Merrill Test Stand Manual

Laboratory Handle Test
Stand
Designed and Built by:
400 Florence Street
Saginaw, Michigan 48602
Phone: (989) 791-6676 Fax (989) 791-6177
http://www.merrillei.com/
Merrill Engineering & Integration Job No. 13-0254-001
Designed and Built for: Huf

Huf Mexico S de RL de CV
Anillo Perifrico Ecolgico
No. 46 Col San Francisco
Coronango Puebla,
Mexico
Purchase Order No. 312660

5/1/2014
2
Laboratory Handle Test Stand
Table of Contents
Chapter 1 Introduction ....................................................................................................... 5
Proprietary Clause & Agreement ............................................................................................................. 5
1.1 MEI Service & Procedures ........................................................................................................... 6
1.1.1 Arranging for Service .......................................................................................................... 6
1.2 General Machine Function ........................................................................................................... 6
1.3 Product Information ..................................................................................................................... 7 1.4
General Machine Data ................................................................................................................. 7
Chapter 2 Safety ................................................................................................................. 9

2.1 Safety Concept .......................................................................................................................... 10
2.2 Personal Safety ......................................................................................................................... 10
2.2.1 Eye Protection ................................................................................................................... 10
2.2.2 Dressing for Safety............................................................................................................ 10
2.2.3 Work Habits ....................................................................................................................... 10
2.2.4 Knowledge ........................................................................................................................ 11
2.2.5 Suggested Safety Practices .............................................................................................. 11
2.3 Work Area Safety ....................................................................................................................... 11
2.3.1 Warning Signs ................................................................................................................... 11
2.3.2 Fixed guarding .................................................................................................................. 11
2.3.3 Avoid Distracting Others ................................................................................................... 11
2.3.4 Reporting Unsafe Working Conditions .............................................................................. 11
2.4 Maintenance Safety ................................................................................................................... 12
2.4.1 Read Manual ..................................................................................................................... 12
2.4.2 Qualified Personnel ........................................................................................................... 12
2.4.3 Electrical Precautions........................................................................................................ 12
2.4.4 Pneumatic Precautions ..................................................................................................... 12
2.4.5 Returning To Operation .................................................................................................... 12
Chapter 3 Installation Instructions ................................................................................. 13

3.1 Shipping & Receiving ................................................................................................................. 13
3.2 Unloading & Lifting ..................................................................................................................... 13 3.3
Cleaning ..................................................................................................................................... 13
3.4 Foundation ................................................................................................................................. 13
3.5 Leveling ...................................................................................................................................... 13
3.6 Connecting Plant Supplies......................................................................................................... 14
3.6.1 Electrical ............................................................................................................................ 14
3.6.2 Pneumatic ......................................................................................................................... 14
Chapter 4 Operating Procedures .................................................................................... 15
1
4.1 Operator Panel Layout ............................................................................................................... 16
4.2 Operator Panel Computer's Touch-Screen Display .................... Error! Bookmark not defined.
4.2.1 Directory Screen ............................................................................................................... 17
4.2.2 Upper Left / Upper Right / Lower Left / Lower Right Auto Screens ................................ 19
4.2.3 Upper Left / Upper Right / Lower Left / Lower Right Manual Screens ............................ 21
4.2.4 Upper Left / Upper Rignt / Lower Left / Lower Right Home & Overtravel Setup Screens
23
4.2.5 Setup Auto Cycle Screen .................................................................................................. 24
4.2.6 Sequence Screen.............................................................................................................. 26
4.2.7 Graph Screen .................................................................................................................... 30
4.2.8 Notes Screen .................................................................................................................... 32
4.2.9 Global Status Screen ........................................................................................................ 33
4.2.10 Database Screen .............................................................................................................. 34
4.2.11 Calibration Screen............................................................................................................. 36
4.2.12 Fault Log Screen ............................................................................................................... 37
4.2.13 Configuration Screen ........................................................................................................ 38
4.2.14 Manufacturer Screen......................................................................................................... 40
4.3 Common Procedures ................................................................................................................. 41
4.3.1 Servo Homing ................................................................................................................... 41
4.3.2 Database Maintenance ..................................................................................................... 43
4.3.3 Graph Setup ...................................................................................................................... 48
4.3.4 Programming Auto Cycle .................................................................................................. 48
4.3.5 Monitoring Auto Cycle ....................................................................................................... 48
4.3.6 Removing handles ............................................................................................................ 48
4.3.7 Installing Handles .............................................................................................................. 51
4.3.8 Set up the push button pusher .......................................................................................... 54
4.3.9 Entering Notes .................................................................................................................. 57
4.3.10 Manual Operation .............................................................................................................. 57 4.4
Complete Machine Shut Down .................................................................................................. 57
Chapter 5 Setup, Adjustment & Maintenance ................................................................ 59

5.1 Pneumatic System ..................................................................................................................... 60
5.1.1 Pneumatic Pressure .......................................................................................................... 60
5.1.2 Flow Controls .................................................................................................................... 60
5.1.3 Drip Leg Drain ................................................................................................................... 60
5.1.4 Particulate Filter/Regulator ............................................................................................... 60
5.1.5 Pressure Sensor ............................................................................................................... 60
5.2 Mechanical System .................................................................................................................... 60
5.2.1 Replacing Shear Pins........................................................................................................ 60
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5.2.2 Maintaining Actuator Shafts .............................................................................................. 61
5.2.3 Replacing Cable ................................................................................................................ 61
5.3 Load Cell Calibration ................................................................................................................. 65
Chapter 6 Troubleshooting Guide .................................................................................. 70

6.1 Fault Recovery Procedure ......................................................................................................... 70
6.2 Fault Message Listing ................................................................................................................ 70 6.2.1
Clearing Overtravels ......................................................................................................... 73
Chapter 7 Recommended Spare Parts ........................................................................... 74

7.1 OEM Components ..................................................................................................................... 75
7.2 Standard Purchased Components ............................................................................................ 75
7.3 Electrical Purchased Components ............................................................................................ 76 7.4
Pneumatic Purchased Components .......................................................................................... 76
Appendix A Assemblies & Parts List ..................................................................................

78
A-1 Drawings & Parts List ................................................................................................................ 78
Appendix B Electrical Diagrams & Parts List ....................................................................

80
B-1 Drawings & Parts List ................................................................................................................ 80
Appendix C Pneumatic Diagrams & Parts List ..................................................................

82
C-1 Drawings & Parts List ................................................................................................................ 82
Appendix D Database Structure..........................................................................................

84
Appendix E Purchased Component Information ...............................................................

86
E-1 Copy on Disk ............................................................................................................................. 86
3
Chapter 1 Introduction
Objective
The primary objective of this manual is to aid and assist in the safe operation and
maintenance of your Merrill Engineering & Integration (MEI) Laboratory Handle Test Stand.
All operating and maintenance personnel should read this manual

carefully before operation and maintenance of this machine .
4
Proprietary Clause & Agreement

This manual discloses information in which Merrill Engineering & Integration (MEI)
may have proprietary rights. Neither receipt nor possession of this manual confers
or transfers any right to the client and by its retention hereof. The client
acknowledges that it will not reproduce nor cause to be reproduced, in whole or in
part, any such information except by written permission from MEI. The client shall
have the right to use and disclose to its employees the information contained herein
for the purpose, of operating and maintaining the MEI machine, and for no other
purpose.
In the event the content of this manual is altered, or sections/items are omitted
during a reproduction, in whole or in part, and instructions of definitions within the
reproduction result in personal injury to those who follow the altered instructions,
the burden of responsibility for personal injury falls solely on the party who effects
the reproduction.
MEI makes no representations or warranties, expressed, implied or statutory with
respect to, and assumes no responsibility for the accuracy, completeness, sufficiency
or usefulness of the information contained herein. No warranties of merchantability
or fitness for purpose shall apply.
Comments concerning the information contained in this manual are welcome.
Please contact:
400 Florence Street

Saginaw, Michigan 48602
Phone: (989) 791-6676 Fax (989) 791-6177
1.1 MEI Service & Procedures

1.1.1 Arranging for Service
To arrange for service, the customer should call (989)791-6676 to speak with a service
representative or email your service evaluation request to infomei@merrilltg.com.
1.2 General Machine Function

The Laboratory Handle Test Stand is meant to run a preset number of continuous test
cycles. The preset number of cycles test the durability of a Door Handle using an
environmental chamber and also checks the functionality of the built-in sensors. The test
sequence is performed according to a predetermined setup that is entered into the HMI
at the beginning of each test.
5
1.3 Product Information
Various Door Handles
1.4 General Machine Data

