Delta Point Lite DeviceNet User Manual
Contents
1. 1 WHT ORG TX 2 WHT GRN RX 3 ORANGE TX 4 GREEN RX DPLEthernetMAN 06 20 08 PDF 25 EtherNet I O Map Input Points From the Water Saver to the EtherNet Master There are 4 bytes associated with the input points as follows e Byte 1 transmitted first OK to Weld Tripped when a fault either flow or temperature occurs 1 bit 1 Valve Closed 1 closed Solenoid valve is shut off due to fault or cap change 0 bit2 Bypass 1 bypass Water saver is in bypass does not close the solenoid valve when a leak Is detected __________ ___ ______ _ ____ _ ________ bit 3 Minimal flow 0 flow is minimal Monitors the supply flow It is tripped when water Below Min Flow flow is below minimum ___ __ __ __________ bit 4 Leak 1 cap lost Cap loss indicator Outlet flow lt inlet flow 1 cap lost 0 ok to operate Pe 1 _ _ bit 6 Temp Fault 1 temp ok Tripped when water temperature exceeds the 0 temp fault limit E p t PowerOn MEN o e Byte 2 Supply flow in GPM analog transmitted as 10x the flow value e Byte 3 Return flow in GPM analog transmitted as 10x the flow value e Byte 4 Water temperature in F analog transmitted as 1x temperature value Output Points From EtherNet Master to the Water Saver There is one byte associated with discrete output points pu Bit4 Notusd2. 5 Notusd Bite Notusd 12 7 Notused o DPLEthernetMAN 06 20 08 PDF 26 MAINTENANCE DeltaPoint water savers require no maintenance If the flow tubes become clogged with debris the unit should be removed for service and cleaning Significant clogging may result in erratic operation errors or faults Do not place tools into the tubes as this may permanently damage the vortex sensor The vortex sensor cannot be repaired To clean the flow tubes remove the shut off valve and check valve Run clean water into the downstream end of each leg Large objects jammed against the bluff body may be dislodged by lightly tapping the upstream end of the flow tube against a firm surface CAUTION Do not tap the flow tube too hard or damage may occur Shut Off Valve The manufacturer recommends that the diaphragm be removed and cleaned periodically The operation of the valve is based on small orifices functioning properly Depending on the level of water contamination cleaning frequency could vary from monthly to yearly If a low maintenance type valve is required and air is available please contact factory and request information on the air operated shut off valve Check Valve If check valve is leaking it may be disassembled and cleaned See APPENDIX for information on this valve Cleaning These meters do not require any special cleaning of the external surfaces If cleaning is deemed necessary strong solvents
3. Cua 16 VIEWING uasa spesa 18 Viewing Flow Comparison ardt tint late 19 FIEwWware BHeVISIOD dad ista ventes Saxa udis d ad romae 19 TEE T NUT 19 PROGRAMMING US ER ato hd or nde dao oho so eae nd us a 20 STANDABB EAGTORY SETPOINTS 38 0 25 99 0002 900 09 2629 8 soda 20 DITE UU 20 wm S 21 a 21 Set Over Under 22 DEI LMG m 23 Rostat Dt 23 ELEGTRIOAL GONNEGTOHMS ue 25 MEN ce 26 Input Points From the Water Saver to the EtherNet 26 Output Points From EtherNet Master to the Water 26 MAINTE NANG NM 27 PUFO E 27 CHECK YV AO TUE
4. B FAULT No water flow ALARM C Water Temperature MIN FLOW Yellow LED Solid VALVE Red LED Solid If an air operated shut off valve is used e Turn air shut off ball valve open DIN connector pilot light deactivated e Activate Override Red Button push and out several times If you hear the sound of air exhaust continue to the next step If not consult Factory WATER ON SLOWLY turn the water shut off ball valves open in both Supply and Return water legs Push the RESET Button located on the front cover to allow circulation to remove air clear all faults and restart the unit A LCD Screen B Status Lights 7 4 GPM FLOW OK Green LED Solid 100 F OK A Actual Supply Water Flow B Water Flow Status OK C Water Temperature MIN FLOW Yellow LED off Shut off valve DIN connector light is ON to indicated valve is open otherwise there will be no flow DPLEthernetMAN 06 20 08 PDF 13 START UP TEST CYCLE Shut Off Fault Alarm and Weld Controller Fault Alarm Test If unit is operational with water flow present 1 2 3 4 6 7 Turn one of the cooling water shutoff valves OFF The LCD screen indicates Water Flow Fault The LED status lights indicate that a Minimum Low Flow Solid Yellow b Shut Off Closed Solid Red The DIN Connector LED on Solenoid Valve is OFF because the shut off valve solenoid coil i
5. 2 1 PSIG 6 GPM 70 F 14 bar 22 7 LPM 21 C Brass PVDF Aluminum 14 6 4 kg 7 0 3 2 59 00 79 20 180 49 80 2 1 15 20 30 40 59 50 s sr 727 ms Measured from inlet shut off valve through the unit 34 1 D 8 ft hose loop back through the unit and check valve N Environmental conditions Caution The unit shall be supplied by a SELV separated extra low voltage source in accordance with CSA Standard C22 2 No 1010 1 92 Annex H This device has been designed for use in Installation Category pollution degree 4 at altitudes up to 2000 meters 6560 ft either indoors or outdoors as defined in CSA Standard C22 2 No 1010 1 92 Note 1 There is an additional 3 second delay at power up associated with displaying the firmware banner This delay is bypassed if a remote restart is sent to the instrument DPLEthernetMAN 06 20 08 PDF 5 HOW VORTEX SHEDDING FLOW METER WORKS LLL ll ll ll ll t LLL GN VORTICES B FLOW BLUFF ow SENSOR WII When fluid passes by a bluff oscillations occur Examples of these oscillations in nature include the swirls produced downstream of a rock in a rapidly flowing river or the waving of a flag in the wind with the bluff being the flag pole DeltaPoint Unit Supply Water Leg example above The fluid strikes a bluff body A generating vortices B eddies
