USER MANUAL - KVL Comp Kft.
Contents
1. 14 4 4 Light and audible 15 4 5 Daily checks before 15 4 6 Errors which detected by the operator and 16 KVL PTLO5 PICK TO LIGHT CONTROL WITH ETHERNET NETWORK Read and Understand this Manual Please read and understand this manual before using the product Please consult your KVL COMP representative if you have any questions or comments I ABOUT THIS MANUAL This guide explains the installation and operation of the product Before installing and using the product read this guide carefully and be sure to understand its contents Also read and follow the safety information described in the next chapter The chapter titled Precautions contains general safety instructions of using the product and the related devices Chapter 1 Introduces the product and its structural units Chapter 2 Explains the structure of the product Chapter 3 Explains the installation of the product the wiring of the power supply and the I O lines and also the functional testing of the product Chapter 4 Explains the setup and operation of the product II RELATED GUIDES The following guides give information on the related devices You can find the necessary information in the following documents Title of Publication KVL1114 i CONTROL WITH ETHERNET2. External USB storage can be connected to the USB connector It can be used for program saving prog ram update Because the connector is used periodically ti avoid contramination after use please put back the cover CHAPTER 3 INSTALLATION AND WIRING 3 1 INSTALLING THE CONTROLLER AT THE WORKPLACE The control cabinet is mounted to a steel structure The cabinet is fixed to posts on its sides using screws 1 The controller should be mounted to a position where the worker can easily read and operate the display unit 2 The worker scans the barcode from the printed worksheet 4 using the cordless barcode reader 3 The wired barcode reader 5 on the left side of the control cabinet is used as backup in emergency strategy The operation of the controller can be tracked on the display and on the signal tower 6 located at the top of the control cabinet Errors can be acknowledged using the E7 key switch 7 on the right of the control cabinet PICK TO LIGHT CONTROL WITH ETHERNET NETWORK 3 2 CONNECTING TO MAINS AND ETHERNET NETWORK The mains socket and Ethernet socket are located on the back of the controller Ethernet socket On off switch Glass tube fuse 5 20 glass tube 230 V 2A SLOW Mains 230 V AC socket MAC address of the controller A For connecting to the mains circuit we recommend the type KVL POW cable Ensure that the controller is switched off when you connect the cable
3. A WARNING Risk of electric shock when using wrong or damaged mains connector cable A WARNING Risk of fire and human injury when using damaged repaired fuses or fuses not of the appropriate type For connecting to the Ethernet network we recommend the type KVL ETN cable KVL PTLO5 CHAPTER 4 SETUP AND OPERATION 4 1 SWITCHING ON THE CONTROLLER The device is switched on with the rocker switch located next to the power supplv connec tor After switching on the Windows operating svstem installed on the controller computer starts After the completion of the boot process of Windows the controller program is started au tomaticallv and its main screen is displaved work can be started After switching off the device alwavs wait at least 5 seconds before switching it on againl 10 PICK TO LIGHT CONTROL WITH ETHERNET NETWORK 4 2 CONTROLS Controls of the pick to light controller 1 TOUCHSCREEN The system is controlled by a computer equipped with touchcreen You can select language and configure settings The controller program is described in separate documentation 2 SIGNAL POST GREEN LAMP Lit if the worker successfully picked up all the necessary part 3 SIGNAL POST YELLOW LAMP In case of server error it lits with the red 4 one 4 SIGNAL POST RED LAMP In case of error it lits 5 SIGNAL POST AUDIBLE SIGNAL In case of control error and wrong pick up audible signal can be hearing
