Applying Yokogawa Recorders and Controllers to Heat Treatment
Contents
1. Technical Applying Yokogawa Recorders and Information Controllers to Heat Treatment Applications in the Aerospace and Automotive Industries TI 04L51B01 05EN SMART 1717 The contents of this Technical Information are subject to change without notice Yokogawa Electric Corporation TI 04L51B01 05EN YOKOGAWA 2 9 32 Nakacho Musashino shi Tokyo 180 8750 Japan Copyright July 2014 1st Edition Oct 24 2014 Contents 1 SEENEN 4 2 What are DXAdvanced SMARTDAC and UTAdvanced 0008 4 2 1 DXAdvanced DX1000 amp DX2000 cecessecesceeeeeeeseseeeeeeeneseeseeeeeeneesseeseeeeeeenaes 4 2 2 SMARTDAC GX10 GX20 GP10 amp GP20 ceeeeeeeeeeeeeeeeeeeseeeeeeeeseeeeeeeeeneeeas 4 2 3 DAQStandard for DXAAVanced sccescceeeeeeseeeseeeseeeseeseneseneseeesneeseeesneeseesenesees 4 2 4 Webserver and Hardware Configurator for SMARTDAC scsseeeeeneees 4 2 5 Data Viewer TE 4 2 6 UTAdvanced UT52A UT55A amp UP5S5A cccceccesseseseeeesneeseseeeeeeseeeeeeseeeeeeeees 4 3 Detail Description of DXAdvanced SMARTDAC and UTAdvanced Operation Securities 5 3 1 Brie ne BE 5 3 2 Log in Security DXAdvanced and SMARTDACG sccesceeteeeseeeeeeeeeeeeeeeeee 5 3 3 Access Security DXAdvanced SMARTDAC and UTAdvanced 5 4 Detail Description of DXAdvanced SMARTDAC Data Security 6 4 1 El ne D 6 4 2 Data file Managemen nt ccescceeceeseeesseesseeseeeenesseesee2. graph and digital format Log information Alarm log operation log can be displayed as well All necessary information can be printed out using standard printers Data conversion to major spreadsheet formats is also supported 2 6 UTAdvanced UT52A UT55A amp UP55A 1 The UTAdvanced is a digital indicating PID controller with ladder sequence control UT55A and UP55A have 1 4 DIN external structure and UT52A has 1 8 DIN external structure Also UP55A is embedded with program pattern control TI04L51B01 05EN 2014 10 24 3 Detail Description of DXAdvanced SMARTDAC and UTAdvanced Operation Securities 3 1 Briefing 1 AMS2750 requires that access to systems that are used to create modify maintain or retrieve electronic records must be limited to authorized individuals 2 Additionally authority checks are required to assure that authorized individuals accessing the systems are able to perform only tasks for which they have the appropriate level of access and for which they have been properly trained 3 DXAdvanced and SMARTDAC have a Log in security and b key lock function as standard 4 UTAdvanced has key lock function and password control for configuration parameters as standard 3 2 Log in Security DXAdvanced and SMARTDAC 1 Both can be configured to utilize a combination of user name and password to limit system access to authorized users Each user name must be unique Permissions can be further defi
3. 7 Description Table AS 7102 E VU 7 1 4 3 1 1 Job Docunishiation lt Traceability secbceanectaesvensscesscetecessecdeceseoeseecsncntics 10 7 2 4 3 1 2 Job Documentation In Process Documentation cscesceeeeeee 10 7 3 4 5 2 Specification Changos cucire arinina nnen r Natar RERNA NEENA RENR 10 7 4 4 7 1 Automated Processes and Recordings Integrity of the process and records 11 7 5 4 7 2 Automated Processes and Recordings Authorization 11 7 6 4 7 3 Automated Processes and Recordings Prevent records from alteration 11 7 7 4 7 4 Automated Processes and Recordings Data back ups es0e 11 7 8 6 3 1 Lot Batch Integrity sosunun 12 7 9 8 1 1 1 Furnace Document Control Operating Instruction cseeee 12 7 10 8 1 2 1 Furnace Document Control Heating Times Controls c0 12 7 11 8 1 2 2 Furnace Document Control Heating Times Records see 12 7 12 8 1 2 3 Furnace Document Control Heating Times Specified Metal Temperature 12 TI 04L51B01 05EN 1st Edition Oct 2014 YK TI 04L51B01 05EN 2014 10 24 All Rights Reserved Copyright 2014 Yokogawa Electric Corporation 7 13 8 7 1 6 Temperature Uniformity Tests Thermocouple Corrections 13 7 14 8 7 2 4 System Accuracy Probe Test Operation Log seeeseeeeeeen 13 7 15 8 7 3 2 Instrument Calibration For Working Instruments cceeseenee 13 R vision Informatio soos dec secce nnee ete cka
