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USER’S MANUAL
1.2 SYMBOLISM
A Functional Test LINE consists of several test stations. All testing stations of a single line are
connected to RecDATA TJ through a communication network, that for example, if the acquiring
device is the Galileo model Captor, will be based on a RS485 serial line.
In general we distinguish between static test lines or moving test lines (carousels). The examples
described in section 2.1 and 2.2 are two possible configurations with the device Captor.
When connected through the RS485 serial line, the maximum number of connected stations per
line is 128.
For the automatic management of the line, it is needed a barcode reader. To start a test cycle
automatically through the barcode reader, the operator will read the barcode relative to the station
(typically a number that identifies the station) and the barcode of the product to be tested. This
double bar code will be received by RecDATA TJ, which will automatically send to the device all the
parameters needed to perform the test.
In the absence of the barcode reader, it is possible to start the test cycles in manual way, by
inserting the necessary codes directly from the user interface of the program.
In this kind of configuration, typically the adopted connection is fully "wired", always to be
preferred for performance and reliability compared to a "wireless" connection. In Figure 1 is shown
an example concerning this type of configuration.
When is needed to install a testing line moving but the distances between the various test stations
are fixed, the most efficient solution is to provide a single "bridge" that puts in wireless
communication RecDATA TJ and the line (see Figure 2). In this way is possible to combine the
flexibility of wireless with the performance of wired.
In this case the only possible installation is a completely wireless data transmission line. This kind
of line can be implemented only with the "Captor K" device in WIFI mode. Examples of these
installations are when the carousel has the "fast return".
CAPTOR K
Figure 3 - Moving test line with variables distances between stations. This kind of configuration is
allowable only with “Captor K” device.
When RecDATA TJ is connected to Captor K device, you can use WIFI standard for a wireless
connection. The connection is made through an access point connected to RecDATA TJ PC by an
Ethernet cable.
In this case the Captor K devices must be equipped with the kit with 2.505.0.125 code. The
access point provided by Galileo TP must also be used, configured and tested specifically to work
with the Captor K.
The two prerequisites in order to guarantee adequate performance for industrial use are listed
below in case of WIFI installation:
PC
RecDATA
TJ
CAPTOR K CAPTOR K CAPTOR K
Uart Uart Uart Uart Uart Uart
Socket
Modem Modem Modem
RS485 RS485 RS485
ETH WiFi WiFi WiFi
11.0.0.251 11.0.0.252
Once the installation and configuration of the test lines are done, you are ready to install the
software. Before proceeding with the installation, make sure your PC meets the minimum
hardware and software requirements listed below. Some of the software requirements are,
however, included in the installation package RecDATA TJ.
The RecDATA TJ installation procedure is very simple as all the necessary operations are
completed automated. It will take a few minutes to complete the installation as most of the time is
used to install and configure the Microsoft SQL Server and Microsoft .NET .
The RecDATA TJ installation package is composed by two executable files:
1. RecDATASqlServer.exe
2. RecDATATJSetup.exe
To start the program, make double click on the Desktop icon or execute the application from
Windows “Start” menu.
To uninstall the programme enter the normal function offered by Windows systems and select
RecDATA TJ from the list of the installed programs. The uninstalling will only regard RecDATA TJ,
while if you need to uninstall Microsoft SQL Server or Microsoft .NET , they will have to be
uninstalled separately.
Before starting RecDATA TJ, be sure you have correctly inserted the
hardware USB key supplied with the application.
Have the PC with the RecDATA TJ working in front of you in order to easily understand this
paragraph.
RecDATA TJ has two operation modality, User and Administrator. When used in Administrator
mode, RecDATA TJ provides all possible functionality while in User mode, it is restricted only to
certain functions.
To access in Administrator mode Password is required. During installation temporary password is
set. The temporary password is: RecDATA.
