service manual segmentation system
Contents
1. 140m 4 Selection of timing of sealing head returns Among 8 bits of SWI the second high bit is used for selection of timing of sealing head returns When the bit slide is set at left each sealing head returns independently when sealing is done at the head When the bit slide is set at right all sealing heads return same time when sealing at all heads is done Factory setting is left returning independently SWI 1108 8TO1 EACH SAME HE 60 m 80m 100m 20m 140m 160m 5 Thickness adjustment Thickness of seals can be adjusted in small range by adjusting a screw at each sealing head Remove the head protector and turn the screw at left of head counter clockwise if seals should become thinner or turn it clockwise if thicker seals are required Turn the screw by only a quarter turn or less each time and check thickness variation then repeat again as this adjustment 1 quite sensitive 6 Set distance between sealing head units Distances between two sealing head units can be set at either one of 75 80 85 90 mm To change mounting position of sealing head unit two screws shall be disassembled at the bottom of segmentation unit 5 5 Fixtures for Remote Mode Control To operate the machine in one of three remote modes a fixture should be prepared by users Refer to Figure 5 2 below REMOTE SWITCH CONTROL UNIT RE2. Y aD 090 009 93908 NOILNAIULSIG YINOd Pa tong Pi o F4 F3 Il DISTRIBUTION BOARD 606 068 TRIGGE3 80 529 735 MATCHING BOARD 589 938 c2 e c o e zu 1 no 8 Part List Each part is identified with manufacturer s part number in the Part List Part location in unit is found by the find number in exploded views and circuit board layouts in Chapter 7 Prefix A in find number denotes that it is not a single component but an assembly so a lower level part list of which is presented at another place Order for servicing parts to distributor or manufacturer should accompany part numbers gt A DL zewwia vo asszevoseoxeozc Amina 1 ____ 1 L 1600 44 vr IVC gt LV6606XV9 11000IN Amana Teen Ti pa 22 name a R a 6 6 6580 0004 LE LES Iz Ls La T o ene ___ ____ AA SA ma 59 59 95 95 tr os Ng c 6 MAYS IT LI EA CS 1 ka 77 QT I A gt OE ARA CI 1MOJANS SAWS l LE d NA I LL 71 XNISLV3IH IV 81 e o o o oc s ve s s sorvtoodw s sz vez
3. Figure 2 2 Segmentation Unit The segmentation unit has all sealing head units and signal distribution board in the base plate All sealing head units are identical in configuration but only the trigger lever in the sealing head unit mounted at 1 position is active and another trigger levers are in inactive state The trigger lever in 1 sealing head unit has two features In local mode of operation a cycle of sealing starts when it is depressed In any one of three remote modes it senses presence of tubing in 1 sealing head unit then makes control circuit be ready to accept a remote start command to be given by a remote start switch a remote start circuit or a remote control computer only when it detects tubing has been loaded in the 1 sealing head Mounting distances between sealing head units are adjustable at 75 80 85 or 90 mm Users can adjust the distances as necessary An ENABLE DISABLE selector switch is prepared on the rear panel of each sealing head unit If the selector switch is selected at DISABLE the sealing head unit does not work even if an ENABLE command is given in remote command mode On each sealing head units are two LED indication lamps The green READY lamp is turned on when the ENABLE DISABLE selector is set at ENABLE position The red SEALING lamp is turned on only while sealing is being done Both lamps will be off if the ENABLE DISABLE selector switch is set at DISABLE position The head protect
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5. 93 bd 53 LJ 11 1081 02 310838 017H043 832208 950 009 98908 7031409 450 009 49908 071 AINN 183493S 017H043 INYIYA LINIHII A 1IWI 5 0 002 3 9 0 002 8 LINN 1091802 NO 0062 3 NOZI Y 1NdNI SEGMENTAT ION UNIT 288 835 DISTRIBUTION BORRO SEALING HEAD UNIT 1 LC JC SS MATCHING BOARD 688 638 2 gt CONTROL UNIT SEALING HEAD UNIT 2 SAME AS 21 SEAL ING HEAD UNIT 3 SAME AS 1 5 SEALING HEAD UNIT 4 FROM UNIT 447 SAME RS 81 CONTROL UNIT a SEALING HEAD UNIT 5 FRON wur 467 SAME AS VI CONTROL UNIT 7 Technical Illustration Figure 7 1 Exploded view of MS950 Control Unit page 1 2 Segmentation Unit page 2 2 Figure 7 2 Control board layout Figure 7 3 T O board layout Figure 7 4 board layout Figure 7 5 Power distribution board layout Figure 7 6 Distribution board layout Figure 7 7 Trigger board layout Figure 7 8 Matching board layout Figure 7 9 Switch board layout Figure 7 10 Filter board layout Figure 7 1 Exploded View of MS950 page 1 2 Control Unit Figure 7 1 Exploded View of MS950 page 2 2 Segmentation Unit 5 E amp 3 9 A Mt o HP E T dem E PER 50 009 93408 O T
6. Communications In Communications dialog box check communication parameters as Baud rate 19200 Data bits 8 Stop bits 1 Parity None Flow control None Connector a port among COMI that is available in your PC If you are not sure which COM port is available try one by one until you don t get a Terminal Error message 5 On menu bar click Settings Terminal Preferences In Terminal Preferences dialog box check Local Echo in Terminal Modes box 6 Turn on the power switch of Segmentation System All status codes indicating Enable Disable selection of each sealing head are displayed once 7 To change system mode from local to remote command mode type in 1 All commands should be typed in capital letters Do not press Enter key after command On monitor screen 1 1 will be displayed The first M 1 gt is an echo of the command that you have typed in and the second M 1 gt is a status code that system replies 8 Place tubing in sealing heads and let 1 trigger lever be depressed When 1 trigger lever is depressed SR 1 is displayed 9 Start sealing by giving the command S 1 gt k On monitor screen 5 1 1 will be displayed The first 5 1 is an echo of the command that you have typed in and the second 55 1 is a status code that system replies 10 When sealing ends status code 55 0 is displayed and all green lamps light Remove tubing Then status code R 0 g