6. Remove the Cover slotted screw driver Step 4 Remove the Key Pad circuit board slotted screw driver Step 5 Remove the LCD screen 2 Phillips screw driver Step 6 Remove screws from hold down bracket of the sensor to be swapped Phillips screw driver Step 7 Using a pair of needle nose pliers remove the sensor Note the position of the slot in the sensor is vertical following the flow Step 8 Install new sensor and ring assembly with needle nose pliers CAUTION Sensor SLOT must be aligned perfectly with the water flow direction Slot can be rotated 180 degrees Step 9 Replace the hold down bracket and screws wipe down any water Step 10 Replace the LCD screen Key Pad and Cover Step 11 Confirm the bleed off fitting is tight and the Supply Return water ball valves OPEN Step 12 Plug in the Power and Ethernet cables Step 13 Re evaluate the unit Push the DOWN Arrow ADVANCED TRAINING NEEDED FOR FOLLOW Adjusting the replaced sensor s flow rate to match the other sensor s flow rate by turning the sensor pot The flow rates should be within 0 1 of a gallon of each other Contact factory for training DPLEthernetMAN 06 20 08 PDF 30 18 If all else fails 19 Bypass 20 Ethernet If both sensors are drastically off the expected flow by more than a gallon and it appears that there is a major problem You have 2 options Option 1 ship the unit to Rocon for recalibra
7. 4 and 5 above See ETHERNET MAP for the correct bit pattern and data format A Shut Off signal was received via EtherNet See ETHERNET MAP for the correct bit pattern Bit 1 must return to 0 Logic 0 after a Shut Off Request Logic 1 has been sent to DeltaPoint A Restart signal was sent via EtherNet and the request is still active EIP RESET will be displayed on the top line of the display See ETHERNET MAP for the correct bit pattern Bit 0 must return to O Logic O after a Restart Request Logic 1 has been sent to DeltaPoint a EtherNet shutoff bit has not been reset by the server b The return sensor affected by debris or malfunctioning Refer COMPARISON TESTING and SUPPLY FLOW IS GREATER THAN RETURN FLOW If either sensor is misreading first flush the Bluffs then work on sensors The test is performed by pressing the DOWN Arrow button on the front cover It can be pressed at any time during operation The display shows both supply return flow rates if the difference is greater than 0 5 GPM return being lower then there might be a problem with the return sensor Refer REPLACING THE SENSOR DPLEthernetMAN 06 20 08 PDF 28 11 Flushing the Bluff 12 Water doesn t shutoff 13 Solenoid Valve Problem 14 Check Valve Problem Procedure to flush the Bluff Chamber Step 1 Closed both Supply Return ball valves Bleed off the water pressure by loosening a hose downstream
8. p LS ar LIPPE A Bluff Top Bluff Body DPLEthernetMAN 06 20 08 PDF 9 UNIT SIDE VIEW A Electrical Tag B Ethernet Connector C Power Connector D Shut Off Valve DIN Connector LED E Manual Override Knob 360 F Stamped REFERENCE MANUAL OVERRIDE C RED Dot Normal C SILVER Dot Bypass DPLEthernetMAN 06 20 08 PDF 10 HOW THE DELTAPOINT MONITORS COOLING WATER IN THE ROBOTICS CELL Each DeltaPoint unit has two vortex shedding flow meters One flow meter monitors the supply path and the other flow meter monitors the return leg The fluid strikes a bluff body generating vortices eddies that move downstream The vortices form alternately from one side to the other A piezoelectric sensor housed in a sensor tube directly downstream of the bluff senses the pressure zones created by the vortices The sensor generates a frequency directly proportional to the vortices flow The pulses are then measured by the microprocessor An internal temperature sensor housed in a small thermo well downstream of the return flow sensor measures the fluid temperature The robotic cooling water enters through the SUPPLY port and travels through the inlet flow sensor continues through the TO CELL port and to the equipment to be cooled Water that has cooled the equipment reenters the unit through the FROM CELL port through the return flow sensor and is then discharged into the plant return water s
9. signal to the robot that the unit is in bypass The coil will continue to be energized until the button is pushed again The manual bypass overrides the solenoid coil completely It does not give a signal to the robot and water flow is maintained regardless of the unit s status If the pushbutton Keypad circuit board is replaced be sure to set the Ethernet IP address and Subnet Mask settings The power must be cycled if either of the settings is changed Both lights for the Ethernet should be a steady green to indicate that it is communicating correctly If either is flashing then the Ethernet handshake has not been established DPLEthernetMAN 06 20 08 PDF 31 DIMENSIONS Unit shown with Mounting Bracket Shut Off Valves in bottom position 6 24 158mm TO CELL FROM CELL 2 343 11 32 MOUNTING HOLES IN OPTIONAL MOUNTING FEET 4 PLACES 8 42 NOMINAL 214mm SPACING I5 ADJUSTABLE BOTH SIDES 1 16 12 NOMINAL pp 4D9rm SUPPLY 2 44 5 45 131mm MOUNTING FEET OPTIONAL DPLEthernetMAN 06 20 08 PDF 32 Unit shown with Shut Off Valves in top position MOUNTING FEET OPTIONAL a 131mm 7 44 189mm SUPPLY RETURN 16 12 NOMINAL 404mm 8 42 NOMINAL SPACING 15 ADJUSTABLE BOTH SIDES 2 343 11 32 MOUNTING HOLES IN OPTIONAL MOUNTING FEET 4 PLACES TO CELL FROM CELI 5 24 158mm DPLEthernetMAN 06 20
