AMETEK 1025 User Manual

Semelex IITM Safetimeter

Operating Manual

Series 1999

Gemco

Self-Contained, Portable Electronic Stop-Time Meter

1080 North Crooks Road Clawson, MI 48017-1097 Phone: (248) 435-0700 FAX: (248) 435-8120 Internet: www.ametek.com www.ameteksensortech.com

Preface

This manual will instruct user in operating the Gemco 1999 Semelex II Safetimeter.

Version 0.1

AMETEK has checked the accuracy of this manual at the time it was printed. Any comments you may have for the improvement of this manual are welcomed.

AMETEK reserves the right to revise and redistribute the entire contents or selected pages of this manual. All rights to the contents of this manual are reserved by AMETEK.

iInstallation & Programming Manual

Contents

Chapter 1: Overview 1

1.1 Safetimeter Switches and Connectors.................................................1

1.2 Theory of Operation............................................................................2

Chapter 2: Unpack & Set-Up 3

2.1 Set-Up and Test .................................................................................3

Chapter 3: Operating Instructions 5

3.1 Placement of Position/Velocity (P/V) Transducer ................................5

3.2 Set the Control Start Point (CSP) ........................................................5

3.3 Set the TIME UP/TIME DOWN Switch ................................................7

3.4 Using Auto-Hand ...............................................................................8

3.5 Using Auto-Flag with Auto-Hand ........................................................9

3.6 Using Optional Manual Start Switches .............................................10

3.7 Using Optional Remote Tachometer..................................................10

3.8 Calculate Stop Angle ........................................................................11

3.9 Using the Safetimeter to Aid in Setting Cam Limit Switch Brake-

Monitors...........................................................................................13

3.10 Test Presses Running in a Continuous Mode ....................................14

3.11 Set Press Counterbalance.................................................................15

3.12 Test Full Revolution Clutch Presses..................................................16

Chapter 4: Certiﬁ cation and Warranty 17

4.1 Optional 5 Year Warranty.................................................................17

Chapter 5: Speciﬁ cations 18

Installation & Programming Manualii

Chapter 1: Overview

The Series 1999 Semelex II Safetimeter is a self-contained, portable electronic stop time meter capable of measuring elapsed time, stop time (Ts) from 1-9999 milliseconds. It also calculates the minimum safety distance (Ds) based on the OSHA formula, as understood by the factory, and will display up to 999.9 inches to the nearest 0.1 inches.

The Semelex II Safetimeter Test Set consists of four components:

Safetimeter This is the “brains” of the unit, with processing electronics that display the test results.

Position/Velocity (P/V) This motion and position sensor attaches to the press with Transducer its base and cable magnets.

Auto-Hand (A/H) This hand-held device is used to automatically release a run

control or press an E-Stop control on the press.

Auto-Flag (A/F) This assembly is attached to the Auto-Hand to test presses equipped with electronic guards, i.e. photoelectric barrier guards (light curtains) or capacitance type guards (conduit rail sensors).

Option: Manual Start Switches These two switches plug into the MANUAL START jack on the

Safetimeter panel and are used to manually start the Safetimeter timing.

Option: Remote Tachometer The tachometer replaces the P/V Transducer and Auto-Hand with Base when testing high speed or continuous stroke presses that

can’t stop within one stroke. With the wheel attachment, it can be used to test conveyors or indexing tables.

1.1: Safetimeter Switches and Connectors

ON/OFF This is the unit’s power switch. In the ON or OFF position

the power cord may be plugged into 115 VAC outlet for recharging the battery. In the ON position, the unit may be operated from the internal battery or 115 VAC line.

NOTE: With the Safetimeter ON and plugged in, the battery charges at a lower rate.

Operating Manual

Chapter 1: Overview

TIME UP/TIME DOWN This switch determines the direction of the test. In the TIME DOWN position you are performing a standard test according to OSHA requirements. The switch should be in the TIME UP position when checking press top stop.

STOP TIME (mSEC)/ This switch is used to select the display mode, either time or SAFETY DISTANCE (IN) distance. Time is measured in milliseconds and distance is

measured in inches.

FULL REV/PART REV This switch is used to determine the press clutch operation mode, either full or part revolution. The majority of tests are run in the part revolution mode.

