Sencon SI9000 plus Operation & User’s Manual

SI9000plus Enamel Rater User Manual REF OPERATION MANUAL No. 092-00900-10 LANGUAGE ENGLISH REVISION 10

3 1. INTRODUCTION 5 1.1 THE ENAMEL RATING TEST 5 1.2 THE SI9000+ 5 1.2.1 BODY CONTACT AND LEVEL CHECKING 6 1.2.2 SEMI-AUTOMATIC OPERATION 6 1.2.3 BATCH OPERATION 6 1.2.4 CONSTRUCTION 6 1.3 THE SI9005 CAN STAND 7 2. GETTING STARTED WITH YOUR SI9000+ 8 2.1 SAFETY 8 2.2 SETTING THE MAINS VOLTAGE 8 2.3 ADJUSTING AND CONNECTING THE CAN STAND 10 2.4 CONNECTING A NON-SENCON PROBE 12 2.5 SWITCHING ON AND THE SELF TEST 13 3. OPERATION 14 3.1 GENERAL DESCRIPTION 14 3.2 CONFIGURATION CHECK 14 3.3 FREE RUN AND REVERSE POLARITY 15 3.4 BATCH MODE 16 3.4.1 RATING CANS 16 3.5 MASTER RESET 17 3.6 ERROR MESSAGES 18 4. CONFIGURING YOUR SI9000 19 4.1 SETTING THE MAINS VOLTAGE 20 4.2 SETTING UP THE STATISTICAL OUTPUT 21 4.3 THE LEVEL INTERLOCK 21 4.4 THE CONTACT INTERLOCK 22 4.5 CHANGING THE RATING VOLTAGE 22 4.6 CHANGING THE RATING DURATION 22 4.7 AUTORANGING OPERATION 23 4.8 LINE NUMBER ENABLE 23 4.9 AUTOSTART 24 4.10 AUTOSAVE 24 5. MAINTENANCE AND SERVICING 25 5.1 CARE OF YOUR SI9000+ 25 5.2 ROUTINE MAINTENANCE 25 5.3 ROUTINE TESTING 25 5.5 FAULT FINDING 27 5.6 REPLACING THE FUSE 28 5.7 OBTAINING HELP FROM SENCON 28 6. USING THE SI9000+ WITH A PRINTER 29 6.1 OVERVIEW 29 6.2 CHOOSING A PRINTER 29 6.3 CONNECTING THE PRINTER 30 6.3.1 THE EPSON FX OR EX PRINTER 30 6.3.2 THE TANDY DMP132 PRINTER 31 6.3.3 USING OTHER PRINTERS 31 6.4 SETTING UP THE RS232 DATA FORMAT 32 6.4.1 SETTING UP THE EPSON PRINTER 32 6.4.2 SETTING UP THE TANDY PRINTER 33

6.4.3 SETTING UP OTHER PRINTERS 33 6.5 ENABLING THE PRINTOUT 33 6.6 SELECTING THE PRINTOUT FORMAT 34 6.7 PRINTER PROBLEMS 35 7. USING THE SI9000+ WITH A COMPUTER 36 7.1 GENERAL 36 7.2 COMPUTER PORT CONNECTIONS 36 7.3 SETTING DATA FORMAT AND SPEED 37 7.4 UNI-DIRECTIONAL PROTOCOL 38 7.5 BI-DIRECTIONAL PROTOCOL 38 7.6 FORMAT OF MESSAGE TRANSMITTED 39 7.7 ERROR MESSAGES 39

5 1. INTRODUCTION 1.1 THE ENAMEL RATING TEST The can industry has established a standard test for lacquer integrity of food and beverage cans. The test involves applying a voltage between a conductive liquid (electrolyte) within the can and the metallic can body. As the internal lacquer coating is an insulator, any current which flows is an indication of imperfections in the lacquer . The larger the current the greater the area of the imperfections and the poorer the quality of the can. There is no definitive standard for the enamel rating test. Different users have their own standards specifying the test voltage and test duration, however a common standard requires a voltage of 6.3V to be supplied for 4 seconds. In its factory supplied configuration the SI9000+ uses this voltage and duration. When a faulty can is detected the normal procedure is to reverse the polarity of the applied voltage, which causes bubbles of gas to be released from the area of the fault. This gives a visual indication of the location of the fault and enables corrective action to be taken. 1.2 THE SI9000+ The following description of operation assumes that the SI9000+ is operated in its factory set configuration (see Appendix A Fig 1 for settings).

1.2.1 BODY CONTACT AND LEVEL CHECKING One of the problems the enamel rating test has suffered in the past is that if any part of the circuit has a poor, high resistance contact only a small current will flow and the instrument will show a bad can as good. This is a particular problem where electrical contact is made with the can body. In order to overcome this problem the SI9000+ has special circuitry which checks the contact with the can body and will not allow the test to proceed until a good contact has been detected. In addition to this, a similar circuit checks that the electrolyte level within the can is adequate and so avoids the problem of the upper zone of the can not being fully tested due to insufficient electrolyte. These two circuits together will also detect a fault anywhere in the connector or wiring to the probe, making the SI9000+ fail-safe in its operation. 1.2.2 SEMI-AUTOMATIC OPERATION Another spin-off of these check-circuits is that the SI9000+ can be configured to detect a change of can and will automatically start the test once a new can is correctly inserted. An internal timer will freeze the reading when a preset time (e.g. 4 seconds) has elapsed and one key press then prepares the instrument for the next can. 1.2.3 BATCH OPERATION As the operator rates cans the SI9000+ will store the readings (up to 99) in its memory as a batch. At any time during the batch statistical information about the batch can be displayed and at the end of the batch the readings in tabular format together with the statistical information can be output to a printer or computer if required. 1.2.4 CONSTRUCTION The acrylic coated steel case and waterproof polyester facia panel are designed to ensure that the SI9000+ will withstand the rigours of a factory environment. Further to this the case, mains-switch and connectors are all sealed to I.P.65 rating, thus preventing any ingress of corrosive electrolytes and allowing operation of the SI9000+ in "hose-down" areas.

