MEK Rub Tester Manual for sn 2125 & up R3

User Guide

DJH Designs MEK Rub Test Machine

©Copyright DJH Designs Inc. 2008 All Rights Reserved. Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws. Publication number A20029-9500M First Edition , January 1992 First Revision, September 1994 Second Edition, June 1995 Third Edition February 1997 Fourth edition January 2000 Revised November 2003 Fifth Edition January 2007 Revised February 2008 Printed in Canada.

Warranty The information contained in this document is subject to change without notice. DJH Designs Inc. Makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties or merchantability and fitness for a particular purpose. DJH Designs Inc. shall not be liable for errors contained herein or for the incidental consequential damages in connection with the furnishing, performance, or use of this material.

Manual Conventions To help you find important information quickly, and make instructions easier to understand, this manual uses the following conventions: Italic refers to a document title or is used for emphasis. Bold refers to new terms or is used for emphasis. _____________________ Note Notes contain important information set off from the text. _____________________ _____________________ CAUTION Caution messages appear before procedures which, if not observed, could _____________________ result in inaccurate data or in damage to the equipment. _____________________ WARNING Warning messages alert you to a specific procedure or practice which, if not _____________________ followed correctly, could cause serious personal injury. _____________________ TIP Contains helpful information about a procedure or practice _____________________

Refer to Related Documentation

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DJH Designs Inc. 2366 Wyecroft Road, Unit D4, Oakville, Ontario, Canada, L6L 6M1

(905)825‐2750 (905)825‐3628 Internet http://www.djh.com

© Copyright DJH Designs 2008

Unpacking and Installation For shipping purposes the safety cover and the MEK reservoir have been removed. Install the cover and reservoir as outlined later in this section. Select a suitable area for the machine. The machine weight is 62.5 lbs. (30 kg) and must be installed on a sturdy work bench that will be able to absorb the inertia of the dead weight rubbing block being shuttled back and forth. It is recommended that the work area have at least 30 cm Clearance on all sides. The machine comes with two (2) mounting plates to secure the machine to the tabletop. Please refer to the diagram below for recommended method of installation. Place the anti-skate pads under the corners of the machine as shown. For metal bench tops mark the screw locations drill pilot holes and then screw the brackets onto the worktable surface. For wood benches and surfaces simply attach using #10 wood screws. ___________ WARNING Failure to secure the machine to the work table may result in the machine falling

off the table, serious damage to the machine and or personal injury can occur due to the weight of the machine.

___________ __________ CAUTION A source of clean dry shop air is required minimum of 90 PSI is required. __________

Anti-skate Pad

Anti-skate Pad

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DJH Designs, 2366 Wyecroft Road, Unit D4, Oakville, Ontario, Canada, L6L 6M1



Installing the MEK Reservoir

Remove the 3 mounting screws form the side of the machine tower

1. Mount the reservoir assembly as shown and tighten

the 3 mounting screws with firm pressure. Do not over tighten the screws as it is possible to strip the rivnuts if too much force is applied.

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2. Connect the flow line coming from the rubbing block to the flow valve located on the bottom of the reservoir as shown.

3. Tighten the fitting by hand then

use a wrench to tighten an additional ¼ turn. Excessive tightening may collapse the Ferrell and restrict the solvent flow.

Connect the air supply line from the machine base to the back of the reservoir assembly.

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Air Supply Connection The MEK Rub Test machine is supplied with a 2 stage air filter assembly pre-installed on the back of the unit, bypassing or removal of these filters will void the machine warranty, if problems due to filters plugging up occur the air supply problem should be addressed before continuing use of the machine.

Air Supply shutoff, before connecting the airsupply to the machine make sure that the machine airshut off valve is in the closed position. (pull up on the handle to shutoff air supply) Connect the air supply to the inlet side of the filter assembly CAUTION Clean, dry, oil free air only, any use of oiler's or dirty air supply will void your warranty. Use of synthetic oils in the air supply can cause severe damage to the internal valve seals and must be avoided

Once the air supply has been connected push the handle on the top of the filter assembly down to supply air the machine pneumatics, check the pressure gauge (located in regulator) on the tower face on the front of the machine. The correct operating pressure is 80 psi (550 Kpa). If the pressure is not correct adjust the regulator to the correct pressure. ________ Note ________

Correct operating pressure is important to achieving accurate test results, incorrect pressure will effect the number of strokes/min. Set pressure to 80 psi (550 Kpa) setting is done statically do not try to adjust the pressure while the machine is running.

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Installing the Safety Cover Align Front of cover to the front edge of the base plate and then align the holes in the cover to the holes in the mounting blocks. You may have to rotate the mounting blocks to be in the correct orientation prior to sitting the cover on the machine.