RecDATA TJ has distributed with its USB HW key. Without inserting USB key into the PC where you
installed RecDATA TJ, the following operations will be denied:
In order to access the test lines configuration screens and those related to the creation of the test
cycles, you need to log in as Administrator.
When RecDATA TJ is started for the first time, it shows the screen configuration for test lines. The
user must enter all the necessary informations for the configuration of lines and the composing
stations.
RecDATA TJ is able to manage up to 4 test lines, for a total of 512 stations. Each line may be
composed of a maximum of 128 stations. In the configuration screen of the lines you have to
enter the number of test lines and the number of stations for each per line.
When the total number of stations is large, the stations should be split over
multiple lines. In this way RecDATA TJ manages the various lines in 'parallel',
obtaining considerable advantages in terms of performance.
Once all the information have been input, press button OK to start the application again and, after
the start, the RecDATA TJ main window will be shown.
• Real time monitoring of the stations: the process lines and the stations input during the
configuration step, are represented in a graphic mode in the window central part. The
stations are represented by buttons which could have different colors according to the
current status:
o : the station is in STAND BY status, so it is ready to work.
o White: the station is in WORK status, but it has not sent any “sample” yet.
o : the station is in WORK status, so it is running a test cycle.
o : the station is in PROGRAMMING mode.
o : the station has communication problems (NO COMM status).
o : the station was disabled by the user (OFFLINE status), RecDATA TJ will not
receive data from this station until it will be enabled again through the
specific function (refer to paragraph 4.6.13).
Pressing the buttons relative to the stations you get different functionality, depending on
the current status of the station:
• STAND BY: in this case the opened screen is that where you can enter the barcode
of the test unit, and start the test cycle for that unit.
• WORK: in this case the opened screen is that where you can see the real time
curves relative to all signals acquired during test (the station must have sent at
least one sample).
• Real time monitoring of the running test:
o The remaining test time will be showed through the specific Bargraph.
o The result of the last test cycle or the status of the running test cycle will be
showed through the colour of the specific Bargraph:
▪ : if the test is running, it is signaled that the result will be PASS. If the
test is finished, it is signaled that the last test result has been PASS.
▪ : it is signaled that the last test result has been FAIL.
▪ : the running test result will be FAIL.
• Display of the test results: The main screen allows you to view real-time results and details
of the last finished test. You can also view a list of all the latest tests completed, and from
this list is also possible go to the screen that allows detailed analysis of the particular test.
• Statistics: it is possible to see “pass” or “fail” statistics.
From the main screen it is possible to access all the optional functionality of the program. These
functions will be described in section 4.6.
The screen that allows you to create a new test cycle is divided into two sections, one section
where you have to enter the general parameters, while the other section is dedicated to the
creation of the Reference Curve.
RecDATA TJ allows the ambient temperature compensation, this means that temperature
reference curves may change depending of temperature measured by an external sensor, or
manually entered from user interface (see par. 4.6.6).
In order to perform the temperature compensation properly, the user must define the ranges of
ambient temperature. For each ambient temperature range defined, it is needed to create one
temperature reference curve. Suppose we have defined 3 ambient temperature ranges (R1: from
10 °C to <20 °C, R2: from 20 °C to <30 °C e R3: from 30 °C to <40 °C), then we have to create
the reference curves for R1, R2 e R3.
At start of the test cycle, RecDATA TJ automatically selects the reference curves on the basis of
the ambient temperature, and it maintains the selected curves during all the test.
RecDATA TJ allows the insertion of specific set point at any point on the graph. The set point can
be defined in both the Upper Reference Curve and the Lower Reference Curve. For example, when
the user defines a upper set point, if at that point the acquired value is greater than the upper set
point, then the tested unit is considered "Fail", regardless of the trend of the test for all other
samples.
The set point must be placed directly on the table to the right of the screen. First of all, the user
must click on the “Set Point” column in correspondence at the interested point. The set point value
must be inserted directly in the cell table, in the "Lower" and/or "Upper" columns. In Figure 4 is
shown an “Upper” set point.
