Subject: RE: B600 Wave Generator
Date: Tue, 28 Sep 1999 16:07:51 -0500
From: "Zappia, Tim" <Tim.Zappia@mts.com>
To: "Wuestemann, Bernhard" <Bernhard.Wuestemann@mts.com>
CC: "Ovsak, Grant" <Grant.Ovsak@mts.com>, "Larson, Rod"
     <Rod.Larson@mts.com>

Hello Bernhard,

Do you know why these Starter Boxes were not designed for the remote
start capability?  This is what we specified in our design and
communications to Joe Ruprecht and Raymond Bretschneider.  For some
reason the work did not get done properly and now we are spending our
time (money) to fix a problem that shouldn't be there.

HPU RESET:

Our electrical engineer, Grant Ovsak, proposes the following solution
that would not require us to rewire the MS connector:

1) Combine the functionality of pin K into pin B.  This would free up
the use of pin K.  This would mean that pin B would be 24V when the pump
is on and if their is no pump estop condition.

2) Use pin K to accept an 24V input to reset the HPU in case of an estop
condition.  This is necessary because ESTOP conditions on the HPU must
be able to be reset.

I have attached a marked-up drawing that shows the proposed connections.
I imagine this solution would require a change in the PLC logic and,
hopefully, not a change in any Starter Box wiring.

PUMP SELECT:
On the drawing you sent us Pins F and A are used to select Pump 1 and
Pump 2.  Do we need to select one of these lines before turning on the
pump (pin H)?  What happens if neither pump is selected when the pump
run goes high?

SUPERCHARGE LOW PRESSURE: I still haven't heard from anybody about this
problem.

PLC BREAKER TRIP ON COLD START:  I still haven't heard from anybody
about this problem.

I think someone from MTS-GmbH should plan on coming to the B600 site to
make sure these problems are corrected the week of October 18th.  I
really need to get them resolved during this visit so that we can move
on with the rest of our work.

Talk with you soon.