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Operation Replacing the Rubbing Pad

The MEK rub test machine is equipped with a safety latch device, this latch will prevent the head from in-advertently falling back down onto the base plate if the machine happens to be bumped or if the head was not raised up fully to the over center position of the head. Raising the head requires no operator interaction with the latch; the unit is spring loaded and will slide back as the head is raised against it. Once the head is raised past the latch point the latching device will snap back into place the head is now in the up and locked position. To lower the head, raise the head up fully if it is resting on the latch and with your free hand depress the latch and lower the head.

1. Rotate the holding plate 90° and lift off. The plate is magnetically held to the rubbing block.

2. Remove the old pad and discard

3. Cut the cotton pad into quarters and place

the clean pad (approximate size 1½ x 1¾), double ply, diagonally over the plastic button, corners of the pad between the magnets.

___________ Caution Do not cover the magnets with the ___________ pad. ___________ Note The pad should be changed ___________ before each new test.

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Filling the MEK Reservoir

1. To fill the MEK reservoir, first remove the filler cap. 2. Use the Squeeze bottle provided to fill the reservoir, approximately 425cc. The reservoir has a site level so that you can see the level of MEK in the reservoir at all times. ___________ CAUTION Do NOT Try and pour MEK or any ___________ other solvent from an open container, use only the squeeze bottle provided or an equivalent type of container. 2. Adjusting the flow rate; the flow rate of the valve has been preset at the factory, however you may find it necessary to adjust the flow rate to suit a particular test or a different pad material type. The rate is adjusted by opening or closing the control valve located on the bottom of the main valve body. You only require enough MEK flowing to keep the sample wet if the MEK begins pooling rapidly then cut down on the flow rate.

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Testing a Panel Minimum size 5” x 12” (unless equipped with variable stroke kit). Place the panel on the test area, butt the right edge up against the locating pins under the panel holding clamp, and slide the top edge against and under the stop bar. The stop bar is machined with a taper so if the panel has a bow it will help to hold it flat. Turn the clamp lever Clock Wise to secure the panel. If the clamp rotates too far clock-wise (i.e. 3 O’ Clock position, return it to the vertical position and turn the knurled knob a quarter turn and try again. Do not use excessive force to clamp the panel), Turn the lever Clock-wise just tight enough to secure the panel.

__________ Caution Do not use a panel shorter than 12”, if the __________ panel is too short and the nozzle is allowed to ride over the edge of the panel as shown, it will damage the solvent nozzle. An optional Variable Stroke Kit is available for testing short panels.

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Optional Variable Stoke Kit: The Variable Stroke Kit is an add kit that allows for the use of non standard size panels ranging in length from 85mm (3.5”) to 127mm (12”). Adjusting the stroke length; when testing non standard length panels it will be necessary to adjust the stroke length so that the nozzle cannot ride over the edge of the panel as shown below and cause damage to the nozzle.

1. Turn off the air supply to the machine by pulling up on the shutoff valve located on the top of the filter assembly.

Off

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2. Move the rubbing head by

hand until the nozzle is positioned completely on the test panel close to the left edge as shown.

3. Loosen the bolt on the stop block

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4. Move the stop block until

the shock absorber is in contact with the head.

5. Push the stop block against the head to compress the shock absorber and remove the gap from between the tip of the shock absorber and the shock absorber body as shown. This will set the stop to the correct position.

6. Lock the block in position by

tightening the locking bolt on back of the stop block.

Gap Compressed

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Adjusting the Rubbing Block

Adjustment to the rubbing block is only required if you want to change to running much thicker test panels. To adjust the rubbing block, remove the MEK Pad and lower the head down onto the sample you want to test. Looking from the side of the block you can see that the button does not sit squarely on the sample. Loosen the 2 bolts that hold the block to the “H” arm, rock the block forward and back to sit it squarely on the sample. Replace the pad and you are ready to begin your test.

Loosen two bolts to allow you to set the block, for thicker or thinner panels.

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Setting the Number of Strokes

Preset the number of strokes (forward and back, a “double rub” counts as one stroke) press the button to the left of the digital counter display and hold it down. Press the buttons under each digit (ones, tens, hundreds, thousands) to select the number of strokes on the display. The counter will count down as the machine runs its test. To reset the counter to your original preset number of strokes simply press the button to left of the display again, only this time just press and release the button, the counter will return to the preset number of strokes.

Running the Rub Test Lower the block onto the panel

Filling the MEK Reservoir Testing a panel

Press the start (Green) button. On completion of the preset number of strokes the machine will stop automatically. __________ Note You can stop and start at any point during the count down with no interruption to the cycle __________ total (i.e. the stop button is depressed during a cycle the counter stops at 25 strokes remaining, pressing the start button will begin the count down from that point, 25 remaining strokes). ___________ Note Different pad materials will affect your test results, if you are trying to correlate your results ____________ with another unit it is important to make sure that you are both using the same pad material. __________ Tip To establish the required number of strokes that is acceptable to your standards, run a known __________ panel by your hand method, and run a parallel test on the same panel with the machine. Stop the machine when the results appear similar. This will be your new test requirement.