Controlled by: Allen Bradley CompactLogix PLC
Cycle Type: Manually Loaded / Manually Unloaded / Test Cycle of
Predetermined Length.
Power Required: 120VAC - Single Phase - 60Hz, 13.35 Amps
Pneumatic Pressure Required: 50 PSI Min., 120 PSI Max.
Pneumatic Lube Fluid Required: - N/A
Hydraulic Fluid Required: - N/A
Lubrication Fluid Required: - Lithium Grease/Teflon Coating ~ Chamber side
Actuators Coolant Fluid Required: - N/A
Test Fluid
Required:
- N/A
6
Chapter 2
Safety
Objective
The objective of this chapter is to provide operating and maintenance personnel
suggestions for safe shop practices. This chapter is intended to supplement, not
replace plant safety rules and codes, state laws and regulations, and OSHA
standards. Also provided is general information on personal safety, work area safety,
operating safety, maintenance safety, and specific safety devices used on this
equipment.
After reading this chapter, machine operators and maintenance personnel will be able
to:
1. Perform daily work functions in a safe manner.
2. Understand the safety concept design of the machine.
3. Identify and use specific safety devices provided on this equipment.
Read and observe all warnings before operating or performing

service to this machine.
Only authorized and properly trained personnel should operate or perform

service to this machine. Untrained personnel present a hazard to
themselves, others, and the machine.
DO NOT attempt to operate the machine before all of the installation
instructions and guarding have been completed and properly installed.
DO NOT operate with doors open.
NEVER service the machine with power connected. When the power plug is
connected to a receptacle, there is high voltage throughout the electrical
panel.
The electrical panel should be closed and the bolts on the control cabinet
should be secured at all times unless being serviced by a qualified electrician.
Check for damaged parts and worn tooling before operating the machine.
Any part or tooling that is damaged or worn should be repaired or replaced
by authorized personnel. If any component does not appear to be functioning
correctly, do not operate the machine. Contact your shop supervisor.
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DO NOT perform tests on unapproved parts. Damage to machine or personal
injury could occur.
Windows must be replaced if damaged or severely scratched.
DO NOT modify or alter this machine in any way. Any modification or
alteration could lead to personal injury and/or mechanical damage.
Never allow anyone to alter or remove any safety decal or symbol. Replace
decals that become damaged or worn.
The ultimate responsibility for safety rests with the shop owner and the
individuals who work with the machine. It is the shop owners responsibility to
make sure that everyone who is involved in installing, operating and servicing
the machine has thorough knowledge of the installation, operation, service,
and safety instructions before they perform any actual work.
2.1 Safety Concept

It is imperative that all persons operating and performing maintenance on this
machine have a complete understanding of the dangers associated with this machine.
2.2 Personal Safety

Personal safety integrates attitudes, knowledge, and habits into safe actions that will
occur when the importance of safety is formed into daily work habits.
2.2.1 Eye Protection

Always wear eye protection. One of the simplest ways to reduce the risk of injury is
to wear proper eye protection. Choose the right equipment to protect your eyes and
face, i.e., safety glasses with side shields, goggles or a full, face shield.
2.2.2 Dressing for Safety

Do not wear loose clothing or jewelry that may become tangled in moving
components of machinery. Gloves should be worn only when handling rough, sharp
or hot parts. Safety toe work shoes are highly recommended.
2.2.3 Work Habits

A neat and clean work environment is always safer. Keep the floor around your
machine clean and free of debris and obstructions. Observe and follow warning
signs and safety instructions.
2.2.4 Knowledge
Learn before working. Read and understand all safety instructions before setting up,
operating or servicing this machinery. Acquaint yourself with all the safety devices
for this machine and check them regularly to see that they are all in place and
working correctly.
8
2.2.5 Suggested Safety Practices
The following is a list of suggested safety practices:
Know your job and follow instructions.
Keep hands, limbs and loose clothing away from moving parts.
Use care when lifting heavy objects and keep fingers out of pinch points.
Take care of injuries immediately and notify proper personnel.
Observe posted warning signs and tags. Follow all safety instructions.
Avoid entering restricted areas without the proper lock outs applied.
Stop machinery and use lockouts when lubricating, cleaning, adjusting or
repairing.
Use the proper tools when performing, maintenance/adjustments and make
sure tools are in good working condition.
2.3 Work Area Safety

2.3.1 Warning Signs
Warning signs should be clearly visible. Do not cover, paint over, alter, deface or
remove them from the machinery.
2.3.2 Fixed guarding

The machine should be operated only when all guards are in place. If these guards
are removed, it should be for maintenance purposes only and by qualified
personnel.
2.3.3 Avoid Distracting Others

Avoid any unnecessary activities that may distract other workers and lead to an unsafe
environment.
2.3.4 Reporting Unsafe Working Conditions

Report any unsafe working conditions immediately to your supervisor or safety
department.
2.4 Maintenance Safety

2.4.1 Read Manual
Personnel responsible for servicing this machinery should read and understand this
manual and heed all of its safety warnings.
2.4.2 Qualified Personnel

Only qualified personnel, trained in both safety and function of the machine should be
allowed to service this machinery.
9
2.4.3 Electrical Precautions
Maintenance should not be performed until the main electrical power plug is removed
from the receptacle and LOCKED OUT to prevent the system from being accidentally
restarted. Only qualified personnel should enter any of the electrical control panels,
push-button panels, junction boxes, etc.
2.4.4 Pneumatic Precautions

Properly block or pin vertical clamp and dump units that could drop when pressure
is relieved. LOCK OUT and relieve any residual pressure in the pneumatic system.
2.4.5 Returning To Operation

Keep all moving parts of the machine free of rags, dirt and excessive oil. All protective
guards and covers must be in position before operating machine.
Chapter 3
Installation Instructions
Objective
The following instructions are provided to aid in the installation of this machine.
Adhering to these instructions assures the correct and proper operation of this machine.
3.1 Shipping & Receiving

All MEI equipment is carefully prepared for shipment to protect it during transit. The
shipping preparation is also designed to minimize the amount of reassembly after
arrival at its final destination.
When received, all equipment should be inspected for visual signs of damage. This
inspection should be done immediately upon receipt. If damaged, notify MEI and
the carrier for a claims inspection. However, with F.O.B. shipments, a claim must
be presented to the carrier by the customer, as the title to the equipment is
accepted by the carrier.
3.2 Unloading & Lifting

Be sure that the crane or hoist of the lift truck is capable of safely lifting the weights
involved. Check the condition of all chains, cables, slings, hooks, etc. before lifting
or moving the equipment into position.
3.3 Cleaning
Before installation, clean all equipment thoroughly to remove any foreign material that
may have accumulated during shipment. Use a good grade of commercial solvent to
10
remove rust preventive compounds. Apply a coating of light oil to all unpainted steel
surfaces to prevent rust.
3.4 Foundation
A normal, concrete factory floor is sufficient for the installation of this machine.
3.5 Leveling
All equipment is to be mounted according to the floor plan layout. This must be followed
to avoid any interference or incorrect operation.
It is important that the machine be leveled before it is put into operation. Using a
precision level placed on the machined surface of the main base, level this machine
in both directions within .005" per foot.
Note: On systems that are mounted on a common base, level by the screws on the
common base only. The individual stations have already been leveled with respect
to the main base.
3.6 Connecting Plant Supplies

3.6.1 Electrical
Connect the electrical power plug into a receptacle that has been preconfigured to
handle the power requirements. See Chapter #1 for requirements.
3.6.2 Pneumatic
Connect plant air to AIR SUPPLY LOCK OUT VALVE that is directly connected to the
pneumatic filtration unit on the machine. Refer to Chapter #1 for requirements.
11
Chapter 4
Operating Procedures
Objective
After reading this chapter, the operator will be able to:
1. Locate the operator panel and describe the function of all entities on the
panel.
2. Have a concept of the machine capabilities.
3. Perform common machine procedures.
4. Perform a TEST SEQUENCE.
5. Perform complete machine SHUT DOWN procedures.
This machine contains hazards from moving components, high voltage

electricity, noise, and compressed fluid and air. When using this machine, basic safety
precautions should always be followed to reduce the risk of personal injury and
mechanical damage.
Please read all appropriate warnings, cautions, and instructions before

operation of this machine.
4.1 Operator Panel Layout

The Operator Panel is mounted on the front of the machine. The panel can easily be
accessed for maintenance purposes or for the operator to perform a test sequence.
Computer Touch Screen Display

Allows operator intervention, and displays machine faults and messages. (See section
4.2.1)
Control Power On (Green Illuminated Push Button)

