KIV-SACS Safe automatic calibration system:

Transcription

1 KIV-SACS Safe automatic calibration system: LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 1 of 14

2 Parts description:... 4 Wash extractors:... 6 Tunnel washers:... 5 Test valve:... 7 SACS in Progress:... 7 SACS Result menu:... 8 SACS Result validations:... 9 Recalibrate SACS: SACS Configuration: SACS Volume test: SACS DISPLAY SACS Check signal switch LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 2 of 14

3 Flow diagram: The drawing below explains how this system works. Dosing (A): Calibrate (B): Flow to M1 enters gate-1 and out gate-2. Flow to M2 enters gate-1 and out gate-3 then trough our calibration unit return to gate-4 and finally out gate-2. P: Product pumps. M: Tunnel modules. A, B, E: Pneumatic valves C: Pressure device to measure mm water level. D: Test column in transparent PVC material F: 4-way SACS valve. E: High digital calibration point. F: Low digital calibration point. G: Tube coil. LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 3 of 14

4 Parts description: The SACS unit is an automatic and safe calibration system for KIV2 dosing system. While a product is dosed to a tunnel or machine, the SACS unit will measure the dosage. The unit will measure the volume and calibrate pump capacity by an analogue signal that continuous read the water level in mm from a transparent tube. During the calibration procedure V-Control software will also create the counter chart. The measured and calculated pump capacity and counter chart are then saved to a file (only after a successfully calibration). During calibration the software will give status messages in the event base. SACS results are also available in a separate menu, see page 8. The flow capacity range for the SACS is from 300ml up to ml/min. Accuracy for flow up to 2000ml > 2%, for flow above 2000ml > 3%. El. Box and the MCU3 unit. Airing, ventilation High digital calibration point (High digital signal). Transparent tube mm divided Product buffer. A coil of PVC tube. Low digital calibration point. (Low digital signal). Analogue pressure unit, (water level in mm). Solinoid valves Pneumatic valves. Drain outlet from SACS LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 4 of 14

5 Tunnel washers: Start SACS for Tunnels: A double Click on the green kilo label will open the menu below, select a group and press the button <Start SACS>. Remark1! -A pump will only be calibrated once. -30 sec of the dosage is pumped to the SACS, if water level in the transparent pipe exceed the High digital calibration point the SACS is closed and the remaining dosage of the 30 sec are used to create the counter chart, if dosage is longer than 30 the remaining seconds are dosed as a normal dosage. Remark2! The calibration procedure for a KIV-system is 30 sec. therefore only pumps that run a dosage longer than that timer are calibrated by the SACS unit. Product used by tunnels may be shorter than this default calibration time and pumps thereby never calibrated. To be able to calibrate pumps with only short dosing time enter a value in col 9 SACS. Length of the flowchart are then set equal to this value, see picture below. Min legal length of this value is 10. LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 5 of 14

6 Wash extractors: Start SACS for washers: From wash extractor frame, activate SACS calibration for washers; by a click on the small button. Select one ore more products from the menu and press <Start SACS>. LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 6 of 14

7 Test valve: 4-way test valve for SACS State of the art special developed 4 way valve are used to redirect dosing lines to the SACS unit. Calibration of pumps and create counter chart has never been easier. SACS in Progress: During calibration by the SACS unit a message is sent to the event base and a message box will appear on the screen, see picture below. When message Click button when closed is given, calibration of selected group is done and a new group may be activated for SACS pump calibration. LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 7 of 14

8 SACS Result menu: Columns in the table above: Date/Time=Actual date time for SACS calibrations. Machine=Actual machine. Product name=calibrated product. Volume=Calculated volume based on: mm SACS * mm_ml. Tim= If value is 30,0 the calibration volume enters the transparent tube, (pump capacity < 2000ml/min). If value less than 30,0 Tim is equal to number of 1/100 seconds used from Low digital point to High digital point in the SACS tube. Pump capacity is then a calculation based on this timer. User Name=Active user for SACS the actual SACS calibrations. Remark! Pump capacity and flowchart are only created if product flow during 30 seconds is proved by the chart validation procedure,(setup from the standard calibration menu). LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 8 of 14

