USER MANUAL - KVL Comp Kft.
Contents
1. 13 KVL PTLO4 PICK TO LIGHT CONTROL WITH ETHERNET NETWORK Read and Understand this Manual Please read and understand this manual before using the product Please consult your KVL COMP representative if you have any questions or comments I ABOUT THIS MANUAL This guide explains the installation and operation of the product Before installing and using the product read this guide carefully and be sure to understand its contents Also read and follow the safety information described in the next chapter The chapter titled Precautions contains general safety instructions of using the product and the related devices 1 Chapter 1 Introduces the product and its structural units 2 Chapter 2 Explains the structure of the product 3 Chapter 3 Explains the installation of the product the wiring of the power supply and the I O lines and also the functional testing of the product 4 Chapter 4 Explains the setup and operation of the product II RELATED GUIDES The following guides give information on the related devices You can find the necessary information in the following documents Title of Publication KVL1112 CONTROL WITH ETHERNET NET MAINTENANCE MANUAL KVL1153 PROGRAMMABLE LIGHT CURTAINS DATASHEET KVL1156 KEY SWITCH MODULE WITH AS I CONTROLLER DATASHEET GREEN YELLOW RED LIGHT TOWER WITH nu ACOUSTIC SIGNAL AND 5 CONTROL PTL DISPLAY PUSH BUTTON ACKNOWLEDGE Rue MODULE WITH 5 CONTROLLER2. 4 2 V PADDING ATIOM CONS 2414 ION een ee ee 2 DIE Amer s o 3 NI NS ee 3 CHAPTER A 5 OVENVIEE dice 5 1 1 Short introduction of pokayoke systems 5 1 2 The location of the pick to light controller in the pokayoke system 5 CHAPTER 2 ee ee ee 6 TECHNICAL DATA ne iii 6 2 1 MTN GINS ION ee ee ee eier 6 PAE o a e ES i A o e 7 2 3 ElhernetNEUWOrk nennen rio EE RTA ee 7 CHAPTER R 8 INSTALLATION AND WIRING une 8 3 1 Installing the controller at the 8 3 2 Connecting to mains and Ethernet network ooocccconnccnnonnccnnnnnacnnnnnaronnnnnccnnonanonnnonanos 8 CHAPTER A n o 9 SETUP AND OPERATION assvaiaid riada 9 A 1 Switching on o 9 2 CONTO r o ao 10 4 3 Devices attached to the controller via AS i 11 4 3 1 LIGHT CURTAINS 11 4 3 2 ACKNOWLEDGEMENT MODULE WITH 5 CONTROLLER KVL PICK007 11 4 3 3 E7 KEY SWITCH MODULE 5 01 12 4 3 4 GREEN YELLOW RED LIGHT TOWER WITH ACOUSTIC SIGNAL KVL LTWO1 12 4 3 5 PTL DISPLAY PUSH BUTTON ACKNOWLEDGE MODULE 11 12 4 4 Light and audible 4 13 4 5 Daily checks before
3. KVL1155 RDE MODULE WITH AS I CON DATASHEET KVL1001 POWER CABLE DATASHEET KVL1002 ETHERNET PATCH CABLE DATASHEET PUBLICATION HISTORY The number of the publication is also indicated on the cover of the publication NUMBER OF PUBLICATION KVL1111 EN 01 Date of Publication No of Publication Chapter Revised content 12 2010 KVL1111 EN 01 0 0 KVL PTLO4 IV WARRANTY AND LIMITATIONS OF LIABILITY WARRANTY KVL COMP s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year or other period if specified from date of sale by KVL COMP LIMITATIONS OF LIABILITY KVL COMP shall not be responsible for special indirect or consequential damages loss of profits or commercial loss in any way connected with the products whether such claim is based on contract warranty negligence or strict liability In no event shall the responsibility of KVL COMP for any act exceed the individual price of the product on which liability is asserted In no event shall KVL COMP be responsible for warranty repair or other claims regarding the products unless KVL COMP s analysis confirms that the products were properly han dled stored installed and maintained and not subject to contamination abuse misuse or inappropriate modification or repair V APPLICATION CONSIDERATIONS SUITABILITY FOR USE The following are some examples of applications for
4. necessary part 3 SIGNAL POST YELLOW LAMP In case of server error it glows with the red 4 one 4 SIGNAL POST RED LAMP In case of error it glows 5 SIGNAL POST AUDIBLE SIGNAL In case of controling error and wrong spare part picking up audible signal can be heard KVL KSW01 KEY SWITCH MODULE WITH AS I CONTROLLER 6 ACKNOWLEDGING ERRORS Errors are acknowledged using the E7 key switch PICK TO LIGHT CONTROL WITH ETHERNET NETWORK 4 3 DEVICES ATTACHED TO THE CONTROLLER VIA AS I BUS 4 3 1 LIGHT CURTAINS KVL PICKO06 a St N lt NA 7 N na 2 4 e _ 6 6 i i a A A A Le 1 3 3 gt y a U ze z I _ A A The light curtains designed for 300mm 400mm and 600mm storage boxes The lights on the front panel of the light curtain instruct the worker to pick a given part 1 If a spare part should be picked the indicator light is green After picking the spare part acknowledgement the light turns red Acknowledgement is performed automatically The picking of a spare part is detected by distance measuring sensors located behind the front panel of the light curtain 2 The measuring range can be changerd between 10 and 60 cm s with a computer program via USB connection see PTL Manager software description The distance between the sensors is 7 8 cm providing reliable hand detection 4 3 2 ACKNOWLEDGEMENT MODULE WITH