When pressed, this button turns on the servo motor supplies, controller
input/output, and pneumatic valve manifold power. Control Power Off
(Red Extended Head Push Button) When pressed, this button stops
12
all machine functions. Emergency Stop (Red Mushroom Head Push
Button) When pressed, this button stops all machine functions.
Figure: 4.1, Operator Panel
4.1.1 Directory Screen
13
Pressing the Scroll button causes the fault display in the upper middle of the
screen to move from the currently displayed fault to another fault, if one exists.
Pressing the Reset button causes any currently displayed fault to be reset, so
long as all conditions which caused the fault have been cleared. If the
conditions which caused the fault are not cleared, the fault will remain on and
the display will not change.
No Messages is displayed whenever all the faults have been cleared.
Pressing the Manual button for any of the four stations will cause the
selected stations Manual screen to appear. From the manual screens the
operator can operate the air cylinders and servo motor when the station is not
in cycle.
Pressing the Auto button for any of the four stations will cause the selected
stations Auto screen to appear. From the auto screen you can start and stop a
station's auto cycle, monitor and adjust cycle count, monitor servo position,
load cells, and capture load cell feedback for graphing.
The Setup Auto Cycle screen navigation button links to a set of screens where
the operator can create testing sequences and choose which stations will run
the sequences.
The Global Status screen navigation button links to a screen that gives the
operator control over all four test stations at once and a high level overview of
test progress.
The Fault Log navigation button links to a screen that will show the fault history
of the test stand.
The Notes navigation button brings up the notes screen which can be used by
the operator to take down notes during handle testing process.
The Configuration button links to a configuration screen where cart testing
parameters can be changed.
Pressing the Shutdown HMI button will close the operator screens and return
to the windows environment.
Pressing the Stop button in the lower right corner of the screen causes an
immediate stop fault to occur. This will bring all of the test stations to an abrupt
halt.
Pressing the Unit Conversion button causes a window to appear on the
screen. Selecting one of the Go buttons in this window causes different unit
systems to display.
14
4.1.2 Upper Left / Upper Right / Lower Left / Lower Right
Auto Screens
There is a separate auto screen for each test station. The auto screens can be
accessed from the directory screen.
The Auto Mode button in the upper left corner of the screen places the machine
in Automatic mode. Once Automatic mode has been selected the indicator
changes color and reads In Automatic. The buttons on the manual screen will
not function in auto mode.
The Cycle Start and Stop buttons control when the station runs the automatic
sequence. Once a cycle has been started, the Start button changes color to
15
amber and displays the In Cycle message. The Stop button will allow the
current cycle to finish but prevent the next cycle from starting.
Pressing the Enable button in the Step Through Cycle box allows the
operator to step through the sequence one step at a time. Disable this and the
station will step through its sequence without pauses in between steps. The
Station Auto Cycle box lists the current number and description for the step
being performed.
The values in the Cycle Timer box show the elapsed time for the current cycle
and the final time of the last cycle.
The Cycle Count box displays the number of cycles that have been run,
followed by the total number of cycles to run. The count can be reset to zero or
changed to some other number by pressing one of the buttons on the screen.
The Handle Servo box lists the servos current mode, along with its Current
Position and Speed. The Position and Speed displays will be black when
updated and dark grey when not. They will flicker when being continuously
updated.
The indicators below the Black Box Inputs and the Auxiliary Inputs header
show whether a signal is being received or not, or if an error has been
detected.
The indicators below the Auxiliary Outputs header show whether a signal is
being sent or not, or if an error has been detected.
A box in the lower left corner of the screen displays the current reading for the
Handle and Cable Load Cells, along with the Profile Tension. The Profile
Tension is determined by the current position of the Handle servo and the red
line graph on the on the graph screen.
Indicators at the bottom of the screen list the current state of the Handle Puller
and the Button Pusher.
The operator can have the resistive force of the cable graphed on the Graphs
screen by pressing the Load Cell Graph Capture button before the Pull
Handle Cycle step begins.
Pressing the Directory, Upper Left Manual, Global Status, Upper Right
Automatic, Lower Left Automatic, Lower Right Automatic, or Graphs
button will cause that screen to display.
Pressing the Stop button in the lower right corner of the screen causes all four
stations of the test stand to immediately stop what they are doing.
4.1.3 Upper Left / Upper Right / Lower Left / Lower Right
Manual Screens
16
There is a separate manual screen for each test station. The manual screens
can be accessed from the directory screen.
Pressing a button in the upper left corner of the screen will allow the machine to
be placed in Automatic or Manual mode. The buttons color and text change
to indicate when a mode has been selected. Manual mode will allow the
operator to control one motion at a time. Automatic mode is required whenever
a sequence of different motions is needed.
When in manual mode, the Release/Engage Handle Puller Cylinder buttons will
rotate the handle pull mechanism 0 90 by opening and closing valves for
the air cylinder.
Also in manual mode, the Extend/Retract Button Presser cylinder moves the
button pressing finger away or towards the operator by opening and closing
valves on an air cylinder.
When the Handle Servo is in Position Mode, the Speed, Position, and
Incremental Move Amount buttons can be changed while in manual mode by
using the buttons in the middle of the box. In manual mode, the Servo can be
moved to the selected Go To Position by pressing the Go button, and the
Speed and Position can be adjusted using the Increment and Jog buttons.
A box near the center of the screen displays the current reading for the
Handle and Cable Load Cells, along with the Cable Tension. Pressing the
Cable Retract Cylinder button, while in manual mode, removes slack from the
cable. This slack is usually caused by cycling through the handle motions in
manual.
The indicators below the Black Box Inputs header show whether a signal is
being received or not, or if an error has been detected. They are setup on the
configuration screen.
17
The Auxiliary Output Control pushbuttons turn on outputs reserved for
auxiliary functions while the output is held down.
Pressing a button in the lower left corner of the screen will cause the directory,
Setup Home & Overtravel, or corresponding Auto screen to appear.
Pressing the Stop button in the lower right corner of the screen causes the test
stand to E-stop.
18
4.1.4 Upper Left / Upper Rignt / Lower Left / Lower Right

Home & Overtravel Setup Screens
(See section 4.1.1 for Servo Homing instructions.)

There is a separate home & overtravel screen for each test station. The home
& overtravel screens can be accessed from the each station's manual screen.
The indicator on the left side of the screen displays the current Servo Position
for the Handle.
The Home buttons command the Animatics motor to set its position and origin
to zero.
The Positive and Negative Overtravel Limits can be changed by pressing a
button on the screen and entering a value.
Bypassing Overtravels will prevent an immediate stop from occurring when the
servo position is outside of the Overtravel limits.
Cable Profile Tension Limit Check

Monitoring of the actual vs. programmed torque during the Run Graph auto
cycle can be enabled or disabled by buttons on this screen. This can be used
to detect problems, like broken shear pins. The level of sensitivity can be
adjusted from 0% to 100%.
19
4.1.5 Setup Auto Cycle Screen
The Select Test listing on the left side of the screen contains headings for tests
that have been previously programmed into the test stand. The arrow keys at
the bottom move the highlighted line up or down. To select a test move the
highlight over the test name.
A new test can be added by arrowing the highlight down to an open slot in the
test list and then pressing the Add Test button. A prompt will appear for the
name of the new test. The name can contain any characters but should be
limited in length to what can fit on the screen displays. Once a test is added a
servo motion profile can be created for the "Run Graph" sequence, described
later in this manual. To start editing the test sequence, select the new test for
one of the four stations and then edit the test with the Edit button at that
station.
After a new test is added then a motion and load profile can be programmed in.
The motion and load profile is defined by clicking points on a graph. With a
test name selected in the test list, press the Edit Graph button to be taken to
the screen to define the motion and load profile.
An old test can be deleted by arrowing the highlight to the test's name and then
pressing the Delete Test button to the lower right of the test selection list. The
test name will be deleted from the list and any graph that was drawn for the
servo motion profile will be deleted. The test will not be deleted from each of
the four stations if it had been selected for any of them. You must go and
select different tests for the stations to clear the old test.
On the right side of the screen are the four stations, Upper Left, Upper Right,
Lower Left, and Lower Right that can be set up to all run the same test or all
20
run different tests. The text boxes below each station's heading show the test
name selected for that station. To change the test selected for the station,
arrow up or down the list until a new test name is highlighted and then press
the Select button for the desired station.
Pressing an Edit button below one of the station selections will cause the
Sequence screen for the listed test to appear.
Pressing the Directory button will return to the Directory.
21
4.1.6 Sequence Screen
The Sequence Edit screen allows the operator to define the steps of the test selected
for editing on the Setup Auto Cycle screen. Each step will be executed by the
controller in the order that they appear on this screen.
The Main Cycle is initially selected on the right-hand list of cycles. This is the handle
program that is run when an Auto Cycle is started. To add steps to the sequence
press the Add a Step button. A step called "Undefined" will show up on the sequence
list. A dialog box will appear on the right-hand side displaying all the options of what
the undefined step could be.
22
Additional dialog boxes will be shown after an operation is selected.
Select
operation
The operations are used to define parameters for the sequence step. For example,
an Aux Output can be selected, and a dialog will appear that allows the operator to
specify if the output should turn ON or OFF
Options for test cycle sequences and their adjustable parameters:
Dwell Timer
Dwell Time (entered in milliseconds)
Move Servo
Absolute or Relative movement (relative to starting position)
Position (mm)
Speed (mm/sec)
Acceleration and Deceleration (mm/sec^2)
Run Graph. This option executes the motion profile on the graph screen. It is a
relative motion so the servo would typically be returned to 0.00mm before execution.
Cable Tension
Tension (lbs.)
Pull Handle to a Force
Force (lbs.)
Speed (mm/sec)
Extend Button Press Cylinder
23
Retract Button Press Cylinder
Engage Handle
Release Handle Run Sub Cycle
Sub cycle number