7. locates in the sealing head unit On the board is an impedance transformer called loading coil It transforms RF board impedance to sealing head impedance 4 Standard Operating Procedure 4 1 Operation Mode Four operation modes are available with this Segmentation System Local mode Remote modes 1 Remote switch mode 2 Remote circuit mode 3 Remote command mode a Local Mode Local mode is a mode that the machine operates by itself without any external device Default mode is the local mode A cycle of sealing operation is initiated by pressing the trigger lever at 1 sealing head unit All the other trigger levers do not work at all b Remote Switch Mode Remote switch mode is a mode that the machine is controlled by an external switch When a connector which should have been specially pre wired and an external switch should have been wired to is connected onto the remote control connector of the control unit the machine works in remote switch mode In this mode sealing starts by pressing the remote switch Before the switch pressed the trigger lever at 1 sealing head should have been pressed by tubing If tubing is not loaded in 1 sealing head sealing does not start The trigger lever at 1 head senses presence of tubing and then enables circuit to accept command given by the remote switch only when tubing has been loaded in 1 sealing head unit All the other trigger levers do not work at all c Remote Circu
8. machine works in remote mode Default factory settings and adjustment procedures are found in Section 5 2 The machine operates in one of four operation modes local remote switch remote circuit and remote command modes Power on default is local mode if no connector is connected on the remote control connector Details are found in Section 4 When sealing is not made at a sealing head audible and visual alarms are activated Alarm condition is set up when any sealing head has not made seal in 3 seconds from start due to circuit failure Alarm continues until the trigger lever at 1 sealing head is released by removing tubing In alarm condition the followings take place 1 The green POWER ON lamp on the front panel of control unit flashes 2 Beeps sound 3 Only in remote command mode operation status code among 2 2 is displayed For example when 3 head does not work C 2 k will be given Not having alarms does not mean that all seals made are perfect Alarm feature is provided not to decide automatically that all seals have been made perfect or incomplete but to detect circuit failure to make the machine stop before starting the next cycle of sealing operation 2 2 Segmentation Unit MS950A E shown 1 2 3 4 5 Front Base plate 6 READY lamp Sealing head unit 7 ENABLE DISABLE switch Protector screw 8 RF IN connector Head protector 9 Data cable connector SEALING lamp
9. operational voltage range is 180 264 volts 3 Cleaning 1 Always keep the sealing head area clean and dry If the sealing heads become wet or dirty arcs may appear during sealing If an arc appears clean the sealing heads and let them dry thoroughly 2 Use a soft cloth and mild detergent to clean the machine After cleaning wait a few minutes until the area cleaned is completely dried Do not use paint thinner benzene solvent or any strong detergent 3 Avoid using or leaving the machine in a location where temperature is higher than 50 122 F Keep it away from any heating source or direct sunlight Contents Important Note Contents List of Figures 1 Introduction 1 1 1 2 1 3 General Feature Specification 2 Appearance and Function 2 1 2 2 Control Unit Segmentation Unit 3 System Description 3 1 General 3 2 Control Board 3 3 Board 3 4 Power Distribution Board 3 5 Power Supply Unit 3 6 Filter Board 3 7 RF Board 3 8 Distribution Board 3 9 Sealing Head Unit 3 10 Switch Board 3 11 Trigger Board 3 12 Matching Board 4 Standard Operating Procedure 4 Operation Mode 4 2 Operation in Local Mode 4 3 Operation in Remote Switch Mode 4 4 Operation in Remote Circuit Mode 4 5 Operation in Remote Command Mode 5 Maintenance and Troubleshooting 5 Precaution 5 2 Test Equipment 5 3 Troubleshooting Procedure 5 4 Adjustment of Variables 5 5 Fixtures for Remote Mo
10. time Available tubing size AC mains voltage control unit segmentation unit inter unit cable local remote switch remote circuit remote command 40 68 MHz 1 3 seconds 2 6 millimeters in diameter Model MS930A MS940A MS950A MS960A MS970A Nominal voltage 100 120 VAC 50 60 Hz single phase Working voltage 90 132 VAC 47 63 Hz single phase Power consumption 600 W 800 W 1000 W 1200 W 1400 W Current rating 6A 8A 10A 12 14 Model MS930E MS940E 950 960 MS970E Nominal voltage 200 240 VAC 50 60 Hz single phase Working voltage 180 262 VAC 47 63 Hz single phase Power consumption 600 W 800 W 1000 W 1200 W 1400 W Current rating 3A 4A SA 6A 7A 7 Over current protection By recoverable circuit breaker Indication lamps Control unit POWER ON green Segmentation unit READY green SEALING red 9 Alarms audible indication by buzzer visual indication by lamps 10 Dimension and weight Model MS930A E MS940A E MS950A E MS960A E MS970A E Control unit Size W H D mm 406 200 310 518 200 310 630 200 310 742 200 310 854 200 310 Weight Kg 9 5 10 5 11 5 12 5 13 5 Segmentation unit Number of head 3 4 5 6 7 Size W H D mm 255 155 210 345 155 210 435 155 210 525 155 210 615 155 210 Weight Kg 7 5 9 0 10 5 12 0 13 5 Set distance mm 75 80 85 90 75 80 85 90 75
