User`s manual complete - Sea
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1. HSL SMS User s Manual SYSTEMS Electronics Group 13 SECTION 2 INSTALLATION HSL SMS User s Manual 2 5 3 D4591 KEYPAD DISPLAY INSTALLATION To install the D4591 perform the following steps 1 2 With the gasket installed on the mounting studs of the D4591 install the D4591 in the cut out either in the HSL SMS enclosure or the cut out in the user s existing control cabinet Secure the display to the enclosure using 4ea 8 32 nuts and external lock washers Connect the display ribbon cable to the connector on the lower back of the display the connector on the cable is polarized and should mate with connector on the M4509 only one way 2 5 4 DOWNLOAD HSLSM8 PROGRAM TO M4500 Once the M4500 P4500 D4591 are installed perform the following to download the HSLSMS application program to the M4500 1 2 3 4 5 Power up the M4500 and the IBM PC or compatible used to interface with the HSL SM8 Connect an RS 232 cable from the computer COM port to the PROG port on the M4500 From the computer s menu program select the HSL SM8 PROGRAM selection this was set in section 2 3 2 SYSdev will be invoked with the HSLSMS application program From the main development menu of SYSdev select 6 Target Board Interface Download the HSLSMS application program to the M4500 by selecting 1 Download Program to Target Board from the target board interface menu A prompt will be displayed verifying2. user s control cabinet door with M4500 Field wiring arms for I O termination of M4500 HSL SMS User s Manual M4500 User s Manual HSL SMS Program Disk SYSTEMS Electronics Group SECTION 2 INSTALLATION HSL SMS User s Manual 2 1 2 HSL SM8 ENCL with NEMA 12 ENCLOSURE lea HSL SM8 NEMA 12 enclosure including the following lea M4500 PLC module lea P4500 Power Supply lea D4591 Display Keypad 2ea 24VDC Power Supply 2ea 15VDC Power Supply 8ea M273 High Speed Solenoid Drivers lea HSL SM8 User s Manual lea M4500 User s Manual lea HSL SM8 Program Disk 2 1 3 HSL SM8 OPTIONS PURCHASED SEPARATELY The following items can be purchased separately as required or desired All items are compatible with both the back panel mountable package or the NEMA 12 enclosed package lea 4516 Data Communications Board MODBUS and DF1 protocols 2 2 HSL SM8 INSTALLATION 2 2 1 POWER REQUIRED The HSL SMS is powered from 115VAC 50 60HZ only The package incorporates 24VDC and 15VDC power supplies used by the M273 solenoid drivers and a 5VDC power supply used to power the M4500 module The total 115VAC current required for the package is 9 amps SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 2 2 MOUNTING AND WIRING THE HSL SM8 If installing the HSL SM8 package mounted in the NEMA 12 enclosure mount the HSL SM8 NEMA 12 enclosure in proximity to the existing control cabinet If installing the
3. Gun 2 Delay Time Machine 2 Gun 3 Delay Time Machine 3 Gun 4 Delay Time Machine 4 Gun 5 Delay Time Machine 5 Gun 6 Delay Time Machine 6 Gun 7 Delay Time Machine 7 Gun 8 Delay Time Machine 8 Gun 1 Spray Time Machine 1 Gun 2 Spray Time Machine 2 Gun 3 Spray Time Machine 3 Gun 4 Spray Time Machine 4 Gun 5 Spray Time Machine 5 Gun 6 Spray Time Machine 6 Gun 7 Spray Time Machine 7 Gun 8 Spray Time Machine 8 Gun 1 Number of Indexes Machine 1 Gun 2 Number of Indexes Machine 2 Gun 3 Number of Indexes Machine 3 Gun 4 Number of Indexes Machine 4 Gun 5 Number of Indexes Machine 5 Gun 6 Number of Indexes Machine 6 Gun 7 Number of Indexes Machine 7 Gun 8 Number of Indexes Machine 8 Gun Life Expectancy Lo 0 to 9 999 Gun Life Expectancy Hi 10 000 s Guns Total Spray Counts Reset bits A4 M4500 Dest Address W900 W902 W904 W906 W908 W910 W912 W914 W916 W918 W920 W922 W924 W926 W928 W930 W932 W934 W936 W938 W940 W942 W944 W946 W948 W950 W952 W954 SYSTEMS Electronics Group APPENDIX A MODBUS COMMUNICATIONS The definitions of the data read from the MODICON to the M4500 are as follows 401761 thru 401776 401777 thru 401784 401786 and 401787 Gun 1 Delay Time Machine 1 Gun 8 Spray Time Machine 8 Two timers are used to control each gun the on delay time or Del
4. The display is initialized with machine 1 gun 1 when the GUN LIFE key is first hit Each gun is then displayed one at a time for a time delay The NEXT MACH or NEXT GUN key can be used to advance to the next gun as well The purpose of this screen is to give the operator and maintenance personnel an idea of how much use each gun has incurred The percentage of use is calculated as number of actual sprays divided by expected gun life see section 3 8 1 times 100 When the actual number of sprays exceeds the expected gun life use equal to or greater than 100 the gun life expectancy exceeded alarm will be displayed for that particular gun indicating that gun should be replaced HSL SMS User s Manual SYSTEMS Electronics Group 21 SECTION 3 USING THE HSL SM8 KEYPAD DISPLAY The RESET key can be used to reset SPRAYS for the currently displayed machine and gun This should only be done when a new spray gun has been installed to allow collection of the total number of spray cycles for the gun This key is disabled if the SET UP switch is in the disabled position to prevent unauthorized personnel from resetting the gun counts 3 8 SET UP KEY This selection is used to invoke the primary set up menu This consists of the following three selections 1 SET EXPECTED GUN LIFE OF SPRAYS 2 PRESET OR RESET OF GUN SPRAYS 3 SET CAN PRX TO GUN INDEXES SHIFTS The set up menu is key switch protected such t
5. comprised of a 3 row by 8 column keypad The group of 12 keys on the right side are used for numeric entry which includes the ENTER and ESC keys The group of 12 keys on the left side are defined as follows DELAY TI ME Used to adjust the On delay of for the selected gun SPRAY TIME Used to adjust the Spray duration for the selected gun SYSTEMS Electronics Group 17 SECTION 3 USING THE HSL SM8 KEYPAD DISPLAY HSL SMS User s Manual NEXT MACH NEXT GUN MAN SPRAY RESET INCR DECR CURR SHIFT Used to select the next machine Pressing this key increments the machine number by one If the machine number was 8 when this key is pressed the machine number will roll over to 1 again The gun times and gun counts displayed are for the selected machine and gun number which is selected with this key Used to select the next gun Pressing this key increments the gun number by one If the machine number was 8 when this key is pressed the gun number will roll over to 1 again The gun times and gun counts displayed are for the selected machine and gun number which is selected with this key Used to fire the selected gun when the machine is stopped for test purposes The selected gun will fire once for the spray time of that gun every time this key is depressed Used to reset the can jam sensor fail alarms and the gun life expectancy exceeded alarm as well as reset the gun spray counts for the