10. that move downstream The vortices form alternately from one side to the other A piezoelectric sensor housed in a sensor tube C directly downstream of the bluff senses the pressure zones created by the vortices The sensor generates a frequency directly proportional to the vortices flow The pulses are then measured by the microprocessor Each DeltaPoint Unit has two vortex shedding flow meters One flow meter monitors the supply path and the other flow meter monitors the return path along with the temperature probe PLEASE NOTE Bluff Sensors not effected by dirty water DPLEthernetMAN 06 20 08 PDF 6 UNIT FRONT VIEW A Solenoid NC 2way Shutoff Valve 1 Supply B Manual Bypass Knob 2 To Cell C Check Valve 3 From Cell D Cover LCD Screen 4 Return E Cover LED Program Buttons F z ID Tag G Power Supply Connector H Ethernet Connector DPLEthernetMAN 06 20 08 PDF 7 FRONT VIEW ELECTRICAL ENCLOSURE COVER REMOVED d 128 ee A Key Pad B LCD Screen Li Electrical Box with Key Pad and LCD Screen Removed C Supply Sensor D Mother Board E Return Sensor F Temperature Probe 1 ids Sensor W ORing Sensor Hold Down Bracket Temperature Probe DPLEthernetMAN 06 20 08 PDF 8 UNIT REAR VIEW er eo d ABP Eh huna pA A TA A I
11. when has received a copy of the completed RMA form and any applicable MSDS 4 A Return Goods shipping label located in the back of the Instruction Manual must be used for returning materials to UFM 5 Returned goods must be shipped prepaid or they will be rejected REPAIRABLE MATERIAL Written or verbal authorization to proceed with the repair under an assigned Purchase Order must be received within 30 days of repair quotation If the unit s are repaired the 90 00 evaluation charge will be applied to the quoted repair costs If no repairs are authorized within this 30 day period the customer will be billed 90 00 plus shipping charges and the materials will be returned to the customer NON REPAIRABLE MATERIAL If materials are found not repairable a written notice that the material is not repairable will be provided to the customer by UFM If no disposition to scrap or return the material is received from the customer within 30 days unrepairable material will be scrapped and the customer will be billed the 90 00 evaluation charge UFM replacement unit is purchased within 30 days of non repairable condition notice the 90 00 evaluation fee will be waived The return of non repairable materials may be ordered by customer Purchase Order providing for shipping and handling charges RETURN FOR RESTOCK goods returned for restock adjustment must A New and unused B Returned to the factory within ONE YEAR of date of orig
12. 08 PDF 33 MODEL CODES DeltaPoint _ HOW TO ORDER Select the appropriate symbols to build a model code EXAMPLE DPL 2 EH 0 5 6 0 GPM 1 9 11 4 LPM 0 8 12 0 GPM 5 7 45 4 LPM DeviceNet EtherNet DPLEthernetMAN 06 20 08 PDF 34 APPENDIX Check Valve Specifications Style Maximum operating pressure Maximum operating temperature Cracking Pressure Material Piston Check Valve with embedded O ring that seals on seat 500 PSI 34 5 bar 180 F 82 C 1 PSI Brass Body and Piston Beryllium Copper Ring Shut Off Valve Specifications Function Ports Pressure Range Temperature Ratings Ambient Fluid Media Coil Power Rating Electrical Connector Materials of Construction Body Seal Other Wetted Parts Coil Contact Factory for Spare Parts 2 Way Normally Closed 34 NPT 2 PSI to 150 PSI 0 14 bar to 10 bar 14 F to 122 F 10 C to 50 C 176 F 80 C Maximum 24VDC 750 mA 10 Watts Maximum DIN Style Plug w Removable Cable Plug Adaptor Brass Buna Stainless Steel PVDF Brass Class F Molded Continuous Duty UL amp CSA Listed Manual Override Bypass SILVER DOT Bypass RED DOT Normal Parker Valve MANUAL OVERRIDE Hotate knob 180 degrees to either position Starting point stamped on valve body PARKER VALVE DPLEthernetMAN 06 20
13. 08 PDF 35 uedo 35 015 ssed g eoiueuo2aui ui JO JO ZO 5 ON ssed g ssed g yea7 ca pis SD ssed g 4 UIN Em EN EN EN _ Em Lor EM 0 8 19 1g vg 9g yg 0 eig uonipuo YO 4 peso 2 ssed g ye n u 4OzL peso z pessedAg UIN O71 XOzL 80 1 511836 did J3OoN3e3d3 REFERENCE EIP Bit Status Table Rev 1 08 DPLEthernetMAN 06 20 08 PDF 36 RMA NOTICE RETURN MATERIAL AUTHORIZATION Please read the following UFM policy information carefully By following the guidelines outlined below you will assist in providing a timely evaluation and response regarding the status of your flow meter UFM evaluates all AUTHORIZED RETURNED MATERIALS in a timely manner and will promptly provide notification regarding the status of the related materials and or a written quotation indicating the total charges and description of the necessary repairs 1 All returns must a RMA form completed by the customer 2 Any meter returned that was previously in service must have the OSHA requirements completed and a MSDS included where applicable 3 An RMA number will only be issued
14. 27 CNS AMIN 27 27 TRODBLESHOOTIB G uideat p pu qnie 28 DIMENSIONS cr TES 32 MODEL So me ee ae ee ee eee eee es 34 APPENDD qe on 35 Gheck Valve SOSCINCATONS ________________ 35 Shut Olf Valve SpecillcallOriS eniro c oot ee 35 REFERENGE EIP Bit Status Table Rev 1 09 d e e e Een Seoul 36 RMA NOTICE RETURN MATERIAL nnne 37 RMA FORM Rm 38 ROCON F DELTAPOINT WARRANTY A 39 DPLEthernetMAN 06 20 08 PDF 2 PROPRIETARY NOTICE The information contained in this publication is derived in part from proprietary and patented data This information has been prepared for the express purpose of assisting in installation operation and maintenance of the instruments described herein Publication of this information does not convey any rights of use or reproduction other than in connection with the installation operation and maintenance of the equipment described herein Universal Flow Monitors Inc and Rocon LLC reserve the right to change the information contained in this publication at any time and without prior notice DPLEthernetMAN 06 20 08 PDF 3 USING