7 1.3 THE SI9005 CAN STAND Due to the corrosive nature of the electrolytes used in enamel rating the life of probe attachments can be very poor. With this in mind, the SI9005 has been designed using nylon parts wherever possible, whilst all metal parts are made from specially selected stainless steels, heat treated where appropriate. The wiring of the can stand is completely sealed against corrosion from electrolytes which not only improves the life but ensures accuracy and reliability of the readings taken. Electrical contact is made with the can by three hardened knife edges, one of which is wired separately to allow electrical contact checking, and the two probes (one for rating and a shorter probe for level checking) are supported on an adjustable arm and telescopic column. This arrangement allows the probes to be lifted and rotated to one side while the can is being inserted.

2. GETTING STARTED WITH YOUR SI9000+ 2.1 SAFETY The test voltages used by the SI9000+ are sufficiently low so as to present no hazard whatsoever under all circumstances. Although potentially dangerous mains voltages are present inside the unit, the construction of the case to I.P.65 rating will prevent any hazard from this whilst the case remains intact. Should the facia become perforated or the case become damaged in such a way as to destroy the seal then the unit must be removed from service immediately and returned to Sencon for repair. Operators should be warned to keep electrolytes away from electrical socket outlets and never handle plugs with wet hands. 2.2 SETTING THE MAINS VOLTAGE The mains voltage of the SI9000+ is factory set as appropriate for the particular country to which it is supplied and the setting will be clearly marked on the back panel. Should you need to change the voltage proceed as follows:- i. Remove the six button head screws in the base of the case using the 2.5mm hex wrench supplied. ii. Remove the base panel taking care not to damage the earthing cable. iii. Referring to Appendix A Fig 1 move the mains voltage switch to the required position. iv. Check that the foam seal on the bottom of the case is intact and replace the base panel and six screws. v. Change or remove the voltage label.

9 Key to Enamel Rater Probe 1 - Bushing 7 - Body Contact 2 - Foot 8 - Locating Ring 3 - Clamp Screw 9 - Probe Arm 4 - Locking Screw 10 - Inner Column - Level Probe 11 - Outer Column 6 - Main Probe 12 - Stand Base FIGURE 2: ENAMEL RATER PROBE

2.3 ADJUSTING AND CONNECTING THE CAN STAND In order to make use of the electrolyte level checking facilities of the SI9000+, it is important that the can stand is adjusted correctly for the height of can to be tested. Referring to Fig.2 proceed as follows:- i. Raise outer column (item 11) and place can through the can locating ring (item 8) onto the body contacts (item 7). ii. Lower the outer column. Note If at any time the outer column will not return to its normal position resting on the stand base (item 12) due to the cable fouling inside, then raise the outer column and rotate clockwise for several turns until the column moves freely again. iii. Slacken clamp screw (item 3) using the 3mm hex wrench supplied, and slide the probe arm (item 9) so that the bottom of the level probe (item 5) is at the minimum permissible electrolyte level and the outer column is firmly against the stand base. iv. Tighten the clamp screw making sure the main probe (item 6) is central in the can. Take care not to overtighten the clamp screw as this will cause the outer column to bind on the inner column. The can stand is now ready for use and should be connected to the SI9000+ via the probe socket (refer to Fig.3). This connector is polarised so it must be aligned before insertion. Always screw in the locking ring and tighten finger-tight to ensure it is sealed against electrolyte.

2.4 CONNECTING A NON-SENCON PROBE If you want to connect another probe to your SI9000+ for specialised tests such as end, or side-seam enamel rating this is always possible using the 5 pin plug supplied, but the following points should be noted:- i. The cable diameter must be in the range 3mm to 5mm to ensure correct sealing. ii. Other probes are unlikely to support body contact and level checking and so these functions will be disabled. iii. If (ii) above applies, then the automatic restart facility after each can will be disabled. Soldering of the cable should be carried out by an electrician as follows:- Pin Function 1 Main probe (electrolyte connection). 2 Level probe (if not used, connect to 1). 3 Body contact check (if not used connect to 4). 4 End or can body contacts. 5 Not connected. The probe can now be connected to the SI9000+ via the probe socket (refer to Fig.3). Ensure the connector is aligned before insertion and screw in the locking ring finger-tight to ensure a good seal.

13 2.5 SWITCHING ON AND THE SELF TEST Having satisfied yourself that the mains voltage setting is correct, connect the mains plug to a suitable socket outlet or if you prefer wire the mains cable directly into a fused outlet. Switch on the SI9000+ by depressing the mains on/off switch on the back panel. On power up, the system will perform a self-test. The numeric displays will cycle through each digit from 0 through to 9 allowing the operator to see that all the segments illuminate correctly. The LED indicators will be illuminated in sequence. Finally the SI9000+ will go to standby mode with the can number and timer set to zero and the milliamp display set to dashes. Enamel rating can then begin by pressing. i. The start key. Enamel rating will start when the level and contact check requirements are satisfied (indicators off) and continue for 4 seconds. ii. The Free Run key. The SI9000+ will enamel rate for up to 99 seconds in free run. iii. The Reverse Polarity key. As ii) but with reversed polarity (can body negative)

