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1. HSL CUP3 User s Manual SYSTEMS Electronics Group 30 SECTION 4 USING THE HSL CUP3 KEYPAD DISPLAY 4 4 1 SET CUPPER PARAMETER This menu is activated when the 1 key SET CUPPER PARAMETERS is pressed while the primary set up menu is active The following four set up parameters may then be adjusted or viewed BRAKE WEAR COMP ENBLE 0 NO 1 YES This prompt is used to enable or disable the brake wear compensation If the compensation is to be disabled enter 0 and press ENTER If the compensation is to be enabled enter 1 and press lt ENTER gt DESIRED TDC STOP POS LOW SPEED This is the desired stopping location in degrees for a TDC stop in low speed when the brake wear compensation is enabled This is typical set to 000 degrees Top Dead Center This prompt is only displayed when the brake wear compensation is enabled DESIRED TDC STOP POS HIGH SPEED This is the desired stopping location in degrees for a TDC stop in high speed when the brake wear compensation is enabled This is typical set to 000 degrees Top Dead Center This prompt is only displayed when the brake wear compensation is enabled MAXIMUM ALLOWED STOPPING RESPONSE This defines what the maximum allowed brake response is before the Brake Response Too Long alarm is generated If the actual brake response number of degrees from when the brake is activated to the position where the press ends up at rest when a TDC stop is performed is long
2. The set up data consists of the cupper and lubricator set up parameters see section 3 1 Timing channel set points are not stored as part of the set up data To upload the set up data perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4500 2 Select 6 Upload Save Set up data from M4500 A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key 3 Once data upload is initiated the current address being uploaded will be displayed Note M4500 program execution is not ceased therefore data upload can be performed while the machine is running 4 Once set up data upload is complete press any key to return to the HSLCUP3 main menu HSL CUP3 User s Manual SYSTEMS Electronics Group OTs SECTION 3 USING THE HSLCUP3 SET UP PROGRAM This Page Intentionally Left Blank HSL CUP3 User s Manual SYSTEMS Electronics Group 28 SECTION 4 USING THE HSL CUP3 KEYPAD DISPLAY The keypad of the HSL CUP3 contains 24 keys consisting of data display commands set up commands and a numeric keypad The display of the HSL CUP3 is 2 line by 40 character back lit LCD display which displays the selected data and set up menus The keypad display can be used by the operator to view data or can be used to adjust the timing and all set up parameters The display keypad allows the fo
3. otherwise it is not used 401710 TDC Timing On Lo BW Comp This is the on set point of the TDC Lo timing CH01 when modified by the brake wear compensation algorithm This is modified by the M4500 when the brake wear compensation is enabled and CHO1 was reprogrammed when the brake response was too long or too short on a low speed TDC stop This is only updated if the brake wear compensation is enabled otherwise it is not used 401711 TDC Timing Off Lo BW Comp This is the off set point of the TDC Lo timing CH01 when modified by the brake wear compensation algorithm This is modified by the M4500 when the brake wear compensation is enabled and CHO1 was reprogrammed when the brake response was too long or too short on a low speed TDC stop This is only updated if the brake wear compensation is enabled otherwise it is not used The bits of the Status register to the MODICON from the M4500 are mapped as follows W 790 Status to MODICON 4x address 401705 in MODICON B790 0 Not Used B790 1 Not Used B790 2 Timing Signal Fail Alarm B790 3 Brake Wear Alarm B790 4 Not Used thru B791 7 Not Used HSL CUP3 User s Manual SYSTEMS Electronics Group A 2 APPENDIX A MODBUS COMMUNICATIONS The Status bits sent to the MODICON PLC are defined as follows B790 2 Timing Signal Fail Alarm The timing signal fail occurs when any of the timing signals generated in the PLS section fail to change state peri
4. 4 USING THE HSL CUP3 KEYPAD DISPLAY This Page Intentionally Left Blank HSL CUP3 User s Manual SYSTEMS Electronics Group 36 SECTION 5 GENERAL TIMING SIGNAL LOCATIONS The following is a general description of the timing signals and the locations they should be set at CHOO CH01 CH02 CH03 CH04 CH05 CH06 CH07 CH10 TDC HIGH TIMING This signal is used to de activate the clutch for a TDC stop at high speed Note The leading edge is used to de activate the clutch thus the width of the signal is not critical generally set 20 degrees wide When the brake wear compensation is enabled this signal is adjusted automatically by the M4500 If the brake wear compensation is disabled this signal must be set manually In this case is should be set such that the press stops at top dead center for a TDC stop at high speed TDC LOW TIMING Same as the TDC High timing CH00 except used when the machine is running in low speed DIE JAM CHECK TIMING This signal is used by the host PLC to perform the Die Jam Check This should be set per the algorithm the host PLC uses to perform the check CUP JAM CHECK TIMING This signal is used by the host PLC to perform the Cup Jam Check This should be set per the algorithm the host PLC uses to perform the check DIE CHECK RESET TIMING This signal is used by the host PLC as part of the Die Jam Cup Jam die protection This should be set per the algorithm the
5. Cup Jam Check timing Die Check Reset timing Air Strip timing Scrap Jam timing Stroke Count timing Motion on for 30 off for 30 thru out SYSTEMS Electronics Group 10 SECTION 2 INSTALLATION In most cases the previous user variables and timing channels will have to be altered to tune the HSL CUP3 to the actual cupper it is controlling Once the HSL CUP3 is installed and the control system is powered back up perform the following to set up and tune the HSL CUP3 The set up is performed using either an IBM PC or compatible running the HSLCUP3 set up program or the Display Keypad of the HSL CUP3 See section 3 for a description of the HSLCUP3 menus and variables and how to use the HSLCUP3 program See section 4 for a description of the Keypad commands and menu displays of the HSL CUP3 Display Keypad 2 4 1 SET CUPPER SET UP PARAMETERS The Cupper set up parameters include enabling or disabling the brake wear compensation setting the desired low and high speed stopping points if the brake wear compensation is enabled setting the maximum allowed stopping response and setting the cupper running low and high speeds Brake Wear Compensation If the brake wear compensation is to be used enable it by setting the Brake Wear Compensation Enable to Y Set the Desired TDC Stop Position Low and High as well if the compensation is enabled The Desired TDC Stop positions are the location you want the ram to b
