Egitron ExtraLab Plus User manual

ExtraLab Plus
Extraction Force and Torque
Measuring System
OperationManual
Version 2.0.0
Valid for PC interface software version 1.4.0
Valid for firmware version 3.0.0
Rua Central da Vergada, 1280
4535 - 166 Mozelos VFR
PORTUGAL
Tel [phone] ●Fax. [phone]
E-mail: [e-mail] ●URL: www.egitron.pt

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RESPONSIBILITY EXEMPTION
This manual was written and revised to explain the ExtraLab Plus characteristics and functioning in
the most correct way possible, particularly regarding PC interface software. However, this user
manual and/or the equipment may be changed without previous notice. EGITRON is not
responsible for any damage caused by any direct or indirect error, omission or discrepancies
between theExtraLab Plus operation and the instructions presented in this Manual.
This document, or any part of this document, cannot be reproduced or transmitted under anyformat
andfor any purpose, without EGITRON written permission.
TRADE MARKS
Excel, Windows and Microsoft are Microsoft Corporation registered trademarks. Other trademarks
or registered trademarks not listed above can be used in this manual.
CONFORMITY DECLARATION
This product exhibitsCEmarking, according to European Union applicable directives.
GENERAL PRECAUTIONS
EGITRON equipment is produced to optimize security and minimize effort. Nevertheless, certain
precautions should be taken to reducethe risk of human physical damage orequipment damage.
Please read carefully the general precautions presented below and take attention to the warning
signs in this manual.
•Keep away from children;
•The machine should be operated only by persons with the appropriate training;
•Do not remove anycover or mechanical protection;
•All maintenance should be executed by specialized technicians;

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•The machine should not operate on facilities with severe environment conditions,
like dust or humidity;
•The equipment should be connected to the ground by the power supply plug;
•In case of successive power supply breakdowns, the equipment should be
disconnected from the power supply;
•The equipment transport and handling should be done with extreme precautions, as
it has fragile parts. For transportation use an adequate packaging so that the
machine remainswell accommodated and protected.
WARRANTY AND TECHNICAL SUPPORT
EGITRON guarantees the correct functioning of its products, in general for 1 year, or for a different
period whenever specifically written. The warranty covers workmanship and materials but not the
equipment transportation or onsite displacements, which will be charged according to the standard
prices in practice at the time.
This is valid with the exception of the first onsite displacement or equipment transport, if required
within the first month of the warranty period, which will be free. In this last case, EGITRON will
decide the most appropriate option between the technician onsite displacement or the equipment
transportation to EGITRON facilities and back to the client.
If the equipment presents any malfunctioning during the warranty period, EGITRON, according to
its own criteria, will repair or replace it without any charge, except in the situations described below.
Any product and/or part that have been replaced will become EGITRON property.
The warranty will have no effect in malfunctioning resulting from causes non imputable to the
equipment, such as:
•Anomalies caused by maltreatment, recklessness or handling contrary to the manual
instructions;
•Modifications or incorporations of non-authorized parts, and/or done by non-authorized
personnel;
•Defects caused by short circuit ormechanical injury;
•Indemnities for personal or material damages directly or indirectly caused by the equipment;

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•Defects caused by any installation service or user training at client facilities, when not
directly imputable to EGITRON technicians;
•Equipment replacement.
To request warranty services contact the EGITRON technical support. EGITRON can ask for the
purchase proof / equipment invoice. This equipment is suitable only for its design purposes and
EGITRON is not responsible for its improper use.
In case of malfunctioning or request for technical support
Before asking for EGITRON support read the Problems Resolution chapter, call your company
technicalsupport (if available) and/or use all existing auto-help tools.
If the problem remains unsolved contact EGITRON, having with you the following information:
•Equipment name
•Serial number
•Purchase date
•Problem description
•Error message that may appear.
You can contact EGITRON by:
•Phone: [phone]
•Fax: [phone]
•E-mail: [e-mail]
•Post: Rua Central da Vergada, 1280
4535-166 Mozelos VFR - PORTUGAL

