FlexPressure System Test Unit

User Manual

H42001DEN
www.emhartglass.com
Copyright © 2011 Emhart Glass SA
All Rights Reserved
 FPS Test Unit
User Manual

Copyright © 2011 by Emhart Glass SA. All rights reserved.

 NOTICE
In order to monitor and improve the quality of this publication,
we would very much appreciate your feedback. Please contact
us with any comments or suggestions you may have at:

he.publication@emhartglass.com

Revision History (Initial release: 2008.11)

DATE & REVISION DESCRIPTION
2009.06, rev.A Information about automatic circuit breaker added in paragraphs 2.2.2, 2.3, 2.3.5,
2.3.6, and 2.3.7.
2010.02, rev.B Correction in Figure 2-1.
2010.08, rev.C Add new valve reference in Table 2-1.
2011.01, rev.D Update paragraph 2.3.8. Add paragraph 2.2.3.1.

Copyright © 2011 by Emhart Glass SA. All rights reserved

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Table of Contents
Preface ............................................................................................................................................... i

Chapter 1 : Safety ....................................................................................................1

1.1 Introduction ............................................................................................................................... 3
1.2 FPS Test Unit Safety Considerations ....................................................................................... 3
1.2.1 Instruction Obligation .......................................................................................................... 3
1.2.2 Application Range ............................................................................................................... 3
1.3 Common Sense Safety ............................................................................................................. 4

Chapter 2 : User Instructions ..................................................................................5

2.1 Introduction ............................................................................................................................... 7
2.2 Description ................................................................................................................................ 7
2.2.1 Delivery Contents ............................................................................................................... 8
2.2.2 Control Panel ...................................................................................................................... 9
2.2.3 Connection ........................................................................................................................ 10
2.2.3.1 Piping Connection Recommendations ...................................................................... 10
2.3 Performing Tests .................................................................................................................... 11
2.3.1 Mounting the FPS Valve onto the Adapter Block .............................................................. 12
2.3.2 Pneumatic Connection ...................................................................................................... 13
2.3.3 Test Program Selection .................................................................................................... 14
2.3.4 Display Reading ................................................................................................................ 15
2.3.5 Single Test ........................................................................................................................ 15
2.3.6 1000-Cycle Test ................................................................................................................ 16
2.3.7 Endless Test ..................................................................................................................... 16
2.3.8 Self-test ............................................................................................................................. 16
2.4 Error Code List ....................................................................................................................... 17
2.5 Software Update ..................................................................................................................... 18

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b Property of Emhart Glass SA. Please refer to license.

 Preface

WARNING!
Procedures in this manual shall be completed only by expert personal, with
thorough knowledge of the forming machine setup and process, and duly trained
on Emhart FlexSIS system and associated equipment.

Intended Use
The FPS Test Unit is designed to test and troubleshoot the different FPS valves used on
the Emhart Glass forming machines.

Range of Application
Refer to Table 2-1.

Manual Description
This manual is the original instruction notice of the Emhart Glass FPS Test Unit.
This manual gives a functional description of the FPS Test Unit processor unit. It
describes the testing procedures for the FPS valves.
NOTE 1: Illustrations in this manual are for reference only and might not reflect current changes to
the engineering drawings for the equipment. When an illustration in this manual is
derived from an Emhart Glass drawing, always refer to the original drawing to verify that
the information is correct.

Manual Conventions
This manual uses a variety of highlighted text to emphasize important information.
Always pay careful attention to this information. The types of highlighted text are:

DANGER!
Indicates an imminently hazardous situation that, if not avoided, will result in death or
serious injury. Use this alert box only for the most extreme situations.

WARNING!
Indicates a potentially hazardous situation that, if not avoided, could result in
death or serious injury.

CAUTION!
Indicates a potentially hazardous that, if not avoided, might result in minor or
moderate injury. It can also indicate possible loss of materials or damage to the
equipment.