4. Liability 2 V PADDING ji ea CONS CE Ia ION ee ea nee een ee 2 VL Die Amer ee 3 Mill Preca ii to AS ee ee 3 CHAPTER L l 5 OVERVIE 5 1 1 Short introduction of pokayoke SYSTEMS sess sseennnnzennnnzzznnnenzznnnenzznntnnzzanenenzznnnnnzzonnna 5 1 2 The location of the pick to light controller in the pokayoke 5 CHAPTER 6 TECEINICAL DATA ee ee o no oo 6 2 1 DIMENSION Sen ee ee ee 6 Aaa A A 7 2 3 O PP Aun 7 ZE SO SON LOL ee o ocioteca 8 CHAPTER ov 8 INSTALLATION AND WIRING na 8 3 1 Installing the controller at the workplace ss sse eeesnnnnnnnzennenenzentrenzznnnenzzznnenzzznenenzzna 8 3 2 Connecting to mains and Ethernet network oooccccocnccnncnnccnnnnnacnnnnnncnnnonanonnnnnncnnnnnnoss 9 A 10 SETUP AND OPERATION Gent ee ae Teen 10 4 1 Switching on the 10 AA CON TOS sek 11 4 3 Devices attached to the controller via as ibDUS ooccccccccccoonoonccnnnnnnnononanncnnnnnnnononanonenoss 13 4 3 1 Light curtains KVL PICKOO6 cccoocccnccnnccnnonononnnnnaconnonanonnonanonononaronnonanonnnnnnonnnonos 13 4 3 2 One digit number display KVL KENNO3 ccccccesscceceesececeesecceeeeseceseeeeceeeenes 14 4 3 3 Acknowledgement module with AS I controller 7
5. part should be installed The display is built with long life high brightness LEDs providing clear visibility even from a dis tance Acknowledgement is performed by operating a pull switch The 2 m long pull string can be cut to the appropriate length The module is mounted to the suspended struc ture located above the large storage boxes PICK TO LIGHT CONTROL WITH ETHERNET NETWORK 4 4 LIGHT AND AUDIBLE SIGNS z NO AUDIBLE OR VISIBLE SIGNALS Indicates normal operation z THE GREEN LIGHT IS ON NO AUDIBLE SIGNALS The device completed the production cycle and sends an IO signal to the SPS z THE RED LIGHT IS ON An error occurred during the cycle The device shows the error on the display and saves the error message to the database and log files z THE YELLOW AND THE RED LIGHTS ARE ON Communication error occurred The device shows the error on the display and saves the error message to the database and log files z THE DEVICE GIVES AN AUDIBLE SIGNAL The error types and their associated audible signals are configurable in the pro gram The default is 1 second 4 5 DAILY CHECKS BEFORE WORK Daily routine check of control cabinet Cabinet door is closed Proper ventilation and protection of the inner parts are only provided with closed cabinet door Touching the inner parts can cause electric shock Via the open door dust can penetrate the cabinet The accumulating dust de creases cooling efficiency and leads t
6. 6 ACKNOWLEDGING ERRORS Errors are acknowledged using the E7 key switch on the side panel of the controller 7 WIRELESS BARCODE READER The worker scans the sheet of paper with this device 8 BARCODE READER RESERVE In case of the cordless barcode reader is malfunctioning use this device to scan barcodes from worksheets Notstrategy 11 KVL PTLO5 A 7 pt y r AE a y AL 9 SEQUENCE DISPLAVS The worker places the parts picked from storage in a given order on the figure the grey boxes in red frame the boxes are numbered from 1 to 6 Displays located above the storage units 9A and on the shelf 9B indicate the box the worker should place the picked part in 10 LIGHT CURTAINS The lamps on the front panel of the light curtain instruct the worker to pick a given part The light curtain automatically performs acknowledgement using its sensors d a hs a A 8 Eu 7 S Ry a Ta 12 PICK TO LIGHT CONTROL WITH ETHERNET NETWORK 11 ACKNOWLEDGEMENT MODULE WITH AS I CONTROLLER Devices located above the large storage boxes Indicates which part should be picked by the worker 11A Acknowledgement is performed by operating a pull switch 11B 4 3 DEVICES ATTACHED TO THE CONTROLLER VIA AS I BUS The devices indicating and acknowledging the picking of parts are connected to an AS I network 4 3 1 Light curtains KVL PICKO06 13 KVL PTLO5 14 The light
7. KVL1113 EN 02 KVL PTLOS PICK TO LIGHT CONTROL WITH ETHERNET NETWORK USER MANUAL KVL PTLOS USER MANUAL PICK TO LIGHT CONTROL WITH ETHERNET NETWORK Notice The following conventions are used to indicate and classify precautions in this manual Always heed the information provided with them Failure to heed precautions can result in injury to people or damage to property A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Additionally there may be severe prop erty damage A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Additionally there may be severe prop erty damage A CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or property damage Trademarks Windows is a registered trademark of Microsoft Corporation in the United States and oth er countries The other brand and product names are trademarks or registered trademarks of their re spective owners Introduction We design and manufacture our devices with the feedback from the enterprises of the in dustry and their specific needs in mind Our pokayoke systems elaborated this way are robust and due to the sophisticated solutions applied in them they provide a long main tenance free lifecycle These devices are recommended for those firms where one of the fol