6. selected gun Increment key used to increment the selected field by one This is used to increment by one any of the following provided it is selected the selected field is the field that contains the cursor on delay spray time or any of the set up parameters Holding this key for one second will increment the currently selected field continuously Decrement key used to decrement the selected field by one This is used to decrement by one any of the following provided it is selected the selected field is the field that contains the cursor on delay spray time or any of the set up parameters Holding this key for one second will decrement the currently selected field continuously Used to display the number of coated cans for each machine so far into the current shift SYSTEMS Electronics Group 18 HSL SMS User s Manual SECTION 3 USING THE HSL SM8 KEYPAD DISPLAY LAST SHIFT Used to display the total number of coated cans for the previous last shift GUN LIFE Used to display the total number of spray cycles and percent of used life for each gun SET UP Initiates the set up menu which contains the following selections 1 Set Expected Gun Life of Sprays 2 Preset or Reset of Gun Sprays 3 Set Can PRX to Gun Number of Indexes shifts 3 2 DEFAULT SCREEN The default screen displayed when no other commands are active contains the following data DELAY xxx SPRAY xxx MACH x GUN x Wh
7. the GUN LIFE key is depressed When this menu is activated the following screen is displayed MACH x GUN x EXPECTD LIFE xxx xxx xxx The menu is initialized to machine 1 gun 1 The NEXT MACH or NEXT GUN key is used to advance to the next machine The existing expected life is displayed for each gun as the NEXT MACH and NEXT GUN keys are depressed To change the expected gun life for the currently selected gun simply enter the desired gun life in counts up to 649 999 999 and press the ENTER key The next gun will then automatically be advanced to In addition the INCR and DECR key can be used to increment or decrement the expected life by one The number entered for the expected life should be based on the manufactures number of cycles rating for that particular gun Once all gun life expectancies have been entered press the ESC key to return to the primary set up menu The ESC key can also be depressed at any time to return back to the primary set up menu without setting or viewing all the guns SYSTEMS Electronics Group 93 2 SECTION 3 USING THE HSL SM8 KEYPAD DISPLAY HSL SMS User s Manual 3 8 2 PRESET OR RESET OF GUN SPRAYS This menu is displayed when the 2 key PRESET OR RESET OF GUN SPRAYS is pressed while the primary set up menu is active This is used to either reset the actual number of spray cycles for the currently selected gun or preset the actual spray count with a number Whe
8. the count for all the machines have been displayed the default screen is returned to The Current shift data is transferred to the Last shift data when the end of shift input transfers from a 0 to a 1 This can be at the end of either an 8 or 12 hour shift This data cannot be reset by the operator only at the end of shift input transition SYSTEMS Electronics Group 20 SECTION 3 USING THE HSL SM8 KEYPAD DISPLAY 3 6 LAST SHIFT KEY The LAST SHIFT key is used to activate the last shift data display The Last shift data menu displays the total number of coated cans for each machine for the previous last shift The number of coated cans is displayed for each machine one at a time for a time delay of 7 to 8 seconds each The NEXT MACH key can also be used to advance to the next machine coated can count if desired Once the count for all the machines have been displayed the default screen is returned to 3 7 GUN LIFE KEY The GUN LIFE key is used to view the actual number of spray cycles for each gun as well as the percent of life used for each gun When the GUN LIFE key is depressed the following screen is displayed MACH x GUN x USE xx SPRAYS XXX XXX XXX Where MACH is the currently displayed machine GUN is the currently displayed gun USE is the percent of gun life that has been used and SPRAY is the actual number of times the spray gun has been fired since 1t was installed
9. 0 s Mach 4 Coated Cans Lo 0 to 9 999 Mach 4 Coated Cans Hi 10 000 s Mach 5 Coated Cans Lo 0 to 9 999 Mach 5 Coated Cans Hi 10 000 s Mach 6 Coated Cans Lo 0 to 9 999 Mach 6 Coated Cans Hi 10 000 s Mach 77 Coated Cans Lo 0 to 9 999 Mach 77 Coated Cans Hi 10 000 s Mach 8 Coated Cans Lo 0 to 9 999 Mach 8 Coated Cans Hi 10 000 s Gun 1 Total Sprays Lo 0 to 9 999 Gun 1 Total Sprays Hi 10 000 s Gun 2 Total Sprays Lo 0 to 9 999 Gun 2 Total Sprays Hi 10 000 s Gun 3 Total Sprays Lo 0 to 9 999 Gun 3 Total Sprays Hi 10 000 s Gun 4 Total Sprays Lo 0 to 9 999 Gun 4 Total Sprays Hi 10 000 s Gun 5 Total Sprays Lo 0 to 9 999 Gun 5 Total Sprays Hi 10 000 s Gun 6 Total Sprays Lo 0 to 9 999 Gun 6 Total Sprays Hi 10 000 s Gun 77 Total Sprays Lo 0 to 9 999 Gun 77 Total Sprays Hi 10 000 s Gun 8 Total Sprays Lo 0 to 9 999 Gun 8 Total Sprays Hi 10 000 s Timing Can PRX Alarms 1 8 Gun Life Exceeded Alarms 1 8 M4500 Source Address W1084 W1086 W1088 W1090 W1092 W1094 W1096 W1098 W1100 W1102 W1104 W1106 W1108 W1110 W1112 WI1114 W1052 W1054 W1056 W1058 W1060 W1062 W1064 W1066 W1068 W1070 W1072 W1074 W1076 W1078 W1080 W1082 W36 B40 SYSTEMS Electronics Group APPENDIX A MODBUS COMMUNICATIONS The definitions of the data sent from the M4500 to the MODICON are as follows 401700 thru 401715 401