6. Electronics Group HSL CUP3 User s Manual 3 Using the HSLCUP3 Set up Program 3 1 3 2 3 3 3 4 3 5 3 6 Set Cupper Lubricator Set up Parameters 3 1 1 Cupper Lubricator Parameter Definitions CONTENTS 19 19 3 1 2 Cupper lubricator Set up Parameter Selections 21 Set Machine Timing 3 2 1 Zeroing the Machine 3 2 2 Adjusting the Timing Channel Set points Shift Data 3 3 1Shift Data Definitions Download Program to M4500 Download Set up Data to M4500 Upload Save Set up Data from M4500 4 Using the HSL CUP3 Keypad Display 4 1 4 2 4 3 44 Default Screen Brake Response Key Last Shift Key 4 3 1 Last Shift Data Definitions Set Up Key 44 1 Set Cupper Parameter 4 4 2 Set Lubricator Parameters 44 3 Set Machine Timing Set Points etc 444 Zero Machine Set Resolver Offset 5 General Timing Signal Locations 6 Recommended Spare Parts MODBUS Communications 21 23 24 24 25 27 39 APPENDICES Appendix A SYSTEMS Electronics Group LATE SECTION 1 GENERAL DESCRIPTION 1 1 FEATURES e Performs high speed control functions of Cupper to speeds in excess of 300 CPM This includes clutch control air strip control as well as brake wear compensation e Performs the following control functions 1 Rapid response control of clutch brake system for emergency stops as well as precise TDC stops 2 Highly repeatable air strip control to reduce die jam problem
7. HSLCUP3 SET UP PROGRAM 3 1 1 CUPPER LUBRICATOR PARAMETER DEFINITIONS Brake Wear Compensation Enable 0 No 1 Yes This prompt is used to enable or disable the brake wear compensation If the compensation is to be disabled enter 0 and press lt ENTER gt If the compensation is to be enabled enter 1 and press lt ENTER gt Desired TDC Stop Position Low Speed This is the desired stopping location in degrees for a TDC stop in low speed when the brake wear compensation is enabled This is typical set to 000 degrees Top Dead Center Desired TDC Stop Position High Speed This is the desired stopping location in degrees for a TDC stop in high speed when the brake wear compensation is enabled This is typical set to 000 degrees Top Dead Center Maximum Allowed Stopping Response degrees This defines what the maximum allowed brake response is before the Brake Response Too Long alarm is generated If the actual brake response number of degrees from when the brake is activated to the position where the press ends up at rest when a TDC stop is performed is longer than this number the alarm is generated If the actual brake response is less the alarm is not generated Set this parameter to the value where the brake response is considered too long and service to the brake should be performed typically 270 to 300 degrees Running Cupper Low Speed SPM This is the speed in strokes per minute that the cupper will run
8. The HSLCUP3 application program is a SYSdev based program which is loaded into the M4500 module and performs the HSL CUP3 logic The HSLCUP3 program is written in a combination of Ladder logic and High level If the user desires to make program changes or perform on line monitoring of the program execution the files which constitute the HSLCUP3 program will have to be loaded onto the hard drive of the PC which is used to support the HSL CUP3 The SYSdev Program Development Software will also have to be loaded on the PC see section 2 3 2 To install this program perform the following 1 Ifnot already done perform steps 1 through 3 of section 2 3 1 This creates the directories and menu selections which will be used to store and select the HSLCUP3 application programs 2 Install the disk labeled HSL CUP3 PROGRAMS into the A drive For each of the HSLCUP directories switch to that directory and install the HSLCUP3 application program by typing the following at the DOS prompt cupper 1 is shown CD HSLCUP1 lt ENTER gt COPY A HSLCUP3 lt ENTER gt CD 3 Add the HSLCUP3 application programs to your computer s menu software by creating selections called HSL CUP3 PROGRAM CUPPER 1 etc for each cupper The DOS commands executed for these selections should be cupper 1 shown CD SYSDEV HSLCUP1 HSLCUP3 4 To initiate SYSdev with the HSLCUP3 program simply select the respective HSL CUP3 PROGRAM selection from the menu sof
9. To exit back to the default screen simply press the ESC key HSL CUP3 User s Manual SYSTEMS Electronics Group 29 SECTION 4 USING THE HSL CUP3 KEYPAD DISPLAY 4 3 LAST SHIFT KEY The Last shift data menu displays the following information TOTAL STROKES This data is the totals for the last previous shift This data is transferred from the current shift to the Last shift data when the end of shift bit set via the RS 232 communications 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 transition Note The Current shift Total Strokes is displayed as part of the default screen see section 4 1 4 3 1 LAST SHIFT DATA DEFINITIONS Total Strokes This is the total number of strokes the press made for the previous shift This is essentially a counter 4 4 SET UP KEY This selection is used to invoke the primary set up menu This consists of the following four selections SET CUPPER PARAMETERS SET LUBRICATOR SPEED REFERENCE SET MACHINE TIMING SET POINTS ETC ZERO MACHINE SET RESOLVER OFFSET A ee 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 4
