Sensory Analytics Specmetrix SA Manuel utilisateur

SA Traversing In-line Coating

Thickness Measurement System

Installation & Operation Manual

The Sensory Building

405 Pomona Drive

Greensboro, NC, 27407 USA

+1 (336) 315-6090

www.specmetrix.com

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Table of Contents

System Description and Usage.................................................................................................................. 7

Product Safety........................................................................................................................................... 7

System Specifications.........................................................................................................................8

Performance Specifications ...................................................................................................................... 8

Environmental Specifications-Customer must provide ............................................................................ 8

Installation and Site Requirements........................................................................................................... 9

Utilities ...................................................................................................................................................... 9

Electronics Mounting and Conduit Work................................................................................................ 10

Probe Installation.................................................................................................................................... 10

Laser Detection Setup ............................................................................................................................. 11

Network and Machine Communications ................................................................................................11

Emergency Stop ...................................................................................................................................... 11

System Start-Up Procedure..................................................................................................................... 12

System Shut down Procedure.................................................................................................................13

Signing On ............................................................................................................................................... 14

SA Services ......................................................................................................................................14

Change User ....................................................................................................................................14

SA UI Configuration..........................................................................................................................15

ColorBands.............................................................................................................................................. 15

CrossWeb ................................................................................................................................................ 15

CrossWeb Line Count

.......................................................................................................................... 15

Default User ............................................................................................................................................ 15

Default Password ................................................................................................................................ 15

Default User Id .................................................................................................................................... 15

Inline ....................................................................................................................................................... 16

Cross web Position Update Rate ......................................................................................................... 16

Decimal Places .................................................................................................................................... 16

Downweb Graph Count....................................................................................................................... 16

Graph Configs Cross Web / Die / Down Web / Lanes / Polar.............................................................. 16

Display Thickness on Bar Graph .......................................................................................................... 16

Invert Crossweb Graph .......................................................................................................................16

Smooth? ..............................................................................................................................................16

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Smoothing Count ................................................................................................................................ 16

Smoothing Level..................................................................................................................................17

Multi-line Graph Display .....................................................................................................................17

Posted Readings Averaged..................................................................................................................17

Polar Graph Config ..............................................................................................................................17

Traverse Left-side Name ..................................................................................................................... 17

Traverse Right-side Name...................................................................................................................17

Logging .................................................................................................................................................... 17

Logging Interface................................................................................................................................. 17

Login Security.......................................................................................................................................... 17

Login Timeout ..................................................................................................................................... 17

Probe Colors............................................................................................................................................ 18

SA ACS ..................................................................................................................................................... 18

SA Blown Film Settings............................................................................................................................ 18

SA Inline (Fixed Differential) ................................................................................................................... 18

Show Base Value ................................................................................................................................. 18

Show Total Value ................................................................................................................................ 18

SA Menu.................................................................................................................................................. 18

Menu Scaling....................................................................................................................................... 18

Shutdown Method .............................................................................................................................. 18

SA Offline (DFT-QA)

................................................................................................................................. 18

SA PLC Traverse Settings......................................................................................................................... 18

Pic Traverse User Options ................................................................................................................... 18

(Fixed Width) Lane Width ................................................................................................................... 18

(Left/Right) Web Percentage .............................................................................................................. 19

Constant Lane Count........................................................................................................................... 19

Relative Distance Unit......................................................................................................................... 19

Web Division Type............................................................................................................................... 19

SA Sheet Type Settings............................................................................................................................ 19

SpecMetrix® SA Data Manager ...................................................................................................................20

General Information ............................................................................................................................... 21

Command Bar ..................................................................................................................................... 21

Data Services Group............................................................................................................................ 21

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New Group ..........................................................................................................................................21

Database Group ..................................................................................................................................21

Delete Group....................................................................................................................................... 22

Screen Control (Recipe Module Only).................................................................................................22

Filter Region ........................................................................................................................................ 22

Selection Region.................................................................................................................................. 22

View Detail Region .............................................................................................................................. 23

Module Navigation Region.................................................................................................................. 23

Recipes ....................................................................................................................................................24

Recipe Assistant ......................................................................................................................................25

Getting Started with the Recipe Assistant .............................................................................................. 25

Lanes (SpecMetrix® Traversing Only)...................................................................................................... 31

Adding / Editing a Lane Definition .......................................................................................................... 32