10. 12 SECTION 2 INSTALLATION 7 Install the cover back over the M4509 making sure all the board connectors protrude through the slots in the cover Tighten the two captive screws on the lower front of the cover and the two captive screws on each side of the M4509 chassis 8 Connect the display ribbon cable to the connector on the back of the M4509 the connector on the cable is polarized and should mate with the connector on the M4509 only one way 9 Mount the M4509 chassis either to the HSL SMS back panel using four 8 32 screws or to the back of the D4591 depending on which package is used 10 With power to the P4500 off install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4509 the connector on the cable is polarized and should mate with the connector on the M4509 only one way 11 Install the respective field wiring arms on all the I O boards of the M4509 I O slots0 0 thru 1 0 and MODBUS connector on USER PORT Make sure all the field wiring connectors are fully mated in the M4509 2 5 2 P4500 POWER SUPPLY INSTALLATION To install the P4500 perform the following steps 1 Mount the P4500 to the HSL SMS in the mounting holes next to the M4509 left side using two 8 32 screws 2 With power to the P4500 off install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4509 the connector on the cable is polarized and should mate with the connector on the M4509 only one way
11. 2 3 HSL SM8 SOFTWARE INSTALLATION Follow the steps below to install the HSL SMS application program onto the IBM PC or compatible which will be used to support the HSL SMS package 2 3 1 SYSdev PROGRAM DEVELOPMENT SOFTWARE INSTALLATION The SYSdev Program Development software is used to perform program down load on line trouble shooting and program modifications to the HSL SM8 If SYSdev was purchased with the HSL SMS package and is not already installed on your computer install SYSdev onto the hard drive of your computer following the steps in section 1 5 of the SYSdev Program Development manual 2 3 2 HSL SM8 APPLICATION PROGRAM INSTALLATION The HSLSMS application program is a SYSdev based program which is loaded into the M4500 module and performs the HSL SMS logic To install the HSLSMS program on your computer s hard drive perform the following steps 1 Create one directory off the root directory of the PC for the HSLSMS program called HSLSMS by typing the following at the DOS prompt MD HSLSM8 lt ENTER gt 2 Install the disk labeled HSL SM8 PROGRAMS into the A drive Switch to the HSLSMS directory and install the HSLSM8 application program by typing the following at the DOS prompt CD HSLSM8 lt ENTER gt COPY A HSLSM8 lt ENTER gt CD SYSTEMS Electronics Group HSL SMS User s Manual SECTION 2 INSTALLATION 3 Add the HSLSMS application program to your computer s menu software by creating a select
12. 716 thru 401731 Mach 1 Coated Cans Lo Mach 8 Coated Cans Hi The Coated Can counts for the machines are the total sprayed cans for the current shift These are reset at the end of the shift The Lo words are 0 9 999 while the Hi words are in 10 000 s Gun 1 Total Sprays Lo Gun 8 Total Sprays Hi The Total Spray counts for each gun are the total accumulated spray cycles for the life of the gun These are reset when the operator changes a gun gun worn out The Lo words are 0 9 999 while the Hi words are in 10 000 s The bits of the Timing Can PRX Alarms 401732 are mapped as follows W36 PRX Alarms to MODICON 4x address 401732 in MODICON B36 0 B36 1 B36 2 B36 3 B36 4 B36 5 B36 6 B36 7 B37 0 B37 1 B37 2 B37 3 B37 4 B37 5 B37 6 B37 7 Timing PRX Fail Machine 1 Timing PRX Fail Machine 2 Timing PRX Fail Machine 3 Timing PRX Fail Machine 4 Timing PRX Fail Machine 5 Timing PRX Fail Machine 6 Timing PRX Fail Machine 7 Timing PRX Fail Machine 8 Can Jam Can PRX Fail Machine 1 Can Jam Can PRX Fail Machine 2 Can Jam Can PRX Fail Machine 3 Can Jam Can PRX Fail Machine 4 Can Jam Can PRX Fail Machine 5 Can Jam Can PRX Fail Machine 6 Can Jam Can PRX Fail Machine 7 Can Jam Can PRX Fail Machine 8 With the respective Sensor Check Enable input on both the can sensor and timing sensor are checked for periodic transit
13. HSL SM8 INSIDE SPRAY GUN CONTROL 8 SINGLE GUN MACHINES User s Manual Systems Engineering Associates Inc 14989 West 69th Avenue Arvada Colorado 80007 U S A Telephone 303 421 0484 Fax 303 421 8108 www sea seg com 01 2004 HSL SM8 INSIDE SPRAY GUN CONTROL 8 SINGLE GUN MACHINES User s Manual Copyright 2002 Systems Engineering Associates Inc All Rights Reserved WARNING To ensure the equipment described by this User Manual as well as the equipment connected to and used with it operates satisfactorily and safely all applicable local and national codes that apply to installing and operating the equipment must be followed This includes the National Electric Code in the USA and other applicable legislation regulations and codes in practice elsewhere Since codes can vary geographically and can change with time it is the user s responsibility to determine which standards and codes apply and to comply with them FAILURE TO COMPLY WITH APPLICABLE CODES AND STANDARDS CAN RESULT IN DAMAGE TO EQUIPMENT AND OR SERIOUS INJURY TO PERSONNEL Persons supervising and performing installation or maintenance must be suitably qualified and competent in these duties and should carefully study this User Manual and any other manuals referred to by it prior to installation and or operation of the equipment The contents of the User Manual are believed to be correct at the time of printing however no responsibility is
14. HSL SM8 back panel mounted package mount the back panels in the existing control cabinet Referring to the M4500 User s manual cut a cut out in the existing control cabinet door and mount the D4591 display in the door Connect the ribbon cable from the M4500 module to the D4591 and mount the M4500 to the inside of the door on the back of the D4591 With the HSL SMS package the M4500 and M273 solenoid drivers are all pre wired either in the HSL SMS enclosure or the back panel the user simply has to mount the enclosure or back panel and wire the field devices to the terminals or fuses in the HSL SMS Referring to the schematic at the back of this manual wire as follows wire AC power to the corresponding fuses of the 24VDC 15VDC and P4500 power supplies Wire spray gun solenoids to the corresponding fuses and terminals per drawing Wire sensor check inputs to existing control system These should go on when the corresponding spray machine is running and the can stop is open Note These are true high 24VDC sourcing inputs Wire the sensor fail outputs to the existing control system as necessary Note These are true high 24VDC sourcing outputs that turn on when a sensor fail is detected This should be used to stop the corresponding spray machine Wire the spray gun Manual On push buttons to the corresponding inputs HSL SM8 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION HSL SMS User s Manual