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12. 5 sealing head units will be used it has to be set as the following SW2 DISABLE ENABLE 12345678 If 23 sealing head will not be used in MS950 model it should be as the following SW2 DISABLE ENABLE 12345678 Factory setting is all head units at ENABLE 2 Selection of time interval of head starts Among 8 bit DIP switch selectors of SW1 lower 6 bits are used for selection of time interval of head starts Time interval of sealing starts between a sealing head and the next sealing head can be changed between 60 160 milliseconds by 20 milliseconds step Only one bit should be positioned to the left If two or more bits are set at left the lowest bit will be acknowledged For example to select 100 milliseconds interval it has to be set as the following SWI 8TOI SAME 8 60 80 100 120 140 160 Factory setting is 100 mS 3 Selection of operation sequence of sealing heads Among 8 bits of SW1 the first high bit is used for selection of operation sequence of sealing heads When the bit slide is set at left sealing starts from 1 sealing head unit then 2 then 3 from right to left When the bit slide is set at right sealing starts from 5 sealing head unit then 4 then 3 from left to right Factory setting is right starting from left head to right head SWI 1708 Tol EACH SAME HE 60 m 80m 100m 120m
13. 80 85 90 75 80 85 90 75 80 85 90 11 Inter unit cable RF Cable Data Cable 12 Communication parameters Baud rate 19200 bps Parity None Data bits 8 Stop bits 1 Flow control None 13 Temperature characteristics 0 40 C 32 104 F Operating Storage 20 70 4 158 F RG 58 1 8 meters 6 feet long BNC male at both ends 1 8 meters long 37 pin D Sub connectors at both ends 2 Appearance and Function 2 1 Control Unit MS950A E shown Front H L I IL PE I L 1 POWER ON lamp 5 RF OUT connector 2 Sealing counter 6 Data cable connector 3 Power switch 7 Remote control connector 4 AC inlet 8 Heatsink Figure 2 1 Control Unit The control unit contains power supplies RF generator boards and control circuit board Each power supply unit supplies 12 volts DC current to each RF generator board that generates 40 68 MHz RF power RF powers go to the segmentation unit through coaxial cables in the inter unit cable assembly The power switch 9 is located on the rear panel When it is turned on the POWER ON lamp lights The power switch module contains recoverable circuit breaker that trips off when an over current condition occurs in the system There is no other control on the control unit Connect
14. DB ATTENUATOR 1885 DUMMY LOAD Figure 5 3 RF Test Set up SEALING HEAD GUN 1 Set up test equipment according to the Figure 5 3 2 Set DC power supply at 12 volts Be sure to set a current limit of the power supply at 20 amperes CAUTION Failure to set current limiter may cause RF transistors blown up 3 If following tests to be done with RF board assembly taken out from its original location prepare sufficient heat sinks and a cooling fan to avoid excess temperature rise at transistors and transformers on RF board 4 5 6 7 8 CAUTION Minimum heat dissipation gears to be prepared shall be 100 watts Failure to prepare sufficient heatsink for RF board assembly may cause the RF transistors blown up Set RF power meter attenuator and spectrum analyzer at proper ranges to check 40 68 MHz power of 150 watts maximum Turn on sealer power switch Every time when you need to measure any characteristics of RF circuit from following paragraph 7 push trigger lever at sealing head or make short circuit at control board between P2 pin4 and ground to trigger RF generation CAUTION NEVER supply continuous power for more than ten seconds unless sufficient heatsink is prepared Watch power meter and spectrum analyzer You should have more than 90 watts when a 50 ohm dummy load is connected at 40 68 MHz If you would have no oscillation turn transformer T1 slowly until osc
15. MOTE SUITCH MODE SHITCH TxD _ Remote CIRCUIT CONF IRM REMOTE TRIGGER TRIG START SW DESKTOP COMPUTER REMOTE COMMAND MODE SERIAL PORT Figure 5 2 Remote Control Scheme The diagram is a conceptual drawing to give users technical understanding concerning interfaces between the machine and the fixture to be designed Users shall prepare the fixtures in accordance with own specific needs and application a Fixture for remote switch mode A fixture for remote switch mode is simple to make It requires a single pole single throw SPST switch e g a foot switch and a 9 pin D Sub male connector 1 Solder the switch at Pin 9 and Pin 5 of the 9 pin D Sub connector 2 Solder to make short between Pin 4 and Pin 5 of the 9 pin D Sub connector b Fixture for remote circuit mode A fixture for remote circuit mode will be a circuit board and needs an external DC power source With this fixture the ground of the fixture can be isolated with the ground of the Segmentation System 1 To turn on the opto coupler chip in the machine 5 10 mA DC current should be supplied between pin 7 and pin 8 of the 9 pin D Sub connector Suggested serial resistance shall vary depending on power source voltage Source voltage 5 VDC 12 VDC 24 VDC Resistance 300 560 ohm 1 1 8 Kohm 2 3 9 Kohm 2 A confirmation signal is gi
16. SERVICE MANUAL SEGMENTATION SYSTEM Model MS930A MS930E MS940A MS940E MS950A MS950E MS960A MS960E MS970A MS970E Centron Technologies Corporation SERVICE MANUAL SEGMENTATION SYSTEM Model MS930A MS930E MS940A MS940E MS950A MS950E MS960A MS960E MS970A MS970E No CAT MS950SM1 1Ee ISSUE 2 DEC 2005 Centron Technologies Corporation 319 25 Sadang 4 dong Dongjak ku Seoul 156 823 KOREA Tel 82 2 522 7807 Fax 82 2 522 7806 Website www centrons com Important Notes WARNING Do not open the covers Risk of electric shock exists Warranty may be voided if the covers are opened WARNING Do not operate this machine in close proximity to any person with a pacemaker or to any sensitive electronic apparatus The recommended minimum safety distance is 12 feet 3 6 m 1 Safety notices This machine generates high level power of 40 68 MHz radio frequency RF Users are requested to be cautious of potential electric shock or hazard e Do not operate the machine without the protectors on the sealing heads e Do not insert fingers into a sealing head e Always turn the power switch off before cleaning the machine e Only authorized and trained personnel should remove covers 2 Installation Nominal AC mains voltage of the models MS930A 970A is 100 120 volts 50 60Hz and operational voltage range is 90 132 volts Nominal AC mains voltage of the models MS930E 970E is 200 240 volts 50 60Hz and