Code: 8.003.7.030_rev.08 pag. 13/22
Figura 4 – “Upper” Set Point.
RecDATA TJ allows the definition of the Reference Curves by manually inserting related values
directly in the table on the left of the screen.
The user can also draw the Reference Curves directly on the chart. In this case, first of all it is
advisable to draw the Main Reference Curve, and then apply the “top” and “bottom” offset
pressing the appropriate button.
After defining the Reference Curves, the user can also insert all the desired set point, thus
combining the reject criteria.
After performing a certain number of tests for a given unit, in production line or in laboratory, it is
possible to recreate the reference curves by selecting a subset from acquired curves.
If one of these requirements is not met, an error message will inform the user that there are no
compatible curves stored in Database, and therefore it is not possible to make the Auto-creation.
After opening the Auto-creation screen, the user can select a subset from the acquired curves set
for the calculation of the new Reference Curves.
All selectable curves meet the compatibility requirements listed above.
For the calculation of the new curves, the user can select the following criteria:
• Min – Max criteria: the new Upper Reference Curve is the set of maximum points while the
new Lower Reference Curve is the set of minimum points. The maximum and minimum are
calculated for each sampling instant, considering all the values of the selected curves. The
Main Reference Curve is calculated for each sampling instant by an arithmetic mean of all
values belonging to all selected curves.
• Mean - Variance criteria: the Main Reference Curve is calculated for each sampling instant
by an arithmetic mean of all values belonging to the selected curves. The Upper Reference
Curve and the Lower Reference Curve is calculated in terms of the variance. The variance
value may be regulated by a "delta" value inserted from the user’s interface.
The Min - Max criteria is to be preferred in case you want to make sure that
all the curves selected (so the product units) for the calculation are
considered "Pass" in a hypothetical test. The Mean – Variance criteria is more
suitable for to emphasize the "trend" represented by the selected curves.
To make the newly-created curves effective, simply exit the Auto-creation screen.
In order to automate the testing process through a Barcode Reader, it is necessary to associate
the test cycle to a family of barcodes.
The family of barcodes representing a given model can be identified with a "mask". The mask is a
code identifying the set of fixed characters together with their position, while the other characters
out of the mask are variable.
RecDATA TJ allows the creation of masks with max 32 characters length.
Once the user has created the mask, RecDATA TJ will display the full set of test cycles stored on
Database for the selection.
RecDATA TJ stores all test data in its own Database. This allows the visualization and analysis of
all tests in offline mode. Selecting the relevant function from the main screen (see par. 4.6.9), the
screen for the construction of the query is shown, then the screen for analysis that will show all
the test retrieved from Database.
The screen for the creation of the query allows user to retrieve tests from Database based on
various criteria:
• Barcode Mask.
• Barcode.
• Model description.
• Date and hour intervals.
• Line description.
• Station number.
• Test result.
The number of tests recovered from Database will depend on the criteria entered in the query.
The Analysis screen is composed by three parts:
• The table with all the tests retrieved from the Database.
• The list of signal buttons for all of the signals included in the test cycle selected from the
table.
• The graph where are displayed all test curves. In this part are available all the necessary
commands to interact with the graphics, and also are displayed all the informations needed
to understand the reasons for any "Fail".
The Analysis screen allows to compare the Reference Curves created in test cycles with the curves
acquired during the tests. It is also possible to print the curves.
From the main window it is possible to enter the RecDATA TJ accessories functions. This
paragraph describes in general all the functions which can be entered from the main window.
Figure 7 shows the functions list as they are shown on the main window.
A B C D E F G H I J K L M
From the screen is also possible to insert and configure the Ri intervals.