15. assumed for inaccuracies In the interests of a commitment to a policy of continuous development and improvement the manufacturer reserves the right to change the specification of the product or it s performance or the contents of the User Manual without notice Copyright 2002 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description 1 Features General Description Spray Gun Control Spray Gun Cycle Counts and Life Expectancy Can Jam Sensor Fail Alarm Data Collection PE ee ES O 1 BR amp D RS NON 2 Installation 5 2 1 What s Included 5 2 1 1 HSL SM8 for back panel mounting 5 2 1 2 HSL SM8 ENCL with NEMA 12 Enclosure ___ 6 2 1 3 HSL SM8 Options 6 2 2 HSL SM68 Installation 6 2 2 1 Power Required 6 2 2 2 Mounting and Wiring the HSL SM8 7 2 3 HSL SM8 Software Installation 8 2 3 1 SYSdev Program Development Software Installation 8 2 3 2 HSL SM8 Application Program Installation 8 2 4 HSL SM8 Set up 9 2 4 1 Set Can Sensor to Gun Number of Indexes 10 2 4 2 Set Gun Life Expectancy 10 2 4 3 Set On Delay and Spray Duration Times 10 24 4 Manually Test each Gun 10 2 4 5 Run Machine and Verify Spray Weights 11 2 5 M4500 P4500 D4591 Installation 11 2 5 1 M4500 Module Installation 11 2 5 2 P4500 Power Supply Installation 13 2 5 3 D4591 Keypad Display Installation 14 2 5 4 Download HSLSM8 Program to M4500 14 HSL SM8 User s Manual SYSTEMS Ele
16. atch these MODBUS Port PLC address 5 MODBUS Baud 19 2K MODBUS framing mode RTU Number of start bits 1 Number of data bits 8 Number of stop bits 1 Parity NONE HSL SM8 User s Manual SYSTEMS Electronics Group A 7
17. ay Time and the spray duration time or Spray Time The on delay time is used to delay when the gun is first fired after the spray timing flag has occurred while the spray time is used to control how long the gun is on once it is fired The times entered for the Delay Time and Spray Time are in milliseconds Both the Delay Time and Spray Time must be in the range of 0 to 999 Gun 1 Number of Indexes Machine 1 Gun 8 Number of Indexes Machine 8 The HSL SMS package supports between 0 and 3 indexes between the location of the can body sensor and the spray gun If the Can Body sensor is located at the same station as the spray gun the index would be set to zero If the spray gun is located at the next station following the Can Body sensor the index would be set to 1 and so on Gun Life Expectancy Lo Gun Life Expectancy hi The expected life cycle count limit is used to generate the Gun Life Exceeded alarm if the number of spray gun cycles exceeds the entered expected life cycle limit This feature is used for preventative maintenance purposes to track the number of spray cycles and flag when a particular gun has exceeded it s rated life The gun can then be changed prior to incurring spray weight problems due to a worn out gun Note The above parameters 401761 thru 401786 are effective only when the Set Up Parameters Enable bit 401760 1 from the MODICON is set to a 1 Otherwise these variables are not up
18. ctronics Group CONTENTS 3 Using the HSL SM8 Keypad Display 17 3 1 Overview of Keypad and Display 17 3 2 Default Screen 19 3 3 Selecting Machine Gun to Adjust 19 3 4 Setting Gun Times On Delay and Spray Time 20 3 5 CURR SHIFT Key 20 3 6 LAST SHIFT Key 21 3 7 GUN LIFE Key 21 3 8 Set Up Key 22 3 8 1 Set Expected Gun Life of Sprays 23 3 8 2 Preset or Reset of Gun Sprays 24 3 8 3 Set Can PRX to Gun Indexes Shifts 25 3 9 Manual Gun Actuation 26 3 10 Resetting Alarms 26 4 Recommended Spare Parts 27 LIST OF FIGURES Figure 3 1 HSL SM8 Keypad Layout 17 APPENDICES MODBUS Communications Appendix A HSL SMS User s Manual SYSTEMS Electronics Group x SECTION 1 GENERAL DESCRIPTION 1 1 FEATURES e Stand alone package used to implement spray gun timer control on inside spray machines or high speed front end upgrade package to interface with existing control system e HSL SM8 package provides spray gun control for up to 8 machines each equipped with one spray gun e Both on delay timers and spray duration timers are built in for each gun accurate millisecond time base for both On delay adjustable from 0 to 999 milliseconds Spray duration time adjustable from 0 to 999 milliseconds e Additional control functions provided include 1 Number of spray cycles count and life expectancy alarm for each gun 2 Can Jam Detection 3 Sensor fail alarm e High spe
19. dated in the M4500 HSL SMS User s Manual SYSTEMS Electronics Group A 5 APPENDIX A MODBUS COMMUNICATIONS The bits of the Status Control register from the MODICON to M4500 are mapped as follows W900 Status Control from MODICON 4x address 401760 in MODICON B900 0 B900 1 B900 2 B900 3 thru B900 7 B901 0 B901 1 B901 2 B901 3 B901 4 B901 5 B901 6 B901 7 End of Shift Set Up Parameters Enable Alarm Reset Not Used Not Used Manual Spray Gun 1 Manual Spray Gun 2 Manual Spray Gun 3 Manual Spray Gun 4 Manual Spray Gun 5 Manual Spray Gun 6 Manual Spray Gun 7 Manual Spray Gun 8 The Status Control bits sent from the MODICON PLC are defined as follows B900 0 B900 1 B900 2 B901 0 thru B901 7 End of Shift Setting this bit to a 1 transfers the current shift data in the M4500 to the last shift data and clears the current shift data to start data collection for the next shift The current shift data in the MODICON should be saved to the last shift data stack prior to setting this bit Set Up Parameters Enable Setting this bit to a 1 enables the set up parameters 401761 thru 401786 in the MODICON to be used in the M4500 If this bit is set to a 0 the values in 401761 thru 401786 in the MODICON are not used as the set up parameters the M4500 instead uses the values set up thru the HSL SMS keypad Alarm Reset Setting this bit to a 1 resets the Timing PRX Fail a