8. NET MAINTENANCE MANUAL KVL1153 PROGRAMMABLE LIGHT CURTAINS DATASHEET KVL1307 DISPLAY WITH AS I CONTROL DATASHEET KVL1155 an MODULE WITH AS I CON DATASHEET KVL1001 POWER CABLE DATASHEET KVL1002 ETHERNET PATCH CABLE DATASHEET HI PUBLICATION HISTORY The number of the publication is also indicated on the cover of the publication NUMBER OF PUBLICATION KVL1113 EN 02 Date of Publication No of Publication 09 2010 KVL1113 EN 01 Istedition 01 2011 KVL1113 EN 02 Hardware modification KVL PTLO5 IV WARRANTY AND LIMITATIONS OF LIABILITY WARRANTY KVL COMP s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year or other period if specified from date of sale by KVL COMP LIMITATIONS OF LIABILITY KVL COMP shall not be responsible for special indirect or consequential damages loss of profits or commercial loss in any way connected with the products whether such claim is based on contract warranty negligence or strict liability In no event shall the responsibility of KVL COMP for any act exceed the individual price of the product on which liability is asserted In no event shall KVL COMP be responsible for warranty repair or other claims regarding the products unless KVL COMP s analysis confirms that the products were properly han dled stored installed and maintained and not subject to contamination abuse misuse or inappropriate mod
9. OOTING In case of error an error screen appears on the screen describing the error 1 Manual data input incorrect data 9783119256 The errors can be acknowledged using the E7 key switch Exception errors related to the IO card and the AS i card these errors are fixed by the maintenance service 16 KVL COMP s r o Komensk ho 35 94301 Sturovo SLOVAKIA Tel 00 36 33 501 616 Fax 00 36 33 501 615 www kvicomp eu info kvlcomp eu KVL COMP Vez rl stechnikai Kft H 2500 Esztergom Nagy Sandor Jozsef utca 3 HUNGARY Tel 00 36 33 501 616 Fax 00 36 33 501 615 www kvicomp eu info kvlcomp eu
10. curtains are designed for 300mm 400mm and 600mm storage boxes The lamps on the front panel of the light curtain instruct the worker to pick a given part 1 If a part should be picked the indicator lights are green After picking the part ac knowledgement the lights turn red Acknowledgement is performed automatically The picking of a part is detected by dis tance measuring sensors located behind the front panel of the light curtain 2 The mea suring range can be set between 10 and 60 cm by computer program via USB connection see PTL Manager software description The distance between sensors is 7 8 cm providing reliable hand detection 4 3 2 One digit number display KVL KENNO3 If the worker prepares multiple parts of a unit in one run the KVL KENNO3 system shows on a digital display which unit of the queue the picked part is associated to This module is built with a large bright 7 digit display These display units are placed behind a red Plexiglas layer which provides better contrast The numbers are clearly vis ible even in extremely bright environments The displays are connected to AS I network The back panel of the display unit is equipped with two connectors the display module and the associated display pull switch ac knowledgement module KVL PICK007 can be connected to one AS I connection 4 3 3 Acknowledgement module with AS I controller KVL PICKOO7 During assembling a red green light indicates which
11. howed by the red light of AS I bus display acknowl edge lamps above the she fes Acknowledge of the component pick up for component storage bay happens with pull switch manually for shelfes happen manually or automati cally After acknowledgement the display s lamp is going to change to green The user manual describes the operation of PTL controllers according to the specific ap plication KVL PTLO5 CHAPTER 2 TECHNICAL DATA 2 1 DIMENSIONS The KVL PTLOS pick to light controller is installed in a metal plate case Dimensions of the controller box 600 380 350 mm Colour of the controller box Grev RAL 7032 2 2 ELECTRICAL DATA Supply voltage Current drain Operating range Operating temperature Operating humidity Storage temperature Storage humidity Mains circuit connection Fuse Recommended mains connector cable PICK TO LIGHT CONTROL WITH ETHERNET NETWORK 230 V AC 50 Hz 10A 100 240 V 48 62 Hz 5 40 C 20 90 RH non condensing 20 70 C 10 95 RH non condensing IEC standard connector with fuse and switch 5 20 glass tube 230 V 10 A SLOW KVL POW 2 3 ETHERNET NETWORK The controller can be connected to standard 10 100 Ethernet network The industrial Ethernet socket is of type VARIOSUB RJ45 The recommended Ethernet cable is of type KVL ETN KVL PTLO5 2 4 USB CONNECTOR The USB connector built in on one side of the control box VARIOSUB VS A F IP67