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INDEX
WELCOME NOTES.................................................................................................................................................8
MANUAL CONTENTS.............................................................................................................................................8
1. CONVENTIONS ...............................................................................................................................................9
2. EXTRALAB PLUS AND PC INTERFACE SOFTWARE SETUP ................................................................9
2.1. ACCESSORIES SUPPLIED................................................................................................................9
2.2. PC INTERFACE SOFTWARE SETUP AND CONFIGURATION.....................................................9
2.3. MACHINE SETUP..............................................................................................................................11
2.3.1. Back acrylic cover....................................................................................................................................................................11
2.3.2. Connecting................................................................................................................................................................................11
3. OPERATION AND EQUIPMENT FEATURES............................................................................................12
3.1. GENERAL ASPECTS........................................................................................................................13
3.1.1. Equipment description ............................................................................................................................................................13
3.2. CONTROL THROUGH THE COMMAND BOX................................................................................15
3.2.1. Operation Basic Concepts......................................................................................................................................................15
3.2.1.1. Template for values introduction ......................................................................................................................................16
3.2.2. WelcomeWindow.....................................................................................................................................................................17
3.2.3. Main screen...............................................................................................................................................................................17
3.2.4. ConfigurationMenu.................................................................................................................................................................18
3.2.4.1. Test Type..............................................................................................................................................................................18
3.2.4.2. Test Mode Configuration....................................................................................................................................................19
3.2.4.3. Clousure Configuration......................................................................................................................................................19
3.2.4.4. Set clock...............................................................................................................................................................................20
3.2.4.5. Set date.................................................................................................................................................................................20
3.2.4.6. Language..............................................................................................................................................................................20
3.2.4.7. About….................................................................................................................................................................................20
3.2.5. Calibration screen....................................................................................................................................................................20
3.2.6. Initialization...............................................................................................................................................................................22
3.2.7. Stopping movements...............................................................................................................................................................23
3.3. PC P ROGRAM .......................................................................................................................................23
3.3.1. Data Tables................................................................................................................................................................................24
3.3.2. Report Configuration...............................................................................................................................................................25
3.3.3. Acquire Values..........................................................................................................................................................................26
3.3.4. Saving Reports.........................................................................................................................................................................28
3.3.5. Open Reports............................................................................................................................................................................29
3.3.6. Printing Reports.......................................................................................................................................................................29
3.3.7. Export to Excel..........................................................................................................................................................................30
3.3.8. Calibration.................................................................................................................................................................................31
3.4. COMMON EQUIPMENT AND SOFTWARE OPERATIONS..........................................................33
3.4.1. States.........................................................................................................................................................................................33
3.4.2. Test Configuration....................................................................................................................................................................33
3.4.3. Values Acquisition...................................................................................................................................................................35
3.4.4. Deleting Test.............................................................................................................................................................................35
3.4.5. Safetyand Protection ..............................................................................................................................................................36
3.5. START A TEST...................................................................................................................................36
3.5.1. Connect the equipment...........................................................................................................................................................36
3.5.2. Place the bottle.........................................................................................................................................................................37
3.5.3. Configure the test.....................................................................................................................................................................37
3.5.4. Starting the Test.......................................................................................................................................................................37
3.5.5. Check information on theDisplay..........................................................................................................................................38
4. EQUIPMENT MAINTENANCE .....................................................................................................................39
5. TROUBLESHOOT.........................................................................................................................................40
5.1. CALIBRATION CURVE LOAD FAILURE AT STARTUP ...............................................................40
5.2. COMMUNICATION ERROR..............................................................................................................40
5.3. SYSTEM BLOCKED..........................................................................................................................40

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ANNEX A – OPERATOR INTERFACE MENU TREE.........................................................................................41
ANNEX B – ACCESSORIES.................................................................................................................................43
1. A NTI - SPLASH PROTECTION APPLICATION ...............................................................................................43
2. C LAMPS ..............................................................................................E RROR ! B OOKMARK NOT DEFINED .
ANNEX C – CALIBRATION...................................................................................................................................45
1. C ALIBRATION SETUP .............................................................................................................................45
2. C ALIBRATE E XTRACTION .......................................................................................................................46
3. T ORQUE CALIBRATION ..........................................................................................................................49
ANNEX D – FIRMWARE ACTUALIZATION ........................................................................................................54
ANNEX E – COMMUNICATION CABLE..............................................................................................................56
ANNEX F – TECHNICAL SPECIFICATIONS......................................................................................................57
NOTES....................................................................................................................................................................58