Number of times to repeat sub cycle
Test Input
Input selection (names defined on the configuration screen)
Signal
Set/Reset Output
Auxiliary Output 1, 2, or 3
Whether to turn the output On or Off Environmental Chamber
Set temperature, humidity, or temperature and humidity both

Temperature and humidity setpoint entries
Wait for temperature/humidity to reach setpoint or don't wait
The operator can then press the Delete a Step button at the bottom in order to
delete a step from the test sequence. If no current test step is selected then the
last step of the sequence will be deleted.
A numeric entry box in the bottom right corner of the screen edits the Frequency
of the Data Logging. This controls how many auto cycles go by before data from
one gets logged to the database and the reports screen.
24
4.1.7 Graph Screen
Press when
complete
The Graphs screen can be accessed in two ways, by pressing the Edit Graph
on the Setup Auto Cycles screen or from any of the four Station Auto screens.
Accessing the graph from the Setup Auto Cycles screen allows the operator to
define the Animatics servo motors position-velocity profiles. These profiles are
used in a certain auto cycle step called "Run Graph". One profile will on the
graph define how far and fast a handle is pulled. Another profile will define the
resistive force that is the latch cable puts on the door handle.
On the other hand, accessing the graph from a station's Auto screen will show
feedback from the load cells, plotted over the original profiles, and give
indication if the load cells are seeing approximately the right handle and cable
loads over the distance the door handle traveled.
The graph can be edited by dragging the points around or by clicking an area on
the graph to add new points. The blue line controls the servo speed and
distance traveled during the "Run Graph" sequence. The red line controls the
tension put on the cable during that travel.
The Rounding Precision selections will change the snap precision when
dragging graph points or adding new ones.
To zoom in on an area of the graph click the Zoom radio button. Clicking the
Drag radio button will allow the graph points to be dragged around the graph.
Pressing the Erase Visible button near the top of the screen clears the
variables shown on the graph out of the database and pressing the Reset
Zoom button causes the graph to zoom to its limits.
25
Typically, the graph will automatically zoom in as far as possible. Pressing the
Zoom button near the top of the screen allows a section of the screen to be
zoomed in on.
After drawing or altering a graph the tension profile needs to be downloaded into the
PLC and the motion profile to the Animatics servo motors. Press the Download To
Servo Motor button once the changes are made. The H and T lights will turn on to
indicate when the set of Handle and Tension points have been sent to the PLC. The
ULH, URH, LLH, and LRH lights will turn on to indicate when a set of Handle profile
points have been downloaded to an Animatics servo motor. The points will only be
downloaded into a station's servo motor where the current test being edited has
been selected for that station.
Press when
completed
with drawing
profile lines
The Refresh button will redraw the graph if it is not displaying correctly.
Pressing theGo Back navigationbutton willreturn thedisplayto the last screen
displayed before the graph.
26
4.1.8 Notes Screen

The Notes screen allows the operator to store any pertinent information relating to
the Test Cycle. This information can then be viewed at a later time to point out
problems or help determine the validity of a Test Cycle.
This screen can be accessed by pressing the Notes button from the Directory
screen.
The Page Address indicator displays the URL (Uniform resource locator) for the
notes screen.
Pressing the View Notes button returns the display to its default view.
A new note can be added to the screen by pressing the Add a Note button.
The existing notes can be removed from the screen by pressing the Clear Notes
button.
The Collapse All button causes the notes to be hidden.
The screen can be Refreshed by pressing the button in the upper right corner of
the screen.
Pressing the button in the top left corner of the screen causes the Directory
screen to appear.
Pressing the Expand All button causes the list to be expanded.
27
4.1.9 Global Status Screen
The Global Status screen allows the operator to monitor and run each of the four
stations in Automatic mode.
This screen can be accessed by pressing the Global Status button from the
Directory screen.
The fault listing, along with the Scroll and Reset buttons, are the same as described
for the Directory screen above.
The buttons at the top of each stations box allow Automatic mode to be selected
and the stations cycle to be Started or Stopped.
The left side of each Cycle Counter row displays the number of cycles that have
been run for that station, followed by the total number of cycles to run. The current
count can be reset to zero or changed to some other number by pressing one of the
other buttons in that same row.
The indicators below the Black Box Signal header show whether a signal is being
received or not, or if an error has been detected.
Pressing a round button on the left-side of the screen will cause all of the station
cycles to Start or Stop. Once the cycles have been started, the Start button
changes color to amber and displays the In Cycle message. The Stop button
will allow the cycle to finish but prevent the next cycle from starting.
The Current Temperature and Relative Humidity are displayed in the lower left
corner of the screen
28
Pressing a button in the lower left corner of the screen will cause the directory
screen to appear.
4.1.10 Database Screen
This is the main means of database manipulation. See section 4.2.1 for further
information.
This screen can be accessed by pressing the Database button from the Directory
screen.
Press the Manage Your Database to cause the following screen to appear.
29
A Table can be managed by selecting one from the list (For example:
selecting general will cause the screen shown below to appear), or a Table can
be Created by pressing the button below the list of tables.
Pressing the X button in the top right corner of the screen closes the window
down and returns you to the Database screen.
30
4.1.11 Calibration Screen
The Calibration screen allows the operator to calibrate both the Handle and Cable
transducer readings for each of the four stations.
This screen can be accessed by pressing the Calibration button from the
Directory screen.
The fault listing, along with the Scroll and Reset buttons, are the same as
described for the Directory screen above.
The Load Cell readings are displayed in each stations box and instructions for
calibrating these readings are listed in the upper left corner of the screen.
Pressing the Directory button will cause that screen to display.
4.1.12 Fault Log Screen
31
This screen lists the faults that have occurred since the last time the Clear button
was pressed. Pressing the Top button will cause the six most recent faults to
appear and pressing the Page Up or Page Down button will cause the next or
previous faults to appear.
4.1.13 Configuration Screen
The Configuration screen is used to adjust variables that change from handle to
handle, or system parameters.
32
This screen can be accessed by pressing the Configuration button from the
Directory screen.
The Door Handle Black Box information can be edited from the box in the upper left
corner of the screen. Pressing one of the Signal Description buttons causes a text
window to appear that allows the operator to change the description. Pressing one
of the Color buttons allows the operator to select the color for the On State as red,
yellow or green. The buttons on the right side of the box display the state and the
number of signals before an On or Off state occurs. These numbers can be set by
pressing a button and entering the desired value in the window that appears. The
PLC input addresses that the black box signals are mapped to are displayed in the
left-hand column starting with the TTL input card in slot 5 and going from the 1 st input
to the 16th input.
Auxiliary inputs are inputs that the machine operator can wire sensors or switches
to. The inputs are available on the Auto Cycle Setup screen. Like the black box
signals, they can be checked during the auto cycle for ON or OFF states. If the
state is not what is programmed, the discrepancy is recorded. If there are
consecutive discrepancies that added up to the programmable value, the station will
fault out with a message and stop running.
Auxiliary outputs are three outputs per station that can be set/reset to communicate
with or control external devices. The outputs are available on the Auto Cycle Setup
screen. The PLC addresses that Aux Outputs 1, 2, and 3 are mapped to are shown
in the left-hand column. They start at the output card in
slot three, with the fifth output down and extend down to the bottom of the card.
Suggestion: if you need an output to turn on at the start or end of a batch of
cycles it can be done in the main cycle with the rest of the test functions
occurring in a looped sub-cycle.
The HMI Date & Time can be changed by exiting the HMI program and using
Windows to change the VersaView's date and time. It is important that this
information be correct because it is used to timestamp database entries.
The PLC Date & Time can be adjusted by pressing each value separately. This
information is used to put timestamps in the fault log.
The Tension Fault Levels can be changed to any value from zero to 100 lbs. and the
Compression Fault Levels can be changed to any value from zero to -100 lbs. by
pressing the appropriate button and entering the value in the window that appears
on the screen. If the load cell measurement exceeds the fault level setting, then the
station will immediately stop.
The HMIs Ethernet address is listed at the bottom of the screen.
Pressing the button in the lower left corner of the screen causes the Directory
screen to appear.
33
4.1.14 Manufacturer Screen
This screen can be accessed by pressing the Manufacturer button from the Directory
screen.
4.2 Common Procedures