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Maintenance Check the coalescing air filter and replace as required. __________ Note If you notice a continued drop in air pressure to the machine, it is a good indication that the __________ coalescing filter element requires replacement. Check the secondary filter assembly service as required Lubricate the rubbing block hinge pin, use the supplied grease gun, and add grease until you see the overflow from both ends of the pin. __________ Note Hinge pin and slide must be lubricated weekly. __________

Lubricate the slide bearings by applying oil to saturate the two oil wiper pads located on the front and back of the slide carriage.

Hinge pin; watch for over flow from both ends

Grease Fitting Located On back of block

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Specifications

Weight of machine 28.3 kg (62.5 lbs) MEK reservoir capacity 425 cc. Mass of Rubbing Block 3kg (6.8 lbs) Stroke Length 203mm (8”) Number of strokes/min (Double Rub) 70 Operational air pressure 550 KPa (80 psi) Max air supply pressure 965 KPa (140 psi) Air consumption @ operational pressure 2.35 SCFM @ 345 KPa (50 psi) Minimum Flexible air line supply size ¼” I.D. Air inlet connection at filter ¼ NPT Cotton Pad size 1½ x 1¾, 2 ply Counter max number of strokes 999 Air supply Clean and dry (non condensing) Dimensions (Width Depth Height) 457x483x483mm (18”x19”x19”) Test panel size 127mm x 305mm (5” x 12”) Panel thickness max** 3.2 mm (1/8”) Electrical Requirements None (all pneumatic system)

__________ Note **Thicker panels can be run, please contact DJH Designs for more information. __________

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Where to Find Help DJH Designs Commitment DJH Designs stands behind the product you have purchased. Depending on how you purchase and use your equipment, the best source of support is either from, DJH Designs, or your own organization. Your warranty statement is included in this chapter. Please read it carefully and retain it for your records. Help From Your Organization If your organization has a number of MEK Rub Test Machines, the best source of assistance may be within your own company. Many companies designate central support personnel to help when you have problems with using your system (i.e. long time, experienced system user’s). 24 Hour Help from DJH Designs World Wide Web Page DJH Designs can also be reached 24 hrs a day 7 days a week via the Internet. Our products and support page can provide you with answers to most problems. You can also E-mail your request to several E-mail accounts. See Service and support page, second last page in this manual for web address and E-mail accounts. Help From DJH Designs Customer Support Center If you are unable to solve a problem, or you require information about your system or other products, DJH Designs would be happy to provide you with the support / information you require. Support is available from 7 a.m. until 6 p.m.; (Eastern Time) Monday to Friday, and on Saturdays from 8:30 a.m. to 1 p.m. Call (905) 825-2750 DJH Designs Technical Support E-mail Address: [email protected] DJH Designs Maintenance Agreements DJH Designs is currently developing several types of maintenance agreements that will meet a wide range of support needs. Service Agreements • Priority On-Site Service is being designed for production critical applications, giving you 24 hour service response to

your site for calls made during normal DJH Designs business hours. • Next Day On-Site Service will provide on-site support within 72 hours following your service request. Extended

coverage hours and extended travel beyond DJH Designs designated service zones will be available for additional charges on most on-site service agreements.

• Yearly On-Site Service Agreement will provide economical, scheduled on-site coverage. This service will provide

annual scheduled maintenance and repair visits to your location. * * Some Service agreements may not be available in your location, contact DJH Designs for specific information **

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One Year Limited Warranty DJH Designs warranties its products against defects in materials and workmanship for a period of one year from the date of purchase. DJH Designs will at its option, either repair or replace products which prove to be defective. Exclusions The warranty on your DJH Designs MEK Rub Test Machine will not apply to defects or damages resulting from; • Improper or inadequate maintenance by the customer. • Unauthorized modification or misuse. • Operation outside of the environmental specifications of the equipment. • Improper site preparation or maintenance. The warranty period begins either on the date of delivery, or when the purchase price includes installation by DJH Designs, on the date of installation. Warranty Limitations The warranty set forth above is exclusive and no other warranty, whether written or oral, is expressed or implied. DJH Designs specifically disclaims the implied warranties of merchantability and fitness for a purpose. Some states or provinces do not allow limitation on how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. However, any implied warranty of merchantability or fitness is limited to the one year duration of this written warranty. Obtaining Service during the Warranty Period Should your hardware fail during the warranty period, send your product to DJH Designs or you may also request service from the component manufacturer or one of their authorized agents. To locate a service center or to receive information about obtaining service, please see the service and support phone list on the next page Obtaining Service after the Warranty Period If your hardware fails after the warranty period, contact DJH Designs to obtain service. When sending equipment to DJH Designs, follow the repacking guidelines listed below. Also, complete and enclose a copy of the service information form at the end of this chapter. Insuring the equipment for shipment is highly recommended. ________________ CAUTION Shipping damages as a result of inadequate packaging is the customer’s responsibility. Use the original packing materials whenever possible.. ________________

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Repacking Guidelines Use the original packing materials whenever possible. If you have already disposed of your packing material, please take care in making sure that the equipment is well packaged and protected. You can also request the proper shipping container from DJH Designs. (Container cost and shipping charges will apply) Instructions for packing MEK Rub Test Machine in ISPM15 compliant crate.