15. 8 seconds each This is only for viewing not for changing the address ID is a pre assigned value by EIP server It cannot be changed by the user View input output status in binary format on the LCD second line It is displayed as 000 00000000 The first 3 bits are the remote command bits from orig into to water saver The next 8 bits are the water saver status bits being sent to the originator View inlet flow on the LCD first line outlet flow on the second line A troubleshooting aid to compare sensor values Push once to force the shut off valve open push again to return to normal operation Caution Unit will not shut off water but will send alarm fault when cap loss is detected Push to manually restart after Fault or push to exit from User Menu Factory default values Press ENTER first While IP Mask and MACID values are being displayed press and hold PROGRAM holding both buttons together The unit will enter Factory Reset When the dots on the LCD reach the end of the line the unit restores all of its factory set points IP address and Subnet mask will not be changed to factory setting as there is no standard setting for these parameters When DONE is displayed release the buttons DPLEthernetMAN 06 20 08 PDF 16 INDICATOR LIGHTS PROGRAMMING KEYPAD AND LCD MESSAGES EXPLAINED CONTINUED 9 0 GPM OK 100 F OK LCD 2 line x 16 character backlit alphanumeric A The current amount
16. DELTA POINT EtherNet IP Installation and Operation Manual 12 GPM EtherNet Unit 2 ROCON LLC 1755 East Nine Mile Road PO Box 249 Hazel Park 48030 0249 TEL 248 542 9635 FAX 248 398 4274 Website http www RHoconLLC com TABLE OF CONTENTS PROPRIETARY NOTIGEs d 3 USING IAIN DUREE 4 INameplate E Dre Qua p 4 SPECIFICATIONS GPM 45 CPM WNT Doe 5 Pressure Drop Dalda mtcr 5 HOW VORTEX SHEDDING FLOW METER WORK Sinanin a a nnne nn nnn nnns 6 BEN 2 9 UM I supr Nt 7 FRONT VIEW ELECTRICAL ENCLOSURE COVER 8 m 9 A VIEW MS 10 HOW THE DELTAPOINT MONITORS COOLING WATER IN THE ROBOTICS CELL 11 ct acca 12 SUGGESTED START UP PROCEDURE ee 13 TEST Ue sse S or 14 INDICATOR LIGHTS PROGRAMMING KEYPAD AND LCD MESSAGES EXPLAINED 15 Programming Via le la dva
17. Information INTERNAL USE ONLY Company Name Contact Name J thorized by ig Phone Document 3 1400 9 Rewsion Rewsion Date 11H 0 2004 DPLEthernetMAN 06 20 08 PDF 38 ROCON DELTAPOINT WARRANTY 1 ACCEPTANCE AND INTEGRATION CLAUSE This Sales Order Acknowledgment and the sales order information that Rocon LLC attaches to or associates with it this Acknowledgement constitutes an acceptance by Rocon of an offer by the buyer upon the conditions and terms and at the prices stated in this Acknowledgement This Acknowledgment contains the entire understanding of Rocon and the buyer regarding the subject matter of this Acknowledgement This Acknowledgement may only be modified by a writing signed by the party against whom enforcement is sought 2 WAIVER Waiver by Rocon of any default s by the buyer shall not constitute waiver by Rocon of any of the conditions of the agreement between Rocon and the buyer as set forth here under with respect to any further or subsequent default by the buyer 3 FORCE MAJEURE Rocon shall not be responsible for failure or delays in deliveries due to fire strikes breakdowns acts of God failure of carriers inability to secure required materials or other causes beyond Rocon s control Buyer waives any claims for damage arising by virtue of delay in delivery of material by Rocon 4 LIMITED WARRANTY a Warranty For a period of one year from the date of manufacture Ro
18. P value use the UP and DOWN arrows When the desired value is selected push ENTER to record in memory SET will be displayed on the LCD and the RESPONSE TIME setting window will appear e To skip this menu and go to the next push PROGRAM DPLEthernetMAN 06 20 08 PDF 22 PROGRAMMING USER MENU CONTINUED Set Response Time Response Time 1 0 Sec What is Displayed 1 0 Sec Current setpoint Adjustable Range 0 5 3 0 seconds in 0 5 increments What Happens DeltaPoint tries to look for a Leak Fault within this timeframe For higher values the flow readings are averaged internally for the defined period This may be a good idea to prevent false errors e change this value use the UP and DOWN arrows When the desired value is selected push ENTER to record in memory SET will be displayed on the LCD and the RESTART time setting window will appear e To skip this menu and go to the next push PROGRAM Restart Delay Restart 3 0 Sec What is Displayed 3 0 Sec Current setpoint Adjustable Range 1 3 0 seconds in 1 0 second increments Note There is an additional 3 second delay at power up associated with displaying the firmware banner This delay is bypassed if a remote restart is sent to the instrument What Happens At power up DeltaPoint waits this long before it starts monitoring the water flow This is the time that it takes for water flow to stabilize throughout the circuit after the sol
19. THIS MANUAL In order to use this manual you will need the model code that can be found on the nameplate of the flowmeter as shown on the example below see MODEL CODES The Model Code allows you to determine minimum and maximum flow capabilities for the Delta Point water saver Nameplate Example DPLEthernetMAN 06 20 08 PDF 4 SPECIFICATIONS 12 GPM 45 LPM UNIT Supply Voltage Minimum Water Flow Maximum Water Flow Flow Measurement Accuracy Flow Measurement Repeatability Minimum Detectable Leak Response Time Cap Pulled To Fault Restart Delay Water Temperature Range Temperature Probe Accuracy Operating Temperature Range Storage Temperature Port Size Supply Water Pressure Minimum Maximum Differential Water Pressure Minimum Maximum Pressure Drop Across Manifold Including shut off valve manifold 32 1 0 8 ft hose check valve Wetted Parts Body and Sensor Electrical Enclosure Weight Pressure Drop Data 4 0 5 0 24 VDC 750 mA valve on 0 8 GPM 3 LPM 12 0 GPM 45 LPM 0 24 GPM 0 9 LPM 0 25 of actual flow 0 5 GPM 1 9 LPM 1 0 sec typical with 30 feet 34 hose 9 meters 1 0 3 0 sec user selectable See Note 1 40 F 4 4 C 180 F 82 2 F 1 C from 32 200 F 0 93 C 32 F 0 C 122 F 50 C 4 F 20 C 158 F 70 C 34 NPTF BSPP 15 PSIG 1 0 bar 100 PSIG 7 bar 2 PSID 14 bar 90 PSID 6 bar