4.2.1 Servo Homing
Each of the four test stations has an Animatics servo motor with a position encoder
built in. These encoders need to be given a meaningful origin position, the 0.00
mm point, before executing automatic cycles where servo move commands will
drive the servo actuators to positions in and around the door handles. It is up to
the operator to set the origin position in a procedure called servo homing.
The homing controls are accessed from the Setup Home & Overtravel screens, which
are sub-screens of the Manual screens.
1. Navigate to the Setup Home & Overtravels screen and press the buttons to
bypass the overtravel limits. This disables the servo overtravel faults so the
servo can be jogged to the fullest extents of its range.
2. Return to the station's Manual screen. Position the servo to the desired home
position using the jog and incremental jog buttons. The ideal position for this
home position is where the handle puller is rotated to "engaged" and the handle
puller and is jogged just to the point where it touches the handle without
actually pulling on the handle. Setting this point as the origin gives the operator
34
an understanding of the relationship between the door handle and the servo
position.
3. Return to the Setup Home & Overtravels screen. Press the home button.
4. Return to the station's Manual screen. Inspect the mechanical situation of the
servo actuator. Jog the servos back and forth and try to gage where the
overtravel limits should be placed. The overtravel limits must include the
distance that the servo actuator returns (toward operator) in order to extend the
pushbutton presser. Set the overtravel limits accordingly. Enable the
overtravels bypass.
When the homing procedure is complete the Bypass Overtravel indicator will
indicate they are not bypassed and the Home indicator will be green indicating that
the home reference has been set. The machine will retain the home reference
position until the machine's power is lost. To improve setup time before the machine
is unplugged, return all servo actuators to the 0.00 mm position before powering
down the machine. That way the next time it is powered up the servos can be
homed without having to adjust their position.
The Animatics encoder position is set to 0.00 mm using the Animatics origin
command O. The PLC will execute the subroutine below when the operator presses
the Home button. '===============================================
'Home Immediate Subroutine
C3
ZS 'Clear any prior Errors
PT=0 'Set Motor Position Target to
Zero
O=0 'Set encoder origin to 0
RETURN
35
4.2.2 Database Maintenance
Common database operations include exporting data, importing data, clearing data
tables, or setting up new data tables for recording values such handle and cable
load cell forces; and pushbutton, hall sensor, and capacitive sensor failures. It is
also used to store test sequences for different customer product lines.
Database maintenance is beyond the scope of this manual but there are a couple
simple operations detailed here that can help operators backup test data or move test
sequences from one test stand to another.
The HMI software that the operator uses to run the valve test machine is a piece of
software that runs on the Windows 7 operating system. While the HMI software runs
in the foreground, Windows 7 is also running several other programs in the
background. One such background program is a database server called the
WAMPserver.
The handle test cart's database can be managed from a piece of software written in
webpage (html) format called phpMyAdmin. The phpMyAdmin software is
accessed by typing http://localhost/phpmyadmin/ into a web browser such as
Firefox or Internet Explorer. Both browsers come installed on the valve test
machine and have this address set as their homepage.
In addition to using a web browser you can access phpMyAdmin through an HMI
screen. Pressing the Database button from the Directory screen will take you to the
phpMyAdmin home screen. There you will find links to Import and Export
databases, along with links to create and delete databases. Therefore caution
should be exercised when using this software.
Exporting the data to an Excel file is particularly useful for creating documentation
summaries. Summary tables can then be created by editing the spreadsheet in
Excel. The following examples show how to Export data and View a database.
There are two databases created for the door handle test carts. The first one called,
"Huf" contains data collected on handles during the auto cycles. The
second database is called, "Huf Sequence" and contains the handle testing sequences.
36
Export an entire database
Select Database
Sel ect Export
37
Select Custo m
Select " huf" or
"huf sequence"
Select Save
Keep the default values for the rest
(Pan down )
Select file format (If CSV for excel, pick this)

Keep native SQL format for backups and transfers to another cart
Check "Put column

names in the first row " for
CSV formatted exports
Click Go
38
Select Open or Save
39
To View a database:
Databases for each station can be viewed by selecting the Databases tab.
This screen lists the databases:

huf has station Run Data
hufsequence stores the sequences built for individual tests.

This screen then allows you to view General info, the station database, or any notes
that were created.
40
4.2.3 Graph Setup
The Graphs are embedded into the Graphs screen on the HMI and they can be
selected and edited from there. Reference the Graph screen descriptions in Section
4.1 for more information.
4.2.4 Programming Auto Cycle

The Cycles can be edited from the HMIs Sequence screen. There is one Main cycle
and nine possible sub cycles that can be called from within the Main. Reference the
Sequence screen descriptions in Section 4.1 for more information.
4.2.5 Monitoring Auto Cycle

The Auto Cycle can best be monitored from the Auto screen. Reference the Auto
screen descriptions in Section 4.1 for more information.
4.2.6 Removing handles

A part changeover will require that the home positions be reset from the Home &
Overtravel screen and the Auto Cycle sequence is setup on the Sequence screen.
Reference the descriptions for the Home & Overtravel and the Sequence screens in
section 4.3.7 more information.
Prior to removing/installing a handle to the tester, enter manual mode for the
applicable station(s). Make sure both the Handle Puller and Button Presser cylinder
are Retracted.
First, remove the electrical connector from the handle by sliding the red clip inward,
then depressing the black clip behind it. Pull connector outward.
41
Next, remove cable from hold down clamp.
The cable Hook can be twisted out of the hole retainer.
42
The wing nut may need to be removed to make it easier.
Finally, remove the face plate bolts (6mm)
4.2.7 Installing Handles

Similar to the instructions, place the station(s) being worked on in manual mode.
43
Next, Screw the bolts into the faceplates of the handle. All bolt holes do not need to
be fastened, only the holes that are presently lined up.
Install the cable hook into the retainer hole. Wing nut may need to be removed.
Assure that the cable is properly aligned so that the cable is straight and in line with
the cable rod from the top view and side view. Once aligned, place the cable outer
jacket in between the clamp blocks and tighten down the wing nut screws. Do not
over tighten. This would add extra tension on the cable giving additional tension to
the handle pull test.
44
Clamp blocks
Test the setup by pulling the handle manually. But first, make sure the station is in
manual mode. Then, set the power brake tension to zero and retract the handle puller
and button pusher.
45
Pull out
When the handle is pulled out, make sure that your other hand is on the return
cylinder on the other side of the plate for when the handle is released and the cable
is pulled back through the powder brake taking up the slack. This will ensure the
cable doesnt get tangled up on the rotating spool.
46
Pull back
4.2.8 Set up the push button pusher

The push button pusher block is mounted on a rod that extends out through the plate. It
can be rotated to orientate it to be in line with the button. It can also be extended to
span over button. See diagram below for bolt location. Loosen and rotate to align.
47
Pusher block span
adjuster
Pusher block rotational

adjuster
Make sure the Handle puller is retracted. Jog the servo (+) toward you as far back as
you can before an over travel occurs.
48
Now, extend the button pusher. The Extended indicator should be yellow verifing
that the prox on the cylinder is made. The servo can be jogged (-) into the push
button now. Once the handle push button is pressed, record the servo position. Use
this location to move the servo to when performing a button test.
The pushbutton presser can be adjusted here.
The extened indicator must turn yellow when extending the button pusher. The servo
doesnt have to be at a particular position but if a target position is preferred (home),
these adjustment screws will allow the pusher to move.
The equipment was shipped with the handle pullers

initial position set to zero. The button pushers were
also set to operate at position zero as well.
Once these initial positions are established, the servo
should be homed.
From the manual screen, goto home screen
49
Refer to Section 4.3.1 for setting over travels.
4.2.9 Entering Notes

Notes can be added to the database from the
Notes screen of the HMI. Like the
Graphs screen and Database Administration screen, the Notes screen is written in
HTML and JavaScript and displayed in an embedded web page. They provide the
machine operator with a time stamped note that can be associated with the timestamps
of a test run when database reports are generated.
The main code that generates the notes screen is located on the HMI hard drive under
C:\huf\huf_notes.php. Other supporting files are huf_notes_save.php,
huf_notes_add.php, huf_notes_style.css, and the contents of C:\huf\js.
Operator notes are stored in the huf database -> notes table. The structure of the notes
table is shown in the database structure
4.2.10 Manual Operation

Manual operations are performed from the HMIs Manual screen once the correct
mode is selected. Reference the Manual screen descriptions in Section 4.1 for more
information.
4.3 Complete Machine Shut Down

1. Verify the machine has completed its test sequence.
2. For each of the four stations in manual mode disengage all handle puller cylinders.
Retract all button presser cylinders. Move the handle pull servos to the 0.00 mm
position.
3. Press the red CONTROL POWER OFF button in the lower left corner of operator
panel.
4. From the directory screen press Shutdown HMI to return to the windows desktop. Use
normal methods to shutdown Windows XP and power off the HMI computer.
5. Turn the UPS (Uninterruptable Power Supply) off. Inside the electrical enclosure there
is a round button on the side of the UPS indicated by the green arrow below. Turning
it off will prevent the battery from draining.
50
6. Unplug the test stand from the wall socket.