20. de pressing the MAN SPRAY key will fire the gun selected in the MACH and GUN field of the display for the time entered in the SPRAY TIME field for that gun To check each gun press the NEXT GUN key on the M4500 keypad to select the next gun and press the MAN SPRAY key to fire that gun SYSTEMS Electronics Group 10 SECTION 2 INSTALLATION 2 4 5 RUN MACHINE AND VERIFY SPRAY WEIGHTS With the machine running verify the spray weight and adjust the spray time and on delay if necessary to achieve the desired spray weight and coverage Increasing the spray time will increase the weight decreasing the time will decrease the weight See section 3 4 for details on adjusting the spray time and on delay 2 5 M4500 P4500 D4591 The following is provided as a reference Section 2 5 4 is performed by the factory prior to shipping the HSL SMS These steps need only be performed in the event either the M4509 module P4500 power supply or D4591 display need to be replaced Refer to the M4500 User s Manual for general details on installing the M4509 P4500 and D4591 2 5 1 M4509 MODULE INSTALLATION To install the M4509 module perform the following 1 Remove the cover from the M4509 chassis retained with two captive screws on the lower front of the cover and two captive screws on each side of the M4500 chassis 2 Install S4563 SLOTO 0 Set the slot address dip switches SW1 on the S4563 to the follo
21. ed solenoid drivers provided to minimize solenoid response time and maximize repeatability e Built in 2 Line X 20 character sealed display with 24 key membrane keypad allows local viewing of collected data coated can count total number of spray cycles for each gun by operator and set up of all spray times key switch enabled by authorized personnel e Based on high performance M4500 PLC PLS module which allows easy trouble shooting and user customization using SYSdev DOS based programming package HSL SM8 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSL SMS User s Manual 1 2 GENERAL DESCRIPTION The HSL SMS spray gun control package is a stand alone package used to implement the spray timer control for up to 8 single gun spray machines Both user adjustable on delay and spray duration timers are provided for each gun The spray times are entered on the keypad of the M4500 and displayed on the built in alphanumeric display All times are adjustable from 0 to 999 milliseconds accurate and stable crystal based time base In addition to the spray gun timer control the HSL SMS also provides spray cycle counts with a life expectancy alarm can jam detection a sensor fail alarm for each gun and data collection including Total coated can count both current shift and previous last shift The package is not a dedicated black box but instead based on the high performance SYSTEMS M4500 PLC wh
22. ere Delay is the on delay time and Spray is the spray duration Mach and Gun specify the currently selected machine and gun for which the delay and spray times are displayed The on delay and spray duration times are adjusted from the screen be selecting the DELAY TIME and SPRAY TIME keys respectively This screen is always returned to when no other commands are active 3 3 SELECTING MACHINE GUN TO ADJUST The NEXT MACH key and NEXT GUN key are used to select the machine gun for adjustment of any of the following variables on delay spray time gun count gun life expectancy limit or Can PRX to Gun indexes The NEXT MACH key increments the machine number as displayed in the MACH field by one when depressed If the previous machine number was 8 pressing NEXT MACH causes the machine number to roll over to 1 again The NEXT GUN key also increments the machine number by one when depressed If the previous machine number was 8 pressing the NEXT GUN causes the machine number to roll over to 1 again SYSTEMS Electronics Group 19 SECTION 3 USING THE HSL SM8 KEYPAD DISPLAY HSL SMS User s Manual 3 4 SETTING GUN TIMES ON DELAY AND SPRAY TIME Two timers are used to control each gun the on delay time or DELAY TIME and the spray duration time or SPRAY TIME The on delay time is used to delay when the gun is first fired after the spray timing flag has occurred while the
23. es is accumulated for each gun and can be displayed on the M4500 display In addition an expected life cycle count limit can be entered by the user and is used to generate an alarm if the number of spray gun cycles exceeds the entered expected life cycle limit This feature is used for preventative maintenance purposes to track the number of spray cycles and flag when a particular gun has exceeded it s rated life The gun can then be changed prior to incurring spray weight problems due to a worn out gun 1 5 CAN JAM SENSOR FAIL ALARM Both the can sensor and timing sensor are checked for proper operation while the spray machine is running A sensor check input is provided which should be turned on when the machine is running and feeding cans can stop open With this input on both the can sensor and timing sensor are checked for periodic transitions If the can sensor fails to transition off to on a can jam alarm is generated for that machine If the timing sensor fails on or off a sensor fail alarm is generated for that machine These alarms are displayed on the M4500 display as well as being provided as an output which can be interlocked to the spray machine control system to stop the corresponding machine when the alarm occurs HSL SM8 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 6 DATA COLLECTION The total number of coated cans is collected for both the current shift and t