5. 5 CONTROLLER KVL PICKOO7 During assembling a red green light indicates which part should be installed The display is built with long life high brightness LEDs providing clear visibility even from a dis tance Acknowledgement is performed by operating a pull switch The 2 m long pull string can be cut to the appropriate length The module is mounted to the suspended struc ture located above the storage boxes 11 KVL PTLO4 4 3 3 E7 KEY SWITCH MODULE KVL KSWO1 m Errors acknowledgement with key switch acknowledge unit can be connected to the AS I network to any place in order to be easily reachable for the operator module be mounted in the TRILOGIQ shelf with plastic clamp If the error is aknowledgable a red light what is placed abpve the E7 switch glows The key switch unit is connected to the AS i network under the 31B NOD number 4 3 4 GREEN YELLOW RED LIGHT TOWER WITH ACOUSTIC SIGNAL KVL LTWO1 Green yellow red light and acoustic signal for information about the function of equipments Green vellow red lightsignal Attentional acoustic signal Long life high brightness LED indication Thelight tower can be fixed by clamps to the TRILOGIQ built shelf system Avoiding from unauthorized disassembly the elements of light tower are locked by special opening screw The KVL LTWO1 is connected to the AS i network under the 31A NOD number 4 3 5 PTL DI
6. KVL1111 EN 01 KVL PTLO4 PICK TO LIGHT CONTROL WITH ETHERNET NETWORK USER MANUAL KVL PTLO4 USER MANUAL PICK TO LIGHT CONTROL WITH ETHERNET NETWORK Notice The following conventions are used to indicate and classify precautions in this manual Always heed the information provided with them Failure to heed precautions can result in injury to people or damage to property A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Additionally there may be severe prop erty damage A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Additionally there may be severe prop erty damage A CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or property damage Trademarks Windows is a registered trademark of Microsoft Corporation in the United States and oth er countries The other brand and product names are trademarks or registered trademarks of their re spective owners Introduction We design and manufacture our devices with the feedback from the enterprises of the in dustry and their specific needs in mind Our pokayoke systems elaborated this way are robust and due to the sophisticated solutions applied in them they provide a long main tenance free lifecycle These devices are recommended for those firms where one of the fol
7. SPLAY PUSH BUTTON ACKNOWLEDGE MODULE KVL PICKO11 Indicate with red light for the worker which part must be built in The acknowledgment happens with push button should be picked the indicator lights are green After acknowledgement the lights turn red Long life high brightness LED indication High persistence contactless switching Hall effect module can be mounted in the TRILOGIQ shelf with plastic clamp 12 PICK TO LIGHT CONTROL WITH ETHERNET NETWORK 4 4 LIGHT AND TONE SIGNALS NO AUDIBLE OR VISIBLE SIGNALS Indicates normal operation z THE GREEN LIGHT IS ON NO AUDIBLE SIGNALS The device completed the production cycle and sends IO signal z THE RED LIGHT IS ON An error occurred during the cycle z THE YELLOW AND THE RED LIGHTS ARE ON Communication error occurred z THE DEVICE GIVES AN AUDIBLE SIGNAL In case of control error and wrong pick up audible signal can be hearing 4 5 DAILY CHECKS BEFORE WORK Daily routine check of control cabinet Cabinet door is closed Proper ventilation and protection of the inner parts are only provided with closed cabinet door Touching the inner parts can cause electric shock Via the open door dust can penetrate the cabinet The accumulating dust de creases cooling efficiency and leads to a higher probability of failure AS I Bus devices Check the correct mounting of devices Connectors The shelves are p
8. eriodically moved for cleaning This makes necessary to discon nect some AS I connectors The affected connectors are marked with red and a warning message If the shelves were moved during cleanup check that the connectors marked with red are properly reconnected If any device failed the above checks immediately call maintenance service 13 KVL PTLO4 A WARNING the following cases switch off the controlbox disconnect network cable and call a service technician immediately The network cable or its connector is damaged or worn Liguids penetrated the controlbox The controlbox was exposed to rain or other forms of water The controlbox fell or its case is damaged The operation of the controlbox is unstable or the controlbox is malfunc tloning The controlbox emits unusual noise smoke or unpleasant smell 14 KVL COMP s r o Komensk ho 35 94301 Sturovo SLOVAKIA Tel 00 36 33 501 616 Fax 00 36 33 501 615 www kvicomp eu info Okvlcomp eu KVL COMP Vez rl stechnikai Kft H 2500 Esztergom Nagy S ndor J zsef utca 3 HUNGARY Tel 00 36 33 501 616 Fax 00 36 33 501 615 www kvlcomp eu info Okvlcomp eu