4. dea caeeeneeenctanencenensnenenciemeniadceesteatedes i TI04L51B01 05EN 2014 10 24 1 Scope 1 This document describes how the DXAdvanced the SMARTDAC and the UTAdvanced of Yokogawa can fulfill the requirements from AMS 2750E and AS7102 2 This document refers to the above regulations The copyright of each regulation belongs to its owner If the quoted passage is different from the original documentation the original documents prevail at all times 2 What are DXAdvanced SMARTDAC and UTAdvanced 2 1 DXAdvanced DX1000 amp DX2000 1 DXAdvanced is a paperless recorder maximum number of directly connected universal measurement inputs is 48 2 2 SMARTDAC GX10 GX20 GP10 amp GP20 1 The SMARTDAC is a paperless recorder with multi touch display maximum number of directly connected universal measurement inputs is 100 2 3 DAQStandard for DXAdvanced 1 DAQStandard is PC based software used for hardware configuration Online and Offline and historical data analysis and playback 2 Users can modify and or upload and download configuration settings of the DXAdvanced 2 4 Webserver and Hardware Configurator for SMARTDAC 1 The Webserver consist of a realtime monitor function and an on line configurator 2 The Hardware Configurator is PC based software used for off line hardware configuration 2 5 Data Viewer software 1 Users can playback the measurement data using the historical viewer in both trend
5. 0 revision E which was originally established by SAE International If there are any incompatibilities the original document always prevails AMS 2750E Requirements Comments DXAdvanced Smartdac UTAdvanced 6 1 3 2 3 1 Minimum Readability The minimum readability is 0 1 F or 0 1 C The minimum readability is 0 1 F or 0 1 C W s least one recording and or controlling instrument for each zone shall have a minimum readability of 1 F or 1 C 6 2 3 2 3 2 Recommended Installation The User s Manual for DXAdvanced Smartdac and UTAdvanced clearly shows the correct Installation of controlling monitoring or recording instruments shall conform installation procedure for the instrument to the manufacturer s recommendations 6 3 3 2 4 Offsets DXAdvanced has up to 15 segment lineariser for UTAdvanced has up to 10 segment If offsets are used a documented procedure shall exist describing when each measurement input channel as a configuration linearizer besides bias function for control and how to perform manual and electronic offsets The procedure shall option CC1 The approximation method is used forjinput channel as a standaed Either biasing address how to account for and reintroduce any intentional offsets Prior to linearization or approximation method is used for reintroducing any intentional offsets any instrument calibration error found Smartdac has up to 11 segment lineariser function linearization shall be taken into accoun
6. a proprietary encrypted binary format and as such cannot be modified by ordinary means once they have been created Acquired data such as temperature values are also stored in a proprietary binary format and cannot be changed once they have been stored DXAdvanced SMARTDAC maintains records of all alarms alarm acknowledgements error messages in the same binary files These files cannot be changed by users or administrators An error message will appear the next time anyone attempts to access the data notifying the user that the file is damaged and cannot be viewed DAQStandard and Viewer display and print data in human readable form The files can be easily copied for backups archiving inspection and review Neither the DXAdvanced SMARTDAC nor the DAQStandard and Viewer software allow a user to overwrite records nor do they automatically overwrite records 4 3 Data Security Data redundancy using the FTP function 1 3 An FTP client mode function allows records created by the DXAdvanced SMARTDAC to be automatically sent to a secure FTP server directory for long term or short term storage The DXAdvanced SMARTDAC has the capability of automatically sending a preconfigured username and password combination if required for file upload access to the FTP directory The SMARTDAC can also send the files by using SSL encryption Access levels at the FTP server directory can be further controlled through good local network security po
7. e batch header information are compiled with measurement record The Viewer software shows such batch header information together with the measurement record 7 9 8 1 1 1 Furnace Document Control Operating Instruction The latest versions of the instruction manuals are available on the Internet Customers can create Current operating manuals or instruction manuals shall be available to operation instructions for furnaces by referring to the manuals furnace operators maintenance personnel and other personnel requiring the information 7 10 8 1 2 1 Furnace Document Control Heating Times Cotrok Not Applicable UP55A Customer can specify the start Procedures shall specify the method for determining heat up time or start of condition ramp rate heating and cooling soaking time and cooling rate and soaking time by each segment PV and time event function and alarm and program function of UP55A s control input helps interlocking advancing and delaying operation to secure the heating condition UT52A UT55A Can be tracked program pattern which is included the start condition ramp rate soaking time and alarm information correctly from UP55A by RS485 communication as option Customer can build zone control for furnace by UP55A and UT55A UT52A 8 1 2 2 Furnace Document Control Heating Times Records Alarm log and message log are included with the Not applicable 7 11 Records on the furnace chart or log shall indicate that t