10. entered and off at the off position entered 4 Exit back to the primary set up menu by pressing lt ESC gt Exit back to the default screen by pressing lt ESC gt again HSL CUP3 User s Manual SYSTEMS Electronics Group 34 SECTION 4 USING THE HSL CUP3 KEYPAD DISPLAY 4 4 4 ZERO MACHINE SET RESOLVER OFFSET This selection is used to auto zero the resolver To set the machine zero resolver offset perform the following 1 2 3 4 5 Select 3 SET MACHINE TIMING and observe the POS field Verify that as the machine is rotated forward either inched or barred that the position increases linearly from 0 through 359 If not swap the S1 and S3 leads of the resolver at the M4500 resolver connector Then verify that the position then indeed does increase with forward movement Press ESC to exit back to the primary set up menu Position the machine at machine zero top dead center Auto zero the resolver by selecting 4 ZERO MACHINE from the primary set up menu Enter 0 to zero the resolver The timing set up menu will be displayed now showing the POS at Zero The M4500 will calculate the actual offset value required to make this the 000 position and will display this number in the offset field Exit back to the primary set up menu by pressing lt ESC gt Exit back to the default screen by pressing lt ESC gt again HSL CUP3 User s Manual SYSTEMS Electronics Group 35 SECTION
11. on the lower front of the cover and the two captive screws on each side of the M4500 chassis 6 Connect the display ribbon cable to the connector on the back of the M4500 the connector on the cable is polarized and should mate with the connector on the M4500 only one way 7 Mount the M4500 chassis to the HSL CUP3 back panel using four 8 32 screws 8 With power to the P4500 off install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4500 the connector on the cable is polarized and should mate with the connector on the M4500 only one way 9 Install the respective field wiring arms on all the I O boards of the M4500 I O slotsO and 1 MODBUS connector on USER PORT resolver connector and INO IN1 connector Make sure all the field wiring connectors are fully mated in the M4500 HSL CUP3 User s Manual SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION 2 5 2 P4500 POWER SUPPLY INSTALLATION To install the P4500 perform the following steps 1 Mount the P4500 to the HSL CUP3 in the mounting holes next to the M4500 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 M4500 the connector on the cable is polarized and should mate with the connector on the M4500 only one way 2 5 3 D4591 KEYPAD DISPLAY INSTALLATION To install the D4591 perform the following steps 1 With the gasket installed on the mou
12. parameter is used to provide the speed reference when the cupper speed is zero Note The above parameters 401777 thru 401773 are effective only when the Set Up Parameters Enable bit 401760 2 from the MODICON is set to a 1 Otherwise these variables are not updated in the M4500 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 End of Shift B900 1 Brake Wear Compensation Enable B900 2 Set Up Parameters Enable B900 3 Timing Channel Program Enable B900 4 Set Resolver Zero Auto Zero B900 5 Alarm Reset B900 6 Not Used thru B901 7 Not Used HSL CUP3 User s Manual SYSTEMS Electronics Group A 5 APPENDIX A MODBUS COMMUNICATIONS The Status Control bits sent from the MODICON PLC are defined as follows B900 0 B900 1 B900 2 B900 3 B900 4 B900 5 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 Brake Wear Compensation Enable This bit is used to enable or disable the brake wear compensation If the compensation is to be disabled set B900 1 to a 0 If the compensation is to be enabled set B900 1 to a 1 Set Up Parameters Enable Set
13. the form XXX Y Y Y lt ENTER gt in the first set point of the given channel Note Up to 50 set points may be entered for any channel However for the cupper only one set point is used per channel and this should be entered in the number set point The XXX is the location the set point will turn on while YYY is the location where the set point will turn off Use the PgUp PgDn F1 Next Chan or F2 Prev Chan keys to select the desired channel for programming 5 Once all channels are programmed press lt ESC gt to exit back to the PLS Main Development Menu Press lt ESC gt again to exit back to the HSLCUP3 set up main menu The new channels will be saved both in the M4500 and in the CUP3TMG file on the hard drive HSL CUP3 User s Manual SYSTEMS Electronics Group 93 2 SECTION 3 USING THE HSLCUP3 SET UP PROGRAM 3 3 SHIFT DATA The shift data menu displays the following information Current Shift Total Strokes Last Shift Total Strokes Brake Response Low Speed High Speed This data is the totals so far into the current shift and the totals for the last previous shift The current shift data is transferred to the Last shift data when the end of shift bit set via the RS 232 data communications 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 either from this menu or by the operator only at the end of shift transition In addition to
14. 918 W920 W922 W924 W926 W928 W930 W932 W934 W936 W938 W940 W942 W944 W946 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 401778 401779 401780 401781 CH00 On TDC Timing Hi CH07 Off Spare Timing Variables 401761 thru 401776 are the On and Off timing set points for CHOO thru CH07 respectively This allows the MODICON to program these timing channels when the Timing Channel Program Enable bit 401760 3 from the MODICON is set to a 1 These are the same On and Off set points that would normally be set through the HSL CUP3 keypad see section 4 4 3 of the HSL_WI3 User s manuals or set through the HSLCUP3 set up program See section 3 2 2 of the HSL CUP3 User s manual See section 5 of the HSL CUP3 user s manual for the definitions of the CH00 through CH07 timing channels BW Comp Desired Stop Lo This is the desired stopping location in degrees for a TDC stop in low speed when the brake wear compensation is enabled This is typical set to 000 degrees Top Dead Center BW Comp Desired Stop H1 This is the desired stopping location in degrees for a TDC stop in high speed when the brake wear compensation is enabled This is typical set to 000 degrees Top Dead Center Max Allowed Stop Response BW Alarm This defines what the maximum allowed brake resp