9. lowing problems has emerged and would like to develop a solution Frequently occurring errors in production processes Products must be called back due to installing parts of wrong type High scrap costs caused by selecting wrong part Workers often forget to tighten the screws fixing the part Workers forget to install one or more parts and this mistake is noticed too late The pokayoke systems of KVL COMP aid the effective troubleshooting of these errors KVL COMP 2010 All rights reserved It is forbidden to reproduce or store this document or part of it in any data retrieval system or transfer it in any form in any way mechanically electronically photocopying recording or with any other technique without prior written permis sion from KVL COMP We do no take patent responsibility for the information disclosed here Also as KVL COMP is constantly striving to improve its high quality products the information included in this guide can change without notice During the creation of this guide we try to be as accurate as possible but KVL COMP does not take responsibility for the possible errors or omissions Also KVL COMP does not take any responsibility for the possible damages resulting from using this guide PICK TO LIGHT CONTROL WITH ETHERNET NETWORK CONTENTS About this Manual een 1 1 Related US cere se lo holo ee ee 1 PUDE CUON ee ee 1 IV Warranty and Limitations of 1
10. not to be used for manufacturing purposes even when tolerances are shown PERFORMANCE DATA Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty It may represent the result of KVL COMP s test conditions and the users must correlate it to actual application requirements ERRORS AND OMISSIONS The information in this manual has been carefully checked and is believed to be accurate however no responsibility is assumed for clerical typographical or proofreading errors or omissions Vil PRECAUTIONS This section provides general precautions for using the related devices The information contained in this section is important for the safe and reliable applica tion of product You must read this section and understand the information contained before attempting to set up or operate a product INTENDED AUDIENCE This manual is intended for the following personnel workers trained to the specific task working on the assembly stations and on the assembly line operating the device work group leaders professionals responsible for the installation setup and maintenance of the device KVL PTLO4 GENERAL PRECAUTIONS The user must operate the product according to the performance specifications described in the operation manuals Before using the product under conditions which are not described in the manual or ap plying the product to other sy
11. oller Mains 230 V AC socket Glass tube fuse 5 20 glass tube 230 V 2A SLOW On off switch Ethernet socket AS i sockets 3pcs PICK TO LIGHT CONTROL WITH ETHERNET NETWORK For connecting to the mains circuit we recommend the type KVL POW cable Ensure that the controller is switched off when you connect the cable A WARNING Risk of electric shock when using wrong or damaged mains connector cable A WARNING Risk of fire and human injury when using damaged repaired fuses or fuses not of the appropriate type For connecting to the Ethernet network we recommend the type KVL ETN cable The AS i network plug is standard M12 sensor plug CHAPTER 4 SETUP AND OPERATION 4 1 SWITCHING ON THE CONTROLLER The device is turned on with the switch located next to the power supply connector After switching off the device always wait at least 5 seconds before switching it on again KVL PTLO4 10 4 2 CONTROLS On the Pick to light controllers front cover a white light is installed what shows if the power is on Devices connected to the AS i bus are displaying fault messages and the aknowledgment as well 11 BER gt ye er pe A 1 POWER ON INDICATOR LIGHT If the controller is on the POWER labeled light glows KVL LTW01 GREEN YELLOW RED LIGHT COLUMN WITH ACOUSTIC SIGNAL AND AS I CONTROL 2 SIGNAL POST GREEN LAMP Glows if the worker successfully picked up all the
