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1. 2 1 Tap on the Operator box located at the top center of the Setup screen to logout 3 Quit 3 1 To quit the program authorization name and password with a supervisor access level is required TPC User Manual Revision 3 2 02 01 2006 Page 4 of 18 4 Status M Tablet Press Controller Version 3 0 6 STATUS SCREEN MC 11 18 2004 10 13 43 AM SETUP BATCH MCC Maintenance SeTUPREGPE DEMO 7 Average Force Tablets Per Hour Compression k 169 576 ON Control Limits Pi Press MANUAL Tablet Count Accept 720 Reject Press Speed RPM 23 1 19 8 16 5 13 2 PreCompression kN 99 1 0 66 Ejection N 98 9 DOSING CONTROL 4 gt 3 3 RECIPE STATUS PUNCHES REPORTS SETUP 4 1 The TPC Status screen is the first screen that comes up after Login It provides real time tablet press information and access to other TPC features 4 2 Status screen Current Information Current information is displayed across the top of the TPC Setup screen for user convenience The information is stored in Recipe file Setup file and Reports The following items are shown 4 2 1 Date amp Time displayed in 24 hour style 4 2 2 Recipe Batch current recipe file name and batch number 4 2 3 Operator operator who logged onto system 4 2 4 Press Mode manual or automatic 4 2 5 Fora double sided press Side A or Side2. B indicates press side This is also a toggle switch between the two sides 4 2 6 Alarm ACK alarm acknowledgement after an alarm 3 21 01 Batch 1 OPERATOR Press Mode 1 35 01 PM Recipe PLACEBO Alarm ACK TPC User Manual Revision 3 2 02 01 2006 Page 5 of 18 4 3 4 4 4 5 4 6 4 7 4 8 4 9 Average Force The Average Force section of the TPC Setup screen displays current average compression kN and optionally precompression KN and ejection N forces in digital format In addition compression force is shown on an analog style meter with high and low control limits indicated Note control limit is a recipe parameter Tablet Count The Tablet Count window displays both Good and Bad tablet count values for the current batch Values are updated in real time Tablets per Hour The Tablets per Hour window displays the actual number of tablets being produced by the press each hour based on press speed and number of tooled stations Press Speed RPM Press speed measured in RPM is determined by the system proximity switch Both Actual and Desired values are displayed The Desired value on the bottom is changeable using the arrow buttons It may take time for the actual value to reach the pre set desired speed value Press Control The operator can shut down the press using the Stop Press button The indicator field above the button corresponds to the logical state on off of
3. Hysteresis The maximum difference between transducer output readings for the same applied load One reading is obtained by increasing the load from zero and the other reading is obtained by decreasing the load from Full Scale rated load Measurements should be taken as rapidly as possible to minimize creep Instrumentation Strain gauge or piezoelectric transducers installed on a tablet press to convert force into voltage Other types of instrumentation measure torque temperature pressure level speed etc Modulation Re Amplitude Modulation Modification of an amplitude of a waveform carrier so that it varies in step with the instantaneous value of another wave signal Modulation Factor In an amplitude modulated wave the ratio of half the difference between the maximum and minimum amplitudes to the average amplitude in percent Non Linearity In Calibration The maximum deviation of the calibration points from a regression line best fit to the data expressed as a percentage of the Full Scale rated output and measured on increasing load only Proximity Switch A proximity switch transducer is a non contact electromagnetic pickup device that senses the presence or absence of metal It is installed on the press in order to mark the beginning of a turret revolution and thus enable station identification by system software Repeatability The maximum difference between transducer output
4. print TPC User Manual Revision 3 2 02 01 2006 Page 10 of 18 8 Setup 8 1 The TPC Setup screen options include Calibration Password Control Setup Parameters and other functions A brief description is given below M Tablet Press Controller Version 3 0 6 SETUP SCREEN 11 18 2004 SETUP BATCH EA here MANUAL 10 30 27 AM SETUP RECIPE a E Transducer Side i Value Last Calibration Date PreCompression Eaa C _ oasa Compression A 20 03 Delete PreCompression E o 7 Li Between compression event ICA a and slow reject gate D1 To keep slow rejecton gate open after a bad tablet was Setup Parameters encountered D2 Between compression event Number of sequential rejected tablets S that will trigger an alarm and fast reject gate D3 4 Number of revolutions R to reject after press startup 15 Number of rejected tablets T in N revolutions that will trigger an alarm EI Number of revolutions N for calculation L25 Number of minutes M of user inactivity to autolock procompression Weight Number of revolutions A to control mode Compression C Hardness Number of stations M3 to keep dosing motor ON G Thickness _mm_ Ejection nx J Diameter Channels Tablet RECIPE STATUS PUNCHES REPORTS SETUP 8 2 Calibration This section displays the current calibration in a table that includes transducer name transducer calibration factor and last calibration date Users with maintenance le