In order to use the Automatic mode, you must use the Ethernet temperature sensor, 5.501.0.198
code. The sensor must be connected to the LAN to be reachable from RecDATA TJ, so you need to
set an IP address on the sensor. This IP address must belong to the same subnet of RecDATA TJ
PC. By default, the IP address of the sensor is 192.168.1.254, so to access the web configuration
page of the sensor you will need to use this IP address.
1. Hourly.
2. Daily (Default).
3. Weekly.
4. Manual.
Another parameter to be set is the time in which the backup has to be performed, so it must be
set a time in which your PC is turned on.
With the manual option the user is totally responsible for making the backup, through the
appropriate button present on the window.
Another important parameter is the one related to the path and/or device where the backup needs
to be physically written. The backups are not “destructive” types; the data of the working
database will remain there even after the backup.
RecDATA TJ continuously monitors the size of the Database, and if its size risks of exceeding the
set limit (this limit cannot be changed by the user), RecDATA TJ will shows a message saying that
user should perform the operation of "cleaning", in which the user can select the oldest data for
deletion.
As default set up RecDATA TJ writes the backup in the folder “C:\RecDATA TJ_DB\Backup”.
The RecDATA TJ database is accessible by anyone through an account with read-only permissions.
To access the database you need to make a connection to the SQL Server instance installed on the
same PC where installed RecDATA TJ. Access can be made with the following credentials:
• Username: RDReader
• Password: GTP000
The database name is “RECDATA”. The instance of SQL Server used by RecDATA TJ cannot be
used for management of other databases. In case you need to install other databases on the same
PC where RecDATA TJ is installed, these databases will necessarily have to be installed on a new
instance of SQL Server.
For installation and configuration of SQL Server, refer to the appropriate Microsoft documentation.
In order to manage the movement of the functional test line automatically, for example through a
Conveyor, RecDATA TJ has to be able to exchange data information without the operator, such as
the barcode.
Since version 2.0 RecDATA TJ is able to use ModBus industrial protocol. There are two kinds of
registers, the General Registers Area and the Specific Registers Area. In General Registers Area
the registers are not specific for any connected device, they are used for miscellaneous data
exchange between Master and Slave, while in Specific Registers Area the registers are used to
exchange data pertaining to specific Captor. Each Captor is assigned 50 registers, beginning with
address #50. This means Captor number 2 registers begin at address #100, Captor number 3
at address #150, and so on.
RecDATA TJ will act as Slave, so it will wait for the ModBus Master data and commands (see
paragraph 6.1 for the command sequence).
• #50 = ‘116’
• #51 = ‘101’
• #52 = ‘115’
• #53 = ‘116’
1. Once booted up, Slave (RecDATA) sets the value of register 0 SLAVE_REBOOTED to 1.
2. Once the connection between Captor and RecDATA is made, Slave sets the value of register 98
STATION_READY to 1.
3. Master writes registers 50 to 89 (BARCODE). Slave stays idle.
4. Master writes the value 0 to registers 94 OUT1 (PASS) and 95 OUT2 (FAIL). Slave stays idle.
5. Master writes the value 1 to register 96 OUT3 (cycle in progress). Slave stays idle.
6. Master checks that the value of register 98 STATION_READY is 1. Slave stays idle. If the value of
this register is 0, Master waits.
7. Master writes the value 1 to register 97 START_TEST. If the value of register 98 is 1, Slave starts
extracting data from registers 50-89 and preparing the test cycle to be executed based on the
Barcode read. Otherwise, Slave ignores the START_TEST request.
8. Slave writes the value 0 to register 98. Master stays idle.
9. Slave executes the vacuum test cycle. Master stays idle.
10. Slave writes the value 1 to either 94 OUT1 or 95 OUT2. Master stays idle.
11. Slave writes the value 0 to register 97 START_TEST. Master stays idle.
12. Slave writes the value 0 to register 96 OUT3 (meaning the cycle is finished). Master can now get
the test result by reading registers 94 e 95 (only one of them will be set to 1).
13. Slave writes the value 1 to register 98. Master stays idle.