7. Turn the plant AIR SUPPLY LOCK OUT VALVE TO THE "OFF" position.
8. Turn off the wireless keyboard and mouse to save the batteries.
Chapter 5 Setup, Adjustment &

Maintenance
Objective
This chapter provides setup, adjustment and maintenance information for linear and
rotary motions, process settings and other settings. It also provides information for
items such as tool changes, model changeovers, etc.
51
5.1 Pneumatic System
5.1.1 Pneumatic Pressure
Regulated system pressure and all individual regulated cylinder pressures are set to
values defined in the pneumatic diagrams (Appendix C). The button presser
cylinder pressure can be adjusted up or down independently to apply different
forces to the door handle lock button. The cable return cylinder pressure can also
be adjusted independently.
5.1.2 Flow Controls

Flow controls limit the air entering a cylinder (meter in). Adjust to desired speed if
required.
5.1.3 Drip Leg Drain

SERVICE WEEKLY: With the air supply valve off, open the drain valve at the bottom
end of the air supply drip leg to drain any accumulated water. Close valve after all
water is drained.
5.1.4 Particulate Filter/Regulator

SERVICE WEEKLY: Inspect for leaks proper regulated pressure (per Pneumatics
Sheet) and filter bowls for minute surface cracks. Replace as required. Drain
water by loosening valve in bottom of bowl.
SERVICE MONTHLY: Disassemble unit and clean any oil residue or contaminates from
inside of filter bowls. Replace filter as necessary.
5.1.5 Pressure Sensor

This machine has an electrical pressure switch to monitor system air pressure, which
should be set to the setpoints shown in the pneumatic prints.
SERVICE MONTHLY: Inspect for leakage and pressure switch function. Replace as
required.
5.2 Mechanical System

5.2.1 Replacing Shear Pins
Shear Pins are attached to both the Handle servo end and the Cable connection
end of the link to prevent damage due to excessive forces. These pins are made
from McMaster-Carr aluminum tube #7237K13 as specified on sheets 3626-013-B &
3626-014-B the mechanical prints.
NOTE: Shear pins are designed as a slip fit.

TIP: Cut material oversized and install. After installation, cut excess material.
52
5.2.2 Maintaining Actuator Shafts
IMPORTANT: Inspect, Clean and Lube shafts after each test cycle.
Should corrosion begin to occur, spray shafts with a mild cleaner and scrub length
wise with a mild abrasive Scotch-Brite pad.
Apply a small amount of a mild lubricant, such as Lithium Grease or Teflon to the
actuator shafts to prevent corrosion and maintain lubricity.
5.2.3 Replacing Cable
1. Unscrew cable adapters from load cell and cylinder piston.

TIP: Cable adapters are thread specific. Mark location for reference.
C able Adapter
C able Adapter
2. Remove Powder Brake from mounting bracket. Held in place by 4 (M5)

socket head cap screws from the opposite side.
53
(4) M5 SHCS
3. Remove the cable pulley from the support block. Pulley is attached to
support by 4 (M3) socket head cap screws.
(4) M3 SHCS
4. After cable pulley is removed from support cable can be easily

removed.
5. Wrap new cable (MEI P/N# 3656-035) around pulley for a total of 3 full
wraps.
54
IMPORTANT: Cable must be cut to length (29 ). Ensure cable
input and output of the wrap are in close alignment with
corresponding actuator and position.
6. Place a piece of tape over cable and pulley. This will help to keep
cable in place while performing the reassembly process.
7. Attach adapters to cable by sliding the cable end through the smaller
clearance hole . Slide compression sleeve (McMaster P/N# 3936T33)
over cable and crimp in place.
8. Reverse Steps 1 3.
Cable Adapter
Compression Sleeve
55
56
5.3 Load Cell Calibration

Each load cell was calibrated by Futek using a specific signal conditioning unit for each
load cell. Each of the signal conditioners has a Shunt Calibration resistor installed within
it, and during the calibration process, Futek linked in the Shunt Calibration resistor and
recorded the volts dc as well as recording the equivalent load. Since no two resistors
are exactly the same, in order to make use of the Shunt Calibration procedure to follow,
it is critical that each load cell be connected to the same signal conditioning unit used
during the original Shunt Calibration. Each load cell was connected to its appropriate
signal conditioner for this purpose. Note that each signal conditioner has a label
indicating to which load cell it belongs. Zero adjustment of the signal conditioner has
been performed at Merrill Engineering & Integration.
Load Cell Calibration via HMI Screen

2 persons are required to perform this calibration
Place Station in manual mode
In order to calibrate the cable load cells, a counteracting force must be applied. Add tension
via the powder brake so the cable will not move when pulling on it. Remove any handle
from the station(s) to be calibrated. In this example we are calibrating the Lower Left
station.
57
Enter 40 for the Powder Brake Tension
Now go to the Calibration Screen. Under the applicable station, for the cable load cell,
press the zero push button before any load is applied.

Attach a hand held force gauge to the handle side of the cable pull rod. In this example, a
force gauge was attached to the S hook retaining hole.
58
This requires one person pulling on the hand held force gauge and another person near the
HMI that will press the Scale pushbutton when the entered force is obtained on the hand
held.
Enter the force value that the hand held is to be pulled to by pressing here to see a pop
59
up keypad.
Once the hand held force is reached, press the Scale push button. Now the load cell is
calibrated. Follow the same procedure for all other stations.
When calibrating Handle load cells, the same procedure is followed with the exception
of attaching the hand held to the pull rod. A tie wrap or a non-flexing strap can be used.
60
Chapter 6
Troubleshooting Guide
Objective
The objective of this chapter is to describe the causes and recovery procedures for
machine faults.
6.1 Fault Recovery Procedure

1. Correct the condition that is causing the fault by performing the action listed in the Fault
Details column below.
2. Clear the fault message by pressing the RESET button on the top right corner of the
operator screen. If the fault will not reset immediately, wait for 10 seconds and try
again. If it still doesnt reset, then go back to step 1.
3. Clearing a fault causes the screen to automatically scroll to the next fault if another is
present. Pressing the SCROLL button in the top left corner will also scroll the faults.
6.2 Fault Message Listing
Fault Category Fault Description Fault Details

The Control Power On input was not
All Stations
Control power off detected. Press the green Control Power On
Immediate Stop
pushbutton.
The Pressure OK input was not detected in
All Stations
Low air pressure time. Check the switch and its programmable
Immediate Stop
settings.
All Stations A "DeviceNet Error" was detected. Press
Immediate Stop DeviceNet Error
Reset.
All Stations Software immediate stop The Immediate Stop Button on the HMI was
Immediate Stop button pressed detected. Press Reset
The Load Cell analog input was not detected
All Stations Load cell graph upload in time. Retry upload. Exit HMI program and
Immediate Stop overtime fault check the terminal window for PLC-HMI
communication activity.
The graphs were not detected as downloaded
in time to the Animatics servos. Retry
All Stations Graphs download overtime
download. Exit HMI program and check the
Immediate Stop fault
terminal window for PLC-HMI communication
activity.
61
The test was not detected as downloaded in
All Stations time to the PLC. Retry download. Exit HMI
Test download overtime fault
Immediate Stop program and check the terminal window for
PLC-HMI communication activity.
All Stations The test sequence database
Immediate Stop Delete the Tests.
has become corrupt
The Released Input was not detected within a

Station Immediate Handle puller cylinder release
preset time after the output was energized.
Stop overtime Check the motion and the switch.
The Engaged Input was not detected within a
Station Immediate Handle puller cylinder engage
Stop overtime Check the motion and the switch.
The Extended Input was not detected within a
Station Immediate Station button presser cylinder
Stop did not reach extended position Check the motion and the switch...
The Retracted Input was not detected within a
Station Immediate Station button presser cylinder
Stop did not reach retracted position Check the motion and the switch.
Station Immediate The signals from the servo indicated a voltage
Handle servo bus voltage fault
Stop problem. Check the servo and the cable.
The signals from the servo indicated an over
Station Immediate Handle servo over temperature
temperature problem. Check the servo and the
Stop fault
cable.
The signals from the servo indicated an
Station Immediate Handle servo excessive
excessive position problem. Check the servo
Stop position error fault
and the cable.
Station Immediate The signals from the servo indicated a velocity
Handle servo velocity limit fault
Stop limit problem. Check the servo and the cable.
The signals from the servo indicated a position
Station Immediate Handle servo 1st derivative of
error over limit problem. Check the servo and
Stop position error over limit fault
the cable.
The signals from the servo indicated a current
Station Immediate Handle servo peak overcurrent
was detected above the upper limit. Check the
Stop occurred
servo and the cable.
The signals from the load cell indicated the
Station Immediate Handle load cell excessive
tension was above the upper limit. Check the
Stop tension fault
load cell and the cable.
Station Immediate Handle load cell excessive
compression was below the lower limit. Check
Stop compression fault
the load cell and the cable.
62
The signals from the servo indicated the
Station Handle servo negative
position value was below the lower limit.
Immediate Stop overtravel Check the servo and the cable.
The signals from the servo indicated the
Station Handle servo positive
position value was above the upper limit.
Immediate Stop overtravel Check the servo and the cable.
Station Cable load cell excessive
tension was above the upper limit. Check the
Immediate Stop tension fault
load cell and the cable.
Station Cable load cell excessive
compression was below the lower limit. Check
Immediate Stop compression fault
the load cell and the cable.
The graph was not detected as downloaded in
Station Graph download to servo
time to the Animatics servo. Check the
Immediate Stop overtime fault
connections.
The graph was not detected as uploaded in
Station Graph upload from servo to
time to the Animatics servo. Check the
Immediate Stop PLC overtime fault
connections.
The On signal from the Black Box was not
Station Cap sensor black box signal on
detected. Check the button and the
connection.
The On signal from the Black Box was
Station Cap sensor black box signal off
connection.
Station Push button black box signal
Immediate Stop on fault
connection.
Station Push button black box signal
Immediate Stop off fault
connection.
Station Hall sensor black box signal on
connection.
Station Hall sensor black box signal off
connection.
Station
Error black box signal on fault detected. Check the button and the
Immediate Stop
connection.
Station
Error black box signal off fault detected. Check the button and the
Immediate Stop
connection.
63
The Released timer timed out and the
Station Handle puller cylinder Down
Engaged input was still detected. Check the
Immediate Stop prox backcheck fault
motion and the switch.
The Engaged timer timed out and the
Station Immediate Handle puller cylinder Up prox
Released input was still detected. Check the
Stop backcheck fault
The Extended timer timed out and the
Station Immediate Button presser cylinder
Retracted input was still detected. Check the
Stop retracted prox backcheck fault
The Retracted timer timed out and the
Station Immediate Button presser cylinder
Extended input was still detected. Check the
Stop extended prox backcheck fault
Station Cycle The cycle count is equal to the cycle count