Place machine base as shown and set the MEK Rub test machine on top of base the machine feet should nest into the 4 holes in the base plate.

Place blocking on the top of the MEK Rub Tester as shown and strap the block and machine to the base plate using banding as shown. Note: The rubbing head should be in the down position under the shipping block as shown.

View of machine and blocking strapped to base.

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Set Machine into crate as shown, orientation of machine is important as the base plate hold down screws must be screwed through the crate base and into the crate footings.

Use 4 screws provided to secure assembly into the crate. Failure to properly secure the machine to the base and to the crate structure may result in damage to the machine.

Band crate as shown; do not ship crate un‐banded doing so may result in damage to crate and machine.

________________ CAUTION Shipping damages as a result of inadequate packaging is the customer’s responsibility. Use the original packing materials whenever possible. ________________

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Service and Support DJH Designs telephone (905) 825-2750 can/usa (800)616-8818 DJH Designs fax (905) 825-3628 DJH Designs technical support E-Mail address [email protected] Question or Comments can be directed to: John Henderson [email protected] Kari-Ann Matthews [email protected] DJH Designs web site http://www.djh.com Service Information Form Please photocopy and complete the service information form on the next page when requesting service.




Service Request Form Company Name Person to contact Date: Phone ( ) Return shipping address: Special shipping instructions: What needs to be done? Describe the conditions of the failure. (What was the failure? What where you doing when the failure occurred?) If the failure is intermediate, how much time occurs between failures? Additional comments: Product is Under Warranty Purchase/received date:___________ Serial # Purchase order number: Except for warranty service, a purchase order and/or authorized signature must accompany any request for service. Authorized signature:___________________________________ Phone: ( ) Billing Address: Special billing instructions:

User Guide for optional data collection software

MEK Genie Data Collection Software

DJH Designs Inc. Copyright © 2008 MEK Genie Software

MEK Genie Setup and Installation Guide.

Hardware Installation System Requirements. MekGenie is a 32 bit application that runs under Windows 2000, and Windows XP. Minimum PC Requirements; Pentium III 750, 128mb RAM, CD-ROM Drive, 10mb free disk space, 1 available PCI slot for interface card. Interface The interface is provided by means of a sensor connected to one of the MEK NOT valves. This will enable the sensor to be triggered once for every double rub. The sensor is connected to the MEK Rub Test Machine via a plug in port that is added to the side of the main box assembly. All new machines built after October 1st 1998 will have the port installed. A connection kit is provided for older machines that do not have this already in place. Due to the volatility of the MEK we cannot place the sensor inside the machine. The sensor is housed in a small instrument box that can be placed up to 3 feet away from the machine. The sensor is then connected to the PC interface device supplied. The hardware kit provided is dependent on the Serial number of the MEK Rub Test Machine. The installation diagram is specific to the kit provided. If you have received the wrong kit please contact DJH Designs to obtain the correct interface kit. The two kits are for machine with NOT Sensors and the second type is for older machines without the NOT Sensor. Machines with the NOT sensor have an Orion Port on the back of the unit and connection is by means of a quick connector. The older machines have external controls for control of the pilot valve. Machines with serial above 2032 have the NOT sensors and have a built in port for the MEK Genie software. Please see Figure 1 for hardware installation details for machines with serial numbers below 2032. Note: Do not increase the length of the air line. The maximum length is 3’. Increasing the length of the air line can produce missed signals due to the increased pressure drop in the line. If you need a longer hook up to reach your PC you can increase the length of the RCA cable by up to 100’.

1 2 121 2 12

Orion InterfaceRCA Cable

PC Interface

Port

2B

ulk

Hea

d

Signal Unit

The View above is shown as looking down on the band cylinder from the front of the machine. 1. Remove the 5/32” air line coming from the back of the machine to port number 2 of the blue valve body. To remove the air line push in the line and

hold the small ring down, while holding the ring in pull the line out of the port. Remove the line from the bulkhead on the back of the machine the same way.

2. Install the new air line supplied with the installation kit. The line has a tee and three air lines preinstalled and labeled as to the port location for each end.