20. W OK screen Please Note MIN FLOW must be 0 5 GPM less then FLOW OK value Set Flow OK 4 0 GPM What is Displayed 4 0 GPM Current setpoint Adjustable Range 12 GPM 1 0 12 0 GPM in 0 2 increments e change this value use the UP and DOWN arrows When the desired value is selected push ENTER to record in memory SET will be displayed on the LCD and the LEAK RATE setting window will appear e To skip this menu and go to the next push PROGRAM Set Leak Rate Set Leak Rate 1 0 GPM What is Displayed 1 0 GPM Current setpoint Adjustable Range 12 GPM 0 5 1 0 GPM in 0 1 increments Note Setting the leak rate to a higher value prevents false errors e change this value use the UP and DOWN arrows When the desired value is selected push ENTER to record in memory SET will be displayed on the LCD and the HIGH TEMP setting window followed by the LOW TEMP setting window will appear e To skip this menu and go to the next push PROGRAM DPLEthernetMAN 06 20 08 PDF 21 PROGRAMMING USER MENU CONTINUED Set Over Temperature oet Over Temp 150 F What is Displayed 150 F Current setpoint Adjustable Range 45 F 210 F in 5 degree increments What Happens When water temperature in the return leg is over this value the LCD displays Fault and the fault signal is transmitted to the weld controller The Green FLOW OK LED on the membrane also flashes ochange the OVER TEM
21. con warrants that each product covered by this Acknowledgement will be free from defects in material and workmanship In order to qualify for any remedy provided in this Acknowledgement buyer must give notice to Rocon within the one year period return the product to Rocon freight paid and intact with Material Safety Data Sheets covering all substances passing through the product or that form a residue on the product b Exclusive Remedy The buyer s EXCLUSIVE REMEDY for failure of any product to conform to any warranty or otherwise for any defect is at Rocon s sole option i repair ii replacement or iii refund of the entire purchase price for the specific product Without limiting the foregoing in no case will Rocon be liable for deinstallation of any defective product or installation of any repaired or replacement product THIS REMEDY IS THE EXCLUSIVE REMEDY AVAILABLE TO THE BUYER OR ANY OTHER PERSON ROCON SHALL NOT BE LIABLE FOR ANY DIRECT INDIRECT INCIDENTAL CONSEQUENTIAL SPECIAL PUNITIVE OR OTHER DAMAGES IN CONNECTION WITH ANY CAUSE OF ACTION WHETHER IN CONTRACT TORT OR OTHERWISE c Disclaimer of Other Warranties The express warranty in this Acknowledgement is in lieu of any other warranty express or implied Without limiting the foregoing ROCON DISCLAIMS THE IMPLIED WARRANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE 5 Products purchased by OEMs original equipment manufacturers a
22. detergents or chemicals should not be used A damp cloth may be used to wipe off dirt or debris Note If used outside the parameters specified in this manual the proper operation of the flowmeter cannot be guaranteed DPLEthernetMAN 06 20 08 PDF 27 TROUBLESHOOTING PROBLEM LCD blank no LEDs LCD Line 2 Return gt Supply EtherNet Network Status EtherNet Module Status DeltaPoint does not respond to remote shut off and or restart commands from EtherNet Master DeltaPoint does not transmit the correct data on EtherNet EIP WATER OFF LCD Line 1 Shows and Solenoid Valve Shuts DeltaPoint continuously restarts DeltaPoint restarts and shows flow briefly then proceeds to shutdown Comparison Testing EXPLANATION SOLUTION Power not present Check power cable Refer LINEARITY TESTING If the LCD shows readings the EtherNet communication may or may not be working Step 1 Remove the faceplate and check if the keypad is plugged onto the motherboard properly Step 2 Check for loose screws on the keypad EtherNet communication problem Make sure the proper EDS file is loaded on the EtherNet Master computer Check the EtherNet Master program to make sure these bits are correctly transmitted to the water saver see ETHERNET MAP Only bits 0 1 and 2 are used Bits 3 7 are ignored by the water saver Make sure the Module Status LED is green on If not see numbers
23. enoid valve is opened and for removing all trapped air in the water line after a cap is replaced Short delays may result in a mismatch between the Supply and Return flow readings thus issuing an incorrect Fault signal e change this value use the UP and DOWN arrows When the desired value is selected push ENTER to record in memory SET will be displayed on the LCD and the UNITS setting window will appear e To skip this menu and go to the next push PROGRAM DPLEthernetMAN 06 20 08 PDF 23 PROGRAMMING USER MENU CONTINUED UNITS UNITS What is Displayed English Current setting Selectable English or Metric What Happens The display will be in GPM F for English or LPM C for Metric e change this value use the UP and DOWN arrows When the desired value is selected push ENTER to record in memory SET will be displayed on the LCD and the UNITS setting window will appear e To skip this menu and go to the next push PROGRAM DPLEthernetMAN 06 20 08 PDF 24 ELECTRICAL CONNECTORS Supply Power Connector EtherNet Connector View of Cable Side View of Cable Side White Orange TX White Green RX Orange Green RX Brown N U White 24V Blue GROUND Black N U SUPPLY POWER 1 BROWN N U 2 WHITE 24V 3 BLUE GROUND 4 BLACK N U t E 3 e _ 5 A lt
