SOP Slide Gate Sensor Install and Timing Setup

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Standard Operating Procedure
Subject:
SOP Slide Gate Sensor Install and Timing Setup
Author:
Troy Humphrey
Approved by:
Don Warf

Contents

Objective

The Objective of this SOP is to give the reader a reference to use when installing sensors on a new gate and a tips for setting the sensor timing.

Scope

This procedure pertains to Slide Gates that have 'anti-slam' sensors install already or to slide gates that are having sensors installed. The sensors are used to give the PLC feed back as to approximately where the gate is at as it is traveling closed. The PLC then uses this information to assign a different travel open time if a RTO (Request To Open) has been received while the gate is traveling closed. This procedure assumes the gate has been properly timed using the SOP Slide Gate Timing and Pneumatic Setup.

The following graphic illustrates the basic concept of 3 sensor control.


Image:Slide Gate RTO States.jpg


Slide Gate RTO States


Responsibilities

PSMFC field personnel are responsible for installing the sensors and adjusting the timing of the sensor logic.

Procedure

Installing the Sensors

The placement of the sensors is only necessary if they have been removed for maintenance. They should be place back in their original positions. If this is not obvious or if their original positions are not obtainable via documentation then the following steps should be taken:

  1. Place sensor 1 so that approximately 1 inch of flag material is remaining for the sensor to pick once the soft close has started.
    • If the sensor is facing away from you and the gate is traveling closed from your left to right you should have approximately 1 inch of flag material to the left of sensor 1 when the soft close engages.
      • You will most likely need two people to perform this task.
  2. Place sensor 2 seven to eight inches from sensor 1 (further for longer gates).
  3. Place sensor 3 seven to eight inches from sensor 2 (further for longer gates).


The placement of sensors is not an exact science nor is precision critical. The placement of the sensors depends a great deal on the length of the gate. The longer the gate the greater the window is between sensors. The greater the window the better chance you have of obtaining a true state. What this means is that as the gate is traveling closed sensors drop out as the flag travels out of their field. By the time the PLC registers this change the gate has traveled 1 to 2 inches in the closed direction. Keep this in mind while you are setting the times. You will not always obtain a true state in that:

  • You push the button to send a RTO when you see the sensor clear but the PLC uses a time that doesn't seem true for the state you sent the RTO. This is due to system latency.

PV300 Screen Navigation and Explanation

Main



Image:GOJ Main.jpg


Typical Main Menu


  1. Each site has a different Main page. This Main page happens to come from GOJ.
  2. The FX buttons are used to navigate to different screens.
  3. The initial Main page is password protected. It is important that when you are done at a site that you return to the Main menu and press the function key that corresponds to EXIT, in this case F5. This protects the gate settings from inadvertently being changed.



Travel Open Times



Image:GOJ TO TIME.jpg


Typical Travel Open Times Page


  1. F1 will take you to the page where you set the Delay Op, (Normal) Travel Open, Time Open and Travel Close. This should be done prior to any sensor tuning.
  2. F2 Allows you to enter in the Secondary Travel Open time.
    • This time is used when the gate is traveling closed, only sensor 1 is on and a RTO is received.
  3. F3 Allows you to enter in the Tertiary Travel Open time.
    • This time is used when the gate is traveling closed, sensor 1 and 2 are on and a RTO is received.
  4. F4 Allow you to enter in the Quaternary Travel Open time.
    • This time is used when the gate is traveling closed, sensor 1,2 and 3 are on and a RTO is received.
  5. T/O USED LAST CYCLE is the Travel Open time used on the last cycle of the gate. This is key information when setting the travel times.
  6. The values to the right under the heading TIMES USED is a count of each time that particular travel open time was used.
  7. F5 will take you to the Counters page.
  8. F6 will take you to the Set up page.
  9. F8 will take you to the Main page.
  10. If there are problems with the sensor F7 TROUBLE will flash in the upper right hand corner. F7 will take you to the Trouble Shooting page. If everything is OK with the sensors the upper right area of the screen will be blank.



Counters



Image:GOJ COUNTERS.jpg


Typical Counter Page


  1. F1 will take you to the page where you set the Delay Op, (Normal) Travel Open, Time Open and Travel Close. This should be done prior to any sensor tuning.
  2. F2 will take you to the Travel Open Times page of the gate you are working on.
  3. F3 will allow you to reset the counters.
  4. F6 will take you to the Set up page.
  5. F8 will take you to the screen you were previously on.
  6. The first column is a count of the number of times each sensor was missed.
  7. The second column is a count of the number of times each sensor is stuck on.
  8. The third column is a count of the number of times each sensor has gone from off to on.
  9. The total number of times the gate has opened is listed just above F3 RESET COUNTERS in the lower left corner of the page.