Station reached its cycle limit
Stop limit.
The station was in cycle and the Cycle Stop
Station Cycle Station cycle stop button
button input was detected. Check the button
Stop pressed
and the wiring.
The signals from the servo indicated that it is
Station Cycle
Handle servo not homed not in the Home position. Check the servo and
Stop
the cable.
64
6.2.1 Clearing Overtravels
An Overtravel can be cleared by pressing the Bypass button on the Home &
Overtravel screen, then repositioning the servo from the Manual screen.
Chapter 7
Recommended Spare Parts
Objective
The following pages consist of recommended spare parts. Spare parts are given
category codes which represent the likelihood of use in descending order, and are listed
as the following:
65
A Perishable Tooling, Miscellaneous Electrical
B Small Hardware & Maintenance
C - Motion and Related Hardware

D Parts Unlikely to Fail, but Stops Production
7.1 OEM Components

Recommended Spare Parts Mechanical Manufactured Items
Item
Ca Q Manufactur
Assembly Numb Description Part Number Comments
t. TY er
er
C AS-365601 34 4 MEI Shear Pin - 3626- McMaster-Carr
Short 013-B #7237K13
C AS-365601 35 4 MEI Shear Pin - 3626- McMaster-Carr
Long 014-B #7237K13
C AS-365601 65 4 MEI Wire Rope 3656-
035- A
66
7.2 Standard Purchased Components

Recommended Spare Parts Mechanical Purchased Items
Item
Cat. Assembly Number QTY Manufacturer Description Part Number Comments
C AS-365601 70 1 Festo Electric Cylinder 555488 _DNCE-32-

80-BS-3P-Q
Servo Motor, 23 Frame Size,
16 Motor, Class 5, DT
C AS-365601 72 1 Animatics Connector SM23165DT-DE-DN
Style, Drive Enable, Device Net
B AS-365601 73 1 THK Rail Assembly SHS20LC1QZSS+220L
A AS-365601 74 1 Futek Load Cell, Model LCM300, FSH02630 Futek Quote
1/4-28 THD. #5883:1
A AS-365601 75 1 Futek Strain Gage Amplifier, FSH01449 Futek Quote
Standard, Enclosed w/ Din Rail #5883:1
Mount
Traceable System Calibration
w/ Amplifier & Certificate, Futek Quote
A AS-365601 76 1 Futek SLB00023
Tension & Compression, #5883:1
Voltage Output, 5 Points
B AS-365601 77 1 McMaster Flange Mount Bearing, Extra 64825K21
Carr Clearance
Pneumatic Cylinder, DSNU,
20mm Bore, 40mm Stroke,
PPV - ADJ. Cushions Both 193990 _DSNU-20-
C AS-365601 78 1 Festo
Ends, Position Sensing 40-PPV-A-S 6
Capable, Heat Resistant
Seals
C AS-365601 79 1 Festo Pneumatic Cylinder, 20mm 193990 _DSNU-20-
Bore, 50mm Stroke, Square 50-PPV-A-MH-Q
Rod
A AS-365601 82 2 Festo Proximity Sensor 543869 _SMT-8M-PS-
24V-K-03_M 12
B AS-365601 84 2 Bunting Bronze Thrust Bearing, 1/2" ID EW081601
(TW51)
A AS-365601 89 1 McMaster Bulb Seal, Silicone, 10 Ft. 1129A8
Carr
A AS-365601 91 2 McMaster Wing Head Thumb Screw, M5 94545A225
Carr x 25MM Lg.
C AS-365601 96 2 Magtrol Convection Powder Brake CPB-5
67
B AS-365601 99 4 McMaster Mounted Bearing Assembly 8600N5
Carr
B AS-365601 100 6 McMaster Neoprene Washer 90133A425
Carr
A AS-365601 102 2 McMaster Wing Head Thumb Screw, M3 94300A310
Carr x 0.5, 20MM Lg.
B AS-365601 105 1 McMaster Adhesive Back Foam Strip, 93625K64
Carr 3/4" Wide x 1/4" Thick x 15'
Long
C AS-365601 108 1 Festo Pneumatic Cylinder, 16mm 193989 _DSNU-16-
Bore, 100mm Stroke 100-P-A-S 11
7.3 Electrical Purchased Components

Recommended Spare Parts Electrical Components
Item
Cat. Assembly QTY Manufacturer Description Part Number Comments
Number
A Electrical 1106 1 Bussmann Fuse, 1 AMP, 250V, Fusetron, Time Delay FNM-1
A Electrical 1116 1 SOLA Power Supply, 120 VAC to 24 VDC, 5 AMP SDN-5-24-100C
A Electrical 1117 1 SOLA Power Supply, 120 VAC to 24 VDC, 4 AMP, SDN-4-24-100LP
Devicenet (Class 2)
A Electrical 1118 1 SOLA Power Supply, 120 VAC to 5 VDC SDP 5-5-100T
A Electrical 1120 1 Allen Bradley Versaview 15" Touch Screen, Performance 6181P-15 TPXP
Version
A Electrical 1122 1 Allen Bradley Power Supply, Compact, 120/240VAC, 1769- PA 4
1A@24V, 4A@5V
A Electrical 1123 1 Allen Bradley CompactLogix PLC, 2 MB 1769-L33 ERM
A Electrical 1124 1 Allen Bradley Dicrete Input Card, 32 Point, 24VDC 1769- IQ 32
A Electrical 1125 1 Allen Bradley Dicrete Output Card, 32 Point, 24VDC 1769- OB 32
A Electrical 1126 1 Allen Bradley Analog Input Card, 8 Point, 16 Bit 1769- IF 8
A Electrical 1127 1 Allen Bradley Devicenet Scanner Card 1769- SDN
A Electrical 1129 1 Allen Bradley TTL Input Card, 16 Point, 5VDC 1769- IG 16
A Electrical 1130 1 Allen Bradley Analog Output Card, 4 Channel, Voltage 1769- OF 4
A Electrical 1137 1 Allen Bradley Contactor, 4 Pole, 24VDC w/ Diode 100-C09 DJ 400
A Electrical 1138 1 Allen Bradley Timing Relay, SPDT, 1 Amp, 24VDC 700- HLF1U 24
A Electrical 1141 1 Allen Bradley Relay, CRM, 3PDT, 24VDC, 10Amp Contacts 700- HA33Z 24
A Electrical 1148 1 Animatics Servo, External Power "DE" Option, SM23165DT-DN-DE
Devicenet
A Electrical 1151 1 Animatics Power Supply, Switch Mode, 1500W PFC1500W-48
68
7.4 Pneumatic Purchased Components

Recommended Spare Parts Pneumatic System
Item
Cat. Assembly QTY Manufacturer Description Part Number Comments
Number
Festo-5/3 Solenoid Valve, Exhaust

B Pneumatic 2101 1 Festo Centered, VSVA-B-P53E-ZDA2-1T1L 539187
Festo-2x2/3 Solenoid Valve,
Normally Closed, VSVA-B-T32CAZD-
B Pneumatic 2101 1 Festo A2-1T1L 539176
B Pneumatic 2103 5 Festo Filter Element, LPF-D-MIDI-5M 159594
B Pneumatic 2108 1 Effector Pressure Switch, 24VDC PN7003
69
Appendix A
Assemblies & Parts List
Objective
The following pages in this chapter consist of parts lists and reduced assembly
drawings of the machine. These documents were current at the time of
publication. Please verify that the information is correct if replacement components
are being purchased. It is also recommended that you check the original drawings
for possible changes BEFORE ORDERING.
A-1 Drawings & Parts List

AS-365601 Door Handle Test Stand
3626-001 thru 014
3656-023
70
Appendix B
Electrical Diagrams & Parts List
Objective
The following pages, in this chapter, consist of parts list and reduced electrical
publication. Please verify that the information is correct if replacement
components are being purchased. It is also recommended that you check the
original drawings for possible changes BEFORE ORDERING.
B-1 Drawings & Parts List