15. CUP3 keypad for details on setting the above set up parameters HSL CUP3 User s Manual SYSTEMS Electronics Group 12 SECTION 2 INSTALLATION 2 4 3 SET MACHINE ZERO Inch the cupper to top dead center TDC and set the M4500 offset per section 3 2 1 HSLCUP3 set up program or section 4 4 4 HSL CUP3 keypad 2 4 4 VERIFY MACHINE OPERATION Once steps 2 4 1 thru 2 4 4 are complete run the machine in normal production both at low and high speeds where practical and verify the following Verify Air Strip Timing With the machine running with the coil stock verify that the cups are stripped with out any problems If a problem is occurring adjust the Air Strip timing CHOS until the problem is corrected See section 3 2 2 HSLCUP3 set up program or section 4 4 3 HSL CUP3 keypad for details on adjusting CHOS Verify Die Protection Adjust the Die Jam Check CH02 Cup Jam Check CH03 and Die Check Reset CH04 timing signals as required by the host PLC to perform die jam and cup jam checks successfully Verify TDC Stops If the brake wear compensation is enabled verify that the press does stop at the desired location in both the high and the low speeds Note When the HSL CUP3 is first installed it will take a few successive stops for the algorithm to program the TDC timing channels to the correct position Also note that the compensation is enabled after the press has been running at a fixed speed in conti
16. HSL CUP3 CUPPER HIGH SPEED FRONT END 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 CUP3 CUPPER HIGH SPEED FRONT END USER S MANUAL Copyright 1996 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 assumed for inaccuracies In the interes
17. POS RPM and observe the POS field Verify that as the machine is rotated forward either inching or barred that the position increases linearly from 0 through 359 If not swap the S1 and S3 leads of the resolver at the M4500 resolver connector Then verify that the position then indeed does increase with forward movement Press ESC to exit the POS RPM update Position the machine at top dead center Auto zero the resolver by selecting F10 Set Offset Enter 0 in the offset field and press lt ENTER gt The M4500 will calculate the actual offset value required to make this the 000 position and will display this number in the offset field The position will now read 0 Exit back to the PLS Main Development menu by pressing lt ESC gt Exit back to the HSLCUP3 set up main menu by pressing lt ESC gt again HSL CUP3 User s Manual SYSTEMS Electronics Group 22 SECTION 3 USING THE HSLCUP3 SET UP PROGRAM 3 2 2 ADJUSTING THE TIMING CHANNEL SET POINTS To set or alter any of the timing signal set points perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4500 2 Select the 2 Set Machine Timing selection from the HSL CUP3 set up program main menu 3 Select 1 Online Channel Setpoint Programming from the Main Development menu 4 Set all channels per section 5 Set points are entered for a particular channel simply by typing in the set point in
18. SYSTEMS Electronics Group 39 SECTION 6 RECOMMENDED SPARE PARTS This Page Intentionally Left Blank HSL CUP3 User s Manual SYSTEMS Electronics Group 40 The MODBUS APPENDIX A MODBUS COMMUNICATIONS 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 M4500 Source 4x Address Data Definition Address 401700 Speed CPM W182 401701 Resolver Position W180 401702 Number of Strokes Lo 0 to 9 999 W1100 401703 Number of Strokes Hi 10 000 s W1102 401704 Spare Count W1104 401705 Status to MODICON W790 401706 Hi Speed Brake Response degrees W1042 401707 Lo Speed Brake Response degrees W1040 401708 TDC Timing On Hi BW Comp W2120 401709 TDC Timing Off Hi BW Comp W2122 401710 TDC Timing On Lo BW Comp W2124 401711 TDC Timing Off Lo BW Comp W2126 The definitions of the data sent from the M4500 to the MODICON are as follows 401700 401701 401702 401704 401706 401707 HSL CUP3 User Speed Current strokes per minute of the cupper Resolver Position Current angular position of the cupper crankshaft in degrees Number of Strokes This is the total number of strokes the press has made so far in the current shift This is essentially a counter Spare Count Not Used Hi Speed Brake Response degrees This is the number of degrees from the when the c
19. Turn off the Clutch On MED input once the press has de clutched and stopped The press will make one stroke Inch Mode 1 To inch the press with the Inch Mode input on simultaneously turn on and off both the Clutch On TDC and Clutch On IMED inputs The clutch is activated as long as both inputs are on or until the TDC low timing signal occurs Bar Mode 1 With both the Cont Single Mode and Inch Mode inputs off the clutch can be activated by simultaneously turning both the Clutch On TDC and Clutch On IMED inputs on The clutch is activated as long as both inputs are on Note In all the above modes the Clutch On TDC and Clutch On IMED inputs must be turned on simultaneously within 0 5 seconds in order for the clutch to activate 1 4 AIR STRIP CONTROL The HSL CUP3 provides a repeatability of 0 5 milliseconds for the air strip thus die jam problems 1 5 BRAKE WEAR COMPENSATION The HSL CUP3 incorporates a brake wear compensation or automatic TDC timing feature which stops the press at TDC regardless of the actual braking response of the clutch brake The stopping compensation is accomplished by automatically adjusting the TDC timing signal based on the previous stop Any overrun is detected and a new TDC timing signal is computed such that the machine will stop at the desired location on the next stop Two TDC signals are provided one for low speed and one for high speed Bot
20. UP2 lt ENTER gt MD HSLCUP3 lt ENTER gt etc 2 Install the disk labeled HSL CUP3 PROGRAMS into the A drive For each HSLCUP directory you created in the previous step switch to that directory and install the HSL CUP3 set up programs by typing the following at the DOS prompt cupper 1 is shown CD HSLCUP1 lt ENTER gt A INSTALL lt ENTER gt 3 Add each cupper s HSL CUP3 set up program to your computer s menu software by creating a selection for each cupper called SET UP CUPPER 1 for cupper 1 SET UP CUPPER 2 for cupper 2 etc The DOS commands executed for these selections should be For the SET UP CUPPER 1 selection CD MHSLCUPI HSLCUP3 HSLCUP3 CD For the SET UP CUPPER 2 selection CD HSLCUP2 HSLCUP3 HSLCUP3 CD etc 4 To execute the respective cupper s set up program simply select the corresponding SET UP CUPPER selection from the menu software s menu HSL CUP3 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 3 2 SYSdev PROGRAM DEVELOPMENT SOFTWARE INSTALLATION The SYSdev Program Development software is used to perform on line trouble shooting and program modifications to the HSL CUP3 If SYSdev was purchased with the HSL CUP3 package and is not already installed on the 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 3 HSL CUP3 APPLICATION PROGRAM INSTALLATION