5. readings for repeated applied loads under identical loading and environmental conditions The ability of an instrument to give identical results in TPC User Manual Revision 3 2 02 01 2006 Page 16 of 18 successive instances Strain Gages Foil wire or semiconductor devices that convert pressure into electrical current Foil gages known for robust application range different nominal resistance and transverse sensitivity control are most commonly used for tablet press instrumentation TPC Tablet A system that performs and monitor tablet rejection for tablet Rejection presses TPC software is monitoring and control program that Controller runs under the Microsoft Windows operating environment Transducer A device that converts energy from one form to another e g force to voltage Wheatstone A special arrangement of strain gages to ensure signal balancing Bridge and temperature sensitivity compensation TPC User Manual Revision 3 2 02 01 2006 Page 17 of 18 12 MCC Support 12 1 Contact MCC for support during normal working hours by any means available below 12 2 For modem support special remote control software was installed Long distance troubleshooting upgrades and training are just a click away Contact MCC to start using the modem support Metropolitan Computing Corporation Process Instrumentation Monitoring and Control 6 Great Meadow Lane East Hanover New Jersey 07936 U S
6. A e mail mail mcc online com Web address www mcc online com Phone 973 887 7800 Fax 973 887 8447 TPC User Manual Revision 3 2 02 01 2006 Page 18 of 18
7. Metropolitan Computing Corporation Process Instrumentation Monitoring and Control 6 Great Meadow Lane East Hanover New Jersey 07936 U S A e mail mail mcc online com Web address www mcc online com Tel 973 887 7800 Fax 973 887 8447 ill Tablet Press Controller TPC User Manual TPC User Manual Revision 3 2 02 01 2006 Page 1 of 18 Table of Contents 1 LOGIN Eo oT PEA N in 3 2 LOG OU i n PA rn EE E E EE E E A E E 4 3 QU A E eee pe mee ee 4 SA AAA dea ca sheeted eee hae ce te eee ess eens eee eee 5 A A A et chest cece E N E E E 7 A sce EPE O A 9 7 ON 10 A O AO 11 9 TFOUDIESNOOUING ees aid 13 10 TPG Maintenance ic 13 11 GOSS ANY esses dete sete ere sauce eaea cuter seni dace ae ce ceei ene ias 16 12 MOC SU p OE arn mE ao 18 TPC User Manual Revision 3 2 02 01 2006 Page 2 of 18 1 Login Logout User Name Password Login Quit 1 1 Touch the User Name field and using the touch screen virtual keyboard enter User Name press enter Note User name is NOT case sensitive TPC User Manual Revision 3 2 02 01 2006 Page 3 of 18 The Virtual Keyboard Enter User Name Caps Shift PELEEL ES weet ye oe tie lock a s shift A z x Date Time 1 2 Touch the Password field and using the touch screen virtual keyboard type in appropriate Password press enter Note Password is case sensitive 1 3 Tap on the Login bar to login 2 Logout
8. Recipe Control box allows the user to select from the list of the existing recipes as well as the ability with proper access level to Add New Delete or Modify existing recipes 5 2 Control Parameters 5 2 1 TPC tablet press control parameters are set in this box Based on the user prescribed Target Force the Upper and Lower Rejection and Shutdown limits are established The rejection and shutdown limits are displayed in digital form at as well as in percentage based on the target force All values are shown in kN 5 2 2 Changes to numerical values are made using the Virtual Numeric Keypad TPC User Manual Revision 3 2 02 01 2006 Page 7 of 18 5 2 3 All changes to target and limits will be used by TPC on the fly That is to say they will be used by the controller but not stored in the Recipe On the fly changes can be made by Operator but any changes to Recipes can be made by Supervisor only To apply the on the fly changes the user has to hit Submit Changes button 5 2 4 When the batch is stopped a supervisor can store changes in the current Recipe by touching the Save Changes button To store changes in a new Recipe touch Add New button 5 3 Recipe Parameters The following entries are part of the Recipe 5 3 1 Target Weight is entered in mg 5 3 2 Target Thickness is entered in mm 5 3 3 Target Hardness is entered in kP 5 3 4 Target turret and feeder RPM can be entered in this section as well 5 3 5 Co
9. SOP 1015 System Hardware Maintenance 10 3 Cleaning procedures In addition to cleaning instructions contained in the manuals for the press scale balance hardness tester and original electrical equipment cleaning of TPC should be done by the user after each usage as follows e Remove the dust and powder deposit from the electrical cabinet and the TPC enclosure using soft brushes and vacuum cleaner e Detach the ejection transducer and remove the material deposit from its lower surface and from the adjacent surface of the ejection plate base e Make sure there is no powder deposits inside the computer enclosure and junction box 10 4 TPC Relocation Instructions Preparation for transportation e Disconnect the cables coming from the tablet press balance and hardness tester e Secure the cables to prevent them from damage during transportation e Disconnect the computer monitor printer keyboard mouse instrument box and remove them from the mobile enclosure e Make sure that the covers and doors of the computer mobile enclosure and instrument box are tightly closed e Pack separately the computer monitor printer Keyboard mouse mobile enclosure balance hardness tester instrument box cables and press e All the components must be thoroughly secured TPC User Manual Revision 3 2 02 01 2006 Page 14 of 18 Assembly after transportation e Check the integrity of all the components e Assemble the system in accor