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NOTE X.Y: Used to identify unusual or unexpected conditions or to identify the need for alternate
procedures. It is also used for emphasis when a DANGER, WARNING, or CAUTION is
not required.
X is the chapter number and Y the note number.
In addition, there are some conventions related to data input and use of the
consoles and display screens that are used throughout the manual.
START
Names of controls are shown as all capital letters. Where a system control panel
uses symbols to label the controls, the name of the symbol plate is used in the text
in place of the symbol.
[ENTER]
Used to indicate a particular key on the keyboard of the console or terminal in this
case the “ENTER” key. With minor exceptions which are noted in the manual, the
proprietary Emhart Glass software, as well as the operating system software (for
example, Windows), are not case-sensitive and information will be interpreted the
same whether it is uppercase, lowercase, or a combination of the two. However,
certain other software is case- sensitive, usually requiring lowercase entry.
Therefore, to distinguish when it is necessary to be careful with uppercase and
lowercase data entry, the words “EXACTLY AS SHOWN” will be used after data
when it is necessary to enter the data with specific uppercase and lowercase
information. The brackets or bars should still not be typed.
“Message”
Used to indicate prompt lines or other information which will be generated on the
console screen by the system. In some cases, where multiple lines are shown, the
quotation marks may be omitted. Where it is necessary to differentiate between
system prompts and user-entered text in descriptive information, the system
prompts are not bold-face.
(x)
Used to refer to an index number of an illustration in the manual.

Data Entry
When data is to be typed with no additional keys pressed, the instruction "type" is used.
When data is to be typed and followed by the use of the [ENTER] key or some other
data entry means as explained in the manual, the instruction "enter" is used.
With minor exceptions, which are noted in the manual, the proprietary Emhart Glass
software, as well as the operating system software (for example Windows®), is not
case-sensitive. Information will be interpreted the same whether it is uppercase,
lowercase, or a combination of the two.

Copyright and Patent Rights

All information contained within this document, such as text, tables, and pictures, is
subject to the generally valid copyright laws as well as any patent rights of Emhart
Glass. Any exemption from copyrights or patent claims cannot be derived here.

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License
This proprietary information (software, manual, and/or presented content) is the
property of Emhart Glass. It presents knowledge developed by Emhart Glass. It is
provided, pursuant to a royalty-free license, to the licensee (the owner of an Emhart
Glass technology), subject to the following terms:
• It will be used only in conjunction with the use of the Emhart Glass technology.
• It will not be copied. Upon request, Emhart Glass will provide additional copies.
• The presented information will be treated as confidential and will accordingly
not be disclosed to any third party.

Trademark Acknowledgments
The following trademarks of Emhart Glass, SA, can be used in this manual:
555
565
535
570
NIS
AIS
SIS
EFRA
Flex
FlexIS
FlexPusher
FlexLine
FlexVector
FlexPressure
FlexReport
VertiFlow
InVertiFlow

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Contact Information
Emhart Glass Worldwide Presence
Principal
Emhart Glass SA
Hinterbergstrasse 22
PO Box 2251
CH-6330 Cham 2, Switzerland
Telephone +41 (41) 749 42 00, telefax +41 (41) 749 42 71
www.emhartglass.com
info@emhartglass.com
GERMANY, NEUSS♦ ITALY, SAVONA♦
Telephone +49 (2131) 3595 0 Telephone +39 (019) 51 66 1
Telefax +49 (2131) 3595 125 Telefax +39 (019) 51 66 302

JAPAN, KAWASAKI♦ MALAYSIA, JOHOR BAHRU

Telephone +81 (44) 222 7371 Telephone +60 07 863 1122
Telefax +81 (44) 222 4868 Telefax +60 07 863 7717

RUSSIA, MOSCOW♦ SINGAPORE♦

Telephone +7 (499) 746 13 40 Telephone +65 6778 1466
Telefax +7 (499) 746 13 41 Telefax +65 6778 9433

SWEDEN, SUNDSVALL SWEDEN, ÖREBRO

Telephone +46 (60) 199 100 Telephone +46 (19) 307 500
Telefax +46 (60) 199 261 Telefax +46 (19) 307 501

UK, MANCHESTER♦ USA, CLEARWATER, FL♦

Telephone +44 161 876 1700 Telephone +1 (727) 535 5502
Telefax +44 161 876 1701 Telefax +1 (727) 532 8513

