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USER MANUAL - KVL Comp Kft.

1. windows are dirty clean them using a soft cloth Never use solvents If any device failed the above checks immediately call maintenance service A WARNING In the following cases switch off the control box disconnect network cable and call a service technician immediately The network cable or its connector is damaged or worn Liquids penetrated the control box The control box was exposed to rain or other forms of water The control box fell or its case is damaged The operation of the control box is unstable or the control box is malfunc tioning The control box emits unusual noise smoke or unpleasant smell 13 KVL COMP s r o SLOVAKIA Komensk ho 35 94301 St rovo SLOVAKIA Tel 00 36 33 501 616 Fax 00 36 33 501 615 www kvlcomp eu info kvlcomp eu KVL COMP Vez rl stechnikai Kft HUNGARY H 2500 Esztergom Nagy S ndor J zsef utca 3 HUNGARY Tel 00 36 33 501 616 Fax 00 36 33 501 615 www kvlcomp eu info kvicomp eu
2. Mains circuit connection IEC standard connector with fuse and switch Fuse 5 20 glass tube 230 V 10 A POWER SUPPLY SLOW KVL POWx en Recommended mains connector cable 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 2 4 USB CONNECTOR The USB connector built in on one side of the control box VARIOSUB VS A F IP67 External USB storage can be connected to the USB connector It can be used for program saving prog ram update Given that the connector is used periodically please put back the cover in order to avoid the accumulation of dust KVL TVPO1 CHAPTER 3 INSTALLATION AND WIRING 3 1 INSTALLING THE CONTROLLER AT THE WORKPLACE The control cabinet is positioned next to the assembly desk The device is fixed using the retainer plates found on its back On placing the controller it must be taken into consideration that the worker has to have a clear sight of the screen and must be able to operate the device The worker reads the barcode using the cordless barcode reader 3 The wired barcode reader 4 serves as backup for emergency strategy The operation of the controller can be tracked on the screen and on the light tower 5 lo cated on top of the control cabinet Errors are acknowledged using the E7 key switch 6 On pushing th
3. 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 1 0 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 PART IDENTIFICATION CONTROL BOX KVL1704 WITH ETHERNET NETWORK MAINTENANCE MANUAL KVL1001 POWER CABLE DATASHEET KVL1002 ETHERNET PATCH CABLE DATASHEET Ill PUBLICATION HISTORY The number of the publication is also indicated on the cover of the publication NUMBER OF PUBLICATION KVL1703 EN 01 Date of Publication No of Publication september 2010 KVL1703 EN 01 st Edition KVL TVPO1 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 p
4. KVL1703 EN 01 KVL TVPO1 PART IDENTIFICATION CONTROL BOX WITH ETHERNET NETWORK USER MANUAL KVL TVPO1 USER MANUAL PART IDENTIFICATION CONTROL BOX 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 property dam age A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Additionally there may be severe property dam age 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 other countries The other brand and product names are trademarks or registered trademarks of their respec tive owners Introduction We design and manufacture our devices with the feedback from the enterprises of the indus try 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 maintenance free lifecycle These devices are recommended for those firms whe
5. LE SIGNS NO AUDIBLE OR VISIBLE SIGNALS Indicates normal operation THE GREEN LIGHT IS ON NO AUDIBLE SIGNALS The device completed the production cycle and sends an IO signal to the SPS 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 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 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 PART IDENTIFICATION CONTROL BOX WITH ETHERNET NETWORK 4 4 DAILY CHECKS BEFORE WORK Daily routine check of control cabinet Cabinet door is closed Proper ventilation and protection of the inner parts are only provided with closed cabinet door Touching the inner parts can cause electric shock Via the open door dust can penetrate the cabinet The accumulating dust de creases cooling efficiency and leads to a higher probability of failure Touchscreen Check 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 Barcode readers Both barcode readers should be operational Check the cordless reader is fully charged If the readers
6. e green push button 7 the program skips to the next sequence PART IDENTIFICATION CONTROL BOX 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 oa ee 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 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 TVPO1 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 supply connec tor After switching on the Windows operating system installed on the controller computer starts After the completion of the boot process of Windows the controller program is started au tomatically and its main screen is displayed work can be started After switching off the device always wait at least 5 seconds before switching it on again 10 PART IDENTIFICATION CONTROL BOX WITH ETHERNET NETWORK 4 2 CONTROLS Controls of the pick to light contro
7. eriod of one year or other period if specified from date of sale by KVL COMP LIMITATIONS OF LIABILITY KVL COMP shall not be responsible for special indirect or consequential damages loss of profits or commercial loss in any way connected with the products whether such claim is based on contract warranty negligence or strict liability In no event shall the responsibility of KVL COMP for any act exceed the individual price of the product on which liability is asserted In no event shall KVL COMP be responsible for warranty repair or other claims regarding the products unless KVL COMP s analysis confirms that the products were properly han dled stored installed and maintained and not subject to contamination abuse misuse Or inappropriate modification or repair V APPLICATION CONSIDERATIONS SUITABILITY FOR USE The following are some examples of applications for 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 e Outdoor use uses involving potential chemical contamination or electrical interfe rence or conditions or uses not described in this manual e Installations subject to separate industry or government regulations e Systems machines and equipment that could present a risk to life or property Please know and observe all prohibitions of use applicable t
