Subject: RE: B600 Wave Generator
Date: Thu, 30 Sep 1999 03:53:30 -0500
From: "Wuestemann, Bernhard" <Bernhard.Wuestemann@mts.com>
To: "Zappia, Tim" <Tim.Zappia@mts.com>, "Elton, Stefan"
     <Stefan.Elton@mts.com>
CC: "Ovsak, Grant" <Grant.Ovsak@mts.com>, "Larson, Rod"
     <Rod.Larson@mts.com>, "Jankowsky, Mario" <Mario.Jankowsky@mts.com>

Hello Tim,
please see my comments below.
Best 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 <mailto:bernhard.wuestemann@mts.com>

        -----Original Message-----
        From:   Zappia, Tim
        Sent:   Tuesday, September 28, 1999 11:08 PM
        To:     Wuestemann, Bernhard
        Cc:     Ovsak, Grant; Larson, Rod
        Subject:        RE: B600 Wave Generator

        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.

        The starter boxes are modified for remote controll. You didn't
get the correct adapter. Sorry for that.

        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.

        Yes we can do as you proposed. But this makes necessary to
rewire the starter boxes.
        Tim this is not the first time that I have discussins about a
remote controlled reset. Untill now nobody gave me a good answer to do
so.
        When are you pressing E-stop? E-stop will be pressed in case of
danger. How offten this situation will occur? We hope never. And for the
reason you do it once in the year I think it's not necessary to put
reset under remote controll. The experience I have is that the customer
( and we too ) use the E-stop button to switch of the pumps because it's
easier to do it with this button than to use a menue point on the PC.

        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?

        Yes there have to be seleted the pump which you want to run. If
there is no pump selected nothing will be happen if run goes high.

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

        The person who is responsible is Stephan Elton his extension is
154. Perhaps you call him? I will forwad this e-mail again to him.

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

        Below in this correspondece you mentioned to provide me the
number of the breaker. Please do so then I will have a look in the
e-schematic.

        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
         << File: 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