Users ....................................................................................................................................................... 34

User Permission levels and their privileges ............................................................................................ 34

Plants....................................................................................................................................................... 35

SpecMetrix® SA Inline Measurements...............................................................................................37

Main User Interface ................................................................................................................................ 37

Adjustable Target Set.......................................................................................................................... 38

Statistics Tab ....................................................................................................................................... 38

Distance to Target............................................................................................................................... 38

Debug .................................................................................................................................................. 39

User Interface Tabs ................................................................................................................................. 40

Thickness Graph.................................................................................................................................. 40

Average Reads..................................................................................................................................... 40

Thickness Data .................................................................................................................................... 41

Historical ............................................................................................................................................. 41

Traversing................................................................................................................................................ 42

Cross Web ........................................................................................................................................... 42

Lane Graph.......................................................................................................................................... 43

Die Graph ............................................................................................................................................ 43

Light Tower ............................................................................................................................................. 44

In-line Wave Analysis Tool................................................................................................................45

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Getting Started............................................................................................................................................ 45

Logging Inline Graph ...........................................................................................................................45

Loading Files........................................................................................................................................ 45

Controls............................................................................................................................................... 46

Calculated Thickness........................................................................................................................... 47

Normalized Data ................................................................................................................................. 47

Raw Data ............................................................................................................................................. 48

Peak Data ............................................................................................................................................ 48

PA Settings .......................................................................................................................................... 52

Layer Settings...................................................................................................................................... 53

Specification & Graph Setup ............................................................................................................... 54

Overview Grid ..................................................................................................................................... 55

Gravimetric ......................................................................................................................................... 55

Making changes with Analysis Tool ........................................................................................................ 56

WHAT TO CHANGE AND HOW IT AFFECTS YOUR READING ..................................................................................................... 56

Peak Tolerance.................................................................................................................................... 56

Fringe Variance ...................................................................................................................................56

Height Threshold................................................................................................................................. 56

Custom Smoothing.............................................................................................................................. 57

Momentum ......................................................................................................................................... 57

Waveform Type................................................................................................................................... 57

Starting/Ending Wavelength............................................................................................................... 57

Index of Refraction.............................................................................................................................. 57

Min/Max Thickness............................................................................................................................. 57

Target Spec.......................................................................................................................................... 57

+/- Tolerance....................................................................................................................................... 57

SpecMetrix® On-Line Support...........................................................................................................58

Other SA Menu Buttons .......................................................................................................................... 59

System Maintenance .............................................................................................................................. 60

Suggested Cleaning Interval................................................................................................................ 60

Maintenance Procedures for Lab and In-line systems........................................................................ 60

Lamp Replacement for In-line Systems............................................................................................... 60

Probe Cleaning ....................................................................................................................................62

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General Maintenance Checklist ..............................................................................................................62

Calibration...............................................................................................................................................62

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System Description and Usage

The SpecMetrix® In-line coating thickness measurement system is designed to measure the thickness or

coat weight of wet or dry coatings applied to flat sheets, continuous coil or plastic film and coatings on

many other substrates. Each system is comprised of one or multiple probes connected by fiber optic

cable to a controls enclosure mounted near the coating line so that the supplied probe cables can

terminate in the controls enclosure. The probes are usually mounted between the coater and the oven

for wet coating measurement and after the oven for dry coating measurement. The enclosure has a

data connection to the SpecMetrix® Display Unit, which can be up to 150 feet (~50 meters) away.

SpecMetrix® systems use proprietary ruggedized optical interference technology to measure the

absolute wet or dry coating thickness. This is a non-contact and non-destructive technology that only

requires minimal prior knowledge of the refractive Index of the coating to evaluate the coating thickness

measurement in microns. When measuring wet coatings, the dry coat weight in units such as MgSI,

Mg4SI, lbs./ream or GSM is then calculated from the wet or dry thickness using data from the coating

manufacturer such as wet density (lbs./gallon or gram/liter) and % solids by weight and %solids by

volume.

Product Safety

Before using your SpecMetrix® System

Your SpecMetrix® System is very safe to use. However, like all electronic equipment, you must follow

these common-sense guidelines to ensure your safety and future integrity of the unit.

•

Please read and follow instructions

It will be helpful if you review this document completely before you attempt to install and use

your SpecMetrix® System.