Figure 1: Installation of sensor in systems prior to SN. 2032


3. Connect the signal unit to the RCA plug on the back of the PC Interface unit. The PC interface must be installed on the port card supplied with the unit. Refer to the installation instructions for the PC interface.

Installing the ISA Encoder Interface Card (Older Systems Only)

***Skip to end of this section for USB or PCI card Configurations***

1. Check the address of the Encoder Interface, the address has been set at the factory to the default address setting of 380. This is a safe place to start as 380 is not a commonly used address in the PC.

You can check for the availability of this address by right clicking on the My Computer icon on the system desktop, click on the properties tab

Click on the Device Manager tab, then double click on the Computer Icon at the top, or single click on Computer then click on the Properties Box


Click the radio button beside Input/output [I/O] scroll down the I/O listing to see if the required address is in use. If you do not see the address listed then it is unused and you can install the interface card without causing any device conflicts.

If you need to change the address please refer to chart 1 and configure the dip switch settings on the card to change the I/O range of the interface card.

Chart 1 ADDR:

DIP SW: 123456

380 310 318 210 230 3AO 3AB

111100 101110 001110 101111 100111 110100 010100

1=ON 0=OFF Install the card into an available ISA slot and close the computer. There is no configuration to run; the card operates transparently to Windows. Refer to the DJH View program configuration to enable the card.

2. PCI Card interface; This is a plug and play card, simply install the card into the available PCI slot and restart the computer. The PC will automatically detect the card. Insert the driver disk when prompted, and windows will then install the correct drivers for the card.

3. USB Interface; This is a plug and play device and requires no additional hardware drivers, connect the interface to the PC and widows will automatically install the correct drivers for the device.

• Installing the software. Insert the installation CD into your CDROM drive. Auto run should startup and begin the install process. The installation needs to add the Microsoft DAO, and ADO database drivers to your system. The installation will automatically detect if the drivers need to be installed or updated. The install program may require you to reboot the system before it has completed the install. Allow the system to reboot and the installation will continue from the point it stopped. Once the install program has completed its task you may be prompted to reboot again. Complete the reboot if required and proceed with the program startup.

Startup and Initialization From the task bars select Start, programs, MEK Genie. From the MEK Genie menu double click on MEK Genie to start the main program. You will see first a splash screen then the logon screen will be displayed. The default user is Admin, which is required to setup the program variables. The default password is MekGenie. It is a good idea to change the admin password at this time, to prevent tampering with the system settings. To change the password, type MekGenie in the password field. Press the tab button on your keyboard or use your mouse to advance to the new password field.


After you type in your new password hit the enter button or click on OK.

A confirm new password dialog box will popup re-enter the new password and click on OK. You will then see the main program screen. See Figure 2; Main Screen Components.

Figure 2; Main Screen Components

Test Status

Count Window

Program Mode

Prior test Information

Specification Lookup

Logoff/Logon new operator

Building the Specification Table The first step in making the program functional is to build a spec table. The Spec table contains all your test specs for the sample panels that will be run. Only the administrator can add or change specification values. All other users have no access to this area of the program. From the menu bar, click on Database, Click on edit Spec Table.

The Specification Window contains a Spec ID, which is your reference number for a given sample, and a MEKSpec Value, which is the target value. To add a record click on the Add button, type in your Spec ID and then type in the MEKSpec Value. Click on add to add another record. When you are done adding records click on the close button.


Adding Users To prevent users from inadvertently changing or deleting specification values, you should add general users to the system. If you are not concerned with which operator performed the test, you can add a general user profile to the system. Name the profile Lab or general to make it simple for everyone to remember. Also give the general account a simple password such 1234 or even make the password the same as the logon. Adding a user account. From the menu bar click on, Options, then Security, Edit Users.

The Edit Users main window will popup. Click on the Add User button

In the New User field, type in the name of the new account to be created, in this example we are adding a general account called lab.

Click on OK to create the account “lab” A new window will popup to create the account password. In the example we have given the lab account a password of lab. Please not that passwords are case sensitive so that a password of Lab (capital L) is not the same as lab (lower case l). Click on OK to exit back to the main program or you can click on Add User to create more user accounts.

Login as new user: From the main program window click on Logout


Now click on Login (notice that once you are logged out of the system all the main program menu items are grayed (locked out), the operator field is also blank.

Clicking on Login will bring up the main logon window. Use the pull down menu to select the user profile to logon with.

Click on the user name that you want to use then enter your password in the password field.

The main window will now return and you will see the new operator id in the Operator field.

You can still view the spec tables and main record table but you are now unable to edit the tables. All other program functions are available to this user.