10. d slow rejection gate 8 6 2 To keep slow rejection gate open after a bad tablet was encountered 8 6 3 Between compression event and fast rejection gate These parameters can be changed by a user with an MCC maintenance level access only TPC User Manual Revision 3 2 02 01 2006 Page 12 of 18 9 Troubleshooting In case there is some software file mix up the user can always restore the system to its original state as of the latest update date by copying the files from the second hard drive This Restore procedure does not affect recipe and batch files created after the latest update date In case the primary hard disk has failed the user can designate the backup disk as the primary one This procedure requires an expert knowledge of the computer hardware and software and should not be attempted without proper support from MCC or user s internal computer support group In all other cases call MCC for support MCC can establish a modem connection and use remote software to virtually take over user s keyboard and screen In this case please e have modem line jack connected to a direct outgoing telephone line non digital e make sure MCC support personnel is available and ready to establish connection e from the desktop click on the MCC support icon Alternatively MCC can establish an Internet connection for your TPC computer support Contact MCC for more information 10 TPC Maintenance 10 1 Visual Inspection Frequenc
11. dance with appropriate project layout drawing e Be sure PC power is OFF prior to making cable connections and powering up system TPC User Manual Revision 3 2 02 01 2006 Page 15 of 18 11 Glossary ADC Analog To Digital Converter A computer board that converts incoming Analog electrical signals into Digital counts according Converter s bit resolution Amplifier Device essential for any instrumentation transducer It is used to provide gain increase the output voltage level and excitation the stable reference voltage and also balance the bridge so that the numerical value of a baseline will be reduced effectively to zero Additional features of the amplifier may include filtering and shunt calibration Calibration Comparison of transducer outputs at standard test loads A line representing a best fit to data is called a calibration graph Calibration Factor A load value in engineering units that a transducer will indicate for each volt of output after amplifier gain and balance Channel A path that interconnects the components of computer and sensing devices across which data and signals can be sent Full Load The greatest load a piece of equipment is designed to carry under specified conditions rated load Full Scale FS The total interval over which an instrument is intended to be operated Also the output from transducer when the maximum rated stimulus is applied to the input
12. mments and notes such as Product Name Product Code and other comments can also be typed in by the user in this section for reference 5 4 Batch Control 5 4 1 The Batch Control box offers options to Start Batch limit the batch size or assign a Lot Number Run Number is assigned automatically by the computer each time you start a new Batch 5 4 2 Tap your finger on the Desired Batch Size space and enter a value using the Virtual Numeric Keypad or use the default value 5 4 3 To assign a Lot Number first tap the Lot Number field then type in the number on the Keypad 5 4 4 When you tap on Start Batch button a new batch will begin You can Stop Batch at any time and after that you can either Resume Batch or Start Batch new batch again When you select to Resume Batch all tablet counters continue from the point the batch was stopped When you Start Batch all tablet counters restart from 0 5 4 5 When you start or resume a batch the screen changes to Setup screen That means the batch is running under the current Recipe If you want to change Recipe go to the Recipe screen and stop the batch first TPC User Manual Revision 3 2 02 01 2006 Page 8 of 18 6 Punches 6 1 Tap on the Punches tab to view punch forces Individual punch forces are displayed on the Punch screen on bar histogram M Tablet Press Controller Version 3 0 6 PUNCH BAR SCREEN 11 18 2004 SETUP BATCH EA Ara MANUAL Bar Histogram of Punch Perf