24. hat only authorized personnel those with the key can activate the selection The Set up Enable input must be on to invoke the set up menu Each selection is displayed for a time delay The INCR key and DECR key can also be used to either advance to the next selection or retard to the previous selection respectively When selected each of the above selections bring up a sub menu with the corresponding set up parameters The following sections describe these sub menus and the definitions of the corresponding variables To select the respective set up sub menu simply press the corresponding numeric key 1 thru 3 HSL SM8 User s Manual SYSTEMS Electronics Group 22 HSL SMS User s Manual SECTION 3 USING THE HSL SM8 KEYPAD DISPLAY 3 8 1 SET EXPECTED GUN LIFE OF SPRAYS This menu is displayed when the 1 key SET EXPECTED GUN LIFE is pressed while the primary set up menu is active The expected gun life limit is a number that is compared to the actual number of accumulated gun spray cycles If the number of spray cycles counts is greater than the expected gun life limit the gun life expectancy exceeded alarm is displayed on the front of the M4500 for that gun Note This alarm does not stop the machine or inhibit the spray function in any way it simply indicates the gun may be worn out and should be replaced The expected gun life is also used in the calculation of percent of life used which is displayed when
25. he previous last shift This data can either be viewed locally on the display by the operator or can be sent to the host PLC via RS 232 communications MODBUS or Allen Bradley DF1 protocols using the optional S4516 communications board This information is updated current shift transferred to Last shift based on the change of state of a discrete input This input can be activated on an 8 or 12 hour shift basis depending on the user s preference HSL SM8 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION The standard HSL SMS package is provided for back panel mounting inside the existing user s control cabinet In addition the HSL SM8 can be purchased in a self contained NEMA 12 enclosure for mounting adjacent to the existing control cabinet by specifying part number HSL SM8 ENCL 2 1 WHAT S INCLUDED Depending on which package is purchased verify that the following items are included when unpacking the HSL SM8 2 1 1 HSL SM8 for back panel mounting 2ea lea lea lea 1set lea lea lea HSL SMS User s Manual HSL SMS back panels for mounting in the existing user s control cabinet each including the following lea 24VDC Power Supplies lea 15VDC Power Supplies 4ea M273 High Speed Solenoid Drivers M4500 PLC module for mounting in the user s control cabinet door P4500 Power Supply for mounting adjacent to M4500 D4591 Display with ribbon cable for mounting in the existing
26. ich allows easy customization by either SEA or the end user The M4500 PLC incorporates a built in keypad and 2 line by 20 character alphanumeric display and is programmed using the DOS based SYSdev programming package SYSdev allows the module to programmed in both Ladder and High level subset of C and is used to perform on line monitoring and trouble shooting as well 1 3 SPRAY GUN CONTROL The HSL SMS package provides spray gun control for up to 8 single gun machines For each gun both an on delay timer and a spray duration timer is provided These are adjustable from 0 to 999 milliseconds in one millisecond increments The spray times are entered on the keypad of the M4500 and displayed in the M4500 display see section 3 4 The basic spray gun control is implemented as follows The on delay is triggered at the leading off to on edge transition of the timing sensor only if a can has been detected by the can sensor Note The can sensor must see the can prior to the leading edge of the timing sensor SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION Once the on delay has timed out the spray gun is activated on and is left on for the time entered in the spray time at which time it is de activated Note Ifthe on delay is set to zero the spray gun is activated immediately at the leading edge of the timing sensor 1 4 SPRAY GUN CYCLE COUNTS AND LIFE EXPECTANCY The number of spray cycl
27. ion called HSL SM8 PROGRAM The DOS commands executed for this selection should be CD SYSDEV HSLSM8 HSLSM8 4 To initiate SYSdev with the HSLSMS program simply select the HSL SM8 PROGRAM selection from the menu software s menu The main development menu of SYSdev will be initiated with the HSLSMS program See the SYSdev Program Development manual and the M4500 Program Development manual for complete details on on line monitoring and program development with SY Sdev 2 4 HSL SM8 SET UP The HSL SMS is shipped from the factory with the program HSLSMS loaded into the M4500 module This is the standard 4 machine by two gun spray gun control program In addition the following variables are set to the following values Mach Gun ON Delay SPRAY time Life Expectancy 1 1 Omsec 100msec 649 999 999 cycles 2 1 Omsec 100msec 649 999 999 cycles 3 1 Omsec 100msec 649 999 999 cycles 4 1 Omsec 100msec 649 999 999 cycles 5 1 Omsec 100msec 649 999 999 cycles 6 1 Omsec 100msec 649 999 999 cycles 7 1 Omsec 100msec 649 999 999 cycles 8 1 Omsec 100msec 649 999 999 cycles In most cases the above variables will have to be adjusted to achieve the desired film weight and to match the rated life expectancy of the spray guns used Once the HSL SMS is installed and the package is powered up perform the following to set up the HSL SMS See section 3 for complete descriptions of the Keypad commands and menu displays SYSTEMS Electronic
28. ions If the can sensor fails to transition off to on a Can Jam Can PRX Fail alarm is generated for that machine If the timing sensor fails on or off a Timing PRX Fail alarm is generated for that machine HSL SMS User s Manual SYSTEMS Electronics Group A 2 APPENDIX A MODBUS COMMUNICATIONS The bits of the Gun Life Exceeded Alarms 401733 are mapped as follows B40 Gun Life Alarms to MODICON 4x address 401733 in MODICON B40 0 Life Exceeded Gun 1 B40 1 Life Exceeded Gun 2 B40 2 Life Exceeded Gun 3 B40 3 Life Exceeded Gun 4 B40 4 Life Exceeded Gun 5 B40 5 Life Exceeded Gun 6 B40 6 Life Exceeded Gun 7 B40 7 Life Exceeded Gun 8 The respective Gun Life Exceeded alarm is set when the accumulated Total Spray count for that gun exceeds the Expected Gun Life preset The alarm is cleared when the accumulated Total Spray count for the gun is reset to zero and the alarm reset is pressed HSL SMS User s Manual SYSTEMS Electronics Group A 3 APPENDIX A MODBUS COMMUNICATIONS The following data is read from the MODICON PLC MODICON Source 4x Address 401760 401761 401762 401763 401764 401765 401766 401767 401768 401769 401770 401771 401772 401773 401774 401775 401776 401777 401778 401779 401780 401781 401782 401783 401784 401785 401786 401787 HSL SMS User s Manual Data Definition Status Control from MODICON Gun 1 Delay Time Machine 1