Using the main program Overview Operator- Displays current user logon Sample ID- Panel ID number Spec. – Panel specification (number of rubs) Current Test- Value from current test updates on test completion 1 &2 Prior - Value of last test, when a new test begins the current value becomes “1 Prior” When another test is then begun the last value becomes “2 Prior” this allows you to quickly view the results of at least the last 3 test, the current, 1 Prior Test and 2 Prior Test. The value displayed is dependent on the mode of count in Pass/Fail mode the results will only display Pass or Fail and not the actual count. In count modes the value displayed will be the actual count. Reset Button- Used to reset main counter, depend on mode. (Refer to mode for more details) Save- Used to save data into database (Disabled in AutoSave mode) Preset-Used to enter a preset value. When a preset is entered the counter will then count down from that value to zero. If no preset is used, then the counter counts up instead of down. Mode- Opens Mode dialog Mode dialog (radio buttons to select options) Select Port- Must use LPT2, at this time the hardware does not support LPT1 (Not used with PCI Interface) Manual Count – This is the simplest test mode, it requires full user input to control all of the program functions. In this mode the Reset delay is disabled so the user must manually reset, and save the data after each test. The Preset button is enabled. If no preset is selected the counter simply counts up until the test is stopped. The operator can then reset the test or save the data.


AutoCount – The AutoCount mode reduces the amount of input the operator has to do with the PC. AutoCount can be fully automatic or semi-automatic depending on the user setup. User defines reset delay in seconds default value 10. In this mode the computer will automatically reset the test after 10 seconds of inactivity. If Autosave is enabled the test result are automatically stored in the database.

Pass/Fail-requires user to input a preset value- returns only a Pass or Fail value to the database. Preset is enabled to allow the operator to modify the number of counts. Preset value is stored with Pass/Fail data. AutoSave- this function is only available in the Auto count and Pass fail testing dialogs. If AutoSave is enabled then the program will update the current record with the appropriate value (either a Count or Pass/Fail & preset value) If AutoSave is disabled the user must manually save the data via the save button. Reset, Save and, Preset buttons are disabled in AutoSave Mode.

Preset – allows the operator to work to a preset value. If a preset is entered the counter operates in a count down mode. If a test is ended before the counter reaches 0 then the test is deemed to have failed. When operating in the count down mode the program will store both the preset value and the actual count value when the test was stopped. Example 1, the operator is in AutoCount mode and selects a preset of 60 with a reset time of 10 seconds. The program detects the first pulse to the trigger and begins its count down, the operator notices a break-through after 25 rubs and stops the machine. The program after 10 seconds ends the current test double beeps the system speaker and stores the following data to a temporary location. Preset: 60, Counts: 25, Pass/Fail: fail. The Save button is now active, the operator will select Save or Reset. If the operator selects Save the data is stored into the database, if the operator selects Reset the data is discarded. The program now resets and is ready to begin the next test. If Autosave is enabled the program will automatically store the data to the database. The operator does not have to interact with the software until they are ready to change the test values. This is useful when testing multiple panels from the same job. You call up the spec, set the unit to autocount and enable autosave. Simply run the test the operator now only works with the rub test machine.

Working with samples. The procedure to properly completing and storing records is as follows. From the Spec ID bring up the spec you want to work with. The pull down can become very long so quick searches are allowed just type in the fist couple of characters into the spec field the drop down will index to the first matching record, you can then scroll down from there. Before you can save records you need to fill in the remaining fields. Work Order #, Sample ID, and Location. Once these are completed the program can store data into the database.


Example of a Test Procedure. Manual Mode Pass/Fail Testing Spec ID 1234, spec value is 10. The mode has been set to Pass/Fail, autosave not used, Auto reset is active. The program automatically enters the preset value of 10 from the spec table. This will operate the counter in a count down mode.

If the operator does not interrupt the test before the counter reaches zero, the status bar on top displays the message as seen below.

After the test the system is waiting for a user input as indicated in the status bar. In this case the program is ready, and is waiting for the operator to save the data or simply reset the test and the data is discarded.

With Autosave enabled the user would enter the required values into the Work Order, sample Id, and location fields.


After the test is complete the database is automatically updated and the program is waiting for the next test to begin. This mode requires no operator intervention to save or reset the counter. The last test data is also updated into the windows displaying the last two test results.

If the operator stops the MEK rub test machine before the test has completed the software detects no further pulses and returns the following.

After a 10 second delay the program has updated the database and status windows. The software is waiting for the next test to begin.

The AutoCount mode works in the same way except that instead of a simple pass/fail being reported the actual counts are recorded.


Calibration testing. Another important function of the software is the ability to test that your MEK Rub Test Machine is calibrated, operating at the correct number of strokes per minute. To test calibration, click on the Options Menu. Select Calibration. You will see the following screen.

The correct calibration for the MEK Rub Test Machine is 70 strokes per minute the allowable tolerance is 55-65 seconds. To test calibration set the counter on your machine to 71 strokes. The reason for setting 1 extra count this is that the software calibration routine ignores the first pulse since it has no timing reference prior to the first pulse being sensed. The first count is used a timing pulse, and the sequence begins from there. Once the test is begun the screen will update as follows.