•

Retain this manual for future reference

Keep this manual handy for others to read and refer to when they operate the unit

•

Obey Warnings

Please follow all the precautions described in this manual. If you modify or use the SpecMetrix®

System in a manner not intended, the built-in safety features may be impaired.

•

Protect from water and moisture

Do not use your SpecMetrix® System in an area where there is a potential hazard of electric

shock from spilled water or other uncontrolled moisture.

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•

Electrical Warning

A professional licensed electrician should perform all

electrical work/installation.

•

Installation Requirements

1. SpecMetrix traversing systems must be

installed inside a cage.

2. Indoor and dry location use only

3. Environmental temperature: 0-50C (32-122F)

4. System mounting elevation: Max 2m (6.5ft)

5. The weight of total system ~1000lbs (453kg, ICU weight 125lbs)

System Specifications

Performance Specifications

1. Coating Thickness Range 0.5 to 250 microns

2. Typical Accuracy 3%

3. Non-contact measurement range 15-33mm

Environmental Specifications-Customer must provide:

•

Dedicated Circuit

•

Single-Phase with neutral and ground

•

50/60Hz

•

120/240VAC

•

15Amp Circuit (min 14AWG (1.63mm

diameter wire)

•

SpecMetrix ICU can be hard-wired to the

main power input or a wall socket

•

Primary Operator Workstation will require

one or two wall sockets depending on the

configuration that must be in the same

dedicated circuit

•

All Ethernet cables must be minimum CAT 6 Shielded

•

ICU can be maximum of 65.5 feet (~20 meters) “cable-routing” distance away from actuators

•

Ethernet cables with a distance more than 45.72m/150ft MUST be converted to an armored

fiber optic multi-mode

•

Highly Recommended to use a 1000VA or better UPS.

1. SpecMetrix® Display Unit 6 amps @ 120VAC, 4 Amp @ 240VAC

2. Operating Humidity 10%-90% relative, non-condensing

3. ICU enclosure protection IP65/66

4. SpecMetrix® display protection IP65/66

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SpecMetrix® Display Unit Requirements

SpecMetrix® will provide a display unit with at least the minimal requirements installed which are

Windows 7 64-bit (SP 1), 16GB Memory, and SSD storage.

Installation and Site Requirements

Utilities

The SpecMetrix® In-line system requires a dedicated 120VAC/240VAC AC 15-amp grounded mains

supply adjacent to the Display Unit and the In-line Control Unit. This means a direct connection back to

the fuse Unit.

The instrumentation should not be spurred off a thyristor-

controlled heater or motor due to the electrical interference

this would cause.

The Control Unit and Display Unit can be run on the same 15-

amp circuit. The Display Unit requires a standard

120VAC/240VAC receptacle; the Control Unit can either be

directly connected via conduit or use a standard

120VAC/240VAC single-phase receptacle.

Ruggedized Probe Assembly

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Electronics Mounting and Conduit Work

An on-site maintenance technician needs to be available to work with SA personnel to mount the probe

holder fixtures to the equipment frame. These attachments will vary depending on the type of system

purchased, and machine configuration.

The control Unit will require four 3/8” holes on a 20” x 20” area to mount.

The SpecMetrix® Display Unit can either be mounted to a supplied pedestal frame or a supplied swing-

arm mount system.

Sensory Analytics will supply the flexible conduit to be installed between the probes and Control Unit,

with the customer providing the means to tie or clamp the conduit down.

The customer is expected to supply and install conduit for an Ethernet connection between the Display

Unit and the Control Unit, and from the Control Unit to the customer’s network if external data storage

is required. Must use minimum CAT 6 Shielded Cable.

SA will supply, install and terminate the Ethernet cable unless agreed otherwise with plant personnel.

The probes are optical devices with no electrical connections and so can be mounted in an explosive

environment. The Control Unit, however, contains electrical components and is not designed for use in

an explosive environment. The fiber optic cables have a standard length of 30 feet and can be up to 60

feet long, and so the Control Unit can be mounted up to 50 feet from the probes and production line.

The Display Unit can be mounted up to 150 feet from the Control Unit.

Probe Installation

Typically, Sensory Analytics technicians will install the probes ¾” – 1 ¼” over the web at a 90° angle using

a Hex bar and collar clamps. If a plant has constructed their own mechanism for probe mounting, the

mechanism must allow for probe height adjustment from ½ inch to 2 inches from the web.

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