17. bd Trigger bd in Sealing head unit Figure 5 1 Troubleshooting Flow Chart Page 2 3 12 U present at Pin 2 EN of connectors 61 68 Depress trigger lever at 1 Head and check P12 pin31 on Control Bd Is it logic LOW In 1 Sealing head unit replace Trigger board or replace Suitch board Do all sealing heads move Check replace bad solenoid Or replace Trigger board or Suitch board If still bad replace Control board Connect 59ohm dummy load at each connector at back of Control unit Measure tin SE Is RF output normal Check and adjust RF board Replace RF board or replace Filter board Measure RF pouer again NO Is RF output normal Check RF route connection in bad Sealing head unit Or replace Filter board Figure 5 1 Troubleshooting Flow Chart Page 3 3 5 4 Adjustment of Variables On the control circuit board in the control unit are two 8 bit DIP switch selectors marked as SW1 and SW2 With these selectors users can change working sealing head units time interval of head starts operation sequence of sealing heads and timing of sealing head returns 1 Selection of working heads SW2 is 8 bit DIP switch Each bit corresponds to each sealing head unit Down position is ENABLE and up position is DISABLE Setting of each bit switch has to be matched with number of sealing head units used For example when 1
18. ble 7 sealing head unit default G 0 Disable 7 sealing head unit 55 1 Start sealing Note 1 All commands should be input with capital letters Note 2 Enable Disable selector switch should be set at ENABLE position in order that sealing head enable disable control commands can work When the selector switch is set at DISABLE position the sealing head unit remains in disabled condition and will not be enabled even if an enable command is given Note 3 Another way to reset system mode to local is turning system power switch off and then on again as power on default mode is local mode b Status Code List to indicate system operation Code Occurrence M 1 X When system mode is changed to remote command mode 0 When system mode is returned to local mode When 1 sealing head unit is disabled A When 1 sealing head unit is enabled 2 When 1 sealing head unit has made incomplete sealing 0 When 2 sealing head unit is disabled B 1k When 2 sealing head unit is enabled 2 When 2 sealing head unit has made incomplete sealing C 0 When 3 sealing head unit is disabled SC Pk When 3 sealing head unit is enabled 2 When 3 sealing head unit has made incomplete sealing 0 0 When 4 sealing head unit is disabled D 1 When 4 sealing head unit is enabled 0 2 When 4 sealing head unit ha
19. de Control 5 6 Adjustment of RF 5 7 Cleaning Sealing Head ii 3 3 3 4 3 5 3 5 3 6 3 6 4 4 4 4 4 4 4 4 4 4 5 1 5 1 5 2 5 3 5 7 5 11 5 13 page 6 Schematic Diagram 6 1 7 Technical Illustration 7 1 8 Parts List 8 1 Figure 1 1 Figure 2 1 Figure 2 2 Figure 3 1 Figure 3 2 Figure 3 3 Figure 5 1 Figure 5 2 Figure 5 3 Figure 6 1 Figure 7 1 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Figure 7 6 Figure 7 7 Figure 7 8 Figure 7 9 Figure 7 10 List of Figures Segmentation system MS950 Control unit Segmentation unit Overall system block diagram RF board functional block diagram Sealing head unit functional block diagram Troubleshooting flow chart Remote control scheme RF test set up System wiring diagram Exploded view of MS950 Control unit Exploded view of MS950 Segmentation unit Control board layout I O board layout RF board layout Power distribution board layout Distribution board layout Trigger board layout Matching board layout Switch board layout Filter board layout iii 2 2 4 3 2 3 4 3 5 5 4 5 9 5 11 6 2 7 2 7 3 7 4 7 5 7 7 7 8 7 9 7 9 7 9 7 9 1 Introduction 1 1 General This Service Manual covers all technical information of Segmentation Systems MS930A E MS970A E for servicing and maintenance of the machines The model numbers of Segmentation System denote the number of sealing
20. head and the voltage range of AC main Model number Number of sealing head AC mains voltage MS930A 3 100 120 VAC MS930E 3 200 240 VAC MS940A 4 100 120 VAC MS940E 4 200 240 VAC MS950A 5 100 120 VAC MS950E 5 200 240 VAC MS960A 6 100 120 VAC MS960E 6 200 240 VAC MS970A 7 100 120 VAC MS970E 7 200 240 VAC This manual contains Introduction Appearance and Function System Description Standard Operating Procedure Troubleshooting and Adjustment Schematic Diagram Technical Illustration Parts List GO SA Dir hoe is The Segmentation Systems are precision electronic equipment Troubleshooting and repair must be carried by authorized service personnel Control unit Segmentation unit Figure 1 1 Segmentation System MS950 1 2 Feature The Segmentation System is a device to make multiple number of seals segments of thermoplastic tubing in a few seconds The machine generates high level power of 40 68 MHz radio frequency signal for a melting process called dielectric heating Tubing in the sealing heads melts quickly in about two to three seconds and then cools to form seals The Segmentation System consists of a control unit a segmentation unit and an inter unit cable assembly The segmentation unit can be installed up to 1 5 meters away from the control unit The system operates in one of four operation modes local remote switch remote circuit and re