USA, ENFIELD, CT♦ USA, OWENSVILLE, MO

Telephone +1 (860) 814 4010 Telephone +1 (573) 437 2132
Telefax +1 (860) 814 4170 Telefax +1 (573) 437 3146

USA, ELMIRA, NY
Telephone +1 (607) 734 3671
Telefax +1 (607) 734 1245

♦ Sales Representative Manufacturing Location

Emergency Call Number

In case of emergency, please contact our service group 24/7, 365 days a year:
+41 41 749 41 41

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Chapter 1

Safety

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Table of Contents
1.1 Introduction .............................................................................................................. 3
1.2 FPS Test Unit Safety Considerations ...................................................................... 3
1.2.1 Instruction Obligation ......................................................................................... 3
1.2.2 Application Range .............................................................................................. 3
1.3 Common Sense Safety ............................................................................................ 4

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1.1 Introduction
WARNING!
Everyone who works on or around this equipment including, but not limited to,
operators, maintenance personnel, and supervisory personnel must read and
understand the information in this chapter prior to commencing work on or around this
equipment. Failure to conform to the information in this chapter could lead to property
damage or serious personal injury, including possible loss of body parts or death.

The FPS test unit is a device to test and display results from testing FPS valves. It can
only be used with standalone FPS valves in the workshop. Always use the FPS test unit
in a clean and cooled air environment room.
This chapter describes proper safety procedures to follow when working around this
equipment.

WARNING!
In addition to the safety information included in this section, always observe all specific
safety information included with the instructions in the balance of this manual. Also,
read and understand all safety information included in the instruction manual for the
forehearth, feeder, shear, gob distributor, IS machine, and any other equipment
associated with the production line.

1.2 FPS Test Unit Safety Considerations

As manufactured, this equipment has been equipped with safety devices which
correspond to current technology standards in accordance with the prescribed
applications of the equipment. However, residual risks remain to which attention is
drawn individually within this machine manual.

1.2.1 Instruction Obligation

The operating company must verify that:
• personnel have the necessary technical, equipment-specific, and safety
knowledge or that this is achieved by means of relevant training before the
equipment is installed, operated, or maintained.
• personnel have the necessary competence to be able to work in accordance
with the regulations and instructions.
• before initial startup, personnel have read and understand all instructions
contained within the supplied documentation.

1.2.2 Application Range

It is the responsibility of the operator to ensure that the FPS Test Unit is used within its
application range as described in this document.
In particular, the FPS Test Unit shall not be used:
• for any application not described in this manual.
• under conditions that deviate from those described in this manual.

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WARNING!
Failure to conform to the above instruction could lead to damage of the FPS test unit.

1.3 Common Sense Safety

Accidents frequently occur due to carelessness or lack of knowledge. To avoid potential
problems, review the information in this section before attempting to install, set up,
operate, or maintain this equipment. Then think safety at all times. Do not let familiarity
with the equipment lead to unsafe short cuts. The following common sense safety
practices must be observed at all times.
1. Follow all procedures and precautions in the manual carefully and completely.
2. Only attempt repairs or adjustments for which proper training has been completed.
3. Always observe all safety warnings and notices on the machine and in the manual.
4. Do not remove or otherwise alter any guards or panels unless the machine is
completely shut down and has been made inoperable. Be sure to replace these
items before restarting machine.
5. Never operate the equipment without guards and safety mechanisms in place and
functional.
6. Do not allow foreign objects to fall into the equipment.
7. Always use the proper tools for performance of any operation on the machine.
whenever feasible, use voltage-isolated tools.
8. Do not touch any parts of the machine which may have become hot during
operation.
9. Be aware that there are high voltages in this device when power is connected.
Power must be disconnected when the device is being repaired. However, because
there are certain checks and adjustments that can be made only with power
connected, it is imperative that only trained personnel, aware of the safety hazards
involved and familiar with this type of work and necessary safety precautions, be
permitted to perform this work.
10. Maintain good housekeeping practices to prevent slips, falls, cuts, burns, and other
possible accidents. Keep the area neat and clean. Put away unneeded items,
discard scrap, and keep all necessary items properly organized.