21. allows extremely fast and repeatable declutching and braking response to be achieved Normally the clutch is controlled via inputs on the HSL CUP3 that are controlled from outputs on the host PLC However detection of any of the alarms timing signal failure etc results in an immediate de clutch of the solenoids 1 3 1 CONTROL OF CLUTCH VIA HOST PLC Four discrete DC inputs to the HSL CUP3 from the host PLC are used to control the clutch Clutch On TDC Clutch On IMED Cont Single Mode and Inch Mode The following description of operation defines the requirements of the host PLC logic to activate the clutch through the HSL CUP3 Continuous Mode 1 To activate the clutch in continuous mode turn both the Clutch On TDC and Clutch On IMED inputs on simultaneously while the Cont Single Mode input is on 2 To perform a TDC stop turn off the Clutch On TDC input while leaving the Clutch On IMED input on Once the clutch is de energized then turn off the Clutch On IMED input 3 To perform an immediate emergency stop turn both the Clutch On TDC and Clutch On IMED inputs off simultaneously HSL CUP3 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION Single Mode 1 To single stroke the press with the Cont Single Mode input on turn the Clutch On TDC input on for 5 to 50 milliseconds while simultaneously turning the Clutch On IMED input on
22. an be used to set the machine timing machine offset timing signal locations etc The set up variables are used to configure and tune the HSL CUP3 to match the configuration and performance of the specific cupper see section 2 4 The main menu of the HSLCUP3 set up program incorporates the following menu selections Set Cupper Lubricator Set up Parameters Set Machine Timing Shift Data Brake Response Download Program to M4500 Download Set up data to M4500 Upload Save Set up data from M4500 DU e o Na Note The HSLCUP3 program is an on line communications program used to interface with the M4500 module The data displayed in the menus and set in the menus is communicated directly to the M4500 Therefore prior to selecting any of the above selections make sure an RS 232 cable is connected from the COM port on the computer running HSLCUP3 to the PROG port on the M4500 The following sections are a complete description of the HSLCUP3 selections and menus 3 1 SET CUPPER LUBRICATOR SET UP PARAMETERS The Cupper Lubricator set up menu is used to set the various set up parameters in the M4500 This menu is invoked by selecting 1 Set Cupper Lubricator Set Up Parameters from the Main Menu Note Prior to selecting this selection make sure the RS 232 cable is connected from the COM port on the computer to the PROG PORT on the M4500 HSL CUP3 User s Manual SYSTEMS Electronics Group 19 SECTION 3 USING THE
23. ation feature which automatically adjusts the TDC timing signal to stop the press at TDC regardless of brake stopping time Alarm detection is provided including timing signal failure and brake response too long alarm Data collection includes Total strokes both for the current shift and previous last shift The package interfaces directly to the machine mounted resolver clutch brake and air strip solenoids as well as the host PLC via discrete DC I O HSL CUP3 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION The package is not a dedicated black box but is instead implemented using the high performance SYSTEMS M4500 PLC PLS module which allows easy customization by either SEA or the end user The M4500 module is programmed using the DOS based SYSdev programming package which allows the module to be programmed in any combination of Ladder or High level subset of C as well as perform on line monitoring and trouble shooting The M4500 module incorporates a built in PLS which interfaces directly with the machine mounted resolver and provides all machine timing eliminating the need for an external PLS 1 3 CLUTCH BRAKE CONTROL The clutch brake solenoids are activated by the HSL CUP3 through the electro mechanical two hand control circuitry provided externally by the user The throughput of the HSL CUP3 is 0 5 milliseconds The fast throughput along with the fact that the PLS is fully integrated into the M4500
24. d SPM High Speed SPM 4 Set Lubricator Speed References Maximum Speed CPM Idle Speed CPM To set a particular variable select the corresponding menu selection and follow the prompts as they occur 3 2 SET MACHINE TIMING The Set Machine Timing selection is used to invoke the PLS programming command menus these are the same menus used in SYSdev to program the PLS section of the M4500 When selected the PLS programming main development menu will be invoked using the default CUP3TMG channel set point file From this menu the user can zero the machine set the resolver offset and adjust the timing signal set points The following sections describe how to perform these functions section 5 provides a complete description of each timing signal Note Prior to selecting the Machine Timing selection make sure the RS 232 cable is connected from the COM port on the computer to the PROG PORT on the M4500 HSL CUP3 User s Manual SYSTEMS Electronics Group 21 SECTION 3 USING THE HSLCUP3 SET UP PROGRAM 3 2 1 ZEROING THE MACHINE To set the machine zero resolver offset perform the following 1 2 3 4 5 6 7 8 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4500 Select the 2 Set Machine Timing selection from the HSL CUP3 set up program main menu Select 1 Online Channel Setpoint Programming from the Main Development menu Select F9
25. d an RSV34 MSI resolver will have to be mounted in it s place If this is the case refer to the RSV34 MSI data sheet for details on mounting the resolver Use the RSV RSCBLE cable to connect the resolver to the HSL CUP3 Route the resolver cable in a separate conduit away from all other high voltage and control wiring Wire the cable directly to the 8 pin resolver connector on the M4500 see section 2 2 2 2 3 HSL CUP3 SOFTWARE INSTALLATION Follow the steps below to install the HSL CUP3 Set up software package and the HSL CUP3 application programs onto the IBM PC or compatible which will be used to support the HSL CUP3 package HSL CUP3 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 3 1 HSL CUP3 SET UP SOFTWARE INSTALLATION The HSL CUP3 set up software is used to download the program to the M4500 module tune set up the user adjustable variables of the HSL CUP3 download and upload save the user set up variables to disk and view shift data on the IBM PC used to support the HSL CUP3 To install the set up software perform the following steps 1 Create one directory off the root directory of the PC for each cupper the HSL CUP3 will be used on called HSLCUP1 for cupper 1 HSLCUP2 for cupper 2 etc These will be used to store the HSLCUP3 EXE setup programs and HSLCUP3 set up data for each cupper Create these directories by typing the following at the DOS prompt MD HSLCUPI lt ENTER gt MD HSLC