8. er software shows such In process information together with the measurement record data file Specification change can be recorded as Batch Not applicable comment which is to be typed by a user combined with measurement data The Viewer software shows in process information together with the measurement record OL NASO LO LS170 IL ve Ol LOZ AS 7102 Requirements DXAdvanced Smartdac UTAdvanced 7 4 4 7 1 Automated Processes and Recordings Integrity of the process Both create measurement data in binary encrypted Not applicable and records data format in its internal memory The internal Where automated heat treating processes and or record keeping are used memory is non volatile Both keep measurement there shall be a system in effect to assure the integrity of the process and data securely even when unexpected power failure occurs Measurement data can be automatically copied to external media mounted on each device Both have an Ethernet interface as standard This enables both to send a copy of measurement data file to the designated ftp server via the connected network 7 5 4 7 2 Automated Processes and Recordings Authorization Both can prevent any illegal access by unauthorized Not applicable Procedures shall include a method of ensuring that electronic magnetic Users using log in authentication and or software programs can not be altered without authorization keylock protection Access to the commun
9. eseneseeeseeesneeseneseeesneeseneeneetes 6 4 3 Data Security Data redundancy using the FTP function scesseeeeeree 6 5 Detail Description of DXAdvanced SMARTDAC Batch Header Function 7 5 1 Briefie 7 5 2 Batch header function of DXAdvanced SMARTDAC assassnsessensenrenenrennnnnne 7 6 Description Table AMS 2750E cccssseeeeseseeeeeeeseeeeeesseeeeeeseseeeeeseeeeees 8 6 1 3 2 3 1 Minimum Readabillity ccccesceseesneeeeeseeeeeeseeeseeeseeeseeeseeeseeeseeesseenenens 8 6 2 3 2 3 2 Recommended Installation cccccescssessneeeeseesseseeeseeeseeseeeseeesseneeees 8 6 3 B22 A OPCS EE 8 6 4 3 2 5 2 Calibration ACCUIAaCy seccnsancecisssananisasisaniisamasiaiiiasiai 8 6 5 F522 sd CAME ATION EE 8 6 6 Di 5 DOMSICIVINY eege ere eege eege 9 6 7 3 2 7 1 1 Electronic Record Manipulation seccssecesseeeeeseeeeeeeeseeeeeeees 9 6 8 3 2 7 1 2 Electric Record Playback ccccssssesnsenseneseneseeseeseeneeeneeenseenseens 9 6 9 3 2 7 1 3 Electric Record Data Output ccsccceseeeeseeeeseeeeseeeeseeeeeseeeeeeeeneeees 9 6 10 3 2 7 1 3 1 Electric Record Signature The system shall be capable of providing evidence the record was reviewed such as by recording an electronic review or a method of printing the record for a physical marking indicating review 0 100 9 6 11 3 2 7 1 5 Electric Record Data ACCESS ccecceecseeeeeeeeeeeeeeseeeseeeeeeseeneeeeeenenes 9
10. he procedure is measurement data DXAdvanced Smartdac as followed well as the Viewer software can indicate those logs to check if the procedure is followed 7 12 8 1 2 3 Furnace Document Control Heating Times Specified Metal The computation option can calculate the time under PV and time event function and alarm function Temperature certain conditions of UTAdvamced s control input can interlock When metal temperature is specified records shall demonstrate that the the operation for furnace metal was at temperature for the specified time CL NASO LOGLS170 IL ve Ol LOZ AS 7102 Requirements EE DXAdvanced Smartdact UTAdvaned 8 7 1 6 Temperature 7 13 8 7 1 6 Temperature Uniformity Tests Thermocouple Corrections Tests Thermocouple Corrections c print out of the DAQStandard or Smartdac Not m Records shall indicate that thermocouple corrections are used ae Configurator shows the correction factors use 8 7 2 4 System Accuracy Probe Test Operation Log Both have batch header function as standard The Not applicable Loos shall show the actual time and date of test and indemnify the operator batch header function in combination with Log in who performed the test function enables the recording of who started the batch at which time and who stopped the batch at which time Such information together with the additional batch comments are combined with the measurement data file The Viwe
