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Ds017 E Rate1

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Ds017 E Rate1

  1. 1. PRODUCTION RATE COUNTER When closure is detected on a remote input, the DS017E- RATE responds according to the operating mode and the DS017E-RATE setup values you define. A bright red four-digit display on the face of the DS017E- RATE shows current values. LEDs to the right of the numeric display show when the line is at or above goal (green), idle or reset (yellow), or producing but below goal (red). Multiple optional larger external displays may also be attached to the unit to show what it shows, both numeric displays and RYG lamps. With each new signal pulse signifying another event to count or another item produced, the decimal point for the least-place character (i.e., at right) will toggle off or on, reversing with each new signal pulse. The DS017E-RATE shows a production line’s process rate, or compares it to a goal you define. Its advantages are: CONTROLS (from left to right, across the lower front of the front panel) 1 Automatic Rate Count: Know your production and Momentary Description rate of production automatically. Avoid manual rate Buttons measurement, hand timing and calculation with the DS017E-RATE. It gives you more time to focus on your Actual Count Display the actual count or priorities. difference between the actual count and the goal count. 2 Show Difference From Goal: The automatic, instant Actual Rate Display the actual rate or difference calculation of when a lines meets/exceeds goal, falls between the actual rate and the goal behind or is idle, alerts you and workers with easy-to- rate. understand color-coded lights, and (if desired) a display of the difference. Everyone can see at a glance when Goal Display the goal rate in units per problems occur and when things run properly, so you minute or units per hour or display accomplish more. You can focus elsewhere when the the running goal count. green light shows your lines are on target. Select Step to the next function while changing settings. 3 Higher Production Rates: The pacing feature helps workers fall into a smooth and steady rhythm. Press and Hold Production increases when pacing helps workers reach Buttons. the optimum steady rate of work, so the system pays for Actual Count Clear the actual count to zero. itself. Actual Rate Clear the rate counter and rate 4 One Counter, Four Production lines: One single averages. DS017E-RATE can monitor up to four (4) production Goal Rate Reload power up defaults and clear lines, and calculate and show the summed rate of all all counters and averages. those lines. Select Enter the setup mode. It requires 9-12VDC or 9-12VAC for operation. AC Knob Change the selected setting. power provides power-line accuracy to the DS017E- RATE. Alzatex, Inc. www.alzatex.com 1 11/08/09
  2. 2. SETUP Press the SETUP button to show or change configuration settings. You enter Setup looking at function one, Mode Setting. Pressing Select steps to the other settings. Setup Rate counter inputs and Outputs functions are described below: Description 1 Mode (see Modes, below) Input 1 Resets the counters to zero. 2 Pause Clearance Delay (in seconds) * Input 2 Increment the count by 1. 3 Average Basis (Lower Digits) 4 Average Basis (Upper Digits) Input 3 Increment the count by 1. 5 Production Goal (Lower Digits) Input 4 Increment the count by 1. 6 Production Goal (Upper Digits) Output 1 Pulses at the goal rate. This output pulses once each time the goal count To make a change, dial in a new value. SELECT steps increments. from function to function to help you get to the function you need. Rate counter serial data Output to Large LED or You can exit from the Setup process by pressing any video displays. other button. Format: Description The values for these functions are retained through a “Laxxxxxx power failure. However, since power spikes and surges Display 0 Display the local controller can occur when power comes back on, and those spikes display. and surges can unpredictably alter memory settings and therefore the values, it’s good to recheck settings when Display A Display the actual count. (range power comes back on after an outage. 0 to 999999) Display B Display the goal count. (range 0 to 999999) RESET Display C Display the difference between the goal count and the actual Clear the actual count and the goal count. Press and hold count. the Actual Count button button for 2 seconds. (range -99999 to 999999) Clear the actual rate and the goal rate. Press and hold the Display D Display the actual rate. (range 0 Actual rate button button for 2 seconds. to 9999) Display E Display the goal rate. (range 0 to Reset all parameters to the power up values and clear all 9999) counters. Press and hold the Goal Rate button button for 2 seconds. Display F Display the difference between the goal rate and the actual rate. (range -999 to 9999) DISPLAY Indicators Display the RYG status. Green=Goal> actual; The Goal Count button changes the display between Red=Goal<actual; Actual Count and the Difference between Actual and Yellow=Paused Goal Count. Actual Count shows the actual count Difference shows the difference between the actual rate, and the goal rate, as defined in Setup Goal Count. Alzatex, Inc. www.alzatex.com 2 11/08/09