26. e at when it comes to rest after a TDC stop Both the Low and High desired stopping positions are generally set to 000 degrees Enabling the brake wear compensation allows the HSL CUP3 to automatically adjust the TDC timing channels CH00 High and CHO1 Low as necessary such that the press will stop at the desired stopping position regardless of the actual brake response If the brake wear compensation is not to be used disable it by setting the Brake Wear Compensation Enable to N Disabling the brake wear compensation requires the TDC High timing CH00 and the TDC Low timing CHO1 signals to be set manually such that the press stops at TDC Note If the brake response then changes the press will not stop at the desired position if the brake wear compensation is disabled HSL CUP3 User s Manual SYSTEMS Electronics Group 1 SECTION 2 INSTALLATION Maximum Allowed Stopping Response This parameter defines what the maximum allowed brake response is before the Brake Response Too Long alarm is generated If the actual brake response number of degrees from when the brake is activated to the position where the press ends up at rest when a TDC stop is performed is longer than this number the alarm is generated If the actual brake response is less the alarm is not generated Set this parameter to the value where the brake response is considered too long and service to the brake should be performed typically 270 to 300 degr
27. ed while the cupper is running All outputs on the M4500 are turned off and no program execution is performed The clutch would therefore be disengaged The cupper should be stopped before the download takes place approximately 15 to 45 seconds depending on the computer used 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4500 2 Select 4 Download Program to M4500 A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key Ifa prompt stating that the HSLCUP3 REV file could not be opened is displayed then the HSLCUP3 application program is not installed in the current directory To install the program perform the steps in section 2 3 3 to install the program 3 Once program download is initiated M4500 program execution will cease the current address being downloaded will be displayed and the RUN LED on the M4500 will flash continuously 4 Once the download is complete the RUN LED on the M4500 will illuminate solid and program execution in the M4500 will resume Press any key to return back to the HSLCUP3 main menu HSL CUP3 User s Manual SYSTEMS Electronics Group 25 SECTION 3 USING THE HSLCUP3 SET UP PROGRAM 3 5 DOWNLOAD SET UP DATA TO M4500 This selection is used to download the previously uploaded saved set up variables to the M4500 This should only be performed w
28. ees Cupper Running Speeds Set the Cupper running Low Speed and High Speed to the speeds that the cupper will actually run at when the respective speed is selected Note This is not a speed reference that will make the cupper run at the speeds entered but is instead simply parameters used by the HSL CUP3 to know when to switch between the TDC Low and TDC High timing etc See section 3 1 HSLCUP3 set up program or section 4 4 1 HSL CUP3 keypad for details on setting the above set up parameters 2 4 2 SET LUBRICATOR SPEED REFERENCES Set both the Lubricator Maximum Speed and Lubricator Idle Speed as desired These two parameters are used to actually control the speed of the lubricator via the 0 10VDC lubricator speed reference output of the M4500 Lubricator Maximum Speed The Lubricator Maximum Speed parameter is used to scale the 0 10VDC analog output such that when the cupper is running at the speed entered in Lubricator Maximum Speed the analog output will be at 10 volts Lubricator Idle Minimum Speed This parameter determines the speed the lubricator will run at when the cupper is stopped de clutched Note When the cupper is running the lubricator speed reference is proportional as set by the Lubricator Maximum Speed scaling to the speed of the cupper This parameter is used to provide the speed reference when the cupper speed is zero See section 3 1 HSLCUP3 set up program or section 4 4 2 HSL
29. efinition Chuu Currently selected channel CH00 thru CH17 where uu is the octal channel number SETPOINT xxx Channel on or off set point where xxx is the set point position State of channel set point blank off solid block character on channel name selected channel name CH00 TDC HIGH TIMING CH01 TDC LOW TIMING etc RPM yyyy Current machine speed where yyyy is in CPM POS zzz Current resolver position where zzz is in degrees OFFSET wwww Resolver offset where wwww is the offset in degrees SCALE 360 Resolver SCALE FACTOR 360 degrees per revolution In addition to displaying the timing set point menu the following keys are also enabled ENTER SET POINT CLEAR CHANNEL SELECT CHANNEL and SEARCH CHANNEL The ENTER SET POINT key is used to enter a new set point both on and off set points in the selected channel The CLEAR CHANNEL key is used to clear all set points from the selected channel The SELECT CHANNEL key is used to select a new channel for programming The SEARCH CHANNEL is used to view both the on and off set points in the selected channel Searching Channel To view the set points in a channel simply press the SEARCH CHANNEL key The next off to on or on to off position is shown in the SETPOINT field If the transition was off to on the state character will be a solid block If the transition was on to off the state character will be blan