11. ication port is controlled by log in authentication as well Authorized users can change the setting parameters once they log in and or unlock the software keylock which is password protected 7 6 4 7 3 Automated Processes and a en Prevent records from Both can prevent any illegal access by unauthorized Not applicable a en users using log in authentication and or software Procedures shall include a method of ensuring that electronic magnetic keylock protection Both protect measurement data record can not be altered securely Even authorized users cannot change or manipulate any of measurement record data 4 7 4 Automated Processes and Recordings Data back ups FTP function is standard which automatically Not applicable transfer data files to a particular location in the connected network This function aims as automated storage of back up data LL NASO LOGLS170 IL v2 Ol VLOZ AS 7102 Requirements eee eee EE 7 8 6 3 1 Lot Batch Integrity D i Aduvanced has a Batch header function as Not applicable Procedures shall specify how lots batches and sub lots sub batch of Standard Customers can provide a batch name and identical parts are to be identified to preclude their mixing and to ensure lot a lot number for each batch A batch name together with a lot number can be used as part of the file name of each measurement data file Customer can provide a batch name and a lot number to each batch For both case of abov
12. iti hall id become useless to the user An error message will e system software and playback utilities shall provide a means o appear the next time anyone attempts to access the data notifying the user that the data has been changed and the file cannot be viewed 6 9 3 2 7 1 3ElectricRecord DataOutput Ue can playback the data record on Notapplicable The system shall provide the re ability to generate accurate and complete DXAdvanced Smartdac in trend graph format copies of records in both human readable and electronic form suitable for The Viewer software displays and prints data in inspection review and copying human readable form using a PC Such files can be easily copied for backups archiving inspection and review 6 10 3 2 7 1 3 1 Electric Record Signature The system shall be capable D XAdvanced Smartdac can provide electronic Not applicable of providing evidence the record was reviewed such as by recording an signature inputs for each record data file on 3 electronic review or a method of printing the record for a physical marking user levels The electronic signature function is also indicating review available on the Viewer PC software 6 11 3 2 7 1 5 Electric Record Data Access DXAdvanced Smartdac can prevent any illegal Not applicable data access by unauthorized users with log in authentication and or software keylock protection examining and or compiling the record data but shall not provide any means for al
13. licy Data files are stored sequentially to the DXAdvanced SMARTDAC external archive media and then to the FTP server when this function is used The data record is always archived even if the network connection to the server is lost If the connection fails data will be automatically transferred via FTP as soon as the connection is restored These records can then be maintained under a company s general electronic records archiving policy TI04L51B01 05EN 2014 10 24 5 Detail Description of DXAdvanced SMARTDAC Batch Header Function 5 1 Briefing 1 AMS 2750 requires that lots batches and sub lots sub batches of identical parts are to be identified to preclude their mixing and to ensure lot integrity 5 2 Batch header function of DXAdvanced SMARTDAC 1 DXAdvanced SMARTDAC has a Batch header function as standard Customers can input a batch name and a lot number for each batch record The batch name together with the lot number can be used as the file name of the data file 2 DXAdvanced SMARTDAC can be operated in either a Batch or Continuous mode for data collection 3 For both cases above batch header information is compiled together with the measurement data 4 The Viewer software shows batch header information together with the measurement record TI04L51B01 05EN 2014 10 24 NASO LO LS170 IL v2 Ol VLOZ 6 Description Table AMS 2750E Please be noted that this table is referring to AMS 275