12. ification or repair V APPLICATION CONSIDERATIONS SUITABILITY FOR USE The following are some examples of applications for which particular attention must be given This is not intended to be an exhaustive list of all possible uses of the products nor is it intended to imply that the uses listed may be suitable for the products Outdoor use uses involving potential chemical contamination or electrical interfe rence or conditions or uses not described in this manual Installations subject to separate industry or government regulations Systems machines and equipment that could present a risk to life or property Please know and observe all prohibitions of use applicable to the products PROGRAMMABLE PRODUCTS KVL COMP shall not be responsible for the user s programming of a programmable prod uct or any consequence thereof PICK TO LIGHT CONTROL WITH ETHERNET NETWORK VI DISCLAIMERS CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons It is our practice to change model numbers when published ratings or features are changed or when significant construction changes are made However some specifica tions of the products may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult with your KVL COMP representative at any ti
13. installation wiring and setup of the KVL PTLO5 Ethernet network pickup controller and describes its operation The installation wiring and setup of the product must be accomplished by experienced professionals The description of operation provides information for the workers working with the pokayoke system 1 1 SHORT INTRODUCTION OF POKAYOKE SYSTEMS The meaning of the Japanese words Poka Yoke in free translation z Poka random unintentional error mistake fault Yoke elimination prevention Meaning mistake free error free work workstation technology process development in order to avoid human errors The aim of pokayoke is the full scale prevention of product defects waste avoidance minimization of quality control costs to provide error free working conditions and work To sum up pokayoke is a system that assists manufacturing and assembling that helps and simultaneously controls the workers Using pokayoke effectively improves waste avoidance The KVL PTLOS is part of the Ethernet network based pokayoke system developed by KVL COMP 1 2 THE LOCATION OF THE PICK TO LIGHT CONTROLLER IN THE POKAYOKE SYSTEM Its purpose is to eliminate the picking of wrong parts due to workers fault KVL PTLOS is an individual PICK TO LIGHT control it is not directly connected to the pro duction line It receives the manufactured components datas from the control computer KVL Server Pick up the necessary components s
14. lowing problems has emerged and would like to develop a solution Frequently occurring errors in production processes Products must be called back due to installing parts of wrong type High scrap costs caused by selecting wrong part Workers often forget to tighten the screws fixing the part Workers forget to install one or more parts and this mistake is noticed too late The pokayoke systems of KVL COMP aid the effective troubleshooting of these errors KVL COMP 2010 All rights reserved It is forbidden to reproduce or store this document or part of it in any data retrieval system or transfer it in any form in any way mechanically electronically photocopying recording or with any other technique without prior written permis sion from KVL COMP We do no take patent responsibility for the information disclosed here Also as KVL COMP is constantly striving to improve its high quality products the information included in this guide can change without notice During the creation of this guide we try to be as accurate as possible but KVL COMP does not take responsibility for the possible errors or omissions Also KVL COMP does not take any responsibility for the possible damages resulting from using this guide PICK TO LIGHT CONTROL WITH ETHERNET NETWORK CONTENTS About this Manual een 1 1 Related US cere ct se sted terme ee 1 PUDE GUON saucer anita asco ee ee 1 IV Warranty and Limitations of