30. er than this number the alarm is generated If the actual brake response is less the alarm is not generated Set this parameter to the value where the brake response is considered too long and service to the brake should be performed typically 270 to 300 degrees RUNNING CUPPER LOW SPEED SPM This is the speed in strokes per minute that the cupper will run when in low speed RUNNING CUPPER HIGH SPEED SPM This is the speed in strokes per minute that the cupper will run when in high speed The NEXT and PREV keys can be used to advance to the next parameter or the previous parameter respectively To change the currently displayed parameter simply enter the new value on the numeric keypad and press lt ENTER gt The value will be entered and the next parameter will automatically be displayed When the last parameter Running Cupper High Speed is entered the primary set up menu is again displayed Pressing lt ESC gt at anytime will also exit you back to the primary set up menu HSL CUP3 User s Manual SYSTEMS Electronics Group 31 SECTION 4 USING THE HSL CUP3 KEYPAD DISPLAY 4 4 2 SET LUBRICATOR SPEED REFERENCE This menu is activated when the 2 key SET LUBRICATOR SPEED REFERENCE is pressed while the primary set up menu is active The following lubricator set up parameters may then be adjusted or viewed LUBRICATOR MAXIMUM SPEED CPM The Lubricator Maximum Speed parameter is used to scale the 0 10VDC analo
31. eturn to the HSL CUP3 main menu See section 3 4 for complete details 5 Download the PLS timing set points to the M4500 by selecting 2 Machine Timing from the HSL CUP3 main menu From the PLS main development menu select 4 Download Channels to PLS Press the lt ENTER gt key to start the download Press any key to return back to the PLS main development menu Press 12 lt ENTER to return back the HSL CUP3 main menu 6 Download the previously saved to disk set up data to the M4500 by selecting 5 Download Set up data to M4500 from the HSL CUP3 main menu Press the lt ENTER gt key to start the download Once the download is complete press any key to return to the HSL CUP3 main menu See section 3 5 for complete details 7 The M4500 is now ready to run loaded with the HSLCUP3 application program timing set points and set up data that was previously saved for the respective cupper Press lt ESC gt to return back to the computer s menu software program HSL CUP3 User s Manual SYSTEMS Electronics Group 17 SECTION 2 INSTALLATION This Page Intentionally Left Blank HSL CUP3 User s Manual SYSTEMS Electronics Group 18 SECTION 3 USING THE HSLCUP3 SET UP PROGRAM The HSLCUP3 set up program is a DOS based menu driven program which allows the user to easily view the HSL CUP3 data or alter the HSL CUP3 set up variables using an IBM PC or compatible In addition to setting the set up variables HSLCUP3 c
32. fer to the M4500 User s Manual for general details on installing the M4500 P4500 and D4591 2 5 1 M4500 MODULE INSTALLATION To install the M4500 module perform the following 1 Remove the cover from the M4500 chassis retained with three captive screws on the lower front of the cover and two captive screws on each side of the M4500 chassis 2 Install S4573 SLOTO 0 Set the slot address dip switches SW1 on the S4573 to the following positions slot0 4573 SWI switchl OFF SWI switch2 OFF Install the 4573 in Slot0 0 furthest left slot of the M4500 chassis 3 Install S4568 SLOTO 1 Set the slot address dip switches SW1 on the S4568 to the following positions slot S4568 SWI switchl ON SWI switch2 OFF Install the 4568 in Slot0 1 slot next to S4573 of the M4500 chassis HSL CUP3 User s Manual SYSTEMS Electronics Group 4 SECTION 2 INSTALLATION 4 Install S4516 SLOTO 3 OPTIONAL Set the slot address dip switches SW2 on the S4516 to the following positions slot3 S4516 SW2 switchl ON SW2 switch2 ON Set the RS 232 RS 422 select dip switches SW1 on the 84516 to the following positions RS 232 selected 4516 SWI switchl ON SWI switch2 OFF Install the S4516 in Slot0 3 of the M4500 chassis 5 Install the cover back over the M4500 making sure all the board connectors protrude through the slots in the cover Tighten the three captive screws
33. g output such that when the cupper is running at the speed entered in Lubricator Maximum Speed the analog output will be at 10 volts This is typically set to the running high speed of the Cupper or slightly higher LUBRICATOR MINIMUM SPEED CPM This parameter determines the speed the lubricator will run at when the cupper is stopped de clutched Note When the cupper is running the lubricator speed reference is proportional as set by the Lubricator Maximum Speed scaling to the speed of the cupper This parameter is used to provide the speed reference when the cupper speed is zero The NEXT and PREV keys can be used to advance to the next parameter or the previous parameter respectively To change the currently displayed parameter simply enter the new value on the numeric keypad and press lt ENTER gt The value will be entered and the next parameter will automatically be displayed When the last parameter Lubricator Minimum Speed is entered the primary set up menu is again displayed Pressing lt ESC gt at anytime will also exit you back to the primary set up menu HSL CUP3 User s Manual SYSTEMS Electronics Group 332 SECTION 4 USING THE HSL CUP3 KEYPAD DISPLAY 4 4 3 SET MACHINE TIMING SET POINTS ETC This selection brings up the timing set point menu which displays the following fields CHuu SETPOINT xxx channel name RPM yyyy POS zzz OFFSET wwww SCALE 360 Each field is defined as follows Field D
34. h incorporate the break wear compensation feature The appropriate TDC timing signal low or high is adjusted based on the speed of the machine when the TDC stop was initiated HSL CUP3 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION In addition to the brake wear compensation the HSL CUP3 also calculates the actual brake response in degrees This is the number of degrees from where the clutch was de activated TDC timing location to where the crankshaft actually ended up stopping This can then be displayed by the operator or maintenance personnel to determine the condition of the brake A Brake Response Too Long alarm is also generated when the actual brake response exceeds a user specified maximum allowed brake response This can be used to indicate that service to the brake should be performed 1 6 ALARM DETECTION The package detects the following alarms timing signal failure and brake response too long TIMING SIGNAL FAIL The timing signal fail occurs when any of the timing signals generated in the PLS section fail to change state periodically while the machine is running BRAKE RESPONSE TOO LONG The Brake Response Too Long alarm is generated when the actual brake response exceeds a user specified maximum allowed brake response This can be used to indicate that service to the brake should be performed The above alarms are available to the host PLC via discrete outputs These should be used to sto