3. OPERATION 3.1 GENERAL DESCRIPTION The SI9000+ will operate in two basic modes, "free run" and "batch". The free run mode includes reverse polarity operation, and is a totally manual operation not using any of the automatic features or interlocks of the SI9000+. Although it can be used as an operating mode on its own it is also available from within batch mode. The normal operating mode is batch mode and this should be used for rating cans even if a batch is not being tested. All instructions assume the SI9000+ is initially in standby mode, i.e. the milliamp display shows dashes and set to the factory configuration given in Appendix A Fig 1. 3.2 CONFIGURATION CHECK The Rating voltage and rating duration can be inspected whilst the SI9000+ is in standby mode (i.e. the milliamp display shows dashes) and before or after rating. To examine the rating voltage and rating duration: i. Press the set key. The rating voltage is displayed on the milliamp display. The ↑ and ↓ key are ignored. ii. Press the set key again. The rating duration is displayed on the timer display. The ↑ and ↓ keys are ignored. iii. Press the End key. The SI9000+ drops back to the condition it was in before the configuration check was made.

15 3.3 FREE RUN AND REVERSE POLARITY i. Place a can in the can stand, fill with electrolyte and lower the probe. ii. Press FREE RUN. The rating indicator will light, the timer display will increment and the current will be displayed in milliamps. The check circuits will be active but will not prevent operation. If either of the red warning indicators is lit then more electrolyte should be added or the can should be rotated against the body contacts as necessary. iii. To freeze the reading at any point press FREE RUN. Rating will stop and the timer will be halted. Rating can be resumed by pressing FREE RUN once more. iv. To reverse the polarity press REVERSE POLARITY. Note that the contact and level check circuits are disabled when reverse polarity is selected. v. To return to normal polarity, press FREE RUN. vi. To return to standby mode, press END. Reverse polarity operation is similar, but press REVERSE POLARITY instead of FREE RUN. If the timer should reach 100 seconds, the mode will be cleared automatically and the SI9000+ will revert to standby mode. Free run and reverse polarity are available from within batch mode and operate as described above except that pressing END or the timer reaching 100 seconds will return the SI9000+ to the stage from where free run or reverse polarity had been selected.

3.4 BATCH MODE 3.4.1 RATING CANS i. Place a can in the can stand, fill with electrolyte and lower the probe. If the body contact and level checks are clear, the can number will change to 1 and rating will commence. If either of the red warning indicators are lit then more electrolyte must be added or the can should be rotated against the body contacts as necessary. After the preset time has elapsed (usually four seconds), rating will stop and the reading will be frozen. The operator has the following options:- i. Save the reading in the internal memory by pressing SAVE. ii. Abandon the reading by pressing CLEAR. iii. Enter free run mode by pressing FREE RUN. iv. Enter reverse polarity mode by pressing REVERSE POLARITY. v. View the set rating time and rating voltage by pressing SET. If options iii or iv are chosen, operation will be as described in section 3.3. Remember that if END is pressed, or timeout occurs, the original timed reading will be redisplayed and the operator must press SAVE or CLEAR to continue. Having pressed SAVE or CLEAR the SI9000+ will be waiting for a new can and it will use its check circuits to detect the can being changed. Free run and reverse polarity are available at this point. To test the next can proceed as follows:- i. Remove the can just tested. ii. Insert a new can, fill with electrolyte, and lower the probe. If the SI9005 can stand is being used, the SI9000+ will detect the new can and as soon as both checks are clear will start rating the new can. If another probe that does not support body contact and level checks is being used, then press START to tell the SI9000+ it has a new can. By repeating the above operations up to 99 cans can be tested and their results stored. When 99 readings have been stored a "batch end" is automatically invoked.

17 3.5 MASTER RESET In the event of a major change, error or fault it may become necessary to completely reset the instrument. This is always required when the operating mode is changed. A reset will erase all stored settings and reading from the units memory. To perform a master reset proceed as follows; A) Switch off power to the unit. B) Simultaneously hold down the SET, ↑ and ↓ keys. C) Switch on the power. D) After 2 seconds release the keys and the system will be reset. When a master reset is performed the operator has the opportunity to change the default times and voltage settings (factory set to 4 seconds and 6.3V) using the SET, ↑ and ↓ keys. The new default values are stored in battery backed memory and are retained until another master reset is performed. The rating voltage and duration can be checked during operation as described in Section 3.2.

3.6 ERROR MESSAGES "OL" The SI9000+ has tripped out on current overload. Remove the cause of the overload and press CLEAR. "ERR" The Err message is displayed if the Batch/Stats key is depressed before any readings have been taken. Under these conditions it is not possible to calculate statistical information and there is no information available to send to a printer. "FAIL" This message may flash on power up and indicates that battery back-up of memory has failed. A master reset should be performed (see section 3.5). The clear key can be pressed to continue operation, but the chance that previously saved readings are corrupted is very high. "BUSY" The SI9000+ is waiting for the printer (see Section 6.7). "BUFFER Scrolling, computer buffer is 90% full NEARLY FULL" (see Section 7.7). "FULL" Flashing, computer buffer is full (see Section 7.7). "PSU" The power supply generating the rating voltage has failed. The SI9000+ may reset when CLEAR or END is pressed, alternatively switch off the SI9000+ for a few seconds. "CLR?" If BATCH/STATS is pressed when no printer is connected and the statistical output is disabled (see section 4.2) the CLR? message is displayed. Press CLEAR to clear the memory or END to return to the condition before BATCH/STATS was pressed. "PR ?" BATCH/STATS has been pressed when the statistical output is off (see section 4.2). The raw data may be printed by pressing SAVE.