E001.dwg
E002.dwg
E003.dwg
E004.dwg
E005.dwg
E006.dwg
E007.dwg
E008.dwg
E009.dwg
E010.dwg
E011.dwg
E012.dwg
E013.dwg
E014.dwg
E015.dwg
E016.dwg
E017.dwg
E018.dwg
E019.dwg
E020.dwg
E021.dwg
E022.dwg
71
E023.dwg
E024.dwg
E025.dwg
72
Appendix C
Pneumatic Diagrams & Parts List
Objective
The following pages, in this chapter, consist of parts list and reduced pneumatic
publication. Please verify that the information is correct if replacement
components are being purchased. It is also recommended that you check the
original drawings for possible changes BEFORE ORDERING.
C-1 Drawings & Parts List

P001.dwg
P002.dwg
P003.dwg
P004.dwg
P005.dwg
73
Appendix D
Database Structure
This table contains details about the huf database structure. After running a batch of
automatic test cycles the database will contain data collected during each test cycle as
well as operator notes and information about the handle being tested.
Goals
Monitor fo ur handles i ndependently and simultaneously
Hold the d ata for four stations and clear them out with each new handle tested
Collect en ough information that you can piece together what happened during a test by studying the database when exp
orted into M S Excel
Database Name
huf
Access Ri ghts
user name huf Use these parameters when connecting to the mysql_server through a php script.
password huf They should be place in the Huf_login.php script
host localhost
List of Ta bles
general a single-row table used to store specific information about the type of parts loaded in the machine
and other misc data
notes a table where the operator can store notes about what's currently being tested
upperleft a table that stores the testing info for the upper left station
upperright a table that stores the testing info for the upper right station
lowerleft a table that stores the testing info for the lower left station
lowerright a table that stores the testing info for the lower right station
handle_gr aph a table that holds an x-y graph that describes the motion of the handle pull servo
cable_gra ph a table that holds an x-y graph that describes the motion of the cable pull servo
tension_gr aph a table that holds an x-y graph that describes the desired tension levels on the cable
loadcell_g raph a table that holds an x-y graph that shows the actual tension levels on the cable
general table structure

partdescription varchar(40) description of door handle typed into a box on the directory HMI screen
loadcellgraphstation varchar(40) description of the last station that produced a loadcell_graph

blackboxsignal1description varchar(82) description of what the first black box signal was
blackboxsignal2description varchar(82) description of what the second black box signal was
blackboxsignal3description varchar(82) description of what the third black box signal was
blackboxsignal4description varchar(82) description of what the fourth black box signal was
notes table structure
74
postid int automatically assigned numerically increasing number
author varchar(40) name of the author who enters the note
subject varchar(80) brief description of the note
body text text field which supports up to 65 thousand bytes of text
time timestamp automatic time stamp
upperleft, upperright, lowerl eft, and lower right table structure

time timestamp automatic time stamp
cycle_number int the cycle number that this information was recorded during
handle_force float the maximum handle force seen during a cable pull step in the auto
cycle
cable_force float the maximum cable force seen during a cable pull step in the auto cycle
blackbox1pass int the number of times bb1 was correctly on or off during the cycle when it
was supposed to be
blackbox1failon int the number of times bb1 did not come on during the cycle when it was
supposed to
blackbox1failoff int the number of times bb1 did not turn off during the cycle when it was
supposed to
blackbox2pass int
blackbox2failon int
blackbox2failoff int
blackbox3pass int
blackbox3failon int
blackbox4pass int
blackbox4failon int
message varchar(82) if a fault occurs during a cycle, either immediate stop (red) or cycle stop
(yellow) the message text will be copied here.
handle_graph, cable_graph, tension_grap h, loadcell_graph table structure

x float an x coordinate of a graph point
y float a y coordinate of a graph point
Appendix E
Purchased Component Information
Objective
Purchased component information is on the following pages.
E-1 Copy on Disk

Component Literature
75
Allen Bradley Compact 32-Point Solid-State 24V DC Source Output Module
Installation Instructions
Allen Bradley Compact 32-Point 24VDC Sink/Source Input Module Installation
Instructions
Allen Bradley Compact I/O 1769-IF8 Analog Input Module Installation
Instructions
Allen Bradley Compact I/O Analog Output Module Installation Instructions
Allen Bradley Compact I/O Devicenet Scanner Module Installation Instructions
Allen Bradley Compact I/O End Caps/Terminators Installation Instructions
Allen Bradley Compact I/O Expansion Power Supplies Installation Instructions
Allen Bradley Compact TTL Input Module Installation Instructions
Allen Bradley CompactLogix Communication and Secos Modules Product
Information
Allen Bradley CompactLogix 5370 Controller Product Information
Allen Bradley CompactLogix Controllers Specifications Technical Data
Allen Bradley Industrial Integrated Display Computers Installation Instructions
Allen Bradley General Purpose Relays Product Profile
Animatics Class 5 SmartMotor Tecnology Information
Animatics Enclosed Switch Mode Power Supply Information
APC Back-UPS BE 450G/550G/650G1 User Manual
APC Back-UPS ES 450/550G User Guide
APC Equipment Protection Policy
APC Product Registration
APC Safety Information Guide
APC Test Results
Festo SME-8M/SMT-8M Proximity Sensors for T-slots Ordering Guide
Futek calibration certificates can be downloaded at the Futek website:
http://www.futek.com/calibrationData.aspx
76
Futek Sensor #537889 & Instrument #497783 Calibration Data
Futek CSG110 Signal Conditioner Information

Futek Tension and Compression Load Cell Information
Grace Panel Mount Housing Dimensions
Hirshmann Spider xTX(/xFX) Industrial Ethernet Rail Switch Operating
Instructions
Hirshmann RMA
IFM Efector PN70xx Pressure Sensor Operating Instructions
Logitech Safety, Registration and Warranty Information
Magtrol Model 5250-2 Power Supply Information
Sola Power Supplies, DIN Rail Series SDN-P Information
Sola Power Supplies SDN 5-24-100C Information
Sola Power Supplies SDN-P Series Information
Sola Power Supplies SDP Low Power DIN Rail Series Information
77
Sola Terms and Conditions of Sale
78
Laboratory HandleTest Stand Operation and Service
MEI Job No. 13-0254-001 Manual
HUF North America
Laboratory HandleTest Stand

Operation and Service
MEI Job No. 13-0254-002
Manual HUF North
America

Merrill Test Stand Manual

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Laboratory Handle Test

Merrill Engineering & Integration Job No. 13-0254-001

Designed and Built for: Huf

Purchase Order No. 312660

Chapter 2 Safety ................................................................................................................. 9

Chapter 3 Installation Instructions ................................................................................. 13

Chapter 5 Setup, Adjustment & Maintenance ................................................................ 59

Chapter 6 Troubleshooting Guide .................................................................................. 70

Chapter 7 Recommended Spare Parts ........................................................................... 74

Appendix A Assemblies & Parts List ..................................................................................

Appendix B Electrical Diagrams & Parts List ....................................................................

Appendix C Pneumatic Diagrams & Parts List ..................................................................

Appendix D Database Structure..........................................................................................

Appendix E Purchased Component Information ...............................................................

All operating and maintenance personnel should read this manual

Proprietary Clause & Agreement

400 Florence Street

1.1 MEI Service & Procedures

1.2 General Machine Function

1.4 General Machine Data

Read and observe all warnings before operating or performing

Only authorized and properly trained personnel should operate or perform

2.1 Safety Concept

2.2 Personal Safety

2.2.1 Eye Protection

2.2.2 Dressing for Safety

2.2.3 Work Habits

2.3 Work Area Safety

2.3.2 Fixed guarding

2.3.3 Avoid Distracting Others

2.3.4 Reporting Unsafe Working Conditions

2.4 Maintenance Safety

2.4.2 Qualified Personnel

2.4.4 Pneumatic Precautions

2.4.5 Returning To Operation

3.1 Shipping & Receiving

3.2 Unloading & Lifting

3.6 Connecting Plant Supplies

This machine contains hazards from moving components, high voltage

Please read all appropriate warnings, cautions, and instructions before

4.1 Operator Panel Layout

Computer Touch Screen Display

Control Power On (Green Illuminated Push Button)

Figure: 4.1, Operator Panel

4.1.1 Directory Screen

4.1.2 Upper Left / Upper Right / Lower Left / Lower Right

4.1.3 Upper Left / Upper Right / Lower Left / Lower Right

4.1.4 Upper Left / Upper Rignt / Lower Left / Lower Right

(See section 4.1.1 for Servo Homing instructions.)

Cable Profile Tension Limit Check

Sub cycle number

Set temperature, humidity, or temperature and humidity both

4.1.7 Graph Screen

4.1.8 Notes Screen

4.1.10 Database Screen

4.1.12 Fault Log Screen

4.1.13 Configuration Screen

4.2 Common Procedures

Sel ect Export

Select file format (If CSV for excel, pick this)

Check "Put column

Select Open or Save

This screen lists the databases:

hufsequence stores the sequences built for individual tests.