with Emitter attached. Right: Bracket Photo-Eye Reflector attached.

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch INSTALLATION to CONVEYOR
FLEX PITCH INSTALLATION MANUAL 8 TM 2017-014 REV01 © 8/2/2017
Section 3: Installation to Conveyor System
Steps:
1. Unwrap the FlexPitch. Carefully unpack the HMI Enclosure from the packing box.
HMI Enclosure in packing box
2. Mount the enclosure to the frame using M5 bolts.
Mounting Location for the HMI
WARNING!
MACHINE MUST BE HOISTED FROM THE BACK AS SHOWN BELOW. SPREAD FORKS APART! THIS
MACHINE HAS A HIGH CENTER OF GRAVITY. FORKS MUST SUPPORT THE ENTIRE GIRTH OF THIS
MACHINE. DAMAGE CAN OCCUR IF MACHINE IS NOT FULLY SUPPORTED FRONT AND BACK.

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch INSTALLATION to CONVEYOR
FLEX PITCH INSTALLATION MANUAL 9 TM 2017-014 REV01 © 8/2/2017
Installation to Conveyor System
3. Hoist the Flex Pitch machine from the pallet and install legs:
There are four brackets securing the Flex Pitch machine at each corner of the pallet. Dispose of the
brackets.
a. Unbolt the Flex Pitch machine from the pallet base.
b. Hoist the Flex Pitch machine from the back as shown and install all four legs.
c. Remove the pallet. Move the pallet a safe distance away where it is out of the way.
Hoist the Flex Pitch machine from the backside. For proper support, spread forks apart. Forks must extend
out the other side.
Note that this machine has a high center of gravity, so
stability is important. Be sure that the forks extend out
beyond the other side of the machine. Tilt the forks back so
that the machine leans in toward the forklift.

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch INSTALLATION to CONVEYOR
FLEX PITCH INSTALLATION MANUAL 10 TM 2017-014 REV01 © 8/2/2017
Installation to Conveyor System
4. Install Support Legs-Adjust and Level the machine:
With the Flex Pitch unit suspended in the air, install all four legs.
a. Adjust leveling feet-do not tighten yet.
b. Lower the Flex Pitch to the floor (supported by the leveling feet) and check adjustments with a
level. Raise the unit again as needed to make further adjustments as needed.
c. When it is determined that all adjustments have been made, raise the Flex Pitch unit and transport
to desired location. Use extreme caution. Make sure there is adequate space to maneuver.
Install all four legs. Adjust leveling feet.
5. Transport the Flex Pitch:
6. Lower the Flex Pitch to the floor when it is in its designated location.
Adjustable Foot
Use a 1-1/8 Open-
End Wrench
Optional Height
settings: Adjust
with a ¾ inch box
wrench or¾ inch
socket wrench.

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch INSTALLATION to CONVEYOR
FLEX PITCH INSTALLATION MANUAL 11 TM 2017-014 REV01 © 8/2/2017
Installation to Conveyor System
7. Uncouple and remove the Front Guard: Begin by disconnecting the Reject-Verification sensor at the
reject chute. Secure cable to the inside body of the machine with tape. Do not allow to drag on the floor,
damage may occur.
Reject Verification Photo-eye.
8. Front Panel Assembly: Unfasten these screws and remove the entire panel assembly as shown in the
photos below. Use a 5mm Allen wrench.
Left: Left side of Flex Pitch Middle: Top Middle of Flex Pitch Right: Right side of Flex Pitch

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch INSTALLATION to CONVEYOR
FLEX PITCH INSTALLATION MANUAL 12 TM 2017-014 REV01 © 8/2/2017
Installation to Conveyor System
Enlist the aid of another person to complete this step.

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch INSTALLATION to CONVEYOR
FLEX PITCH INSTALLATION MANUAL 13 TM 2017-014 REV01 © 8/2/2017
Installation to Conveyor System
9. Positioning the machine: With the machine lowered onto its set of wheels (or by using a forktruck),
gently move the Flex Pitch machine to the conveyor system. The machine must be positioned perfectly
parallel with the conveyor.

AIR LOGIC POWER SYSTEMS (ALPS) Flex Pitch INSTALLATION to CONVEYOR
FLEX PITCH INSTALLATION MANUAL 14 TM 2017-014 REV01 © 8/2/2017
Installation to Conveyor System
10. Centering the probes over the conveyor: This assures that the machine is parallel to the conveyor.
Ease the machine into position with the probes centered over the center of the conveyor. Lock and
immobilize all casters. Raise the machine onto the adjustable feet. The machine has assumed its
permanent position to the conveyor.