13. ormance Compression Force kN AT a ut els IIA IS AMA M WM WNI IEA AAA iiti asar Tn O ANA A AI INN A Station Number Batch High 5 2 kN Batch Low 4 8 kN RECIPE STATUS PUNCHES REPORTS SETUP 6 2 Forces outside the rejection limits change color to red TPC User Manual Revision 3 2 02 01 2006 Page 9 of 18 7 Reports 7 1 Tap on the Reports tab to view the Batch report that makes all the current batch and recipe information available to the user for review and printout M Tablet Press Controller Version 3 0 6 REPORTS SCREEN MC 11 18 2004 Batch SETUP BATCH MCC Maintenance Press vest27 AM SETUPREGIPE DEMO wode MANUAL TABLET PRESS CONTROLLER REPORT Batch File Path c tpc reports report_11182004 103024AM_BatchAutoNo_1 txt 11 18 2004 10 47 44 AM Current Operator DEMO Current Recipe SETUP RECIPE Product Code Placebo Product Name Placebo Upper Shutdown Limit 5 3 kN Upper Rejection Limit 5 3 kN Upper Control Limit 7 8 kN Target Compression Force 5 0 kN Lower Control Limit 3 5 kN Lower Rejection Limit 4 7 kN Lower Shutdown Limit 3 7 kN i Update Print AL Batch Report Batch Report RECIPE STATUS PUNCHES REPORTS SETUP 7 2 Batch reports can be updated upon request by hitting the Update Batch Report button 7 3 Review the Audit Trail Event Log separately by tapping on the Audit Trail button You can also select historical Audit Trail files to view or
14. the press motor Dosing Control In the Dosing Control box the tablet press dosing cam position can be adjusted by the user when the system is in MANUAL mode Feeder Speed optional In the Feeder Speed the tablet press feeder speed is displayed in digital format Both Desired and Actual values are displayed The Desired value is changeable using the arrow buttons below the digital display TPC User Manual Revision 3 2 02 01 2006 Page 6 of 18 5 Recipe A Recipe is basically a file of user prescribed software control parameters including upper and lower tablet rejection and press shutdown values and individual tablet parameters including weight thickness and hardness In addition product name tooling type and various user information is stored M Tablet Press Controller Version 3 0 6 RECIPE SCREEN MC 11 18 2004 Batch SETUP BATCH MCC Maintenance Press Mode MANUAL Recipe Name Product Name Product Code Target Weight Target Thickness Target Hardness Comments Target Turret RPM eae E Target Feeder RPM ps Max Tool Force kN Upper Shutdown Upper Rejection Upper Control Target Force Desired Batch Size 0 Batch Name SETUP BATCH Stop Batch RECIPE STATUS PUNCHES REPORTS SETUP Lot Number Lower Control Lower Rejection AMP Lower Shutdown N gt 5 1 Recipe Control The
15. vel access can change calibration factors 8 3 Password Control Users with Supervisor authority can add edit or delete user information and change passwords To exercise this feature simply tap on the Add Edit or Delete button 8 4 Setup Parameters These parameters can be changed by a user with a maintenance level access only 8 4 1 Number S of sequentially rejected tablets that will trigger alarm If set at 0 no rejected tablets are reported in the Audit Trail TPC User Manual Revision 3 2 02 01 2006 Page 11 of 18 8 4 2 Number R of revolutions for auto startup rejection 8 4 3 Number N of revolutions for average compression force calculation 8 4 4 Number T of rejected tablets in N revolutions that will trigger alarm 8 4 5 Number M of minutes of user inactivity to auto lock 8 4 6 Number A of revolutions to switch to control mode 8 4 7 Number M3 of stations that will pass under the compression rolls while the dosing adjustment signal is active do not change this parameter without proper training 8 5 Units of Measurement Various units of measurement used in the software can be changed in the Units of Measurement dialog box on this screen Transducer force units can be changed as well as tablet properties units 8 6 Rejection Gate Delays Rejection gate delays are viewable in the Rejection Gate Delays dialog box shown The delays in terms of the number of stations include 8 6 1 Between compression event an
16. y before each batch Check e The integrity of the cables connecting computer printer monitor mouse keyboard instrument box junction box transducers balance and hardness tester e The reliability of all the connections e Whether the compression transducer holder is properly installed and two 5 mm diameter holes of the compression pin are positioned on the vertical axis e Whether the locating screw and nut fasten the precompression transducer tightly e Whether the instrument box and TPC system enclosure are locked If not check if there is any damage or dust inside 10 2 Other procedures Cleaning after each usage to be performed by the users Lubrication as per press manual TPC User Manual Revision 3 2 02 01 2006 Page 13 of 18 Transducer recalibration annually In addition perform the following checks on a weekly basis e The integrity of the transducers protection coating e Visual inspection see that there are no cracks or rust on the transducers surfaces Make sure transducers are not bent e See that there is no dust or powder inside the instrument box junction box and System enclosure e See that there is no visible wiring damage of the connectors and other components inside the instrument box junction box and System enclosure Dust filters replacement computer cabinet enclosure every 24 months under normal operating conditions Hardware maintenance is conducted in accordance with MCC
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