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Chapter 2

User Instructions

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Table of Contents
2.1 Introduction .............................................................................................................. 7
2.2 Description ............................................................................................................... 7
2.2.1 Delivery Contents .............................................................................................. 8
2.2.2 Control Panel ..................................................................................................... 9
2.2.3 Connection ....................................................................................................... 10
2.2.3.1 Piping Connection Recommendations ....................................................... 10
2.3 Performing Tests ................................................................................................... 11
2.3.1 Mounting the FPS Valve onto the Adapter Block ............................................. 12
2.3.2 Pneumatic Connection ..................................................................................... 13
2.3.3 Test Program Selection ................................................................................... 14
2.3.4 Display Reading ............................................................................................... 15
2.3.5 Single Test ....................................................................................................... 15
2.3.6 1000-Cycle Test ............................................................................................... 16
2.3.7 Endless Test .................................................................................................... 16
2.3.8 Self-test ............................................................................................................ 16
2.4 Error Code List ....................................................................................................... 17
2.5 Software Update .................................................................................................... 18

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2.1 Introduction
This chapter describes how to use the FPS test unit, Emhart part number 59-90316, and
contains information about all necessary equipment, technical specifications, and how
to proceed when performing tests of FPS valves listed below:
Table 2-1: Type of FPS valves supported

Type of valve Emhart part number

ND07 spade terminal 59-90272
ND07 harting connector SE-12552-1
ED07 M12 Connector with exhaust 59-90311 & 59-27249
ED07 M12 Connector without exhaust 59-27229
ND12 spade terminal 59-90281
ND12 harting connector SE-12552-2
ED12 M12 connector with exhaust 59-90319
ED12 M12 connector without exhaust 59-27230
ED 19 ISO interface 59-27262-1
ED19 Ross 21 interface 59-27262-2

2.2 Description
The FlexPressure System (FPS) test unit is a troubleshooting device for FPS valves. It
automatically tests all FPS valves from original versions to later ones, with a single and
non-stop test.
The FPS test unit measures rise-time, fall-time, leakage, oscillation, and deviation of
output pressure on the FPS valves.
Table 2-2: FPS test unit characteristics
Characteristic Data
Emhart part number 59-90316
Size (H x W x D) 220 x 535 x 500 (mm)
Weight 28 kg CAUTION: Heavy load!
Material Plastic housing

Table 2-3: FPS test unit specifications

Utility Data
Power supply 93-264V 47-63Hz
Air supply pressure 4.5 to 10 bar
Temperature 10 to 50oC (non condensing)

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2.2.1 Delivery Contents

The FPS test unit kit includes (see Figure 2-1):

Figure 2-1: PPC mobile test unit

1. FlexPressure test unit 5. Adapter cable with M12 plug
2. Pneumatic adapter ED12 with tubes 6. Adapter cable with “harting plug”
3. Pneumatic adapter ED07 with tubes 7. Self kit: jumper cable and jumper pipe
4. Power cord

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2.2.2 Control Panel

Figure 2-2: FPS mobile test unit control panel.

1. Test selection switches 6. Test OK indicator
2. Display 7. Test ERROR indicator
3. Monitoring LED 8. Automatic circuit breaker
4. Power switch 9. Air supply switch
5. Test button

See Figure 2-2:

The power button (4) is used to turn on and off the FPS test unit power.
The pressure supply button (9) is used to turn on and off the air pressure supply.
The rotary switches (1) is used to select the test mode.
The display (2) is used to read the test results.
NOTE 2.1: The grey touch buttons around the display have no function.
Use the green test button (5) is used to start tests.
Monitoring lights “Test ok” (6) and “Test error” (7) indicate the test results.
The LED (3) indicate that the 24V power supply to the valve is OK and that the 3A
automatic circuit breaker (8) is on.

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2.2.3 Connection
Connectors and plug are located on the right-hand side of the test unit.