12. omati cally After acknowledgement the display s lamp is going to change to green KVL PTLO4 CHAPTER 2 TECHNICAL DATA 2 1 DIMENSIONS KVL PTLO4 pick to light controller is installed in a metal plate case Dimensions of the controller box 400 300 210 mm Colour of the controller box Grey RAL 7032 2428 6 2 2 ELECTRICAL DATA Supply voltage Current drain Operating range Operating temperature Operating humidity Storage temperature Storage humidity Mains circuit connection Fuse Recommended mains connector cable PICK TO LIGHT CONTROL WITH ETHERNET NETWORK 230 V AC 50 Hz 10A 100 240 V 48 62 Hz 5 40 C 20 90 RH non condensing 20 70 C 10 95 RH non condensing IEC standard connector with fuse and switch 5 20 glass tube 230 V 10 A SLOW KVL POW 2 3 ETHERNET NETWORK The controller can be connected to standard 10 100 Ethernet network The industrial Ethernet socket is of type VARIOSUB RJ45 The recommended Ethernet cable is of type KVL ETN KVL PTLO4 INSTALLATION AND V VIRING 3 1 INSTALLING THE CONTROLLER AT THE V The control box wil be installed on TRILOGIQ shelf system The plastic clamps what is necessary for the installation is fixed to the back cover of the control box Accesory ge 3 2 CONNECTING TO MAINS AND ETHERNET NETWORK The sockets are located on the back of the contr
13. stems machines and equipment that may have a serious in fluence on lives and property if used improperly consult your KVL COMP representative Make sure that the ratings and performance characteristics of the product are sufficient for the systems machines and equipment This manual provides information for setup and operating the product Be sure to read this manual before attempting to use the product and keep this manual close at hand for reference during operation A WARNING It is extremely important that a product be used for the specified purpose and under the specified conditions especially in applications that can directly or indirectly affect human life You must consult with vour KVL COMP representative before applying a product to the above mentioned applications SAFETY PRECAUTIONS A CAUTION When power is ON or has just been turned OFF do not touch the power supply I O terminals or the surrounding areas A CAUTION Secure the AC power supply line to the terminal block with a 0 5 of torgue Loosening the screw may result in a fire or malfunction APPLICATION PRECAUTIONS A CAUTION On modifying the program always ensure that switching to MONITOR or RUN mode does not lead to unexpected effects PICK TO LIGHT CONTROL WITH ETHERNET NETWORK CHAPTER 1 OVERVIEW This guide explains the installation wiring and setup of the KVL PTLO4 Ethernet network pickup controller and describes its operation The installation
14. which particular attention must be given This is not intended to be an exhaustive list of all possible uses of the products nor is it intended to imply that the uses listed may be suitable for the products Outdoor use uses involving potential chemical contamination or electrical interfe rence or conditions or uses not described in this manual Installations subject to separate industry or government regulations Systems machines and equipment that could present a risk to life or property Please know and observe all prohibitions of use applicable to the products PROGRAMMABLE PRODUCTS KVL COMP shall not be responsible for the user s programming of a programmable prod uct or any consequence thereof PICK TO LIGHT CONTROL WITH ETHERNET NETWORK VI DISCLAIMERS CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons It is our practice to change model numbers when published ratings or features are changed or when significant construction changes are made However some specifica tions of the products may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult with your KVL COMP representative at any time to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are
15. wiring and setup of the product must be accomplished by experienced professionals The description of operation provides information for the workers working with the pokayoke system 1 1 SHORT INTRODUCTION OF POKAYOKE SYSTEMS The meaning of the Japanese words Poka Yoke in free translation z Poka random unintentional error mistake fault Yoke elimination prevention Meaning mistake free error free work workstation technology process development in order to avoid human errors The aim of pokayoke is the full scale prevention of product defects waste avoidance minimization of quality control costs to provide error free working conditions and work To sum up pokayoke is a system that assists manufacturing and assembling that helps and simultaneously controls the workers Using pokayoke effectively improves waste avoidance The KVL PTLO4 is part of the Ethernet network based pokayoke system developed by KVL COMP 1 2 THE LOCATION OF THE PICK TO LIGHT CONTROLLER IN THE POKAYOKE SYSTEM The purpose of this system is to eliminate picking the wrong spare parts due to an em ployees fault It receives the manufactured components datas from the control computer KVL Server Pick up the necessary components showed by the red light of AS I bus display acknowl edge lamps above the shelves Acknowledge of the component pick up for component storage bay happens with pull switch manually for shelves happen manually or aut
Download Pdf Manuals
Related Search