  3. 3. EXAMPLES: If the Actual count is 233, and 200 items were 0.0.3.0. produced, the Difference shows as: If the Goal rate is 30 units per hour, two hours has passed, the running goal count will be: 33 If the Actual count was 195, and 200 items 60 were produced, the Difference would be : SELECT - 5 The SELECT button steps to the next choice once you’ve started with SETUP. Press SELECT to step to each function in turn, cycling through the values of the six The Actual Rate button changes the display between different functions. You start in 1 Mode, and pressing Actual Rate and the Difference between Actual and SELECT six times returns you to function 1 Mode. You Goal Rate. may avoid changing values in functions you don’t want to change, by pressing SELECT without moving the dial. Actual Rate shows the actual rate. Difference shows the difference between the actual rate, and the goal rate, as defined in Setup Goal Rate. Knob EXAMPLES: You can dial in changes to setup and mode values using the dial on the front panel. As soon as you make a If the Actual rate was 195/hour, and 200 items change, the new value is stored. If you don’t alter a were produced in an hour, the Difference setting before the counter either receives another signal would be : pulse (indicating another item counted), or press the DISPLAY or RESET buttons, the value originally shown - 5 when you entered Setup will not change. If the Actual rate is 146/hour, and the goal is 150/hour, the Difference would show as - 4 If the Actual rate is 175/hour, and the goal is 150/hour, the Difference would be: 25 The Goal Rate button changes the display between Goal Rate and the Running Goal Count. Goal Rate shows the goal rate in units per minute or units per hour. The Running Goal Count increments at the goal rate, as defined in Setup Goal Rate. EXAMPLES: If the Goal rate is 30 units per minute, the goal rate is displayed as: Alzatex, Inc. www.alzatex.com 3 11/08/09
  4. 4. 2 Pause Clearance Delay in seconds CHOICES CONTROLLED BY SETUP (1-6) Auto-Clear must be enabled to use this feature (requires Mode 2, 3, 5 or 7). When setting the Pause Clearance Delay, the decimal points after each digit on the display are all dark. This should be set to from one (1) to 99 1 Modes (ninety-nine) seconds. When entering into Modes from Setup, the decimal 3 Average Basis (Lower Digits) point after the least-significant digit (i.e., rightmost) is lit. When setting the Average Basis (Lower Digits), the decimal points after each digit are all dark. Both upper Eight modes, numbered from 0 to 7, represent a matrix and lower digits will display, but you can only alter the of three different conditions. Here’s a table, showing lower digits in this step. the three conditions, and the modes for each condition when its value is set to 0 or off. This value is the lower two digits for the raw number of events (items produced, or signal pulses received by the DS017E-RATE) to use as the basis for averaging. Examples: MODES Bit 2 Bit 1 Bit 0 0 0 0 0 If you want to know the average rate for the past 1 0 0 1 two minutes (2) and the typical rate is 20 2 0 1 0 (twenty) units per minute, set the Rate Average 3 0 1 1 (Lower Digits) to 2 times 20 or 40 (fourty) and 4 1 0 0 00 as the Rate Average (Upper Digits). The rate 5 1 0 1 counter will display the average production rate 6 1 1 0 for the most recent 40 events. 7 1 1 1 For a rate average of 25 per minute over 10 Bit 0: Goal count time basis: Calculate the goal minutes, or a count of 250 as the basis for and averaging, per: 1 = Hour, 0 = Minute. averaging, enter the last two digits, 50, as the Rate Average (Lower Digits), and 02 as the Rate Bit 1: Auto-clear: When a pause over nn seconds* Average (Upper Digits). The rate counter will occurs: 1 = Clear the counter, 0 = Pause counting. calculate and show the average production rate for the most recent 250 units produced. Bit 2: Sequencer Lights: 1 = Enable, 0 = Disable. 