29. larms Can Jam Can PRX Fail alarms and Gun Life Exceeded Alarms Manual Spray Gun 1 Manual Spray Gun 8 Manual Spray Gun 1 thru 8 are used to fire the respective gun for test purposes while the machine is stopped The gun is fired for the spray time entered for that gun The gun is fired every time the respective Manual bit transitions from a 0 to a 1 This is generally done to verify that the gun is operating properly HSL SMS User s Manual SYSTEMS Electronics Group A 6 APPENDIX A MODBUS COMMUNICATIONS The bits of the Guns Total Spray Counts Reset register from the MODICON to M4500 are mapped as follows W954 Counts Reset from MODICON 4x address 401787 in MODICON B954 0 Reset Gun 1 Total Spray Counts Life Expectancy B954 1 Reset Gun 2 Total Spray Counts Life Expectancy B954 2 Reset Gun 3 Total Spray Counts Life Expectancy B954 3 Reset Gun 4 Total Spray Counts Life Expectancy B954 4 Reset Gun 5 Total Spray Counts Life Expectancy B954 5 Reset Gun 6 Total Spray Counts Life Expectancy B954 6 Reset Gun 7 Total Spray Counts Life Expectancy B954 7 Reset Gun 8 Total Spray Counts Life Expectancy The above bits are used to reset the respective Total Spray counts 401716 thru 401731 for the corresponding gun This is typically done when a gun is replaced worn out The MODBUS driver uses the following data format and parameters the MODBUS port on the MODICON PLC must be set to m
30. n this menu is activated the following screen is displayed MACH x GUN x ACTUAL SPRAYS xxx XXX XXX The menu is initialized to machine 1 gun 1 The NEXT MACH or NEXT GUN key is used to advance to the next machine The actual number of accumulated spray cycles is displayed for each gun as the NEXT MACH and NEXT GUN keys are depressed To reset the actual number of sprays for the currently selected gun simply press the RESET key The actual number of sprays will be reset to zero To preset the actual number of sprays to a count simply enter the number of sprays in counts up to 649 999 999 and press the ENTER key The next gun will then automatically be advanced to The actual number of spray counts can be preset to a number in the case where a previously used gun is installed on the machine When a new gun is installed the actual number of sprays would be reset to Zero Once all gun actual sprays are reset or preset press the ESC key to return to the primary set up menu The ESC key can also be depressed at any time to return back to the primary set up menu without resetting or viewing all the guns SYSTEMS Electronics Group 24 SECTION 3 USING THE HSL SM8 KEYPAD DISPLAY 3 8 3 SET CAN PRX TO GUN INDEXES SHIFTS This menu is displayed when the 3 key SET CAN PRX TO GUN INDEXES is pressed while the primary set up menu is active This is used to set the number of indexes from the Can Body sensor to the s
31. pray gun for the currently selected gun When this menu is activated the following screen is displayed MACH x GUN x INDEXES CAN PRX TO GUN x The menu is initialized to machine 1 gun 1 The NEXT MACH and NEXT GUN key is used to advance to the next machine The number of indexes from the Can sensor to the gun is displayed for each gun as the NEXT MACH and NEXT GUN keys are depressed The HSL SMS package supports between 0 and 3 indexes between the location of the can body sensor and the spray gun If the Can Body sensor is located at the same station as the spray gun the index would be set to zero If the spray gun was located at the next station following the Can Body sensor the index would be set to 1 and so on To set the number of indexes for the currently selected gun simply enter the number of indexes 0 to 3 and press the ENTER key The next gun will then automatically be advanced to In addition the INCR and DECR key can be used to increment or decrement the number of indexes by one Once the indexes for all the guns have been entered press the ESC key to return to the primary set up menu The ESC key can also be depressed at any time to return back to the primary set up menu without setting or viewing all the guns HSL SMS User s Manual SYSTEMS Electronics Group 25 SECTION 3 USING THE HSL SM8 KEYPAD DISPLAY HSL SMS User s Manual 3 9 MANUAL GUN ACTUATION The MAN SPRA Y key can be u
32. s Group SECTION 2 INSTALLATION HSL SMS User s Manual 2 4 1 SET CAN SENSOR TO GUN NUMBER OF INDEXES The HSL SMS package supports between 0 and 3 indexes between the location of the can body sensor and the spray gun If the Can Body sensor is located at the same station as the spray gun the index would be set to zero If the spray gun was located at the next station following the Can Body sensor the index would be set to 1 and so on See section 3 8 3 for details on setting the number of indexes 2 4 2 SET GUN LIFE EXPECTANCY Based on the number of cycles rating of the spray guns used set the gun life expectancy limit for each gun see section 3 8 1 If the number of spray cycles the gun has actually fired exceeds this limit the Gun Life Expectancy Exceeded alarm will be displayed This indicates the gun has exceeded it s rated life and should be replaced 2 4 3 SET ON DELAY AND SPRAY DURATION TIMES Set the desired approximate on delay time and spray duration time for each gun see section 3 4 These will be adjusted once the machine is running to the desired film weight but some number must be entered to start with 2 4 4 MANUALLY TEST EACH GUN Using the MAN SPRAY key on the M4500 keypad or the manual spray push buttons manually fire each gun one at a time with the machine stopped This is done to verify that the solenoids were wired correctly and that the gun itself is working properly In this mo