The software displays the Elapsed time of the test the current stoke time, and the projected average stroke time. The status on top displays the current count. We can see at this point that the machine will pass the test. This is particularly useful when making adjustments to the machine, as you need not run the full test to see what the results will be. You can make minor adjustments to the speed by adjusting the air pressure regulator. If you need to change the air pressure more then 5psi from the correct operating pressure, then the speed adjustment must be made by adjusting the speed control valves internally. Contact DJH Designs for details on the procedure to adjust the speed control valves.

Once the calibration test is complete you will be displayed the following

If the calibration was not within specification the message would display that the test had failed and was not within the specified tolerance.


Index Adding Users, 6 AutoCount, 11 Building The Specification Table, 5 Calibration testing., 17 Example of a Test Procedure, 13 Hardware Installation, 1 Installing the software., 3 Interface, 1 Login as new user, 7 Manual Count, 10 Mode, 10 Operator, 10 Preset, 12 Select Port, 10 Startup and Initialization, 3 System Requirements., 1 Using the main program, 10 Working with samples, 12

DJH Designs MEK Rub Test Machine

Assembly Drawings and Parts List

DJH Designs Inc.

MEK201494MEK Rub Test Machine

Copyright © 2008 DJH Designs Inc. All rights reserved

DJH Designs Inc.

Lexan Safety Cover Assembly


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For all fittings and valves refer to Fittings and Valves detailed view



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Flow Valve AssemblyA


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B Face Plate Assembly

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16MEK201494MEK Rub Test Machine

C Head Assembly detailed View

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F Clyinder & Mounting Assembly


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I Panel Hold Down Bar


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J Base Plate


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K Base and Tower Assembly


TITLE

SIZE CAGE CODE DWG NO REV

SCALE SHEETAPPLICATIONNEXT ASSY USED ON D

UNLESS OTHERWISE SPECIFIED DIM ARE IN INCHES

TOL ON ANGLE ± .XX°2 PL ± .XX 3 PL .XXX

INTERPRET DIM AND TOL PERASME Y14.5M - 1994

THIRD ANGLE PROJECTION

1458

7 5 4 1

A

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Group L Fittings and Valves

MEK22-GrpL

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Group L fittings and Valves


MEK201494 Mek Rub Test Machine Parts List

Item # Part Number Description Unit Qty

1 MEK22-5022 Lexan Safety Cover ea 12 MEK22-5022b Cover screws ea 2

Group A Flow Valve AssemblyMEK22-5032 MEK Auto Flow Control Assembly

1 31052 Filler/vent cap ea 12 MEK22-5049 Solvent reservior ea 13 BG0425-2 Liquid level ea 14 MEK22-5050 Valve body ea 15 B-2MA4 Flow control valve ea 16 MEK22-5039 Mounting bracket ea 17 SHCS 1/4-20x3/4 Socket head cap screw ea 37 SHCS 1/4-20x1/2 Socket head cap screw ea 1

Group B Face Plate Assembly1 MEK22-5001 Face Plate ea 12 ZB2BA3P Green Push Button ea 13 ZB2BA4P Red Push Button ea 14 BH 8-32x1/2 Button head screw ea 45 FH 8-32-1/2 Flat head Screw ea 26 0-498-550 Counter ea 17 3101-04-19 Fitting (not shown) ea 3

Group C Rubbing Head Assembly1 MEK22-5016 Block ea 12 MEK22-5021 H Frame ea 13 MEK22-5017 Cover Plate (MEK Block) ea 14 MEK22-5011 H Frame Non Pivoting Block ea 15 MEK22-5020 MEK Pad Retaining Plate ea 17 MEK22-5015 Handle for Rubbing Block ea 28 269P02X02 1/8 Polyx1/8MNPT-90 Fitting ea 19 14-832000 Magnet Plate Retaining ea 410 MEK22-5014 Solvent Nozzel ea 111 SS 1/4-20x1/4 Set Screw handle retaining ea 212 SS 10-32x1/8 Set Scew magnet retaining ea 413 SHCS 1/4-20x1/2 Screw Cover Plate ea 214 SHCS 8-32x1-1/4 Screw Non pivot block mounting ea 415 FW 5/16 Flat washer ea 416 HHCS 5/16x3/4 5/16 Bolt H frame mounting ea 4

Group D Pivot Assembly1 MEK22-5046 Cylinder Adapter & H Frame Pivot ea 12 MEK22-5025 Hinge Pin ea 13 GN 1/4-28 st Grease Nipple ea 14 MEK22-5047 Latch ea 15 C0180-022-0690 Spring ea 16 DP 3/16x1/2 Dowel Pin ea 17 SHCS M6x35 Screw ea 28 SHCS M6x16 Screw ea 29 SB 5/16x5/8 Sholder Bolt ea 1