Figure 2-3: Air Connections and power supply

1. Pneumatic connection 1 3. Pressure supply connection
2. Pneumatic connection 2 4. IEC power supply

2.2.3.1 Piping Connection Recommendations

To ensure the reliability and accuracy of the performed test, following recommendations
for piping connection shall be followed (see Figure 2-4):
• Supply air flow shall be minimum 1000 liter/minute
• Supply pressure shall be between 4.5 and 10 bar.
• Make sure the inner diameter of air supply pipe (including the connector) has a12-
mm diameter minimum.
• No sharp bending in the total piping
• No additional 90°-fittings
• Fixed M12-connector, no loose one
• Piping between test unit and valve adapter shall be no longer than 50 cm.
• Use only direct piping connection between test unit and valve adapter.

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Figure 2-4: Piping recommendations

2.3 Performing Tests

CAUTION!
Make sure there is no under voltage or under pressure condition on the test unit.

Before every test, the FPS test unit and valve must be properly connected and installed
to minimize the risk of error during FPS valve troubleshooting.

IMPORTANT!
After the FPS valve been connected, let the test unit be activated for 10 minutes
before starting the test, so that the electronics in the valve gets warm.
If the circuit breaker has tripped it has to be reset before every new test.
NOTE 2.1: Strictly follow the piping recommendations in paragraph 2.2.3.1!

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2.3.1 Mounting the FPS Valve onto the Adapter Block

Figure 2-5: Mounting of FPS valve onto adapter

1. Screws (4) 4. Pin
2. FPS valve 5. Adapter block
3. Gasket 6. Plug for adapter cable

In order to test it, the valve needs to be mounted on the adapter block (see Figure 2-5).
1. Check that the pin (4) fits into the corresponding bore of the FPS valve.
2. Check that the gasket (3) between the valve (2) and the adapter block (5) is in place.
3. Mount and tighten on the four screws (1).
Not shown on Figure 2-5, two flexible pipes are connected to both sides of the adapter
block in position 1 and 2.
NOTE 2.2: The same procedure applies for both ED07 and ED12.

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2.3.2 Pneumatic Connection

IL_FPSAdapapterED07.cdr

Figure 2-6: FPS Valve adapter ED07

The adapter block needs to be connected to the FPS test unit (see Figure 2-6):
1. Connect the pneumatic flexible pipes from the adapter block, position 1 and 2, to the
FPS test unit, position 1 and 2.
2. Make sure that connection 1 on adapter block is linked to connection 1 on FPS test
unit, and that connection 2 on adapter block is linked to connection 2 on FPS test
unit.
3. Connect the adapter cable between the FPS test unit and the FPS valve. The color
of the wires should match the connection tab legend on the FPS test unit (see
Figure 2-7).
NOTE 2.3: The same procedure applies for both ED07 and ED12.

Figure 2-7: FPS test unit wire connections

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2.3.3 Test Program Selection

All functions of the FPS valves will be tested according to the type of valve and
according to the application, plunger up or counter blow/plunger cooling.
Four different test modes are available:
• Single test
• 1000 cycle test
• Endless test
• Self-test
Each test mode requires its own program selection configuration.

Figure 2-8: Test mode selection rotary switches

1. Plus button 3. Number indicator
2. Minus button

Four rotary switches buttons are used for:

• Switch A sets the type of FPS valve.
• Switch B sets the pressure range.
• Switch C sets the application.
• Switch D sets the test type
Press the plus or minus button to change the number and to set the test unit in the right
mode. Use the Table 2-4 to select the setting sequence of the rotary switch button.

Table 2-4: Switch selection chart

Switch Position Functions

1 ED07 with exhaust
2 ED12 with exhaust
A
3 ED07 without exhaust
4 ED12 without exhaust
1 0 to 4 bar
B
2 0 to 6 bar

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Table 2-4: Switch selection chart

Switch Position Functions

1 Closed volume (plunger Up)
C
2 Open volume (counter blow/plunger cooling)
1 Single test (including leakage test)
D 2 1000-cycle test (excluding leakage test)
3 Endless test/stop after first error (excluding leakage test)

2.3.4 Display Reading

A four line display indicates test codes and errors. The test results are shown while the
test is processed (see Figure 2-9).