Regards,

Tim
 <<HPS Drawing.jpg>>

> -----Original Message-----
> From: Wuestemann, Bernhard
> Sent: Tuesday, September 28, 1999 7:15 AM
> To:   Zappia, Tim
> Subject:      RE: B600 Wave Generator
>
> Hello Tim,
> I didn't forget you But I was very busy in the last days.
> As you can see on the drawing you got, reset is not routed to the
> connector. And the other problem is that all pins in J1 are used.
> When we designed this starter box we decided that it is not necessary
> to have this input under remote controll. If there occurs an interlock
> anybody have to go to the HPU and have to look whats happen and on the
> way back he can press the reset button.
> If it is a must to have reset under remote control, I suggest to
> remove the MS connector an connect the wires direct to the big HARTING
> connector.
> Regards
> Bernhard
> Bernhard Wstemann
> mMTS Systems GmbH
> Hohentwielsteig 3   D - 14163 Berlin
> Tel.: +49 30 81002-201
> Fax:  +49 30 81002-100
> e-mail:       bernhard.wuestemann@mts.com
>
>
>       -----Original Message-----
>       From:   Zappia, Tim
>       Sent:   Monday, September 27, 1999 9:04 PM
>       To:     Wuestemann, Bernhard
>       Subject:        RE: B600 Wave Generator
>
>       Hello Bernhard,
>
>       Have you made any progress on our problem?  We are planning on
> being on-site starting October 13th for 2 - 3 weeks and we want to be
> sure to have this problem taken care of.
>
>       Thanks - Tim
>
>
>               -----Original Message-----
>               From:   Wuestemann, Bernhard
>               Sent:   Tuesday, September 21, 1999 9:35 AM
>               To:     Zappia, Tim
>               Cc:     Ovsak, Grant
>               Subject:        RE: B600 Wave Generator
>
>               Hello Tim,
>               to your questions.
>               1)      Now it's clear for me what you mean with reset.
> Up to now I thought with reset you mean to switch off the pumps. Now
> we have a problem. Let me think about that.
>               2)      Normaly the HPU shutdown automatically when an
> over-temperature condition happens.
>               3)      I forwarded this message to the hydraulic people
> with an urgent mark.
>               I'll come back tomorrow.
>               Best regards
>               Bernhard Wstemann
>               mMTS Systems GmbH
>               Hohentwielsteig 3   D - 14163 Berlin
>               Tel.:   +49 30 81002-201
>               Fax:    +49 30 81002-100
>               e-mail: bernhard.wuestemann@mts.com
>
>
>                       -----Original Message-----
>                       From:   Zappia, Tim
>                       Sent:   Tuesday, September 21, 1999 3:24 PM
>                       To:     Wuestemann, Bernhard
>                       Cc:     Ovsak, Grant
>                       Subject:        RE: B600 Wave Generator
>
>                       Hi Bernhard,
>
>                       Thanks for your response.  A couple more
> questions:
>
>                       1) We're still not clear on the reset condition.
> When an e-stop condition occurs, either locally within the HPU,
> remotely from the controller, or when an e-stop button is pressed,
> will we be able to remotely reset the HPU's from the control computer
> without having to go down and physically reset the HPU Starter Boxes?
>
>                       2) It seems to me that the over-temperature
> problem has to do with the logic of the PLC rather than the connector
> to the controller.  Shouldn't the HPU's automatically shutdown when an
> over-temperature condition happens?
>
>                       3) I still haven't heard from your hydraulic
> people about the under pressure on the super-charge.  Can you try to
> push this along so we get it taken care of?
>
>                       Thanks - Tim
>
>
>
>                       Best Regards,
>
>
>                       Tim Zappia
>                       =======================
>                       Project Engineer
>                       MTS Systems Corporation
>                       Advanced Engineering Solutions Division
>                       14000 Technology Drive, Eden Prairie, MN 55344
>                       Ph: (612) 937-4422
>                       Fax: (612) 937-4515
>                       e-mail: tim.zappia@mts.com
>
>
>                       -----Original Message-----
>                       From:   Wuestemann, Bernhard
>                       Sent:   Thursday, September 16, 1999 9:07 AM
>                       To:     Zappia, Tim
>                       Subject:        RE: B600 Wave Generator
>
>                       Hello Tim,
>                       here you get the drawing in PDF format.
>                       It was created with claris draw for PC's
>
>                        << File: 219 833 HPS adaptor J4 spec.pdf >>
>
>                       regards
>                       Bernhard Wstemann
>                       mMTS Systems GmbH
>                       Hohentwielsteig 3   D - 14163 Berlin
>                       Tel.:   +49 30 81002-201
>                       Fax:    +49 30 81002-100
>                       e-mail: bernhard.wuestemann@mts.com
>
>
>                       -----Original Message-----
>                       From:   Zappia, Tim
>                       Sent:   Wednesday, September 15, 1999 4:22 PM
>                       To:     Wuestemann, Bernhard
>                       Subject:        RE: B600 Wave Generator
>
>                       Hello Bernhard,
>
>                       We are having difficulty opening the attached
> file.  It came across as a ASCII Text file.
>                       Claris Draw is not typically used here.  If you
> can save the drawing to another format, perhaps DXF, it would be
> easier for us.    In any case, I need you to resend the drawing.
>
>                       Is this Claris Draw for a PC or Mac?
>
>                       Thanks - Tim
>
>
>                       -----Original Message-----
>                       From:   Wuestemann, Bernhard
>                       Sent:   Monday, September 13, 1999 4:00 AM
>                       To:     Zappia, Tim; Bretschneider, Raymond
>                       Subject:        RE: B600 Wave Generator
>
>                       Hello Tim;
>
>                       here you get the promesed drawing. I modified
> the drawing of the adaptor so you can see on one page whats necessary.
> You are able to start and stop the selected pumps with the pump
> run/stop contact.
>                       Please let me know if you agree.
>
>                       Thanks and best regards
>
>                       Bernhard
>
>                        << File: 219 833 HPS adaptor J4 spec.cdd >>
>
>                       It's a claris draw document
>
>
>                       Bernhard Wstemann
>                       mMTS Systems GmbH
>                       Hohentwielsteig 3   D - 14163 Berlin
>                       Tel.:   +49 30 81002-201
>                       Fax:    +49 30 81002-100
>                       e-mail: bernhard.wuestemann@mts.com
>
>
>                       -----Original Message-----
>                       From:   Zappia, Tim
>                       Sent:   Friday, September 10, 1999 10:34 PM
>                       To:     Wuestemann, Bernhard
>                       Subject:        RE: B600 Wave Generator
>
>                       Hi Bernhard,
>
>                       Thanks for your quick response.
>
>                       1) With your proposed fix, will we be able to do
> a remote reset and start of the HPU's?
>