33. sed to fire the currently selected gun for test purposes while the machine is stopped Only one gun is fired the one that 1s selected in the MACH and GUN field and it is fired for the spray time entered for that gun The gun is fired every time the MAN SPRAY key is depressed This is generally done to verify that the gun is operating properly The spray gun can also be fired from the respective manual spray push button located on the operators PB station 3 10 RESETTING ALARMS The can jam timing sensor fail and the gun life expectancy exceeded alarms are reset by pressing the RESET key The can jam alarm indicates both a legitimate can jam and a can body sensor fail In either case the alarm is activated when no change of state 1s detected at the can body sensor after the can gate has been opened The timing sensor is activated on when the timing flag is in front of the sensor The can sensor is activated on when the can is in front of the can sensor Verify that both of these conditions occur and press RESET to clear the alarm If the condition persists the alarm will simply occur as soon as the machine is running with cans again In the case of the gun life expectancy exceeded alarm the gun counts will have to either be reset to zero or the life expectancy limit increased see sections 3 8 1 and 3 8 2 above the gun counts in order to be able to reset the alarm by pressing the RESET key Of course the gun co
34. spray time is used to control how long the gun is on once it is fired see section 1 3 for a complete description of the spray gun control The times entered for the DELAY TIME and SPRAY TIME are in milliseconds The gun times can only be adjusted if the SET UP switch is in the enable position The DELAY TIME key is used to set the on delay time while the SPRAY TIME key is used to set the spray duration time To set the on delay time simply press the DELAY TIME key The cursor will be positioned in the DELAY field Either enter the desired on delay time as a number between 0 and 999 and press the ENTER key or press the INCR or DECR key to increase or decrease the on delay time by one To set the spray duration time simply press the SPRAY TIME key The cursor will be positioned in the SPRAY field Either enter the desired spray duration time as a number between 0 and 999 and press the ENTER key or press the INCR or DECR key to increase or decrease the spray duration time by one 3 5 CURR SHIFT KEY The CURR SHIFT key is used to activate the current shift data display The Current shift data menu displays the number of coated cans for each machine so far into the current shift The number of coated cans is displayed for each machine one at a time for a time delay of 7 to 8 seconds each The NEXT MACH key can also be used to advance to the next machine coated can count if desired Once
35. the download press the lt ENTER gt key to start the download Once the download is complete press any key to return to the target board interface menu Return to the SYSdev main menu and then exit SYSdev SYSTEMS Electronics Group 14 SECTION 2 INSTALLATION 6 Set the on delay and spray duration times as well as the can PRX to gun indexes and expected gun life expectancies per the steps in section 2 4 7 The M4500 is now ready to run loaded with HSLSMS application program HSL SMS User s Manual SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION This Page Intentionally Left Blank HSL SMS User s Manual SYSTEMS Electronics Group 16 HSL SMS User s Manual SECTION 3 USING THE HSL SM8 KEYPAD DISPLAY The spray gun times on delay and spray time Can Sensor to Gun Number of Indexes as well as the gun life expectancy limit are all set through the keypad of the M4500 The following sections describe the steps in setting these variables as well as using the M4500 keypad and display in general 3 1 OVERVIEW OF KEYPAD AND DISPLAY kJ SYSTEMS ELECTRONICS GROUP INC DELAY 000 SPRAY 000 MACH 1 GUN 1 DELAY SPRAY MANUAL 1 2 3 om TIME TIME SPRAY INC DEC meer 4 5 6 E3ESEJE 7 solo Figure 3 1 HSL SM8 Keypad Lay out The M4500 keypad is
36. unts should not be reset unless the gun is replaced SYSTEMS Electronics Group 26 HSL SM8 User s Manual SECTION 4 RECOMMENDED SPARE PARTS The following are recommended spares for the HSL SM8 These parts are available through Systems Engineering Assoc Inc PLC PLS Processor Chassis 16 Point 10 30Vdc Input Board 16 Point 10 30Vdc Output Board Quantity Part Number Description lea M4508 lea P4500 Power Supply lea S4563 lea S4573 lea D4591 Display Keypad 2ea M273 DOTE High Speed Solenoid Drivers SYSTEMS Electronics Group SECTION 4 RECOMMENDED SPARE PARTS This Page Intentionally Left Blank HSL SMS User s Manual SYSTEMS Electronics Group 28 APPENDIX A MODBUS COMMUNICATIONS The MODBUS communications driver uses the S4516 communications board to both read and write data to a MODICON PLC The following data is written to the MODICON PLC MODICON Dest 4x Address 401700 401701 401702 401703 401704 401705 401706 401707 401708 401709 401710 401711 401712 401713 401714 401715 401716 401717 401718 401719 401720 401721 401722 401723 401724 401725 401726 401727 401728 401729 401730 401731 401732 401733 HSL SMS User s Manual Data Definition Mach 1 Coated Cans Lo 0 to 9 999 Mach 1 Coated Cans Hi 10 000 s Mach 2 Coated Cans Lo 0 to 9 999 Mach 2 Coated Cans Hi 10 000 s Mach 3 Coated Cans Lo 0 to 9 999 Mach 3 Coated Cans Hi 10 00
37. wing positions slot0 S4563 SW switch OFF SW1 switch2 OFF Install the 4563 in Slot0 0 furthest left slot of the M4500 chassis HSL SMS User s Manual SYSTEMS Electronics Group 1 SECTION 2 INSTALLATION 3 4 5 6 HSL SMS User s Manual Install S4573 SLOTO 1 Set the slot address dip switches SW1 on the 4573 to the following positions slot1 4573 SW switchl ON SWI switch2 OFF Install the 4573 in Slot0 1 slot next to 4563 of the M4509 chassis Install 4563 SLOTO 2 Set the slot address dip switches SW1 on the S4563 to the following positions slot2 84563 SW switchl OFF SWI switch2 ON Install the 4563 in Slot0 2 slot next to the S4573 of the M4509 chassis Install S4516 SLOTO 3 OPTIONAL Set the slot address dip switches SW2 on the S4516 to the following positions slot3 4516 SW2 switchl ON SW2 switch2 ON Set the RS 232 RS 422 select dip switches SW1 on the S4516 to the following positions RS 232 selected 84516 SW switchl ON SWI switch2 OFF Install the 4516 in Slot0 3 slot next to S4563 of the M4509 chassis Install 4563 SLOT1 0 NOT USED ON HSL SMg8 6 Set the slot address dip switches SW1 on the S4563 to the following positions slot 4563 SW switchl OFF SWI switch2 OFF Install the 4563 in Slot1 0 slot next to the S4516 of the M4509 chassis SYSTEMS Electronics Group
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