9 SACS Result validations: From the menu above SACS pump capacity and charts are validated by the authorized user. If the pump capacity is validated select actual row by adding a check marks (see column Update), and then press the button Update tunnel pump capacity. Unselected rows will be removed from the table if Delete unused flow is set to on. The menu below show the table after button Update tunnel pump capacity is pressed. LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 9 of 14

10 Recalibrate SACS: The calibration of SACS is automatically done by the software V-Control, a extra calibration of the SACS unit is therefore never needed. To do a calibration follow the description below. 1. Open water valve for washers and SACS valve for washers. 2. Press button <MENU> and enter password Arrow up to factory calibration 4. Start calibration procedure by pressing the button <E>. 5. SACS will now start filling water to the top point (transparent tube) and then slowly empty out the water by short signals. Wait for the message Factory calibration level + [Ok] 6. Read number of mm from the transparent pipe, and enter it by using the numeric keypad. Save to e-prom by the button <OK>. 7. SACS will now empty the water level to the low point. Wait for the message Factory calibration level + [Ok] 8. Read number of mm from the transparent pipe, and enter it by using the numeric keypad. Save to e-prom by the button <OK>. 9. Press button <MENU> 10. Close water valve for washers. 11. SACS unit is now ready to use. LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 10 of 14

11 SACS Configuration: Setup of SACS, do that from menu <SACS>, SACS-Setup. Active MCU3 ch. Only visible if more than one SACS are in use. Timeout (max time) for SACS during customer calibration. Delay timer before water is drained out of the transparent tube (after a SACS calibration). Checked, indicate that SACS unit is calibrated. The SACS unit will only be calibrated when used for washers. To start a calibration procedure uncheck this menu, (next time SACS is in use for washers a calibration procedure will bed executed). Diameter of the transparent tube Water-timer before SACS is used. Set to on only when SACS valve position check signal switches are in use. For more info see last page. ml Volume of 1 mm in transparent tube. LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 11 of 14

12 SACS Volume test: Use SACS to test a defined volume. Selected machine number for pump volume test. Dosing column for pump volume test. Volume (ml) for pump volume test. Button to start pump volume test. Button to drain out water in the transparent tube. Stop Button for pump volume test. (Used if something is wrong after test procedure is started) The Pump volume test is used to check that SACS is working ok and that accuracy of the unit are as expected. Start the volume check by selecting a product (column), the system will calculate pulses (not time) for actual product and start pump to run actual number of pulses. When pulses received from product counter is equal to calculated pulses, the pump will stop and pumped volume is calculated by the SACS unit. The result is shown in the SACS display and in the event base. Remark! Pump test for washers are free to be tested anytime, but before checking a pump for a tunnel, put the tunnel on hold. LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 12 of 14

13 SACS DISPLAY F-keys SACS Setup menu: Error-Led There are 6 menus available from the SACS display. Activate it by the button <MENU> and password 183. Press arrow up to step in the menu. Menu-1, Customer calibration Menu-2, Factory calibration Menu-3, A1 Upper level in mm [Num+Ok]: Menu-4, A1 Lover level in mm [Num+Ok]: Menu-5, A1 Low threshold ( ) [Num+Ok] Menu-6, Com address. Activation outputs by F keys: Press orange button to force SACS to manually mode Press F1 to activate inlet pneumatic valve. Press F2 to activate outlet pneumatic valve. Set back to automatic mode by the <Green> button. Error-led: Error-led is set to ON if High digital calibration point is ON (transparent tube filled with water) and at the same moment the Low digital calibration point. is OFF. In case of error check the digital sensors. LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 13 of 14

14 SACS Check signal switch As an option, it is possible to install a signal switch on the SACS test valve, the signal from the switch will then continuous check position of the handle. Example of mistakes checked by this signal: Error message if too many valves are activated at same time. Error message if wrong valve is selected. Error message when SACS valve still are open after calibration is done. LOK: g:\prosjekter\calibration_system\kiv safe calibration system.doc Page: 14 of 14