>                       8)  Occasionally, when turning on the main power
> switch on the front of the Starter Box, one of the breakers inside the
> Starter Box (sorry I can't remember which one - I'll have a look at
> the drawings on Monday) switches off.  When this happened I opened the
> left side Starter Box door and reset the breaker switch.  It's appears
> that the initial power surge causes this breaker to switch off.
>
>                       Best Regards,
>
>                       Tim
>
>                       -----Original Message-----
>                       From:   Wuestemann, Bernhard
>                       Sent:   Friday, September 10, 1999 4:43 AM
>                       To:     Zappia, Tim
>                       Cc:     Bretschneider, Raymond; Elton, Stefan
>                       Subject:        RE: B600 Wave Generator
>
>                       Hello Tim,
>
>                       nice to hear from you. Since I heard nothing
> more from your side, I thought all problems are solved.
>                       Now I read that the complete remote control
> isn't working.
>
>                       Please read my comment to your e-mail.
>
>                       1a You will get two new adaptors. (The big
> Harting connector to our standard MS connector J1). Included in the
> wiring of the new adaptors will be the select inputs to the HPU PLC.
> You will get a drawing of the wiring of this adaptors and you will get
> a modified sketch that we got from your side (interface to remote
> control).
>                       Via pin B we provide the information HPS ON.
>
>                       1b So far I know pin D does not provide any
> information. Via pin D the HPU starter box supplies 24VDC to MTS
> electronic permanently. Start and Stop of the selected pumps is
> possible via pin H. Close contact to start the selected pumps and open
> the contact stop these pumps.
>
>                       2 - 3 You will find these singals with using the
> new adaptors.
>
>                       4 Overtemp should be detected with the new
> adaptors, too.
>
>                       6 You will get any lamps.
>
>                       8 Please explain what you mean. I don't
> understand this point
>
>                       9 Please see 1b
>
>                       5 and 7 I forwarded this e-mail to our hydraulic
> specialists. As far as I understand they will contact you to get more
> information about the described hydraulic problems.
>
>                       For conclusion:
>                       Please wait until you have got the two papers
> which I  announced above, have a look on it and then lets discuss the
> situation. The only news in this case are the under temp signal and
> the remote select function. All other functions are multiple tested in
> starter boxes for other customers. So in my mind it's not necessary to
> change the PLC program.
>
>                       Today im I am available till 12 o'clock, only.
>
>                       Best regards and have a nice weekend
>
>                       Bernhard Wstemann
>                       mMTS Systems GmbH
>                       Hohentwielsteig 3   D - 14163 Berlin
>                       Tel.:   +49 30 81002-201
>                       Fax:    +49 30 81002-100
>                       e-mail: bernhard.wuestemann@mts.com
>
>
>                       -----Original Message-----
>                       From:   Zappia, Tim
>                       Sent:   Thursday, September 09, 1999 5:12 AM
>                       To:     Wuestemann, Bernhard
>                       Cc:     Ovsak, Grant; Larson, Rod;
> Bretschneider, Raymond; Ruprecht, Joe
>                       Subject:        B600 Wave Generator
>
>                       Hello Bernhard,
>
>                       First, I would like to thank you for your help
> last May when we were trying to bring the B600 wave generator up.
> Your help was invaluable and greatly appreciated.  I apologize for not
> communicating with you earlier about our progress.  With your help, we
> were able to get the system going to the point where we could check
> out the actuators and run the system under high pressure.
>                       However, there are some problems with the system
> that need to be addressed and will need your support.  Much of the
> functionality that we specified for these pumps is missing, not
> working, or we don't understand its operation.  Here's the list:
>
>                       1)      The pumps can not be run remotely.
> Also, we are unable to remotely reset the pumps.  We need to be able
> to reset the pumps from the control computer.  HPU pin B is not
> carried through to the MS connector.  Without this pin we do not know
> the pumps on/off status and we can't provide a start signal from our
> control console.  From past experience, we believe this pin also
> resets the pumps e-stop chain.  Possible solutions we can think of
> are:
>                       a)      Wire and program this functionality the
> way it is normally done on all other pumps used in the U.S.
>                       b)      Make pin B a RESET signal and rely on
> pin D for pump status.
>                       2)      We are unable to detect HPU low level
> status.  HPU (pin J) is not carried through to the MS connector.
>                       3)      We are unable to detect HPU under
> temperature status. HPU (pins I and K) are not carried through to the
> MS connector.
>                       4)      The HPU's do not stop on an overtemp
> condition.
>                       5)      The HPU's were not set for low enough
> supercharge pressure when we brought both motors to high pressure.  On
> one of the HPU's we adjusted the low supercharge pressure switch and
> were able to get it to run.  On the other we tried to adjust it but
> became concerned that we were going to set it too low.  We need to
> have someone come who can set these pressures properly.  Why do you
> think they worked in MTS-GMBH for checkout and not in the field?
>                       6)      One of the Starter Boxes Local/Remote
> lamp is not working.
>                       7)      The thermostat on both HPU's leak.
>                       8)      One of the Starter Boxes PLC breaker
> turns off on when turning on the Starter Box main power switch (a cold
> start).
>                       9)      Please confirm that pin D goes from 24
> VDC to 0 VDC to indicate pump status.
>
>                       We will be returning to the site to complete
> installation on October 11th.  I would like to have you think about
> these problems and schedule to have someone come to the site to fix
> them while we have our electrical and control person available.  I'd
> like to do this on October 18th.   The person should be able to add
> pins to the Starter Box connector that connects to the MS connector,
> and reprogram the PLC's.
>
>                       I'm on travel and will be back in the office on
> Friday.  I'll try to give you a call then.
>
>                       Best Regards,
>
>
>                       Tim Zappia
>                       =======================
>                       Project Engineer
>                       MTS Systems Corporation
>                       Advanced Engineering Solutions Division
>                       14000 Technology Drive, Eden Prairie, MN 55344
>                       Ph: (612) 937-4422
>                       Fax: (612) 937-4515
>                       e-mail: tim.zappia@mts.com
>
>

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