21. hen makes control circuit be ready to accept a remote start command to be given by a remote start switch a remote start circuit or a remote control computer only when it detects tubing has been loaded in 1 sealing head ENABLE DISABLE selector switch is prepared on the rear panel of each sealing head unit If the selector switch is selected at DISABLE the sealing head unit does not work even if an ENABLE command is given in remote command mode On each sealing head units are two LED indication lamps The green READY lamp is turned on when the ENABLE DISABLE selector is set at ENABLE position The red SEALING lamp is turned on only while sealing is being done Both lamps will be off if the ENABLE DISABLE selector switch is set at DISABLE position When tubing melts two parts of sealing head come close hence the limit switch in the sealing head is depressed This signal from limit switch goes to control board and turns RF power generation of the sealing head unit off 3 10 Switch Board An ENABLE DISABLE selector switch is prepared on the switch board If the selector switch is set at DISABLE the sealing head unit does not work even if an ENABLE command is given in remote command mode 3 11 Trigger Board The Trigger board is mounted on sealing head structure in the sealing head unit The board houses a trigger micro switch and two LED indication lamps that display either READY or SEAL status 3 12 Matching Board The Matching board
22. ile File extension will be trm When the file is called by clicking File Open you will have same settings as before 5 Maintenance and Troubleshooting This Chapter describes how to check adjust and troubleshoot the machine with proper test equipment Troubleshooting flow chart leads service personnel to a faulty assembly or to one or a few suspicious components When a faulty assembly or component is isolated it would be adjusted in accordance with the procedures in this chapter or be replaced with a good one Followings are the topics covered in this chapter Precautions for troubleshooting Test equipment necessary Troubleshooting flow charts Adjustments of major characteristics Cleaning of sealing head section 5 1 Precaution When performing troubleshooting keep following general precaution Use proper test equipment and tools careful enough not to touch any AC main line Set a current limit at DC power supply to protect RF power transistor Prepare sufficient heatsink for RF board to avoid temperature increase When replacing a component use proper rated component careful not to touch RF circuits and electrodes with your finger when RF is being generated You may be shocked and burnt CAUTION Dangerous high voltage over a hundred volts may exist at RF circuits while RF is turned on Finger may be burnt by induction heating if it s placed between two electrodes of
23. illation starts Set T1 at mid point of the adjustable ranges where you have oscillation Read power meter Be sure to read effective power when a sealing gun unit is connected as RF load Effective power is calculated as forward power reverse power NOTE Watch the ammeter to read supply current Normal current will be less than 15 when a dummy load is connected When a sealing head is connected maximum current could be as high as 18 amperes 9 If RF board would not function properly really there is not much thing to do What you can do on the board is a Justexamine the board by eyes to find any part is burnt or badly soldered b Adjust transformer T1 as para 7 above to get stable oscillation c Touch to alter shapes of the coil L2 and L4 to change power level a little 10 Turn powers off and disconnect test equipment 5 7 Cleaning Sealing Head Sealing head area and the trigger lever can easily be stained by dust spilled or leaked blood or blood components Frequent cleaning will offer users the best long term results Never put sharp objects or metal objects on sealing head electrodes as they can easily be marred For proper cleaning use a dry cloth or a cloth dampened with water A mild detergent may be used Do not use paint thinner benzene solvent or any strong detergent Thoroughly dry sealing head area before applying power If any sealing head is wet when RF energy is applied an arc may a
24. ions with the segmentation unit are made from rear panel An end of each cable in inter unit cable assembly is plugged at RF OUT connectors and data cable connector Remote control connector is used only when the machine is operating in remote mode A cycle of sealing process starts by a signal from the segmentation unit given through the inter unit cable or by a signal from a remote control device connected at the remote control connector The control unit feeds RF powers to all sealing head units for a determined period of time as well as it controls movement of each sealing head The sealing counter counts up by 1 at each one cycle of sealing process Upon receiving start signal the sealing heads start not at same time but one by one in series Time interval between start of one sealing head and start of the next sealing head can be selected between 60 160 milliseconds with 20 milliseconds step Operation sequence of sealing heads can be also selected to start them from the right head to the left head or from the left head to the right head Return timing of sealing heads can be selected too Each sealing head can be returned individually at the moment when sealing ends at that sealing head unit or all sealing heads can be returned simultaneously when the last working sealing head ends its job Each sealing head can be enabled or disabled individually by switches on the control circuit board as well as by software command if the
25. is connected onto the remote control connector through an RS 232C serial communication cable operation mode of the machine is changed from local mode to remote command mode by software command from the microprocessor circuit or the PC In remote command mode the machine is controlled by software command only Sealing starts by start command only when the trigger lever at 1 head is depressed by tubing If tubing is not loaded in 1 unit sealing does not start Trigger lever at 1 head senses presence of tubing then enables circuit to accept the start command only when tubing has been loaded in 1 sealing head unit When sealing has ended confirmation commands are given to the external control computer a Command List to control the system Command Function M 1 X Change system mode from local to remote command mode 0 Change system mode from remote command to local default 1 Enable 1 sealing head unit default 0 Disable 1 sealing head unit B 1 Enable 2 sealing head unit default 0 Disable 2 sealing head unit C 1K Enable 3 sealing head unit default 0 Disable 3 sealing head unit D 1 Enable 4 sealing head unit default D 0 gt k Disable 4 sealing head unit E 1 Enable 5 sealing head unit default 0 Disable 5 sealing head unit F 1 Enable 6 sealing head unit default 0 Disable 6 sealing head unit G 1 Ena