Set Up



Image:GOJ SET UP.jpg


Typical Set Up Page


  1. F1 will take you to the page where you set the Delay Op, (Normal) Travel Open, Time Open and Travel Close. This should be done prior to any sensor tuning.
  2. F2 will take you to the Travel Open Times page of the gate you are working on.
  3. F3 allows you to enable or disable the sensors in the PLC logic. If the sensors are disabled they will not help with double slamming of the gate.
    • It should be noted that due to communication latency pressing F3 doesn't always toggle the bit in the PLC and should be double verified that the sensors are truly disabled or enabled. The message on the top of the screen will give you the option to do the opposite of the state it is currently in.
      • If the sensors are already disabled the message you see at the top of this graphic will be present: F3 ENABLE A GATE SENSORS.
  4. F4 will take you to the Main page.
  5. F5 will take you to the Counters page.
  6. F7 will take you to the Trouble Shooting page.
  7. F8 will take you to the screen you were previously on.

This page is primarily used to enable or disable the sensors from the logic. The times you see listed on this page are times captured during the last travel open sequence and can be used as initial travel open times. These times are only relevant if the previous RTO was sent when the gate was fully closed.

  • SOL TO SENSOR 1 time is approximately equal to the Secondary Travel Open Time
  • SOL TO SENSOR 2 time is approximately equal to the Tertiary Travel Open Time
  • SOL TO SENSOR 3 time is approximately equal to the Quaternary Travel Open Time



Trouble Shooting



Image:GOJ TROUBLE SHOOTING.jpg


Typical Trouble Shooting Page


  1. F1 will take you to the page where you set the Delay Op, (Normal) Travel Open, Time Open and Travel Close. This should be done prior to any sensor tuning.
  2. F2 will take you to the Travel Open Times page of the gate you are working on.
  3. F3 will clear a sensor alarm. If the top message is flashing F3 CLEAR SENSOR TROUBLE, note the sensor(s) that are having trouble and press F3 when you are ready to clear the sensor trouble.
    • If there is sensor trouble the double slam logic will not be in effect.
  4. F4 will take you to the Set Up page.
  5. F5 will take you to the Counters page.
  6. F8 will return you to the screen you were previously on.
  7. If all sensors are OK and enabled the double slam logic will be in effect.
  8. If one of the sensors is having trouble the sensor and the reason will flash and the double slam logic will not be in effect.
  9. The following are conditions that will remove the double slam logic from being in effect.
    • Sensor 1 Missed
    • Sensor 2 Missed
    • Sensor 2 Stuck On
    • Sensor 3 Stuck On
  10. Each condition has to happen 3 times in order to cause an alarm. A sensor has to be stuck on for more than 3 seconds while the gate isn't traveling open or closed or being held open due to sample such as at GRJ.
    • Sensor 1 Stuck On and Sensor 3 Stuck On are not detrimental to the control and do not disable the double slam logic.



Tuning the T/0 times

When you first start you should

  1. Ensure that the gate is set up as described in SOP Slide Gate Timing and Pneumatic Setup with out the sensors enabled.
    • THE 6 INCHES FROM BEING FULLY OPEN AND WHERE THE SOFT CLOSE STARTS IS IMPERATIVE!
  2. Once you are satisfied with the initial gate timing navigate to the Trouble Shooting page to ensure that all the sensor alarms are clear.
    • Note and clear any alarms that may be present.
  3. Navigate to the Set Up page and enable the sensors.
  4. Test fire the gate and note the times listed on the Set Up page.
    • You can use these times if previous times are not documented somewhere.
  5. Make sure that the Secondary time you enter is longer than the Tertiary and that the Tertiary is longer than the Quaternary.


Setting the Secondary T/O

The Secondary Travel Open time is moved to the Travel Open timer if a RTO is received while the gate is closing and only sensor 1 is on. This time should be slightly less than the Normal Travel Open time.