15. me to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes even when tolerances are shown PERFORMANCE DATA Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty It may represent the result of KVL COMP s test conditions and the users must correlate it to actual application requirements ERRORS AND OMISSIONS The information in this manual has been carefully checked and is believed to be accurate however no responsibility is assumed for clerical typographical or proofreading errors or omissions Vil PRECAUTIONS This section provides general precautions for using the related devices The information contained in this section is important for the safe and reliable applica tion of product You must read this section and understand the information contained before attempting to set up or operate a product INTENDED AUDIENCE This manual is intended for the following personnel workers trained to the specific task working on the assembly stations and on the assembly line operating the device work group leaders professionals responsible for the installation setup and maintenance of the device KVL PTLO5 GENERAL PRECAUTIONS The user must operate the product according to the performance specifications described in the operatio
16. n manuals Before using the product under conditions which are not described in the manual or ap plving the product to other svstems machines and equipment that mav have a serious in fluence on lives and propertv if used improperlv consult vour KVL COMP representative Make sure that the ratings and performance characteristics of the product are sufficient for the svstems machines and equipment This manual provides information for setup and operating the product Be sure to read this manual before attempting to use the product and keep this manual close at hand for reference during operation AN WARNING It is extremelv important that a product be used for the specified purpose and under the specified conditions especiallv in applications that can directly or indirectly affect human life You must consult with your KVL COMP representative before applying a product to the above mentioned applications SAFETY PRECAUTIONS A CAUTION When power is ON or has just been turned OFF do not touch the power supply I O terminals or the surrounding areas A CAUTION Secure the AC power supply line to the terminal block with a 0 5N m of torgue Loosening the screw may result in a fire or malfunction APPLICATION PRECAUTIONS A CAUTION On modifying the program always ensure that switching to MONITOR or RUN mode does not lead to unexpected effects PICK TO LIGHT CONTROL WITH ETHERNET NETWORK CHAPTER 1 OVERVIEW This guide explains the
17. o a higher probability of failure Touchscreen heck the touch screen for damages If the touch screen is damaged immediately call maintenance service Check the touch screen is clean The touch screen can be cleaned using special wipe AS I Bus devices Check the correct mounting of devices Connectors The shelves are periodically moved for cleaning This makes necessary to discon nect some AS I connectors The affected connectors are marked with red and a warning message If the shelves were moved during cleanup check that the con nectors marked with red and warning messages are properly reconnected 15 KVL PTLO5 Barcode readers Both barcode readers should be operational Check the cordless reader is fully charged If the readers windows are dirty clean them using a soft cloth Never use solvents IF ANY DEVICE FAILED THE ABOVE CHECKS IMMEDIATELY CALL MAINTENANCE SERVICE IN WARNING In the following cases switch off the controlbox disconnect network cable and call a service technician immediately The network cable or its connector is damaged or worn Liquids penetrated the controlbox The controlbox was exposed to rain or other forms of water The controlbox fell or its case is damaged The operation of the controlbox is unstable or the controlbox is malfunc tioning The controlbox emits unusual noise smoke or unpleasant smell 4 6 ERRORS WHICH DETECTED BY THE OPERATOR AND TROUBLESH
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