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WELCOME NOTES
Congratulations for purchase ExtraLab Plus – Extraction Force and Torque Measuring System.
With this excellent equipment it is possible to assess the closure qualitythru the analysis of different
physical tests, namely extraction force, opening torque, closing torque or breakage resistance,
following the standards in practice, allowing the user measuring a simple and reliable way to
perform these tests.
The users have at their disposal an equipment of control, with small dimensions, developed with
metrological precise techniques, assuring, a high standard and innovative quality control.
ExtraLab Plus is supplied with software for Windows compatible with all Microsoft Windows
9x/Me/NT/2000/XP/Vista/7 operating systems. This software was specifically developed for the
ExtraLab Plus and it allows the user to:
•Monitor the equipment;
•Collect the tests data from the ExtraLab Plus and present them graphically;
•Save the tests into a database for later use;
•Print reports in several languages;
•Setup the quality control tests configuration;
•Perform equipment calibration;
•Export data to Microsoft Excel.
This operation manual contains instructions to setup the ExtraLab Plus, providing detailed
information regarding its operation.
MANUALCONTENTS
This operation manual describes the ExtraLab Plus and also the PC interface software. It starts with
ExtraLab Plus characteristics, the setup procedure, the connection to a PC and the interface control
software setup. After the setup, are described the ExtraLab Plus functionalities; the test process
and the data acquisition thru the interface software. In the following chapters, you can find
information about saving the tests, opening saved tests and printing reports. Next, the operation
manual explains how to export data to Microsoft Excel. At the end, the equipment calibration,
maintenance and troubleshooting are described.

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1. CONVENTIONS
Abbreviations:
In this operation manual you can find the following abbreviations:
•ExtraLab Plus – Extraction Force and Torque Measuring System
•Report – Group of tests on one ormore corks
•Test – Extraction/Detaching/Rupture test for a single cork
•PC – personal computer
Messages
Some messages are used in this manual to call your attention for important information. Each
message type is identified as follows:
Pay attention! A warning signal informs that an improper equipment use or not following
the instructions, can cause personal and/or equipment damages.
Please read. This is a suggestion or advice which can help you to get more benefits from
the equipment.
2. EXTRALAB PLUSAND PC INTERFACE SOFTWARE SETUP
2.1. ACCESSORIESSUPPLIED
Along with this user manual you can find the following items:
1. Installation Guide;
2. Software interface for PC ;
3. Set of accessories, according to the order made and as the package contents sheet.
2.2.PCINTERFACESOFTWARESETUPANDCONFIGURATION
To install the PC interface software, please follow the next steps:
1. Place the setup CD or PENDISK at thecomputer CD/DVD drive or USB port;

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Figure 1 – Communication settings
2. Using the Start button, select the Run command and write “D:\Setup\setup.exe”, where D is
the CD/DVD or PENDISK drive letter. If the CD-ROM or PENDISK is accessed by another
letter, the user must type the corresponding drive letter. Afterwards press Enter. The
installation program must be executed following the indications until the installation is
successfully completed. The user can also run “Setup”, accessing installation folder thru
“My Computer” or using Windows Explorer.
After software installation, the user can start the Interface software from the shortcut “ExtraLab
Plus” on the programs menu (or a desktop shortcut may be created).
At startup, the software makes a communication test with the equipment. If there is no
communication, the user receives a warning with the possible causes. In this case, some software
options are inactive, including the option of performing tests. However, the user can still see the
existing tests on the Database and print some reports.
The most common causes for communication failure are:
1. Equipment not connected: connect the ExtraLab Plus (see next chapter).
2. The connection with the communication cable is not correct (see next chapter).
3. Communication parameters are not correct: For changing the communication settings the
user should select “Communications” on the “Configuration” menu at the main toolbar. After
this, a new window like Figure 1 shows up. On the interface software it is possible to
configure the PC serial
port number (COM) where
the communication cable
is connected, and the
communication settings,
including Baud-Rate,
parity, bits number and
Stop bits number. The communication settings for ExtraLab Plus are: “19200, N, 8, 1”.
After checking the causes for the communication fail, it will be necessary to press Test on the
communications settings window ( Figure 1 ) or press the identical button on the main window to test
the communication with the equipment. If successful all software options will be activated.