24. id Solid Solid or Flashing Function OK Temperature Fault Low Flow Minimal Flow Valve Shut Valve Shut Off Failure In Bypass Flow Fault in Bypass Power On EtherNet Module EtherNet Network Comments Programmable Flow gt Flow OK setpoint LCD shows Flow Ok Programmable Temperature exceeds Temp Fault setpoints LCD shows Fault on the second line Non programmable Flow is between Min Flow and Flow OK setpoints LCD shows Low Flow Programmable Flow lt Min Flow setpoint LCD shows Min Flow Note Text on the instrument cover plate may show Flashing Minimal Flow This is no longer the case The firmware has been revised to keep the yellow LED solid under both Low and Minimal flow conditions Shut off valve closed Can happen when leak exceeds Leak Rate setpoint or flow lt Low Flow Shut off valve failure Power off to coil but water flow is still present BYPASS button pushed shut off valve forced open Flow fault detected but valve cannot be shut off because the unit is in Bypass 24V DC Aux power present Green LED OK Red LED indicates error Flashing Green LED means waiting for server communication Red LED indicates error DPLEthernetMAN 06 20 08 PDF 15 INDICATOR LIGHTS PROGRAMMING KEYPAD AND LCD MESSAGES EXPLAINED CONTINUED Programming Via Keypad D Push and hold for 1 second to enter User Menu View IP address Subnet Mask and MAC ID
25. inal shipment C Returned through the distributor where the goods were originally purchased This material will also be subject to an evaluation charge of 90 00 The customer will be advised of the restocking adjustment for all restockable goods Upon acceptance of the restocking adjustment by the customer the 90 00 evaluation fee will be waived and a credit issued by UFM The customer will be advised of any non restockable goods and will be charged the 90 00 evaluation fee plus any shipping charges if returned to the customer If no disposition is received by UFM within 30 days the goods will be scrapped and the 90 00 evaluation fee will be billed WARRANTY RETURNS Warranty returns must be shipped prepaid to UFM UFM will review the goods and advise the customer of the evaluation and validity of the warranty claim Valid warranty claims will be repaired or replaced at no charge No evaluation fee will be charged for repairs made under warranty Return shipping costs will be prepaid by UFM Should UFM determine the returned material is not defective under the provisions of UFM s standard warranty the customer will be advised of needed repairs and associated costs All materials returned for warranty repair that are determined to not have a valid warranty claim will be subject to the Repairable Material policy outlined above DPLEthernetMAN 06 20 08 PDF 37 RMA FORM UNIVERSAL RETURN MATERIAL AUTHORIZATION E MAIL ufmeflowmeters co
26. m PH 248 542 9635 FLOW MONITORS Fax 248 398 4274 IMPORTANT his farm must be filled out completely and faxed to the Repair Department prior ta issuing a NRA Customer Product Information Oty Model Cade S N Sales Order Contact Name Phone eeFEFEEE c FAX Are before as found and after readings required E mail Yes No Reason for return Please be detailed as possible Lack of Information may increase labor charges Mechanical Electronics Leaks M signal Sticks Inaccurate signal Calibration O No Display Switch does not work O Other describe below Other describe below Details Note There Wil be minimum vaiuafion change of 390 00 for al retumed excluding units covered under warranty WILL NOT be accepted without valid Heturn Maternal Authorization Number AMA A Materia Safely Data Sheet on process must be received when applicable prior the issued OSHA Requirements to be filled out by customer NO EXCEPTIONS Process Fluid Meter must be flushed fo remove all process fluids hereby certify that the material being returned has been properly flushed and cleaned of all hazardous materials and does not require any special handling Print or Type Mame Signature Title Date Distributor
27. m the manual bypass knob to insure that the orifice is not blocked Step Remove the Sleeve Assembly The internal parts will be the Plunger and Plunger Spring Do they move up and down freely If NO then clean or replace with new Sleeve Assembly Step 4 Replace the valve cap and the coil reassemble and confirm that this has resolved the problem by removing another tip Check Valve will not shut off the water Step 1 The only way to remove the debris is to change out the check valve with a replacement and then clean out the check valve on the bench Step 2 Remove the snap ring and push the piston out to remove any debris Step 3 Replace the new check valve with the cleaned valve reassemble and confirm that this has resolved the problem by removing another tip DPLEthernetMAN 06 20 08 PDF 29 15 SUPPLY FLOW is greater than RETURN FLOW UNIT CONTINUOUSLY FAULTS OUT 16 RETURN FLOW 15 greater than SUPPLY FLOW 17 Replacing the Sensor This usually is a return sensor problem Refer COMPARISON TESTING and FLUSHING THE BLUFF This usually is a supply sensor problem Refer COMPARISON TESTING and FLUSHING THE BLUFF Procedure to replace the a sensor Step 1 Remove Power Ethernet Cables Step 2 Turn off the water and bleed off the pressure by loosening the hosing downstream drains water out of sensor chamber preventing water leaking into electrical box Step 3
28. nd the fault LED will be flashing The Bypass and OK to Weld bits will remain on allowing the robot to weld Water Shutoff Leak or No flow faults cause the water to shut off Remote command EIP Water OFF also de energizes the valve shut EXCEPT when there is a remote Bypass request If EIP Bypass is ON the EIP Water OFF command will not shut the valve Remote Water OFF command overrides local Bypass if the unit is in bypass via the pushbutton the remote command can still shut the valve Reset Local pushbutton and EIP Reset command Startup delay user programmable or 1 3 seconds Viewing EtherNet Bit Patterns Bytes 1 and 4 can be viewed on the LCD for informational and or troubleshooting purposes When the instrument is run mode press and hold the UP arrow on the keypad the second line on the LCD will look like this 5 0 GPM OK 000 10001001 From EtherNet Master From Watersaver to EtherNet Master Push and hold DPLEthernetMAN 06 20 08 PDF 18 INDICATOR LIGHTS PROGRAMMING KEYPAD AND LCD MESSAGES EXPLAINED CONTINUED Viewing Flow Comparison Values Supply and Return flows can be viewed simultaneously to aid in Sensor Verification Troubleshooting Supply 5 0 GPM OK Return 5 0 OUTLET Push and hold Viewing Firmware Revision Firmware revision displayed at power up only R5 1 1 09 EIP 1 01 3 19 08 Factory Reset To change all the setpoints back to the original fac