4 Average Basis (Upper Digits) Example: If you want to use the sequencer lights, your choices are modes 4 5 6 7. When setting the Average Basis (Upper Digits), the If you want also to pause counting when a pause of decimal points after each digit are all lit. All digits will greater than nn seconds* happens, select from modes 0 display, but you can only alter the upper digits in this 1 4 5. step. This value should be the upper two places of the raw If a count by minutes is desired for goals and averages, number of events (items produced, or signal pulses modes 0 2 4 6 would work. received by the DS017E-RATE ) to use as the basis for averaging, as explained in 3 Average Basis (Lower The mode providing all three conditions is mode 0. Digits) above. * Make sure not to leave the Pause Clearance Delay set 5 Production Goal (Lower Digits) to 0, else spontaneous clearances of counter and rates may occur. The Production Goal serves two functions. If a beeper or other feedback device, audio or visual, is connected, the output sent to it pulses at the production goal rate. Also, if the display is set to Difference, the difference between goal and actual rate is shown. Alzatex, Inc. www.alzatex.com 4 11/08/09
  5. 5. When setting the Production Goal (Lower Digits), the 1. Hour (choose one of the Modes 1, 3, 5, or 7) decimal points after each digit are all lit. Both upper or and lower digits will display, only the the lower digits 2. Minute (choose one of the Modes 0, 2, 4, or can be altered in this step. Enter the lower two digits of 6) your production goal, in events per minute or events per hour. Exampes: The mode in common to your answers for the three questions above tell you which mode to choose in the If the typical rate is 20 (twenty) units per first function of Setup. The chart on page 3 can be minute, and the Goal count time basis is set to helpful here. minutes, set the Production Goal (Lower Digits) to 20 (twenty) and the Production Goal Now, move on to the other items to determine. (Different (Upper Digits) to 00. fields in examples below have different kinds of underlining). If the typical rate is 250 (two hundred and fifty) units per hour, and the Goal count time 2. Pause Clearance Delay: How long should the above basis is set to hours, set the Production Goal pause be, in seconds, from 1 to 99? (Lower Digits) to 50 (fifty) and the Production Goal (Upper Digits) to 02. We’ll skip over items 3 & 4 for a moment, and move on to items 5 & 6. What’s your production goal, the raw 6 Production Goal (Upper Digits) number, per hour or per minute? How many items do you want the line to be paced against? When setting the Production Goal (Upper Digits), decimal points after each digit are all lit. All digits will 5. Production Goal (Lower Digits): The least display, but only the upper digits can be changed in this significant two digits, the two on the right, go here step. See 5 Production Goal (Lower Digits) for details. 6. Production Goal (Upper Digits): The most significant two digits, the two on the left, go here SETUP WORKSHEET Before showing some Setup examples, let’s determine Now, let’s go back to items 3 & 4. You chose above, in a few things. Here’s a checklist which will help, 1B, whether you measured in items/hour or items/minute. covering the six Setup functions. You also chose above, in items 5 & 6, your numeric goal. Multiply the raw number of items times the number of 1. First, let’s review your choices of Modes. minutes or hours you want to count the average in. A. Do you have reliable 60Hz (“60 cycle”) AC power? (Choose one of the Modes 0, 1, 2, or 3. Average Basis (Lower Digits): The least significant 3). Alternatively, you can use the internal two digits, the two on the right, go here 100Hz timer (choose one of the Modes 4, 5, 6, or 7) which has 50 ppm accuracy. 4. Average Basis (Upper Digits): The most significant two digits, the two on the left, go here B. When there’s a pause of (99 seconds or less) in the signals from your system which signify another item’s produced, do you want to 1. Clear the counter timer (choose one of the Modes 2, 3, 6, or 7) or 2. Pause Counting? (choose one of the Modes 0, 1, 4, or 5) C. Do you want to set your goal in items per Alzatex, Inc. www.alzatex.com 5 11/08/09