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2.3.MACHINESETUP
Before making any connection it is very important that the user understands the technical
specifications of the machine (see Annex F). The technical specifications and the
information next to the connectors must be followed, otherwise damages in the equipment may
occur which will not be covered by the warranty (see warranty conditions above). In case of doubt,
please contact EGITRON for technical support.
2.3.1. Back acrylic cover
a) After placing the equipment at its
workplace.
b) Apply the back cover (when supplied
separately) on the back of the
equipment and tight it with the existing
screws.
2.3.2. Connecting
a) Connect the ExtraLab Plus equipment to the pneumatic feeding thru the pneumatic
connection on the back panel. The feeding tube should have 6 mm of diameter (type
FESTO PUN-H-6x1-nt) and the pressure must be between 6 and 8 bar.
b) Connect the power cable according the indication on the label next to the power connector
(Figure 7 - Command Box).
c) Connect the communication cable on the PC communication port. If the PC only has USB
ports available, use a RS232/USB converter (If required contact EGITRON to order a
RS232/USB converter).
Apply the cover
Screw with the existing
screws (4)
Figure 2 - Back cover application
Figure 3 - PC Serial
Communication Ports RS232
Figure 4 - ExtraLab Plus Serial Communication Port
(Rear Command Box)

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3. OPERATIONAND EQUIPMENTFEATURES
On this chapter we will explain the functionalities of ExtraLab Plus, including the control by the
command box and the control by the interface software, in order to enable the user to correctly
operate the equipment and perform tests. On the next subchapters, the most important aspects to
consider when operating ExtraLab Plus will be analyzed, so that, after a careful reading the user will
be able to fully operatethe equipment and understand some less intuitive operations.
Command
Box
Upper group of
the equipment
(encoder+ extraction motor)
Working
area
Power SwitchON/OFF
Adjustment
EMERG
ENCY
button
Command
Console
(Keys and display)
Gripper
Security
door
ElevationBase
Measurement unit
(Extraction+Detaching)
Figure 5 - ExtraLab Plus (front panel)

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3.1. GENERALASPECTS
3.1.1. Equipment description
The ExtraLab Plus has a tower format, supported by two cylindrical guides and an aluminum
enclosure which contains the electronic control (commands and processing unit). On the next
paragraphs, we will describe the main parts.
The upper group of this equipment is composed by:
•a motor which is responsible by the extractionmovement,
•a vertical position sensor (encoder) and the initial position sensor;
•a lever to hold / release the security door
Below there is the measurement unit, composed by two load cells, used to measure the extraction
force and torque. In this unit, there is also a motor and a sensor for the torque movement. Finally
there is a gripper and a set of optical fibers to detect the approach to the closure.
Below the measurement unit, there is the working area, used for positioning the bottle, adjusting the
measurement unit to the test type and performing tests.
On the lower part of the equipment, there is the command box which contains the electronic control
system. Onthe frontal panel of the command box, there are the following items:
Programming port
Power connector
Communication port
Calibration buttons
Compressed air
feeding (6mm)
Pressure regulators
Pressure gauges
Figure 6 - ExtraLab Plus (back panel)
(ELEVATION)(GRIPPER)

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•Operator interface where it is possible to easily operate the equipment.
•Regulators to set the speed of the extraction test and the torque test
•Emergency buttonto stop the equipment in case of emergency.
•Power Switch ON/OFF that allows the user to turn-on and off the equipment.
On the command box back panel, illustrated in Figure 6 , the user will find the power supply
connector, the communication and programming ports. The first used to communicate with the PC
and the second used port is used for programming the machine and it should not be used
except when performing a firmware update. For more details, please see ANNEX D –
Firmware Actualization that contains information related tofirmware update.
On the right of the power plug, there are two red buttons (one for the Extraction load cell and
another for the Torque load cell), used for checking if there are discrepancies between the factory
calibration values and the current values.
Over the right side, there is the plug for compressed air where the pneumatic connection is done.
And there are also two pressure gauges that indicate the pressure for the elevation cylinder
(Elevation) and the pressure applied on the pneumatic Gripper (Gripper). To adjust the pressure
there is a regulator for which actuator (gripper and elevation cylinder). Both adjustments are
important:
•Gripper pressure: should be adjusted to prevent the sliding of the cork when testing
champagne or bar top cork, without damaging the cork. Generally, the pressure should be
between 2 and 2.5 bar, however the operator should adjust the equipment pressure having
in mind the following scenarios
- Insufficient pressure: Cork stopper “slides” during the test.
- Excessive pressure: After the test, the cork stopper shows damage, for example
disruptions in the clamps tightening area. This will change the test values.
•Elevation cylinder pressure: adjust so the bottle is not too much compressed against
bottle positioner (it may burst) and so the bottle does not rotate during torque tests.
Generally the pressure should be between 4 and 4.5 bar.
Please find information about the accessories usage at ANNEX B – Accessories .

