Alps Electric FlexPitch User manual

Original Instructions [English] 2111241555 Rev A
Operator Manual
PLACEHOLDER
Flex Pitch Leak Tester

Copyright © 2020 ALPS
All rights reserved. Printed in the USA.
Due to continued product development this information may change without notice. The
information and intellectual property contained herein is condential between ALPS and the client
and remains the exclusive property of ALPS. If you nd any problems in the documentation, please
report them to us in writing. ALPS does not warrant that this document is error-free.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the
prior written permission of ALPS.
This manual reects the product conguration as was current at the time of its writing. An item’s
display in this manual does not guarantee the item’s availability at any time in the future. Images
shown are for representation purposes only. Products may vary from the images displayed. ALPS
is not liable for typographical errors or changes to specications presented.

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Contents
1 Introduction ..................................................................................................................................1
1.1 About This Manual .........................................................................................................................1
1.2 Software............................................................................................................................................1
1.3 System Modications.....................................................................................................................1
1.4 Machine Designation and Serial Number Location ...............................................................2
2 Safety ..............................................................................................................................................3
2.1 Safety Labels....................................................................................................................................3
2.2 Cautions and Warnings.................................................................................................................4
2.3 Safety: Warning Messages............................................................................................................6
3 Flex Pitch Specications ............................................................................................................7
4 Safety-Operational Status/Conditional Status...................................................................... 8
4.1 Operational Status: Conditional status of the machine........................................................8
5 Glossary of Common Terms ..................................................................................................... 8
6 Introduction to Components..................................................................................................10
7 Theory of Operations................................................................................................................11
7.1 Leak Test Operations...................................................................................................................11
7.2 Pressure Test.................................................................................................................................11
7.3 Test 1 (T1) (Stabilize Test) ...........................................................................................................11
7.4 Test 2 (T2) (Leak Test) ..................................................................................................................12
7.5 Pressure Decay Values................................................................................................................12
8 Photo Eye Function and Position...........................................................................................12
8.1 Photo Eyes Introduction and Positions...................................................................................12
9 Emergency Door Sensors Positions .....................................................................................13
10 Advanced Operator HMI Use ...............................................................................................13
10.1 HMI Password Protection ........................................................................................................14
10.2 How to Log In and Out..............................................................................................................14
10.3 How to Enter Passwords ..........................................................................................................15
11 How to Edit Settings with the HMI ......................................................................................16
11.1 Changing settings and values .................................................................................................16
11.2 Test Pressures & Reject Limits Overview .............................................................................20
11.3 Test Pressures & Reject Limits Helpful Hints ......................................................................21
11.4 Container Size and Stroke Overview.....................................................................................21
11.5 How to Use Container Size and Stroke ................................................................................22

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11.6 Probe Take O Overview..........................................................................................................24
11.7 How to Use Probe Take O .....................................................................................................24
11.8 Reject Timing ...............................................................................................................................26
11.9 Conveyor Speed Setting ...........................................................................................................27
12 Optional Functions Overview & Use...................................................................................27
12.1 Spacing Wheel (Optional).........................................................................................................28
12.2 Automatic Rail Guide (Optional) .............................................................................................29
12.3 Automatic Carriage Height (Optional)...................................................................................29
12.4 Reject Verication (Optional)...................................................................................................30
12.5 Down Stream Jam Timer (Optional).......................................................................................30
13 Recipes Overview ...................................................................................................................31
13.1 How to Use Recipes...................................................................................................................32
13.2 Test Results Menu......................................................................................................................36
14 All Results, Individual Results, Timer Details and Recent Rejects Overview..............38
14.1 How to Use All Results ..............................................................................................................38
14.2 How to Use Individual Results ................................................................................................39
14.3 How to Use The Cycle Time Statistics ...................................................................................40
15 Alarm Log & Counters Overview .........................................................................................43
15.1 How to Use Alarm Counters....................................................................................................44
15.2 How to Use Alarm Log ..............................................................................................................44
16 Manual Test Overview............................................................................................................46
16.1 How to Use Manual Test ..........................................................................................................47
17 Inputs and Outputs Overview ..............................................................................................48
17.1 Analog Inputs ..............................................................................................................................48
17.2 Digital Inputs................................................................................................................................49
17.3 Analog Inputs ..............................................................................................................................49
17.4 Digital Outputs............................................................................................................................50
17.5 I/O Forcing, and Maintenance.................................................................................................50
17.6 Interface I/O Screen...................................................................................................................53
18 How to Use Inputs and Outputs..........................................................................................54
18.1 How to Use Analog Inputs .......................................................................................................55
18.2 How to Use Digital Inputs.........................................................................................................55
18.3 How to Use Analog Outputs....................................................................................................55
18.4 How to Use Digital Outputs.....................................................................................................55
19 Station Diagnostic overview..................................................................................................55