29. of water flow through the Supply side Return side water flow is not displayed but it is always close to Supply side otherwise a leak fault would occur Expressed in GPM or LPM the amount can vary per unit used B The status of the current water flow OK Low Min or Fault When in Fault condition unit sends alarm to weld controller C The current temperature of the water Expressed in Fahrenheit or Celsius D The status of the current water temperature OK or Fault Power up Unit starts out by displaying DPII R5 1 1 09 EIP1 01 3 19 08 After 1 second the second line shows Going Online After 5 seconds the unit enters RUN mode and starts monitoring flow and temperature The 5 second startup is not user adjustable This is part of the Ethernet communication startup sequence Faults Leak Closes the valve sends the corresponding bits to EIP No Flow Closes the valve sends the corresponding bits to EIP Temperature Does not closes the valve sends the corresponding bit to EIP Green LED no longer flashes in temperature fault LCD messages Local RESET Reset button pushed shown while the startup delay is counting down EIP RESET Remote reset command is active It remains in this state and continues counting down through the startup delay repeatedly until this bit is cleared by the EIP server EIP Bypass ON Remote bypass command is active EIP BP SO Remote Bypass and water Shut Off are both acti
30. or pulling a weld gun arm cap Step 2 Using a 3 32 Allen Head Wrench remove both Bluffs hold down screws Remove bluffs is there debris on ether bluff remove Step 3 Solenoid Valve switch to BYPASS position Step 4 Tighten the bleed off hose fitting or replace cap Step 5 Supply Ball Valve With the bluffs removed flush the sensor bodies by partially opening the valve and spraying with short bursts for 10 seconds to flush out the bodies Any contamination build up should have been removed Step 6 Reverse above steps and activate the Unit for proper operation Once both shutoff devices are closed no electrical power Step 1 Partially open the supply ball valve If the water flows then there is a problem with the solenoid valve Step 2 If the water does NOT flow shut the supply ball valve off Step 3 Partially open the return valve If the water flows then there is a problem with the check valve Solenoid Valve will not shutoff the water Step 1 Check the manual override on the valve Confirm that it is in the NORMAL OPERATION position Refer to APPENDIX Shutoff Valve Specification The valve could have debris blocking the balancing orifice or the Plunger Assembly is stuck in the open position in the Sleeve Assembly Step 2 Remove the coil Din connector assembly Remove the 4 screws holding the cover to the body Turn cover over and insert a thin wire in the balance hole farthest fro
31. oved They are needed for proper operation of the flow sensors See DIMENSIONS for mounting hole pattern Connecting fluid ports The unit has 34 inch NPT female pipe ports Port 1 SUPPLY cooling water into the unit Port 2 TO CELL cooling water to tooling or robot Port 3 FROM CELL returns water from the cell or robot Port 4 RETURN cooling water leaving the DeltaPoint unit Units can be installed where the pipe or hose diameter is larger than the port size Do not exceed 34 pipe or hose diameter with the 4 GPM unit and 1 inch pipe or hose diameter with the 12 GPM unit Caution Water flow cannot exceed 5 GPM for a 4 GPM unit and 15 GPM for a 12 GPM unit Connecting electrical power All units have an Electrical Callout Tag reference page 20 that describes the pin number location wire color and function Caution When the water inlet ball valves is opened do it SLOWLY to prevent water hammer damage to the SENSORS 10 Installation is complete If problems contact the factory 248 542 9635 or 1 877 684 0589 DPLEthernetMAN 06 20 08 PDF 12 SUGGESTED START UP PROCEDURE 1 2 Water OFF Power OFF Connect electrical cable to Switch Box turn Power ON The LCD Screen and Power Light will be activated If a problem occurs see TROUBLESHOOTING A Power activated LCD Screen B Power activated Status Lights 0 0 GPM Fault FLOW OK Green LED off TOT OK A 0 0 GPM Water flow not present
32. re warranted only for the specific programs installations for specific customers designated when so identified 6 Flow sensors are warranted for 5 years electronic parts for 2 years and ancillary check valves and shut off valves for 6 months Document 1400 9 Revision 6 Revision Date 11 10 2004 DPLEthernetMAN 06 20 08 PDF 39
33. s deactivated Confirm that the Weld Controller received Water Flow Fault through the EtherNet communication see ETHERNET I O MAP Open the cooling water ball valve push RESTART Unit should be activated as described above If no problems occurred proceed to the next test If unit did not pass see TROUBLESHOOTING Leak and Response Time Test If unit is operational with water flow present 1 2 3 4 oon Pull off one of the weld gun arm electrode caps The water shuts off and the LCD screen indicates Fault Status Lights 1 and 3 are activated Reinstall weld gun cap Send a remote RESTART through EtherNet or push RESTART on the front panel of the unit and wait 3 seconds for the unit to return to normal operation Pull off the other weld gun arm cap And verify Steps 1 4 above If a faster response time is needed lower the response time and or the leak rate see USER MENU CAUTION e If the setting gets too low or is too fast false leak faults could occur Continue testing until satisfactory results are obtained If the unit passed the above tests it is ready for the production line DPLEthernetMAN 06 20 08 PDF 14 INDICATOR LIGHTS PROGRAMMING KEYPAD AND LCD MESSAGES EXPLAINED Color 1 Green 1 Green 2 Yellow 2 Yellow Red Red Yellow Yellow Green O oa A A Green 7 Green Status Solid Flashing Solid Solid Solid Flashing Solid Flashing Sol