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3.2. CONTROLTHROUGHTHECOMMANDBOX
3.2.1. Operation Basic Concepts
In this chapter we will be explain the basic concepts of navigation between the different windows
available in the operator interface (display) that is in the command box, as illustrated on Figure 7 .
On de operator interface there is a graphic display and a keypad.
There arethree operating modes:
•Test Mode: the default mode, in which it is possible to perform tests.
•Calibration Mode: accessible through the option “CALIB” in the main menu ( Figure 8 ). In
this mode are provided some features for calibration and for performing “manual”
movements.
•Configuration Mode: accessible through the option“CONFIG” in the main menu ( Figure 8 ),
where it is possible to configure the equipment and configure also the test to be done.
On the display it will be available, at every time, the information related with the active mode, i.e.,
the display will show information related with the tests when in test mode, will show information
about calibration in calibration mode and will show the configuration menus when in configuration
mode.
Figure 7 - Command Box

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Figure 9 – Values introduction
The keys are the control means available for
navigating between the different modes. These also
allow to command individual movements
(Calibration Mode) and to configure the equipment
(Configuration Mode). The keys have the following
functionalities:
•Function Keys ( Figure 8/A ): These keys
command the equipment according to the function that appears on the lower edge of the
display.
•Navigation Keys ( Figure 8/B – lighter background): these keys assume distinct functions
depending on the mode. Further the keys and will be designated as “up” and
“down”. And the keys and will be designated as “right” and “left”.
•Central Key ( Figure 8/C ): The role of this key will also depend on the active mode. On Test
Mode the function is for “OK” and the equipment will perform a test, or start the equipment
depending on the equipment status. On Calibration mode, it will be for raising the base for
bottle elevation and on configuration mode it will be used to confirm the selected option.
3.2.1.1. Template for values introduction
On the configuration menu there are some templates
for introducing values ( Figure 9 ) which will be
validated by the range of values indicated on the
upper side of the screen. To select a value, browse
through the characters available and press the
central key to confirm the value. Repeat this
operation until the end of the introduction. To confirm
the value, press “RET” and to cancel the introduction,
press “ESC”. If the value that is being introduced is
out of the validation range, this introduction will not be
allowed.
Figure 8 - Keys of the console
A
B C

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A
B
C
D
E
Figure 11 – Main screen
Figure
10
-
Welcome
screen
3.2.2. Welcome Window
Press the “Power” bottom on the front panel of the
command box to start the equipment. At starting, a
welcome screen will appear with an indication of the
installed Firmware version ( Figure 10 ). After 2 seconds the
main screen will show ( Figure 11 ).
3.2.3. Main screen
The main screen is illustrated on Figure 11 . Here it is
represented, in a condensed way, the memory state, the
tests results, the current test configuration and time and
date information. For better understanding the different
information areas, these were identified in Figure 11 by
letters, whose meanings we will describe below.
A. Information about time and date (chapters 3.2.4.4 and 3.2.4.5).
B. Information about memory state: on the example we have Test 1that has been visualized
in a TOTAL of 1test in memory.
C. Current test configuration, in this example we have the Test Type T + E (chapter 3.2.4.2),
Cork Type Plus (chapter Error! Reference source not found.) and Torque Angle 75
degrees (chapter Error! Reference source not found.).
D. Information about test results: On the example above, the Torque test had the maximum
value of 12.8 daN.cm at 28º and the Extraction Test had the maximum value of 12.3 daN at
a displacement of 2 mm. If one of the tests was not done, asterisks (****)will appear on the
corresponding column. Use the horizontal arrow keys to navigate between the
tests in memory.
E. Functions: show themodes / functionsavailable since the main window:
oCALIB: Enter in the calibration screen (see chapter3.2.5).
oSTART: Start a test (it may also be done by the central key).
oCONFIG: Enter in the configuration menu (see chapter3.2.4).
oDELETE: Open the confirmation screen in order to delete all tests in memory.