8. ity 2 V PADDING ATIOM CONS CE Wa ION inicios aio 2 VL DECINE sado anios 3 MU Pre caos ee 3 CHAPTER 5 V ise dice 5 1 1 Short introduction Of pokayoke SYSTEMS occcccoocccnconoccnncnnocnnonononnnonanonnonanonnnnononnnonanonoss 5 1 2 Place of the controller in pokayoke systeM oooccccccnccnnconocnnncnncnnnonanonnonononnnonaconnnnanonnos 5 CHAPTER Z 6 TECHNICAL DATA nee 6 2 1 DIME ION ee ee ee E EE EE E E 6 Pages APP ee 7 2 3 O A PP UE A un 7 2 VSB CONNEL LOL ee K oa ee 7 CTT Eo pusa ov 8 INSTALLATION AND WIRING au rain 8 3 1 Installing the controller at the workplace oooocccconocnnncnnnnnnonononnnonaronnnnnccnnonanonononanos 8 3 2 Connecting to Mains and Ethernet network oooccccocnccnncnnccnnnnnacnnnnnncnnnonanonnnnnncnnnnnnoss 9 CHAPTER A ee Non 10 SETUP AND OPERATION ee 10 4 1 Switching on the 10 CON TOS r ono ono 11 4 3 ISht and audible SINS rica 12 4 4 Daily checks before 13 PART IDENTIFICATION CONTROL BOX 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
9. ller AE AA 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 chapter 2 SIGNAL POST GREEN LAMP After a correct scan it flashes 3 SIGNAL POST YELLOW LAMP In case of server error it flashes with the red 4 one 4 SIGNAL POST RED LAMP In case of error it flashes 5 SIGNAL POST AUDIBLE SIGNAL It gives a short audible signal in case of control error and false part remove 6 ACKNOWLEDGING ERRORS Errors are acknowledged using the E7 key switch on the side panel of the controller 7 POWER ON LIGHT The white light labeled Power indicates the opera tional state of the controller the Windows system and the controller program are running 8 NEXT PART PUSHBUTTON Green mushroom shaped pushbutton labeled NEXT Pushing this button on completion of the work cycle instructs the controller to continue with the next sequence 11 KVL TVPO1 12 9 WIRELESS BARCODE READER The worker scans the sheet of paper with this device 10 BARCODE READER RESERVE In case the cordless barcode reader is malfunctioning use this device to scan barcodes from worksheets Notstrat gia 11 LABEL PRINTER OPTIONAL If the workflow includes label printing an INTERMEC PM4i printer can be connected to the controller via serial port 4 3 LIGHT AND AUDIB
10. o the products PROGRAMMABLE PRODUCTS KVL COMP shall not be responsible for the user s programming of a programmable prod uct or any consequence thereof PART IDENTIFICATION CONTROL BOX WITH ETHERNET NETWORK VI DISCLAIMERS CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons It is our practice to change model numbers when published ratings or features are changed or when significant construction changes are made However some specifica tions of the products may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult with your KVL COMP representative at any time to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are 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 error
11. oduct 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 TVPO is part of the Ethernet network based pokayoke system developed by KVL COMP 1 2 PLACE OF THE CONTROLLER IN POKAYOKE SYSTEM Its purpose is to eliminate the picking of wrong parts due to workers fault KVL TVPO1 is an individual part identification it is not directly connected to the produc tion line The controller receives the data of the unit to be manufactured from the computer KVL server The software manual describes the operation of part identification according to the spe cific application KVL TVPO1 CHAPTER 2 TECHNICAL DATA 2 1 DIMENSIONS The KVL TVPO1 controller is installed in a metal plate case Dimensions of the controller box 600 500 150 mm Colour of the controller box Grey RAL 7032 JE 8 900 PART IDENTIFICATION CONTROL BOX WITH ETHERNET NETWORK 2 2 ELECTRICAL DATA Supply voltage 230 V AC 50 Hz FUSE 230V 10 SLOW Current drain 10 A Operating range 100 240 V 48 62 Hz Operating temperature 5 40 C Operating humidity 20 90 RH non consending Storage temperature 20 70 C Storage humidity 10 95 RH non consending
12. purpose and under the specified conditions especially 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 PART IDENTIFICATION CONTROL BOX WITH ETHERNET NETWORK CHAPTER 1 OVERVIEW This guide explains the installation wiring and setup of the KVL TVPO1 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 pr
13. re one of the following 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 permission 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 quali ty 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 responsi bility for the possible damages resulting from using this guide PART IDENTIFICATION CONTROL BOX WITH ETHERNET NETWORK CONTENTS About this Manual een 1 1 Related US 1 PUBL ION ee ee 1 IV Warranty and Limitations of Liabil
14. s 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 e professionals responsible for the installation setup and maintenance of the device KVL TVPO1 GENERAL PRECAUTIONS The user must operate the product according to the performance specifications described in the operation manuals Before using the product under conditions which are not described in the manual or ap plying the product to other systems machines and equipment that may have a serious in fluence on lives and property if used improperly consult your KVL COMP representative Make sure that the ratings and performance characteristics of the product are sufficient for the systems machines and equipment This manual provides information for setup and operating the product Be sure to read this manual before attempting to use the product and keep this manual close at hand for reference during operation A WARNING It is extremely important that a product be used for the specified

USER MANUAL - KVL Comp Kft.

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