19 4. CONFIGURING YOUR SI9000+ In order to change the configuration of the SI9000+ it is necessary to remove the base panel. Instructions for doing this are given in section 4.1 (i) and (ii). Before changing the configuration of the SI9000+ it is recommended that users familiarise themselves with the internal layout shown in Appendix A Figure 1. A list of the switches and jumpers of interest follows: SWITCH/ JUMPER NAME LOCATION TYPE OPERATION SW1 Micro board (Top Board) To right of SW2 Block of 8 miniature rocker switches numbered 1 to 8 on the device A switch is off when its rocker is pressed down adjacent to the "open" legend. SW2 Micro board (Top Board) To left of SW1 Block of miniature rocker switches numbered 1 to 8 on the device A switch is off when its rocker is pressed down adjacent to the "open" legend. SW11 Applications board (Lower Board) Below Fuses Block of miniature rocker switches numbered 1 to 8 on the device A switch is off when its rocker is pressed down adjacent to the "open" legend. Mains Selector Switch Applications board (Lower Board) To the right of the fuses Slide Switch Slide to correct position for supply voltage. J1 Micro board (Upper Board) R.H.S. 3 position jumper Connect the pair of pins adjacent to the required legend A,B or C using the jumper. J2 Micro board (Upper Board) 2 position jumper Connect the upper pair of pins for A or the lower pair for B, using the jumper.

SWITCH/ JUMPER NAME LOCATION TYPE OPERATION J3 Micro board (Upper Board) 2 position jumper Connect the left hand pair of pins for A or the right hand pair for B, using the jumper. VR1VR5 Applications board (Lower board) below the transformer Multiturn Pot Adjust in accordance with Section 5.4.1. VR6VR7 Applications board (Lower board) to the right of the transformer Multiturn Pot Adjust in accordance with Section 5.4.2. The factory settings for the jumpers and switches are shown in Appendix A Fig 1. 4.1 SETTING THE MAINS VOLTAGE The mains voltage of the SI9000+ is factory set as appropriate for the particular country to which it is supplied and the setting will be clearly marked on the back panel. Should you need to change the voltage proceed as follows:- i. Remove the six button head screws in the base of the case using the 2.5mm hex wrench supplied. ii. Remove the base panel taking care not to damage the earthing cable. iii. Referring to Appendix A Fig 1 move the mains voltage switch to the required position. iv. Check that the foam seal on the bottom of the case is intact and replace the base panel and six screws. v. Change or remove the voltage label.

21 4.2 SETTING UP THE STATISTICAL OUTPUT When SW11/1 and SW11/2 on the applications board (see Appendix A Fig 1) are set according to the following table statistical information is available when the Batch/Stats key is pressed. SW11/1 SW11/2 AVAILABLE STATISTICAL OUTPUT Off Off None Off On Average followed by Range On Off Average followed by Standard Deviation On On Average followed by 3 x Standard Deviation The statistical information is available after the reading from any can within the batch has been saved. When the statistical information has been examined, 3 choices are available: i. Press the END key to add further cans to the batch. ii. Press the SAVE key to download the batch data to a printer (assuming the printer and SI9000+ are correctly configured, see Section 6). iii. Press the CLEAR key to erase the batch information from the SI9000+'s memory. 4.3 THE LEVEL INTERLOCK When SW11/5 on the applications board (see Appendix A Fig 1) is set off the operation of the SI9000+ changes as follows: i The SI9000+ can no longer detect when a can change has occurred and will not auto start after the change. Note that the level check indicator continues to operate normally. ii Enamel rating with the level check indicator on is allowed and commences when START is pressed.

4.4 THE CONTACT INTERLOCK When SW11/6 on the applications board (see Appendix A Fig 1) is set off the operation of the SI9000+ changes as follows: i The SI9000+ can no longer detect when a can change has occurred and will not autostart after the change. Note that the contact check indicator continues to operate normally. ii Enamel rating with the contact check indicator on is allowed and commences when START is pressed. 4.5 CHANGING THE RATING VOLTAGE When SW11/7 on the applications board (see Appendix A Fig 1) is set on the operation of the SI9000+ changes as follows: i On completion of the power up self test the default voltage setting of 6.3V is displayed on the mA display. This can be changed to 4,10,12 or 15V using the ↑ and ↓ keys. When the required rating voltage is displayed, press END to "drop back" to normal rating operation. ii The rating voltage may then be changed at the start or end of a rating cycle, by pressing SET and using the ↑ and ↓ keys. When the required rating voltage is displayed, press END to "drop back" to normal rating operation. 4.6 CHANGING THE RATING DURATION When SW11/8 on the applications board (see Appendix A Fig 1) is set on the operation of the SI9000+ changes as follows: i. On completion of the power up self test the default rating duration of 4 seconds is displayed on the timer display. This can be altered over the range 2 to 99 seconds using the ↑ and ↓ keys. When the required rating voltage is displayed, press END to "drop back" to normal rating operation. ii. The rating duration may then be changed at the start or end of a rating cycle, by pressing SET and using the ↑ and ↓ keys. When the required rating duration is displayed, press END to "drop back" to normal rating operation.

23 4.7 AUTORANGING OPERATION When SW1/1 on the micro board (see Appendix A Fig 1) is set on the operation of the SI9000+ changes as follows: 1. All enamel rating currents up to 45mA are displayed and saved to two decimal places (10μA). Note that 5mA of hysteresis is incorporated in the design, so that with a decreasing current the SI9000+ does not operate to two decimal places until the current drops below 40mA. Currents above the thresholds continue to be displayed to one decimal place (100μA). 4.8 LINE NUMBER ENABLE When SW1/2 on the micro board (see Appendix A Fig 1) is set on the operation of the SI9000+ changes as follows: 1. On power up the SI9000+ prompts for a line number. This can be set to any value between 0 and 99 using the ↑ and ↓ keys. One or more cans can then be enamel rated as a batch. When the data is sent to a printer or host computer the line number is also sent. 2. When a batch of measurements have been taken and statistical information, a printout or data transfer completed, pressing END will cause the SI9000+ to prompt for a new line number. Note that once a new line number is entered, all data from a previous line is erased. The line number facility is provided primarily so that a complete set of data can be sent to a printer or host computer.