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19.1 Station Diagnostics ....................................................................................................................55
20 How to use Station Diagnostic.............................................................................................56
20.1 Station Diagnostics Results......................................................................................................56
21 Analog Calibration Overview and Use................................................................................57
22 About Overview and Use.......................................................................................................57
23 Supervisor Menu Introduction.............................................................................................60
23.1 System Options Overview and Interface I/O .......................................................................61
24 Auxiliary Test Overview ..........................................................................................................62
25 How to use Auxiliary Test ......................................................................................................63
26 Reject Alarms Overview .........................................................................................................63
27 How to Use Reject Alarm.......................................................................................................64
28 System Bypass Overview and Use ......................................................................................65
29 Set Up New Bottle...................................................................................................................65
30 Auto Self-Test Overview.........................................................................................................68
30.1 How to Use Auto Self-Test .......................................................................................................69
31 Laser Height Quick Reference Procedure (IB-1500).......................................................69
32 Part One Changeover/Setup New Container: ..................................................................70
32.1 Part 1: Setting the Display High/Low....................................................................................70
32.2 Part two Zero-Shift Function: Adjusting vertical position of the laser sensor mount:71
32.3 Part three FlexPitch Container Height Calibration.............................................................73
32.4 Part 4: Access Initial Setup Screens:......................................................................................74
32.5 Part 5: Laser Controller - Initial Setup:..................................................................................75
32.6 Reference Light Registration-Gain Adjust ............................................................................75
32.7 Perform basic settings in this order:....................................................................................76
32.8 Receiving/Blocked Light Mode (2.L-d) ...................................................................................77
32.9 Averaging/High-Pass Filter .......................................................................................................77
32.10 Averaging: (AvE) ........................................................................................................................77
32.11 Output Mode (4.out) ...............................................................................................................78
32.12 Output Mode ............................................................................................................................78
32.13 Set for judgment value (P.V.).................................................................................................78
33 Maintenance Menu ................................................................................................................79
33.1 Flex Pitch Routine Maintenance Schedule...........................................................................80
34 HMI Reference Tables ............................................................................................................81
34.1 Software........................................................................................................................................81

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35 HMI Navigation and Information .........................................................................................82
35.1 HMI Serial Number Location...................................................................................................82
35.2 Screen Navigation ......................................................................................................................82
35.3 Home Screen...............................................................................................................................83
35.4 Information (Alarm Screens and Event History) .................................................................85
35.5 Reports .........................................................................................................................................87
35.6 Documentation...........................................................................................................................88
35.7 Diagnostics...................................................................................................................................89
35.8 Options .........................................................................................................................................91
35.9 Interface I/O.................................................................................................................................93
35.10 Calibration .................................................................................................................................94
35.11 I/O Status ...................................................................................................................................96
35.13 I/O Forcing .................................................................................................................................99
35.14 Large Values........................................................................................................................... 100
35.16 Systems ................................................................................................................................... 101
35.18 Station Overview ................................................................................................................... 103
35.19 Pressure Curves.................................................................................................................... 104
35.20 Test Statistics ......................................................................................................................... 105
35.21 Main Counters....................................................................................................................... 109
35.22 Alarm Counters ..................................................................................................................... 112
35.23 Setting Options Main ........................................................................................................... 113
35.24 Settings Options 1 ................................................................................................................ 115
35.25 Settings Option 2 .................................................................................................................. 117
35.26 Change Container................................................................................................................. 119
35.27 Recipes .................................................................................................................................... 121
35.28 Counters ................................................................................................................................. 123

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1 Introduction
1.1 About This Manual
The ALPS Flex Pitch Multi-Moving head leak tester provides high speed leak testing of a wide range
of container types including shingling, reverse-taper, and small containers which are traditionally
dicult to test. The Flex Pitch has a smaller footprint to perform leak testing on an existing conveyor
line, requiring no conveyor line modications. The Flex Pitch has built in exibility with 2-4 test
heads for a variety of container sizes up to 350oz. This makes the Flex Pitch ideal to leak test
dicult containers. The Flex Pitch Multi-Moving head leak tester provides tool-less adjustments
and no formatted parts to change, making quick container changeovers. 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 containers enter the machine, the Multi-
Moving test heads locate and leak test each container. After the test is completed, good containers
pass through the machine, and defective containers are ejected from 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.
1.2 Software
Installation of any new or modication of existing software into the FlexPitch machine not approved
by Air Logic Power Systems LLC may adversely aect 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.
1.3 System Modications
Mechanical or electrical modications not approved by Air Logic Power Systems LLC to the FlexPitch
system may also void the warranty and/or service agreements. Please contact the Air Logic Power
Systems Sales or Service Department 1-800-325-8717 for approval or assistance with any machine
modications.

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1.4 Machine Designation and Serial Number Location
This individual machine is identied with an ID and Serial Number plaque axed to the inside door
surface of the control enclosure as shown below. Along with it are the 24-Hour service hotline
phone number 1-800-325-8717 and the UL Panel Rating plate.
Table 1: Machine Label Locations
Label
1 ALPS 24-hour service hotline phone number 1-800-325-8717
2 Identification and serial number plaque
3 ALPS rating label
4UL Certification Sticker