14. ned to provide a variety of access levels ranging from view only access to full administrative and remote communication and configuration rights DXAdvanced allows the configuration of a maximum of five 5 administrators and up to thirty 30 users SMARTDAC allows the configuration of a maximum of fifty 50 administrators and users in total Individual users cannot modify their own access levels 2 Limiting system access to authorized users and controlling individual levels of access provides effective security for the use of the instrument 3 3 Access Security DXAdvanced SMARTDAC and UTAdvanced 1 DXAdvanced and SMARTDAC have physical locking system on its front door which prevents unauthorized access to the external media and to the power switch 2 UTAdvanced has locking function for front operation button and can be used password control for configuration parameters Both functions prevent unauthorized access and misoperation TI04L51B01 05EN 2014 10 24 4 Detail Description of DXAdvanced SMARTDAC Data Security 4 1 Briefing 1 AMS 2750 requires that records are protected so that they can be retrieved readily and accurately throughout any required retention period This requirement applies not only to records at their time of creation but also to archived electronic records for the duration of their storage period 4 2 Data file Management 1 2 4 DXAdvanced SMARTDAC data files are stored in
15. r software indicates batch operation log information 7 15 8 7 3 2 Instrument Calibration For Working Instruments DXAdvanced Accuracy of measurement inputs less Accuracy of control input less than 0 6 C For working instruments than 0 6 C can be achieved with the use of 10 segment lineariser and bias function b For digital instruments readability shall be within 1 F or 1 C SE Accuracy of measurement inputs less an 0 6 C EL Revision Information Title Applying Yokogawa Recorders and Controllers to Heat Treatment Applications in the Aerospace and Automotive Industries Manual number TI 04L51B01 05EN Oct 2014 1st Edition Newly published Written by Yokogawa Electric Corporation Edited by Yokogawa Europe B V Published by Yokogawa Electric Corporation 2 9 32 Nakacho Musashino shi Tokyo 180 8750 JAPAN
16. t Adjustments offsets greater than those shown for each input channel as standard Either biasing or in Tables 6 or 7 shall not be used approximation method is used for linearization 3 2 5 2 Calibration Accuracy The User s Manual for DXAdvanced Smartdactand UTAdvanced describe required instruments Calibration accuracy and frequency requirements shall be in accordance and procedure to ensure its measurement accuracy with Table 3 6 5 3 2 5 3 Calibration The calibration procedure is clearly described in the User Manual for DXAdvanced Smartdac and UT Advanced NASO LO LS170 IL ve Ol LOZ AMS 2750E Requirements DXAdvanced Smartdac UTAdvanced 6 6 3 2 5 3 Sensitivity Minimum sensitivity of measurement input channel Minimum sensitivity of control input is 0 1 F Sensitivity shall be checked during calibration See Table 3 footnote 4 is 0 1 F and 0 1 C and 0 1 C Class 3 through 6 instruments shall have a minimum sensitivity of 3 F 2 C 1 amp 2 instruments shall have a minimum sensitivity of 1 F 1 C 3 2 7 1 1 Electronic Record Manipulation Acquired data are stored in a proprietary binary Not applicable oe system must create electronic records that cannot be altered without format and cannot be changed once they have been detection stored Should a user attempt to change any data 6 8 3 2 7 1 2 Electric Record Playback by directly accessing the binary data the file will Th t ft d playback util
17. tering the source data NASO LOGLS170 IL v2 Ol VLOZ T Description Table AS 7102 Please be noted that this table is referring to AS7102 which was originally established by SAE International If there are any incompatibilities the original document always prevails AS 7102 Requirements 7 1 4 3 1 1 Job Documentation Traceability Procedures shall specify how lots and sub lots of identical parts are to be identified to preclude their mixing and to ensure lot integrity 7 2 4 3 1 2 Job Documentation In Process Documentation In process documentation shall include process status inspection status engineering change notice and all other relevant information 7 3 4 5 2 Specification changes Records shall indicate that the procedure is followed and that old specifications are used only when specified DXAdvanced Smartdac UTAdvanced Both have a Batch header function as standard Not applicable Customer can provide a batch name and a lot number to each record A batch name together with a lot number can be used as part of the file name of the measurement data The Viewer software shows such batch header information together with the measurement record In process status such as alarm logs and operation Not applicable logs are combined with the measurement data file Inspection status and engineering change notice can be recorded as Batch comment combined with the measurement data file The View
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