26. it Mode Remote circuit mode is a mode that the machine is controlled by an external signal When a connector which should have been specially pre wired with a circuit is connected onto the remote control connector of the control unit the machine works in remote circuit mode In this mode sealing starts by giving a signal from the remote circuit Before the signal is given the trigger lever at 1 sealing head should have been pressed by tubing If tubing is not loaded in 1 sealing head sealing does not start The trigger lever at 1 head senses presence of tubing and then enables circuit to accept command given by the remote circuit only when tubing has been loaded in 1 sealing head unit All the other trigger levers do not work at all In remote circuit mode a confirmation signal is given to the remote circuit to confirm that the sealing cycle has ended If an indication lamp is prepared in the remote circuit the lamp will act as followings It is turned on when a sealing cycle ends that means tubing can be taken out now It is turned off when tubing is loaded in 1 that means it s ready to start sealing This mode is useful to use the machine in an automated production line d Remote Command Mode Remote command mode is a mode that the machine is controlled by an external microprocessor circuit or a PC For this mode of operation a microprocessor circuit or a desktop PC is required When the microprocessor circuit or the PC
27. mote command modes The system works in local mode if no connector is connected to the remote control connector on the rear panel of control unit Either remote switch mode or remote circuit mode is selected when a specially made remote control connector is put on the 9 pin D sub connector on the rear panel of control unit Remote command mode is selected by software commands from an external computer circuit or a personal computer connected to the 9 pin D sub connector on the rear panel of control unit with RS 232C serial communication The system has versatile features as the followings The machine can be operated stand alone or be controlled by a circuit or a PC The control unit can be placed under the table It saves bench space Distance between sealing heads is adjustable to one of 75 80 85 90 mm Each sealing head can be enabled or disabled individually by switches or by PC Time interval of sealing head starts is selectable between 60 160 milliseconds Operation sequence of sealing heads is selectable right to left or left to right Timing of sealing head returns is selectable simultaneously or individually Thickness of seals can be adjusted Indication lamp blinks and buzzer beeps in case of improper operation The event counter on rear panel counts number of sealing cycles done 1 3 1 2 3 4 5 6 8 Specification System configuration Operation modes Operation frequency Overall sealing
28. ontrol mode The microprocessor generates all timings to turn each RF board on and off and to make each solenoid work Working timing and sequence of each sealing head unit are adjustable at switches SW1 and SW2 on the control board VO Board board has EMI filters on each signal lines and two opto couplers for isolation of remote control fixtures Power Distribution Board This board distributes AC mains to eight identical channels It has a buzzer on the board Power Supply Unit Power supply units are switching mode power supplies Each unit takes either 200 240 VAC or 100 120 VAC as input and provides regulated voltage of 12 VDC as output The power supply units in an A suffix model take 100 120 VAC only and the ones in an E suffix model take 200 240 VAC only Filter Board Filter board has RF filters to decrease high order harmonic frequency components 3 7 Board RF board comprises an oscillator drive amplifier stages and power amplifier and filter networks Figure 3 2 represents the functional block diagram of RF board DRIVE AMPLIFIER POWER AMPLIFIER OSCILLATOR HARMONIC T FILTER 120 gt FILTER QU BOARD FROM TRIGGER SUPPLY FILTER UNIT TRIGGER RF CONTROL 12U 120 TO CONTROL BOARD Figure 3 2 RF board Functional Block Diagram A crystal oscillator generates stable RF signal when control command is applied The signal i
29. ors should be placed securely all the time with protector screws 0 Risk of electric shocks at the sealing head may exist if the protector is removed Behind the head protector are sealing head section and the trigger lever Pressing the trigger lever initiates a cycle of sealing process The moving part of sealing head comes out to squeeze tubing and then RF power is applied Tubing melts in second After tubing melted and hardened again the moving head retreats automatically 3 System Description 3 1 General The Segmentation System consists of the control unit the segmentation unit and an inter unit cable assembly The control unit contains one control circuit board and 3 7 pieces of power supply and RF board depending on the model E g MS950A E has 5 power supplies and RF boards The segmentation unit has same number of sealing head unit and a signal distribution board in the base plate All sealing head units are identical in configuration but only the trigger lever in the sealing head unit mounted at 1 position works The inter unit cable assembly is a bundle of data cable and RF coaxial cables Refer to Figure 3 1 to find overall system configuration The control board in control unit contains all logic circuits and timing gates It receives trigger command signal from 1 sealing head unit and controls overall function of this equipment RF board assemblies locate in control unit which are high power RF oscilla