4.9 AUTOSTART When SW1/3 on the micro board (see Appendix A Fig 1) is set off the operation of the SI9000+ changes as follows: 1. The semi-automatic operation described in Para 1.2.2. does not operate. After placing a can in the can stand the operator must press start and ensure that the level and contact check indicators are off before enamel rating will commence. Note that if either SW11/5 or SW11/6 is off then the autostart function is disabled, and rating will commence only when START is pressed. 4.10 AUTOSAVE When SW1/4 on the micro board (see Appendix A Fig 1) is set on the operation of the SI9000+ changes as follows: 1. The SI9000+ operates in a "fully automatic" mode. After each can has been rated the displayed reading is automatically saved as the can is removed from the can stand and the contact check and level check indicators are illuminated. The combination of autosave and autostart results in a "fully automatic" operation.

25 5. MAINTENANCE AND SERVICING 5.1 CARE OF YOUR SI9000+ The SI9000+ is a precision instrument and should be treated as such. Avoid exposure to extremes of temperature, humidity, mechanical vibration and shocks. Although the case is sealed to I.P.65, electrolytes and other liquids should be kept away from the unit as much as possible. These few simple precautions will ensure your SI9000+ will hold its calibration closely and give years of reliable service. 5.2 ROUTINE MAINTENANCE The following procedures should be carried out weekly or more frequently depending on usage:- i. Clean the enamel rater case and can stand with a cloth dampened with water. Do not use solvents or abrasives under any circumstances. If greasy or oily deposits are present the use of dishwashing detergent is permissible. ii. Check the facia panel, case and seals of the SI9000+ for damage. iii. Check the external wiring for damage. iv. Check all connectors for security. v. Check the operation of both the enamel rater and the can stand. 5.3 ROUTINE TESTING Once a day or more frequently depending on usage the following test should be carried out using the test cable supplied with the SI9000+:- Referring to Fig.2 (Page 4) i. Remove the can locating ring (item 8). ii. Attach the large crocodile clip of the test cable to the body contact (item 7) furthest from the inner column (item 10). iii. Attach the smaller crocodile clip to the main probe (item 6). iv. Press FREE RUN.

The 'Rating', 'Low Level' and 'Contact Fault' indicators should be lit and the milliamp display should show the reading given in the table below for the rating voltage in use: RATING VOLTAGE MILLIAMP DISPLAY READING 4 4+0.2mA 6.3 6.3+0.2mA 10 10+0.3mA 12 12+0.4mA 15 15+0.5mA If this is not the case first check that the crocodile clips are making good contact. If this does not cure the fault refer to section 5.5 'Fault Finding'. v. Repeat the test in reverse polarity. Now the 'Low Level' and 'Contact Fault' indicators should be off and the 'Reverse Polarity' and rating indicators should be lit. The milliamp reading should be the same. Note: This test is far superior to internal calibration tests as it will detect the more likely faults such as corroded or dirty connectors and damaged probe cables. It will not, however, show up equal and opposite drift of internal voltage and current references. This test should therefore be supplemented with calibration against a good quality external meter as detailed in section 5.4.

27 5.5 FAULT FINDING None of the LED indicators or displays light when the on/off switch is depressed. i. Check that the mains supply is connected. ii. Check that the fuse in the mains plug (if any) has not blown. iii. Check that the internal fuse has not blown (Refer to Section 5.6) iv. Contact Sencon. The operation has "locked up" and/or the displays show meaningless information. i. Perform a master reset (refer to Section 3.5). All readings will be lost from memory. Ensure that the rating voltage and duration is correctly reset. ii. Check that the mains voltage setting is correct. iii. Contact Sencon. NOTE: If this fault occurs frequently and operation 1 cures the fault, it is likely that the mains supply to the unit is noisy or interrupted. This must be corrected for reliable operation. The milliamp reading is incorrect with the test cable connected. i. Check that the mains voltage setting is correct. ii. Check that the probe plug is secure in its socket. iii. Inspect the probe wiring and connectors for damage or corrosion. iv. Proceed to Section 5.4 "Calibration".

5.6 REPLACING THE FUSE The internal fuse is 500mA anti-surge type, size 20mm x 5mm. A spare fuse is contained inside the case. Proceed as follows :- i. Switch off the SI9000+ and isolate from the mains supply. ii. Remove the six button head screws using the 2.5mm hex wrench supplied. iii. Remove the base panel taking care not to damage the earthing wire. iv. Referring to Appendix A Fig.1 locate the working fuse and the spare fuse. v. Remove the fuse carrier and fuse by lifting at one end. NOTE: The fuse type fitted may not show a break in the conductor when it has blown. If in doubt test with an ohm- meter. vi. Replace or exchange the fuse as necessary. vii. Refit the base panel, checking that the seal is intact. viii. Refit the six button head screws. 5.7 OBTAINING HELP FROM SENCON If you have a problem with your SI9000+ and require help from Sencon, the following information will greatly help us to assist you :- i. Serial number of the unit. ii. Version number of the software (This can be obtained by pressing CLEAR and SAVE simultaneously whilst in Standby mode). iii. Exact description of the fault. iv. When it happens or what actions cause the fault to occur. v. Name of a contact (preferably technical) at the location.