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Figure 12 – Configuration Menu
Figure 13 – Test type configuration
3.2.4. Configuration Menu
The configuration menu gives access to a set of settings that allow the user to choose some
generic parameters, such as language, date, time, and other parameters related with tests
preparation. These last parameters should be adjusted every time the user starts a new report (set
of tests) according with the test type to perform.
To access the configuration menu, press “CONFIG” and
the display should show the configuration menu ( Figure
12 ).
Before we present each menu, it is important to have in
mind the following concepts, concerning the navigability
within the menus.
•As seen in 3.2.1 the keys “up” and “down” allows
the navigation between the available options
•The central key selects the highlighted option being a submenu selection or a value
selection.
•Every time the user wants to leave a menu, select the key “EXIT” on the right. Next press
the central key to confirm. After this, the program returns the previous menu or exits the
configuration menu and returning to the main screen (for an overview of the screens tree
see ANNEX A – Operator interfacemenu tree ).
3.2.4.1. Test Type
T he ExtraLab Plus allows the execution of 4 test
types:
•Champagne/Capsulated;
•Still Wine Cork;
•Screw Cap;
•Breakage.

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Figure 14 – Test mode configuration
Figure 15 – Closure configuration
3.2.4.2. Test Mode Configuration
T he ExtraLab Plus allows the execution of 6 test modes. To
ease the identification of each test mode on the main
screen, these were coded through related letters. Next we
will describe the different tests types and the associated
letters:
•Extraction (E): Only extraction test, without anyrotation movement.
•Torque (T): only detaching test. The measurement unit moves towards the closure (cork
stopper or bar top), detaches it and at the end releases it without removing it from the bottle.
•Torque + Extraction (T + E): Torque (detaching) test followed by Extraction test.
•Torque and Extraction (T & E): Torque (detaching) test performed simultaneously with the
Extraction test.
•Overtorque (O): Overtorque test.
•Torque + Overtorque (T+O): Torque (detaching) test followed by Overtorque test.
•Insertion (INSER): Only insertion test (applies only to flat top capsulated corks).
3.2.4.3. Closure Configuration
Based on this parameter, the measurement unit
will define the position of the clamps on the
pneumatic gripper. The user can select one of the
five options available. The closure configuration is
also coded to ease the visualization on the main
screen. The closure options are:
•Champagne (Plus): 19 mm;
•Long Cap (Cap A): 15 mm;
•Short Cap (Cap B): 5 mm;
•Poly: 24 mm;
•Other (D(xx)): The distance may be set by the user, being xx a value between 5 and 30
(24mm for models before serial number 005). Selecting this option, the user will have to

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Figure 16 – Language
Figure 17 – Calibration screen
manually introduce the exterior cork length value (part of the cork that that remains out of
the bottle), according to the range validation and as referred on the chapter 3.2.1.1.
The appropriate configuration for the clousure type is very important. An incorrect
configuration can damage both the equipment and the bottle to be tested.
3.2.4.4. Setclock
After selecting this option, the user will have to use a value introduction template to enter the current
time. Which must be done according with the indications in chapter 3.2.1.1 and following the time
representation on the top of the template (HH-MM-SS) in an 24 hours format (example: 13-10-00 to
13 hours, 10 minutes and 0 seconds).
3.2.4.5. Setdate
In this menu the user can set the date thought a value introduction template. This must be
completed according with the indications in chapter 3.2.1.1 and according to the date representation
on the top of the template (DD-MM-YYYY ex: 24-10-2009).
3.2.4.6. Language
In this menu it is possible to choose the language that the
user wants for the equipment operation. The options are
Portuguese and English ( Figure 16 ).
3.2.4.7. About…
Screen with information about the embedded software
(Firmware) and EGITRON contacts.
3.2.5. Calibration screen
Pressing the “CALIB” key on the main window ( Figure 11 ),
it is possible to access the calibration screen ( Figure 17 ). In
this screen are displayed ‘live’ readings of the load cells
used in each test type and is also available a set of
commands which allow to command manually the
equipment.