30. ppear Follow the decontamination procedure of your facility when a blood spill occurs Avoid spraying liquids on the sealing heads Refer to the procedures below 1 Turn off the power switch 2 Remove the protector screws and the head protectors 3 Clean sealing heads and trigger levers carefully as described above 4 Dry sealing heads thoroughly 5 Reassemble the protectors and protector screws 6 If you have used water detergent or decontamination liquid wait for a few minutes to allow for thorough drying 7 Turn on the power switch and test the machine 6 Schematic Diagram Figure 6 1 System wiring diagram IM SU 3495 5 LINA SEE LIM 01 d 2I 0 2499 H S LINN 44 I 5 IMOd A IM SU 3005 bi LINN JU LINA 1 8 AlddNS 33109 Fa LINO QU3H 01 936 m pol 1 SU 34951 ET en LINN o s zoas 2 01 096 QU3H 01 Or LINN JH Per dans B3rod 3 A gt zum 15 14 SU E 49 kina ayan 236 21 0045 H Z LINN du 3 D Z Cr8 009 188 281 5 1 150 201 8 o 1 60 0 Of II LINO QU3H 01 O 9 9 100 MI 53 du Lr US OR TH LINO JH ELI En za coin bee I
31. s amplified at drive amplifiers then fed to power amplifier stage It works only when control command is applied A strong RF push pull power amplifiers amplify RF power The power is then supplied to sealing head through filters and impedance transformer Harmonic filter networks filter harmonic spurious frequency components With the filter networks harmonic frequency spectrum other than 40 680 MHz are all reduced to below sufficient level 3 8 Distribution Board Command data and solenoid powers are distributed to eight identical channels 1 channel only has the trigger command line 3 9 Sealing Head Unit Sealing head unit comprises sealing electrode solenoid trigger board assembly trigger micro switch limit micro switch matching board and switch board Figure 3 3 represents the functional block diagram of sealing head unit RF IN FROM MATCHING CONTROL BOARD UNIT SEALING LIMIT ELECTRODE p SU SOLENOID MEE v RERDY C Lane SERL ING HERD oy SEAL FROM TO ASSEMBLY LAMP CONTROL UNIT TRIGGER gt TRIGGER LIMIT 3 SWITCH EI 12U gt QU BOARD ENABLE DISABLE SOLENOID SELECTOR SW CONTROL Figure 3 3 Sealing head Unit Functional Block Diagram The trigger lever in 1 sealing head unit has two features In local mode of operation a cycle of sealing starts when it is depressed In any one of three remote modes it senses presence of tubing in 1 sealing head unit t
32. s made incomplete sealing 0 When 5 sealing head unit is disabled 1 When 5 sealing head unit is enabled 2 When 5 sealing head unit has made incomplete sealing 0 When 6 sealing head unit is disabled F 1 When 6 sealing head unit is enabled 2 When 6 sealing head unit has made incomplete sealing G 0 k When 77 sealing head unit is disabled G 1 When 7 sealing head unit is enabled G 2 When 7 sealing head unit has made incomplete sealing 55 1 When sealing starts 5 0 When sealing ends 1 When tubing is loaded in 1 head so system is ready to start sealing R 0 When tubing is removed from sealing head unit Note 1 At the moment when the power switch is turned on the status codes 1 through 1 are given once Note 2 The control command 5 1 works only after the status code R 1 gt has been received 4 2 Operation in Local Mode 1 Install the machine 2 If a connector or a cable is connected to the remote control connector on the rear panel of control unit remove it 3 Turn on the power switch 4 Place tubing in sealing heads from the left to the right and press the trigger lever in 1 sealing head 5 When all green indication lamps are lit remove tubing 4 3 Operation in Remote Switch Mode 1 Install the machine 2 Connect a remote switch fixture to the remote control connector 3 Turn on the power switch 4 Place tubing in
33. sealing head or near RF transistors and transformers 5 2 Test Equipment Test equipment and tools listed below are necessary to do troubleshooting 1 Minimum test equipment and tools for troubleshooting Multimeter Regulated DC power supply 12 volts 20 amperes Oscilloscope 10 MHz Frequency counter 100 MHz RF power meter 100 MHz 200 Watts Screwdrivers cross tips flat tips 2 More test equipment necessary for complete troubleshooting DC Ammeter 20 amperes Regulated DC power supply 12 V 20 A with current limiting feature Oscilloscope 100 MHz dual trace Spectrum analyzer 300 MHz Network analyzer S parameters Impedance curve display feature RF power meter 200 Watts forward reverse effective powers RF dummy load 50 ohm 100 W RF attenuator 60 DB Coaxial cables RG 58 BNC male BNC male 5 3 Troubleshooting Procedure The troubleshooting flow charts in Figure 5 1 will guide service personnel to a faulty assembly or components that should be replaced or corrected When a faulty assembly is isolated it will be adjusted to correct state or be replaced with a new good assembly In case that service people have good knowledge in electronics proper test equipment and components they can troubleshoot to a single faulty component All technical documentation necessary for adjustments and troubleshooting are prepared in the Chapters 6 7 and 8 Legend of Troubleshooting Flow Chart Sq
34. sealing heads The 1 trigger lever should be depressed 5 Activate the switch in the fixture 6 When all green indication lamps are lit remove tubing 4 4 Operation in Remote Circuit Mode 1 Install the machine 2 Connect a remote circuit fixture to the remote control connector 3 Turn on the power switch 4 Place tubing in sealing heads The 1 trigger lever should be depressed 5 Let DC current flow between pin 7 pin 8 by circuits or by activating a switch 6 When all green indication lamps are lit remove tubing 7 If required use the confirmation signal at pin 1 4 5 Operation in Remote Command Mode If users would design specific remote control fixtures various applications would be available with this mode But the simplest way could be to use a personal computer as a remote controller And available ready made communication programs are the files terminal exe and hypertrm exe given by Microsoft with operating systems Windows 3 1 95 98 2000 ME Terminal exe in Windows 3 1 is better and more convenient to use for remote control of the machine As a demonstration of an application described below are operation procedures with using the program file terminal exe in a PC with Windows operating system 1 Install the machine 2 Connect a standard serial communication cable to the remote control connector and to the PC 3 Turn on the computer and run the file terminal exe 4 On menu bar click Settings