CONTROL START Known as CSP, this dial is used to set the point in the POINT (IN) stroke at which the command to start timing and ﬁ res

the Auto-Hand is given. When the CSP dial is turned clockwise, the dial will increment and de-increment when turned counterclockwise. The CSP dial reads in tenths of an inch. Example: 123 equals 12.3”.

MANUAL START This jack is used with the optional manual start switches.

AUTO-HAND This connector is used to connect the Auto-Hand to the

Safetimeter.

1.2: Theory of Operation

The P/V transducer measures the open height of a press. When this measurement coincides with the preset CSP position, and the ram is traveling in the direction selected on the TIME UP/TIME DOWN switch, the Auto-Hand will release one of the two run controls or press an E-STOP control to initiate the press stop. When the ram stops, the P/V transducer sends a stop signal to the Safetimeter and the meter displays either stop time or safety distance, whichever display mode was selected prior to the test.

NOTE: No OSHA standard exists for deﬁ ning when a press has stopped (at what

ram velocity). The Safetimeter ends its measurement when the ram velocity is approximately .17 inches per second (10 inches per minute). When measuring stop time, you must take into account all elements and devices used to bring the ram to rest. These include the “ﬂ ight time” of the run and E-STOP buttons (time for switch to activate), control relays, solenoids valves and clutch and brake mechanical elements. Where an electronic guard (light curtain) is used, response time of the device and the depth penetration factor must be added to that measured by the Safetimeter before calculating safety distance. Response time is generally stated by manufacturers of electronic guards. However, to verify systems, the Auto-Flag can be used.

Operating Manual

Chapter 2: Unpack & Set-Up

Chapter 2: Unpack & Set-up

The Series 1999 Semelex II Safetimeter has been carefully inspected and tested before shipment. Unpack the unit and perform a visual inspection to assure that no damage has occurred during shipping. If damage is found, notify the transportation company immediately. Only the consignee may institute a claim with the carrier for damage during shipment.

2.1: Set-Up and Test

1. The Safetimeter battery is shipped with a partial charge. Plug in the unit and charge the battery until the green LED goes off (maximum charge time is eight (8) hours).

2. Connect the P/V transducer with the appropriate connector.

3. Make the following Safetimeter switch settings: Display SAFETY DISTANCE (IN) Revolution PART REV Timing Direction TIME DOWN Control Start Point (CSP) 200 (20.0 inches)

4. Push the ON/OFF switch ON.

5. Place the P/V transducer on a metal desk or steel plate. The magnetic base will hold the unit in place.

6. Carefully slide the cable magnet from its keeper. Do not let the cable run free, it can be damaged by impact from sudden release. Pull the cable magnet out approximately 24 inches.

7. Bring the magnet back towards the P/V transducer. The P/V transducer will reel in the cable automatically. When the cable magnet is about 20 inches from the base of the P/V transducer, the Safetimeter will start counting. The unit will continue counting as long as the cable velocity is .17 inch per second (10 inches/minute) or greater.

8. Stop the cable from rewinding or pull the magnet out. The display will stop incrementing and show the results.

9. Again, pull the cable out approximately 24 inches. The display’s current value will remain because the Safetimeter is set in the TIME DOWN direction.

10. Let the cable rewind. The display will reset to “0” and start counting. The zero reset occurs automatically at the beginning of the count and cannot be seen.

NOTE: The Safetimeter will count when the cable is rewinding and stop when the

cable stops or the direction is reversed.

Operating Manual

Chapter 2: Unpack & Set-up

11. Change the TIME UP/TIME DOWN switch to the TIME UP position and start

with the cable rewound. The Safetimeter will begin to count when the 20 inch CSP setting is reached and continue until the cable stops or the direction is reversed.

12. Set the CSP dial to several values and check that the Safetimeter begins to

count at the preset positions when the cable is moving in the direction selected by the TIME UP/TIME DOWN switch.

13. If the optional Manual Start Switches are available, continue with steps 14-15.

If not, move to Chapter 3: Operating Instructions.

14. Plug one of the Manual Start Switches in the MANUAL Start jack. If the

Safetimeter is ON, the counter will begin to run. Switch the Safetimeter OFF and then ON to reset the counter.

15. If the Manual Start Switch is normally closed (red plug), the Safetimeter will

begin to count when the switch is pushed. If the Manual Start Switch is normally open (black plug), the Safetimeter will begin to count when the switch is released.

Operating Manual

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