  1. Set the time from the X T/O TIME page by pressing F2 and entering in the time.
  2. Position yourself so that you can see the gate and/or sensors and attempt to send another RTO when Sensor 2 has cleared. Your goal is to fire the gate when it is 1/2 way between sensor 2 and sensor 1. If the gate is closer to sensor 2 when the RTO is received it may make it look like the T/O Time is too long. If the gate is closer to sensor 1 when the RTO is received it may make it look like the T/O Time is too short.
  3. You are looking to see if the gate is opened a second time far enough that the travel close time isn't too long to stop the gate but doesn't slam open.
  4. If you cannot keep it from slamming open with out the travel close time being too long, error on the slam open. If the travel close time is too long it will cause the gate to slam closed possibly killing fish.



Setting the Tertiary T/O

The Tertiary Travel Open time is moved to the Travel Open timer if a RTO is received while the gate is closing and sensor 1 and sensor 2 are on. This time should be less than the Secondary Travel Open time.

  1. Set the time from the X T/O TIME page by pressing F3 and entering in the time.
  2. Position yourself so that you can see the gate and/or sensors and attempt to send another RTO when Sensor 3 has cleared. Your goal is to fire the gate when it is 1/2 way between sensor 3 and sensor 2. If the gate is closer to sensor 3 when the RTO is received it may make it look like the T/O Time is too long. If the gate is closer to sensor 2 when the RTO is received it may make it look like the T/O Time is too short.
  3. You are looking to see if the gate is opened a second time far enough that the travel close time isn't too long to stop the gate but doesn't slam open.
  4. If you cannot keep it from slamming open with out the travel close time being too long, error on the slam open. If the travel close time is too long it will cause the gate to slam closed possibly killing fish.



Setting the Quaternary T/O

The Quaternary Travel Open time is moved to the Travel Open timer if a RTO is received while the gate is closing and sensor 1, sensor 2 and sensor 3 are on. This time should be less than the Tertiary Travel Open time.

  1. Set the time from the X T/O TIME page by pressing F4 and entering in the time.
  2. Position yourself so that you can see the gate and/or sensors and attempt to send another RTO when the gate is just starting to close. Your goal is to fire the gate when it is 1/2 way between fully open and sensor 3. If the gate is closer to fully open when the RTO is received it may make it look like the T/O Time is too long. If the gate is closer to sensor 3 when the RTO is received it may make it look like the T/O Time is too short.
  3. You are looking to see if the gate is opened a second time far enough that the travel close time isn't too long to stop the gate but doesn't slam open.
  4. If you cannot keep it from slamming open with out the travel close time being too long, error on the slam open. If the travel close time is too long it will cause the gate to slam closed possibly killing fish.



Fine Tuning

  1. Once you have all the T/O times set you will want to try and catch the gate in different positions to see how it reacts.
  2. A good rule of thumb is that it is better to slam open than to slam closed.
  3. While you are test firing the gate and it slams open immediately stop and go to the T/O Times page and note the last T/O time used. Find the T/O time that it corresponds to and reduce it.
  4. Try to duplicate the condition. If the gate now doesn't open far enough under that condition go back to the original setting.
  5. While you are test firing the gate and it slams closed immediately stop and go to the T/O Time page and note the last T/O time used. Find the T/O time that it corresponds to and increase it.
  6. Try to duplicate the condition. If the gate now slams open leave the time you just entered.

Trouble Shooting

  1. Determine which sensor is having trouble and what type of trouble.
  2. If a sensor is missed you may need someone to fire the gate for you while you look to see if the red dot produced by the sensor is actually hitting the flag. If it is not, this is the cause of the sensor being missed and you will have to determine why.
  3. One thing you can try if a sensor is being missed is to remove the sensor, flip it over and re-install it.
  4. If a sensor is stuck on investigate the sensor and ensure that there isn't something obstructing the sensor.
    • If the sensor has a build up clean it off.



Installation Considerations

Ideally sensors will be installed in a clean environment where testing can take place. For example NMFS shop. If this is not possible a few things must be considered.

  1. The Length and Width of the gate.
    • The Length of the gate will determine how far apart you can place the sensors.
    • The Width of the gate will determine what 'field of view' your sensors have. If the sensor field of view is wider than the gate you have to ensure that there are no objects on the opposite side of the gate that will cause to a sensor to come on.
  2. You will need a flag of some sort that the sensors can pick up as the gate is traveling. This flag has to be reliable and repeatable.
  3. It is preferable to have a installation that allows you to easily place the sensors at different points in the travel of the gate.





References


Contact PSMFC at (509) 735-2773

Name Extension
Don Warf 1
Scott Livingston 2
Darren Chase 3
Alan Brower 4
Troy Humphrey 5
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