34. tion or Option 2 Rocon can furnish electronics kit which will have the motherboard and both sensors This would be equivalent to replacing the entire unit To replace the Ethernet motherboard with its accompanying sensors S or I Supply and or O Return Step 1 Shut off the supply return water ball valves Step 2 Remove Power and Ethernet cables Step 3 Remove the LCD display 4 Phillips head screws and keypad 2 slot head screws Step 4 Unplug all sensors 2 flow and 1 temp Step 5 Remove the 2 slot head screws and 1 Phillips head screws holding the mother board to the box Step 6 Remove the Keypad standoff Step 7 Remove motherboard Step 8 Remove supply sensor hold down bracket and pull the sensor assembly out Label with tape SUPPLY Step 9 Remove the return sensor as describe in step 8 Step 10 Replace the sensors from the kit follow the same procedure as describe in Replacing the Sensor Please note Kit Supply Return Sensor must be installed in their respective chambers Step 11 Install the Kit Motherboard Keypad and LCD screen as describe above Step 12 Reconnect the power cables The unit should be operating properly If not refer to Flushing the Bluff Consult factory if problem There are both electronic and manual bypasses on the units The electronic bypass is a button on the face of the unit and once pushed energizes the solenoid valve coil and sends a
35. tory values proceed as follows n Run mode push and hold ENTER While holding ENTER push and hold PROGRAM e The LCD will show Factory Reset on Line 1 followed by on Line 2 After 5 seconds the LCD displays DONE release pushbuttons The unit reverts back to the original setpoints See FACTORY SETPOINTS DPLEthernetMAN 06 20 08 PDF 19 PROGRAMMING USER MENU Press the PROGRAM button on the keyboard to enter the User Menu PROGRAM button is used to enter or skip each individual menu For example to change Response Time push PROGRAM 6 times until Response Time is displayed In any of the above menus if no buttons are pushed for 5 seconds the User Menu reverts back to Run mode REFERENCE STANDARD FACTORY SETPOINTS Parameter J 148PM _ Factory Setpoin TT Engineering Units Set Min Flow Push PROGRAM button the MIN FLOW setting window will aopear set Min Flow 2 0 GPM What is Displayed 2 0 GPM Current setpoint Adjustable Range 12 GPM 8 11 5 GPM in 0 1 increments e To change this value use the UP and DOWN arrows When the desired value is selected push ENTER to record in memory SET will be displayed on the LCD and then the FLOW OK setting window will appear e To skip this menu and go to the next push PROGRAM DPLEthernetMAN 06 20 08 PDF 20 PROGRAMMING USER MENU CONTINUED Set Flow OK The MIN FLOW value must change to enter into the FLO
36. ve Bypass overrides Shutoff and keeps the valve open Heartbeat Flashing dot on the last LCD position end of second line Flashing means the flow is being monitored and results displayed on the LCD No flashing means flow is no longer being monitored reset is needed DPLEthernetMAN 06 20 08 PDF 17 INDICATOR LIGHTS PROGRAMMING KEYPAD AND LCD MESSAGES EXPLAINED CONTINUED Bypass Button CAUTION PLEASE NOTE ONCE THE ROCON DELTAPOINT UNIT IS PLACED IN BYPASS THE OPERATOR IS CHOOSING TO IGNORE THE MONITORING OF THE WATER FLOW TO THE CELL IE WATER OFF OR LEAK THEREFORE ROCON IS THEN RELIEVED OF RESPONSIBILITY FOR ANY RESULTING PERSONAL OR EQUIPMENT DAMAGE All faults can be bypassed either locally or remotely EIP bypass overrides the local pushbutton bypass local bypass cannot undo the remote bypass command Note Unit must be restarted after a fault even if bypass has opened the valve to allow water flow The reset can be either local or through EIP This allows the faults to reset and the unit to resume monitoring When in bypass the unit will energize and continue to energize the solenoid shutoff valve SV as well as set the Bypass and OK to Weld bits allowing the robot to weld The SV will remain on until the bypass command is released from its origin or the unit is reset locally If the unit is placed in bypass and a fault occurs water will continue to flow however the Min Flow bit will turn off a
37. ystem The inlet and outlet flow meter signals are compared When a cap is pulled or a hose bursts the flow in the return leg drops below the supply leg The microprocessor detects this difference and signals the weld controller to stop welding It also shuts off the cooling water via a solenoid valve in the supply leg and a check valve in the return leg thus stopping the water flow in both directions No field adjustment required each unit is calibrated and tested at the factory In fact no adjustments or tweaking needed even out of the box Just connect the power and the unit is ready for operation If custom adjustments preferred the unit is very easy to program for the following FLOW OK MINIMUM FLOW OVER TEMPERATURE LEAK RATE RESPONSE TIME or RESTART DELAY and finally USA or METRIC setting DPLEthernetMAN 06 20 08 PDF 11 INSTALLATION 1 2 DeltaPoint unit is preferred to be mounted on the outside of the fence line for ease of service DeltaPoint can be mounted in any orientation horizontally vertically or at any other angle The orientation has no effect on performance It is suggested that unions or hosing be used when connecting to the main supply and return piping this will facilitate ease of maintenance or removal of unit if needed The Cover be rotated 180 to change the location of the shut off devices Contact factory Caution Brass pipe nipples installed on the Supply and From Cell ports cannot be rem
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