Page 1 of Parts List



Group E Clamp Assembly1 MEK22-5007 Clamp Cam ea 12 MEK22-5006 Mounting Block ea 23 C180-022-0690 Spring Clamp Return ea 24 61010A Thumb Screw Plate Adjustment ea 15 SHCS 10-32x1-3/8 Screw ea 26 MEK22-5008 Clamp Plate ea 17 MEK22-5009 Clamp Plate Bumpers ea 28 SS-1/4-28 x 3/4 HD Set Screw ea 2

Group F Cylinder Mounting1 C/46225B/M/8 Cylinder ea 12 MEK22-5048 Clinder/Shock Mounting Block ea 23 MC75-3 Shock Absorber ea 24 MC75-3JN Jam Nut ea 25 SHCS M5x20 Screw ea 86 O-Ring O-Ring End play damper ea 27 MEK22-5026 Cover Mounting Block ea 28 MEK22-5004 Cross Bar ea 19 SHCS 1/4-20x1 Screw ea 410 SHCS1/4-20x3/4 Screw ea 2

Group G Filter AssemblyMC104-F-US99-5TF Filter Assembly

1 MC104-V01TF Shutoff ea 12 MC104-F10TF Prmary Filter ea 13 MC104-FB0TF Coalescing Filter ea 14 MC104-AVTF Smooth Start ea 15 SHCS 10-32 x 2-1/2" Screw ea 2

Group I Panel Hold Down1 MEK22-5005 Panel Hold Down Bar ea 12 FH 8-32x1/2 Screw ea 3

Group J Base Plate1 MEK22-5002 Base Plate ea 12 SHCS 10-32x3/4 Screw ea 73 SP 3/16x1/2 Spring Pin ea 2




Group K Base and Tower1 MEK22-5027 Tower ea 12 MEK22-5028 Base ea 13 ARG20K-N02G2-Z Regulator ea 13a P6520-04-04 Fitting (not shown) ea 13b P6510-04-04 Fitting (not shown) ea 14 4248-01 Regulator mounting nut ea 16 MEK22-5000 Tower Mounting Bracket ea 27 SHCS 8-32x1/2 Screw ea 48 RF001 Rubber Foot (not shown) ea 48 NT 8-32LN Lock nut Foot mounting (not shown) ea 48 PHP 8-32x1/2 Screw Foot mounting (not shown) ea 49 245-006 Snap in cover speed control port (not Shown) ea 1

Group L Fittings Valves1 MINI18-18MM-MEK Valve Assembly ea 12 3101-04-19 Fitting ea 23 127B-04 Street T ea 14 P6510-04-04 Fitting ea 25 TMC28 Speed Control Valve ea 16 3103-04-20 Fitting ea 17 3109-04-20 Fitting ea 18 P6520-04-04 Fitting ea 19 P6520-04-02 Fitting ea 210 P6510-53-02 Fitting ea 111 3142-04-00 Plug in Y ea 312 7808-04-11 Pnuematic Sensor ea 213 SCS668-06-NPT Shuttle ea 114 3199-04-10 Fitting ea 315 3116-56-00 Bulk Head Fitting 1/4" ea 316 88050-53 Bulk Head Fitting 5/32" ea 117 TMBHF-A Orion Port Assembly ea 1




Misc.Tube 1/4 I/4 OD Tubing Clear ft 9140-54-00 5/32 OD Tube Clear ft 22140-53-00 1/8 OD Tube Clear ft 2MEK22-5029 Anti-skate Pad ea 230-132 Grease Gun Kit ea 11963-1 Package rubbing pads ea 1B7895-750 Plastic Bottle ea 1


REVISION HISTORYREV DESCRIPTION DATE APPROVED

REVSTATUS

REV SH

TITLE

SIZE CAGE CODE DWG NO REV

SCALE SHEETAPPLICATIONNEXT ASSY USED ON D

UNLESS OTHERWISE SPECIFIED DIM ARE IN INCHES

TOL ON ANGLE ± .XX°2 PL ± .XX 3 PL .XXX

INTERPRET DIM AND TOL PERASME Y14.5M - 1994

THIRD ANGLE PROJECTION

1458

7 5 4 1

A

B

C

DD

C

B

A

2367

2368

MEK Rub Test MachineSchematic for SN. 2125 & Up

2 MEK Schematic 06/27/2006 J. Henderson

MEK22-Pneumatic

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20"

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26"

11"

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24"

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12.5"

9.5"

9.5"

11"

34"

29"

29"

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28"

29"

25"

11"

21.5"

1/4" Tubing PN 1094P56-005/32 Tubing PN 1094P54-00

1/4" Tubing

5/32" Tubing

1/8" Tubing

28"

11"

9"

20"

To Block

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2

Documents

MEK Rub Tester Manual for sn 2125 & up R3