29 6. USING THE SI9000+ WITH A PRINTER 6.1 OVERVIEW The use of a printer with the SI9000+ relieves the operator from having to record the results using pen and paper which is time consuming and can be a source of errors. The unit is shipped with the printer output off and this must be enabled before a printer is connected. 6.2 CHOOSING A PRINTER A large variety of printers could be used with the SI9000+, the most obvious choice probably being a low cost 80 column dot matrix printer intended for home or office use. In essence, the SI9000+ should work with any type of printer that is equipped with an RS232 serial interface, however, because of the large range available Sencon cannot accept responsibility for the performance or settings of a particular printer. A word of caution is required regarding the RS232 interface. Firstly, most printers intended for office use are fitted as standard with a parallel or centronics interface, this is not suitable for connection to the SI9000+ so the requirement for RS232 interface must be clearly stated to your supplier. Secondly, it must be accepted that the RS232 interface on the printer and possibly on the SI9000+ will have to be set up, sometimes a confusing operation for the uninitiated and thirdly, it may be necessary to obtain and solder a different connector onto the printer lead supplied by Sencon as standard. Your printer supplier should be able to assist you with any of these problems if they occur. The following printers have been successfully tested with the SI9000+; 1) Any printer from the Epson FX or EX range provided it is fitted with the Epson #8143 serial interface. 2) The Tandy DMP132 printer. This model is fitted with an RS232 interface as standard.

6.3 CONNECTING THE PRINTER The printer connection is the 3 pin socket at the side of the instrument as shown. The pin out and cable colour code for printer connections are given below; FIG 3: SIDE PANEL PIN FUNCTION SENCON CABLE COLOUR 1 GROUND BLUE 2 TxD (TRANSMIT DATA) RED 3 CTS (CLEAR TO SEND) YELLOW 6.3.1 THE EPSON FX OR EX PRINTER This printer will need to be fitted with the Epson #8143 serial interface which offers a 25 way D type female connector. The wire connection is as follows. SI9000+ PIN SENCON CABLE COLOUR EPSON PIN 1 BLUE 7 2 RED 3 3 YELLOW 11 It should be noted that a number of other printers share this type of connector and pin connection. PRINTER CONNECTOR

31 6.3.2 THE TANDY DMP132 PRINTER This printer utilises a 4 pin DIN style connector for its serial interface (Radio Shack Cat No. 274-007). Wire connection is; SI9000+ PIN SENCON CABLE COLOUR EPSON PIN 1 BLUE 3 2 RED 4 3 YELLOW 2 6.3.3 USING OTHER PRINTERS If a different printer is used the connector type and pin numbers will be given in the printer user manual. Having obtained the correct connector it will be necessary to connect to it as follows; SI900+ PIN COLOUR PRINTER CONNECTION 1 BLUE Signal Ground or OV. Not to be confused with screen or protective ground which may be a different pin. 2 RED TxD or Transmit Data. This is the wire that carries the data signal with respect to OV out of the SI9000+. 3 YELLOW CTS or clear to send. This signal is generated by the printer and is used to stop and start the flow of data from the SI9000+. It must be connected otherwise it will stop data transmission.

6.4 SETTING UP THE RS232 DATA FORMAT The RS232 standard allows a large number of permutations in its data transmission format. It is therefore necessary to ensure that the printer is set to the same transmission format as the SI9000+. The format of the data transmission on the printer port of the SI9000+ is; 300/1200/9600 Baud - Selectable 8 DATA BITS NO PARITY BIT 1 STOP BIT It is possible to change the baud rate as described in section 6.5 below, however, Sencon recommend the 1200 baud is used. 6.4.1 SETTING UP THE EPSON PRINTER The Epson printer fitted with the #8143 serial interface has a bank of 8 small switches on the interface board that are used to select the transmission format. This switch bank is marked SW1 and should be set as below to achieve the correct format and 1200 baud. SWITCH NO. SWITCH NAME SETTING FUNCTION 1-1 JB3 OFF BAUD RATE SELECTION 1-2 J8/7 OFF WORD LENGTH 1-3 JB1 OFF BAUD RATE SELECTION 1-4 JB2 OFF BAUD RATE SELECTION 1-5 JO/E OFF PARITY ODD/EVEN 1-6 JPDS OFF PARITY ON/OFF 1-7 JB4 ON BAUD RATE SELECTION 1-8 P/2 ON SERIAL/PARALLEL

33 6.4.2 SETTING UP THE TANDY PRINTER The Tandy DMP132 has two sets of switches used to configure the printer. These are accessed through an opening in the back of the unit, near the serial port connector. The recommended settings for these switches are; SWITCH NO. SETTING FUNCTION 1-1 OFF TANDY CODES 1-2 ON CR=CR 1-3 OFF LF=LF 1-4 OFF 11 INCH FORM 1-5 OFF SKIP INVALID 1-6 OFF 1//6 INCH LF 1-7 OFF TANDY CHARACTERS 1-8 ON WP MODE 2-1 ON 1200 BAUD 2-2 OFF SERIAL PORT 6.4.3 SETTING UP OTHER PRINTERS For other printers it is essential that the serial port is set to match the format as given in section 6.4 above. This may entail the operation of switches or jumpers inside the printer as described in the printer instruction manual. The SI9000+ does allow the baud rate to be changed between 300, 1200 and 9600 baud. We recommend the use of 1200 baud as this provides the optimum compromise between printout speed and reliable operation. 6.5 ENABLING THE PRINTOUT The SI9000+ is shipped with its printer port disabled. This is to prevent the SI9000+ from attempting to send data to a non-existent printer and subsequently reporting a communications failure. The printout is enabled by SW1/7 and SW1/8 on the micro board (Refer to Appendix A Fig 1). The settings of switches SW1/7 and SW1/8 not only enable the printer but also set the baud rate of transmission. We recommend the use of 1200 baud as the ideal compromise between speed of operation and noise immunity and if the settings detailed in sections 6.4.1 and 6.4.2 are used, 1200 baud must be selected. Switch positions and corresponding selections are given below;