35. t is displayed 11 Repeat sealing from paragraph 8 to 10 Note 1 The Enable Disable selector switch on each sealing head unit should be set at ENABLE position in order that sealing head enable disable control commands can work Selection at Enable Disable selector switch has priority over enable disable control command When the selector is set at DISABLE position a command A 1 E 1 gt cannot turn the sealing head unit into enabled condition When the selector is set at ENABLE position a command 5 0 0 can turn the sealing head unit into disabled condition and then a command A 1 k 1 can turn the sealing head unit into enabled condition again Note 2 The command M 0 changes system mode from remote command mode to local mode Another way to change system mode to local is turning system power switch off and then on again as power on default mode is local mode Note 3 To enter the command SS 1 to start sealing you should hit 5 keys every time It is not an easy job to repeat 5 keys every time To do it simple you can save the command in a Function key in the program On menu bar click Settings Function Keys In Function Keys dialog box you can set up to 8 function keys and then only one stroke inputs a command once Note 4 You can save the settings you have used in a configuration file to use later On menu bar click File Save In File Save As dialog box give a name for your f
36. tor amplifiers generating RF power and sends RF power to all sealing head units through inter unit cable assembly Each sealing head unit consists of a solenoid sealing electrode matching board assembly trigger board assembly micro switches and a ENABLE DISABLE switch The ENABLE DISABLE selector switch is prepared on the rear panel of each sealing head unit If the selector switch is selected at DISABLE the sealing head unit does not work even if an ENABLE command is given in remote command mode Matching board assembly has an impedance transformer Trigger board assembly has a trigger micro switch and two indication lamps Following paragraphs describe theory and function of each assembly in detail AC MAIN INLET POWER SWITCH AC LINE FILTER POWER DISTRIBUTION BOARD POWER POWER POWER POWER POWER SUPPLY SUPPLY SUPPLY SUPPLY SUPPLY EE LEANER OTD CONTROL EIU BORRD CONTROL FIXTURE SEALING SEALING SEAL ING SEAL ING HEAD HEAD HEAD HEAD UNIT UNIT UNIT UNIT SEALING HEAD UNIT Figure 3 1 Overall System Block Diagram 3 2 3 3 3 4 3 5 3 6 Control Board Control board is a microprocessor based circuit and has eight identical channels of control circuitry The board is powered by 1 power supply unit Sealing operation starts by a trigger signal either come from the trigger switch in 1 sealing head unit or given by command at a remote c
37. uare Action Diamond Decision A Circle 2222 Connection to from other branch Vertical line YES path Horiz line NO path Set all suitches back panels of Sealing head units to ENABLE Turn Pouer Suitch e POWER lamp and all READY lamps turned on YES Make a feu seals uith tubing Are all seals made 0 XC YES Are shapes of seals good Clean sealing head area and make seals again Adjust thickness adjustment screu and make seals again Are shapes good nou NO a pt Connect remote control fixture to check it NO oes it uork good YES N Turn Pouer Suitch OFF Replace Control board N END Figure 5 1 Troubleshooting Flow Chart Page 1 3 Check AC voltages at Power Dist Bd Ld _ Are AC voltages __ measured on the board 2 Replace Pouer Dist Board Or replace RC Line Filter Or replace RC Inlet module YES Check 12U at output terminal of each Pouer Supply Unit y ars gt Are 12UDC measured lt _ at all 5 Units Replace the bad P S Unit Do 12 U present a P12 pin 47678718713 on Control bd YES Check continuity of Interunit cable Are all READY lamps turned on Replace Control board Check Dist Bd in Segmen Unit N Replace Distribution Bd YES Replace Suitch
38. ven between pin 1 collector and pin 6 emitter of the photo transistor in opto coupler chip Suggested serial resistance shall vary depending on power source voltage A same resistor as above can be used 3 Solder to make short between Pin 4 and Pin 5 at 9 pin D Sub connector c Fixture for remote command mode For operation in remote command mode a fixture may or may not be necessary If users want to design a specific fixture for use in an automated production line refer to Command List and Status Code List All commands and status codes should be given in ASCII code format If users want to use a desktop personal computer as a remote controller no fixture but a communication program is necessary Users may design a communication program for own use But it will be a convenient way to use an open program provided by the Microsoft The file terminal exe in Windows 3 1 or hypertrm exe in Windows 95 98 2000 ME is a communication program good to use for this purpose Communication parameters should be set as the followings Baud 19200 Data bits 8 Stop bits 1 Parity None Flow control None 5 6 Adjustment of RF Following procedures describe standard check procedures for the RF circuitry Refer to Figure 5 3 below for test set up and schematic diagrams and board layout diagrams in Chapter 7 DC POWER SUPPLY 12U 20AMP SEALER OR RF BOARD UNDER TEST AMMETER SPECTRUM ANALYZER 60
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