Figure 2-9: FPS test unit display

1. TCC - Test Cycle Counter 3. EC - Error Counter
2. EN - Error Number 4. EE - Electronic Error

NOTE 2.4: The grey touch buttons around the display have no function.
See Figure 2-9:
1. TCC (Test Cycle Counter): It displays the count of completed test cycles.
2. EN (Error Number): It displays which type of error is detected (see chapter 2.4).
3. EC (Error Counter): It displays the number of errors.
4. EE (Electronic Error): It displays malfunction of electronics in the FPS valve.

2.3.5 Single Test

An initial one-cycle test is used for testing the function of the valve and provides a go/
no-go result with the related error code.
1. Switch on the pressure and power supplies.

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2. Set button D=1 for single test.

3. Check the LED. If the circuit breaker has tripped it has to be reset.
4. Push the test button to reset the memory. The test button light starts flashing.
5. Push the test button again to start the program. The test button light is green
illuminated.
6. If detected, the error codes are displayed.

2.3.6 1000-Cycle Test

The 1000-cycle test is used to detect multiple error sources which may occur randomly.
The errors are counted during 1000 cycles and the error codes are displayed together
with the number of errors.
1. Switch on the pressure and power supplies.
2. Set button D=2 for 1000-cycle test.
3. Check the LED. If the circuit breaker has tripped it has to be reset.
4. Push the test button to reset the memory. The test button light starts flashing.
5. Push the test button again to start the program. The test button light is green
illuminated.
6. If detected, the error codes are displayed.
7. To cancel the test, push the test button while the test is processed. The test button
light goes off.

2.3.7 Endless Test

The endless test stops after the first error has been detected and displayed. This test is
normally used to verify the performance of a valve after a valve repair.
1. Switch on the pressure and power supplies.
2. Set button D=3 for endless test.
3. Check the LED. If the circuit breaker has tripped it has to be reset.
4. Push the test button to reset the memory. The test button light starts flashing.
5. Push the test button again to start the program. The test button light is green
illuminated.
6. If detected, the error code is displayed.
7. To cancel the test, push the test button while the test is processed. The test button
light goes off.

2.3.8 Self-test
The self-test is used to check the FPS test unit itself.

IMPORTANT!
The self-test shall be ALWAYS performed prior to testing a FPS valve, or if the number
of rejected valves is abnormally high.
1. Make sure the test unit is powered off.
2. Use the jumper cable from the self-test kit to bypass female connector 3 and 5 (see
Figure 2-7).
3. Bypass pneumatic connections 1 and 2 (see Figure 2-3) using the self-test kit
jumper pipe.
4. Select the self-test program by setting switch D=0. Switches A, B and C have no
function.
5. Switch on the power and pressure supplies.

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6. Push the test button to delete the memory. The test button light starts flashing.
7. Push the test button again to start the test program. The test button light is green
illuminated, and the current pressure is displayed [“TP: 3.5 (+/-0.3) bar”].
8. After 5 seconds the results are shown on the display. Either EST (Error Self Test)=0
(Test OK) or EST=1 (Test Error). In addition the corresponding test monitoring lights
indicates the result. The test button light goes off.

CAUTION!
If the self-test shows an error (EST=1), please contact Emhart Glass.

2.4 Error Code List

Up to four different error numbers can be displayed.
Table 2-5: Error code list

Error number Type of error

0 No error detected

1 Rise time out of time

2 Fall time out of range

3 Output pressure out of range

4 Oscillation output pressure out of range

5 Feedback signal out of range (if feedback test is activated)

6 Oscillation feedback signal out of range (if feedback test is activated)

7 Leakage supply cartridge

8 Leakage exhaust cartridge

9 Supply pressure short or long term to low

10 Invalid programme selection or program does not exist

11 Malfunction of the electronics

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2.5 Software Update

Software release versions are distributed on a flash memory card which has to be
inserted in the memory slot of the FPS test unit processor unit.

Figure 2-10: FPS test unit processor unit with front plate removed
1. Flash memory card

For software update of FPS test unit following instructions must be followed.
1. Switch off the FPS test unit processor unit.
2. Remove the four screws holding the control panel.
3. Remove the control panel.
4. Locate and exchange the actual flash memory card with the new one (see Figure 2-
10).
5. Reinstall the control panel and the four screws.

18 Property of Emhart Glass SA.