SWITCH SW1/7 SWITCH SW1/8 SELECTION OFF OFF PRINTOUT OFF OFF ON PRINTOUT ON-9600 BAUD ON OFF PRINTOUT ON-1200 BAUD ON ON PRINTOUT ON-300 BAUD Having enabled the SI9000+'s printer port and selected the printout Format (see Section 6.6), the SI9000+ should be connected to a printer configured as described in Section 6.4. The SI9000+ will transmit data to the printer when SAVE is pressed after BATCH/STATS. At this point the values of the cans rated in the batch, the statistical conformation and the line number, if enabled, will be printed. 6.6 SELECTING THE PRINTOUT FORMAT The printed output is arranged in columns according to the settings of SW1/5 and SW1/6 on the micro board (refer to Appendix A Fig 1). The relationship is given in the table below: SW1:5 SW1:6 COLUMNS OFF OFF 1 OFF ON 4 ON OFF 6 ON ON 8 The statistical information selected by SW11/1 and SW11/2 on the applications board will also be printed (refer to Appendix A Fig 1 and Section 4.2). If the prompt for line number option has been selected (See section 4.8) then the line number will be included on the printout.

35 6.7 PRINTER PROBLEMS If the printer option has been enabled (section 6.5) the instrument will attempt to transmit the data when SAVE is pressed after BATCH/STATS. Whilst the transmission takes place the word "busy" will appear in the display. If the printer is disconnected, is turned off or has some other problem the transmission will not take place and the word busy will remain until the printer problem has been corrected or the CLEAR key is pressed. If the word "busy" appears check that the printer is O.K. (i.e. no paper jam etc), check that it is on line, check the cable and connections, and check the printer set up. If the printout takes place but not correctly, check that both the printer and SI9000+ are set to the same baud rate and that the printer is set to the data format as given in section 6.4.

7. USING THE SI9000+ WITH A COMPUTER 7.1 GENERAL The SI9000+ incorporates a second serial port intended for connection to a host computer. This enables readings taken by the SI9000+ to be transferred to the computer for statistical analysis and archiving. The data format and communications protocol are selectable and it will require a suitably experienced person to organise and set up such a connection. It will also be necessary to have software produced for the computer that is capable of receiving and understanding the data from the SI9000+. The SI9000+ supports bi-directional or uni-directional communication. Internal jumpers are used to select between RS232C, RS422 and RS485 communication standards. 7.2 COMPUTER PORT CONNECTIONS Serial Port 2 is the 4-way connector on the side of the SI9000+. The pinout of this connector is shown below. FIG 6: COMPUTER PORT CONNECTOR

37 A suitable 4 way plug is supplied with each SI9000+. 7.3 SETTING DATA FORMAT AND SPEED The computer port is set up using SW2, J1, J2 and J3 on the micro board and SW11/3 and SW11/4 on the applications board (Refer to Appendix A Fig 1. All switches must be set to match the data transmission set up of the serial port on the host computer. SW2/1 on the micro board must be on to enable the computer port output. The switch functions are as follows: SWITCH BANK 2 SWITCH POSITION OPEN CLOSED S2/1 Computer Output Off Computer Output On S2/2 Software Handshake Off Software handshake On Computer Transmission Data Format as below:- S2/3 S2/4 S2/5 FORMAT OPEN OPEN OPEN 7 data bits-Even Parity-2 Stop Bits OPEN OPEN CLOSED 7 data bits-Odd Parity-2 Stop Bits OPEN CLOSED OPEN 7 data bits-Even Parity-1 Stop Bits OPEN CLOSED CLOSED 7 data bits-Odd Parity-1 Stop Bits CLOSED OPEN OPEN 8 data bits-No Parity-2 Stop Bits CLOSED OPEN CLOSED 8 data bits-No Parity-1 Stop Bits CLOSED CLOSED OPEN 8 data bits-Even Parity-1 Stop Bits CLOSED CLOSED CLOSED 8 data bits-Odd Parity-1 Stop Bits S2/6} Computer Transmission Baud Rate as defined below: S2/8 S2/7 S2/6 Baud Rate OPEN OPEN OPEN 76800 * OPEN OPEN CLOSED 38400 OPEN CLOSED OPEN 19200 OPEN CLOSED CLOSED 9600 CLOSED OPEN OPEN 4800 CLOSED OPEN CLOSED 2400 CLOSED CLOSED OPEN 1200 CLOSED CLOSED CLOSED 300 *NOTE: Sencon do not guarantee operation at this speed.

The jumpers on the micro board must be changed according to the communications standard used: RS232 RS422 RS485 J1 C A B J2 B A A J3 B A A SW11/4 on the applications board selects between RS422 and RS485. When SW11/4 is off RS422 is selected. If RS422 or RS485 is to be used the plug connecting the socket on the rear panel to the microboard should be moved from P2 to P3. These connectors are marked on the circuit board. 7.4 UNI-DIRECTIONAL PROTOCOL If SW11/3 on the applications board is off (open), uni-directional protocol is used. As each reading is saved it is automatically sent down the serial port, if the hardware handshaking line is clear. 7.5 BI-DIRECTIONAL PROTOCOL If SW11/3 on the applications board is on (closed), bi-directional protocol is used. As each reading is saved it is stored in an internal buffer, which is battery backed in case of power failure. When the enamel rater receives a data request message from the host computer the data stored in the buffer is sent. Data Request message: <40h><01h> where: <40h> (1 byte) ASCII character '@' <01h> (1 byte) When using bi-directional communications, software handshaking is available as an option as well as hardware handshaking. If selected, (SW2/2 closed on the micro board) the XON/XOFF protocol is used. If XOFF is sent to the enamel rater it must be followed by XON before any further transmission will occur.