  6. 6. OPTIONS ACCURACY OPTICALLY-COUPLED INTERFACE PERMITS If DC power is used to control the DS017E-RATE, the SAFE AND RELIABLE CONNECTION TO internal time reference must be selected by choosing one MACHINERY of the modes numbered four (4) through seven (7). Using the internal time reference provides 50ppm An optional optically-coupled, electrically-isolated accuracy. The AC power line frequency in most areas of interface is available. Removing a direct electrical the United States and Canada has a long-term accuracy of connection to other equipment eliminates the possibility three to five seconds per year, but short term inaccuracies of ground loops, diminishes chances of interference and may occur. increases safety. At production rates of more than ten times the time SEVEN SEGMENT DISPLAY WITH LARGE reference frequency, whether derived from the 60Hz DIGITS FROM 2.33” (5.9cm) TO 36" (91.4cm) power line or the 100Hz internal oscillator, the DS017E- TALL RATE may be inaccurate. Small, large and very large external displays may be Electrical power, whether AC or DC, should be added to repeat what the internal display shows. connected to the DS017E-RATE, not connected only to an Displays can be directly wired, connected through a external display. Some external displays do not have network, or radio can be used for wireless control. internal time references. The 100Hz internal time reference must be used in these applications. ANDON RED / YELLOW / GREEN INDICATOR LIGHTS SHOW ABOVE OR AT GOAL / BELOW GOAL USE OUTSIDE OF NORTH Small, large and very large external lights may be added AMERICA to show when a production line is below (red), idle (yellow) or at or above the current goal (green). The standard DS017E-RATE is not designed for 50Hz Displays can be directly wired, connected through a power line frequencies found in many places outside of network, or radio can be used for wireless control. North America. Use the 100Hz internal reference when only 50Hz power is available. ANDON FLASHING AT GOAL RATE TO PACE WORKERS An optional output from the DS017E-RATE sends a signal pulse when an event should occur, based on the goal set and elapsed time. That signal could control a flashing light or other feedback device to encourage an efficient rhythm of production, to set a pace for work. An LED on the circuit board blinks when that pulse would be sent. BEEPER OR HORN SOUND AT GOAL RATE TO INDICATE WHEN AN ITEM SHOULD BE COMPLETED An optional output from the DS017E-RATE signals every time an event should occur, based on the programmed goal and elapsed time. That signal could drive a chime, horn, buzzer, beeper, or other feedback device to encourage an efficient rhythm of production. An LED on the circuit board blinks to show when that pulse would be sent. Alzatex, Inc. www.alzatex.com 6 11/08/09
  7. 7. C. Two displays may be connected using an RJ-45 INSTALLATION CONNECTIONS splitter, but a large display may require its own power supply. If so, make sure the DS017E-RATE has a reliable power supply of its own. Sensors: D. If the distance between the DS017E-RATE and an A. Direct Connection: Connect pins 6 and 8 on external display will be long, use a ‘crossover’ the eight-pin polarized connector to a sensor six-wire cable with an RJ25 modular phone type on customer’s equipment. When closure of the connector to a KT422 type interface between the circuit is sensed, the counter will recognize it DS017E-RATE and the display, with a as another count. prefabricated 4 wire cable of 100’ or less between the KT422 and the display. The display B. Isolated Connection (Optional): Use an opto- side uses a 4-pin round connector plug. Color isolator, with the output from the isolator codes for wiring small displays are: V=Red, connected to pins 6 and 8 on the eight-pin G=Black, A=Green and B=White (if problems polarized connector. occur, try switching A and B); larg displays use +V=Red, GND=Black, RX+=Green and RX- =White. Power Supplies (Three options): A. Plug a 9-12V AC transformer into a 60Hz standard wall outlet. The supply’s coaxial connector plug is inserted into the matching IN connector on the Main Interface board INSTALLATION PIN ASSIGNMENTS (KT10260A0). The DS017E-RATE relies on a sensor connection, direct or B. Plug a 9-12V DC power supply into a 60Hz isolated, on pins 6 and 8 of the eight-pin polarized standard wall outlet. The supply’s coaxial connector. connector plug is inserted into the matching IN connector on the Main Interface board (KT10260A0). Make sure to select modes 4, 5, 6 or 7 in the Setup process. C. Attach a supply’s coaxial connector plug to a cable from a 12V DC battery into a 60Hz standard wall outlet. The supply’s coaxial connector plug is inserted into the matching IN connector on the Main Interface board (KT10260A0). Make sure to select modes 4, 5, 6 or 7 in the Setup process. External Displays: All attach to the TX (out) port on the DS017E-RATE A. Alzatex external digital displays run by a KT10260 type controller attach using a standard CAT-3 or better network cable, with RJ-45 eight-pin connectors on each end, with a run of 100’ or less. B. Alzatex external RYG displays attach using a standard CAT-3 or better network cable, with RJ-45 eight-pin connectors on each end, with a run of 100’ or less. Alzatex, Inc. www.alzatex.com 7 11/08/09

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