39 7.6 FORMAT OF MESSAGE TRANSMITTED The format of the message sent is dependent on the settings of the appropriate DIP switches, and the mode of communication selected. If all options are selected the message is as follows: <4CH><20H><52h><20h> where: <4CH> (1 byte) ASCII 'L' <20H> (1 byte) ASCII ' ' (2 bytes) ASCII characters for digits, a decimal point e.g. 99 = '9' '9' <52H> (1 byte) ASCII 'R' <20H> (1 byte) ASCII ' ' (5 bytes) ASCII characters for digits, and a decimal point e.g. 126.4 = '1'' 2'' 6'' . ''4' If the LINE NUMBER option is not selected then the appropriate header and associated message are not transmitted and the two byte header before the actual enamel reading is not sent. When bi-directional communications are used an end-of-data byte is transmitted when the whole buffer has been sent. This byte is also sent if the buffer is empty when the data request message is received. End-of-data byte: <04H> NOTE: RS485 communications facilities are not available. They will be implemented at a later date. 7.7 ERROR MESSAGES "Buffer nearly full" will scroll across the large display when the internal buffer is 90% full. The message is cleared automatically when the level drops below 90%. Alternatively the CLEAR key can be pressed. FULL will flash on the large display when the internal buffer is full. The message will clear automatically when space is available in the buffer, i.e. after a message is sent. If CLEAR is pressed the oldest data, not sent, in the buffer will be overwritten next time a reading is saved.

APPENDIX A Voltage regulation switch Working Fuse Spare fuse Voltage trim pots Current trim pots See note 1 See note 1 FIGURE 1: PCB LAYOUT

41 1. The factory switch and jumper settings are: MICROBOARD J1 = C J2 = B J3 = B J4 = ON SW1 SW2 1 OFF OFF 2 OFF OFF 3 ON OFF 4 OFF OFF 5 OFF OFF 6 OFF OFF 7 OFF OFF 8 OFF OFF APPLICATIONS BOARD SW11 1 OFF 2 OFF 3 OFF 4 OFF 5 ON 6 ON 7 OFF 8 OFF Switches are off when the rockers are pressed down adjacent to the open legend.

2. SWITCH AND JUMPER FUNCTIONS: REF SECTION REF SECTION SW1/1 AUTORANGING OPERATION 4.7 SW2/1 COMPUTER OUTPUT 7.3 SW1/2 LINE NUMBER ENABLE 4.8 SW2/2 SOFTWARE HANDSHAKING 7.3 SW1/3 AUTOSTART 4.9 SW2/3 COMPUTER } 7.3 SW1/4 AUTOSAVE 4.10 SW2/4 DATA SW1/5 PRINTOUT FORMAT 6.6 SW2/5 FORMAT } SW1/6 PRINTOUT FORMAT 6.6 SW2/6 AND } SW1/7 PRINTOUT ENABLE AND BAUD 6.5 SW2/7 BAUD SW1/8 PRINTOUT ENABLE AND BAUD 6.5 SW2/8 RATE SW11/1 STATISTICAL OUTPUT 4.2 SW11/2 STATISTICAL OUTPUT 4.2 SW11/3 BI-DIRECTIONAL COMMS 7.5 SW11/4 422/485 7.3 SW11/5 LEVEL INTERLOCK 4.3 SW11/6 CONTACT INTERLOCK 4.4 SW11/7 RATING VOLTAGE 4.5 SW11/8 RATING DURATION 4.6 JUMPERS J1, J2 AND J3 MUST BE CONFIGURED TO SUIT THE COMMS STANDARD USED (REF SECTION 7.3).

Specification Operating voltage 220 setting 220-250 V a.c. 50-60 Hz 110 setting 100-125 V a.c. 50-60 Hz Power consumption 30 watts Rating Voltage 4.0 volts +/- 1% for rating 6.3 volts +/- 1% currents in 10.0 volts +/- 1% the range 12.0 volts +/- 1% 0 to 100mA 15.0 volts +/- 1% Accuracy of milliamp reading +/- 1% of reading +/- 1 L.S.D. Milliamp measurement range 0.00mA to 800.0mA Operating Temperature 5°C to 40°C Environmental Protection I.P. 65

45 REVISION AT V.01 i. Para 3.6 "PSU" - "The SI9000+ may reset when CLEAR or END is pressed " was "The Si9000+ may reset automatically". ii. Para 6.1 - Paragraph revised for clarity. iii. Para 7.3 - Switch S2/8 and S2/6 settings have been swapped. Computer Transmission Baud rate was incorrectly defined as: S2/6 S2/7 S2/8 Baud Rate OPEN OPEN OPEN 76800 OPEN OPEN CLOSED 38400 OPEN CLOSED OPEN 19200 OPEN CLOSED CLOSED 9600 CLOSED OPEN OPEN 4800 CLOSED OPEN CLOSED 2400 CLOSED CLOSED OPEN 1200 CLOSED CLOSED CLOSED 300 iv. P.40 Figure 7 - The front Panel drawing added. REVISION AT V.02 i. Manual Format Change.