35. hen replacing the M4500 module see section 2 5 Note The set up data consists of the cupper and lubricator set up parameters see section 3 1 Timing channel set points are not stored as part of the set up data To download the set up data perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4500 2 Select 5 Download Set up data to M4500 A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key 3 Once data download is initiated the current address being downloaded will be displayed Note M4500 program execution is not ceased therefore data download can be performed while the machine is running 4 Once set up data download is complete press any key to return to the HSLCUP3 main menu HSL CUP3 User s Manual SYSTEMS Electronics Group 26 SECTION 3 USING THE HSLCUP3 SET UP PROGRAM 3 6 UPLOAD SAVE SET UP DATA FROM M4500 This selection is used to save the set up variables from the M4500 to the hard drive current directory selected This should be performed anytime any of the set up variables have been changed Note When the set up variables are changed they are changed directly in the M4500 not on the file in the computer By uploading saving the set up variables to disk they can be downloaded to the M4500 in the event the module must be replaced
36. host PLC uses to perform the check AIR STRIP TIMING This signal is used to activate the air strip solenoid The air strip is on for the entire window that CHOS is on while the machine is running This signal is generally set on about 120 degrees and then set off at about 200 SCRAP JAM TIMING This signal is used by the host PLC to perform the Scrap Jam Check This should be set per the algorithm the host PLC uses to perform the check STROKE COUNT TIMING This signal is used by the host PLC to count strokes MOTION TIMING This signal is provided to the PLC via a discrete DC output This is used by the host PLC to detect when the crankshaft is moving as a back up to verify that the clutch was activated when commanded to This is a pulse train set on for 30 degrees and then set off for 30 degrees through out the entire channel HSL CUP3 User s Manual SYSTEMS Electronics Group 37 SECTION 5 GENERAL TIMING SIGNAL LOCATIONS This Page Intentionally Left Blank HSL CUP3 User s Manual SYSTEMS Electronics Group 38 SECTION 6 RECOMMENDED SPARE PARTS The following are recommended spares for the HSL CUP3 These parts are available through Systems Engineering Assoc Inc Quantity Part Number Description lea M4500 PLC PLS Processor Chassis 4 Slot lea P4500 Power Supply lea S4568 8 input 8 output 10 30VDC 1 0 Board lea S4573 16 point 10 30VDC Output Board lea D4591 Display Keypad HSL CUP3 User s Manual
37. installing the HSL CUP3 ENCL package mounted in the NEMA 12 enclosure mount the HSL CUP3 NEMA 12 enclosure in proximity to the existing control cabinet If installing the HSL CUP3 package mount the back panel 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 Note The D4591 must be located within 6 feet of the M4500 module to avoid EMI pick up on the Display ribbon cable Connect the ribbon cable from the M4500 module to the D4591 module HSL CUP3 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION Wire the HSL CUP3 to the existing control system referring to the electrical control schematic at the back of this manual keeping all 24VDC wiring away from high voltage wiring Wire the machine mounted resolver directly to the 8 pin resolver input connector on the M4500 module using a three pair two conductor shielded cable The shield of the resolver cable should be tied to the SHLD terminal of the M4500 resolver input connector Make sure the resolver cable shield is left floating at the resolver Refer to the electrical control schematic at the back of this manual for details 2 2 3 MOUNTING THE RSV34 MS1 RESOLVER IF REQUIRED The HSL CUP3 is designed to interface to a resolver not encoder for machine timing If the machine is not already equipped with a resolver then the existing encoder will have to be removed an
38. k HSL CUP3 User s Manual SYSTEMS Electronics Group 33 SECTION 4 USING THE HSL CUP3 KEYPAD DISPLAY Entering or Adjusting Set point To set or adjust a timing channel perform the following 1 Select the channel to be adjusted by pressing the SELECT CHANNEL key entering the channel number 00 to 17 and pressing enter In addition the NEXT and PREV keys can be used to advance to the next channel or retard to the previous channel 2 Press CLEAR CHANNEL to clear the existing set point out Note Entering a new set point does not automatically clear the old set point out If the two set points are not in the same place the channel will simply have two set points in it if the old one is not cleared out first Therefore always clear the channel before entering a new set point A set point may however be extended by programming another set point onto an existing set point using either the existing on or off set point as the starting position for the new set point This will result in one larger set point 3 Press ENTER SET POINT to enter the new set point The display will then prompt ON SETPOINT Enter the position in degrees where the set point should go on and press lt ENTER gt The display will now prompt OFF SETPOINT Enter the position in degrees where the set point should go off and press lt ENTER gt The channel will now be programmed with a set point that goes on at the on position
39. llowing to be viewed or adjusted 1 Set the Cupper Set Up Parameters 2 Set the Lubricator Speed References 3 Set Machine Timing 4 Set Machine Zero 5 View the Actual Brake Response in degrees 6 View the Current Shift Data 7 View the Last Shift Data The definitions of the keypad commands and menus are described in the following sections Note For virtually all the menus the NEXT and PREV keys can be used to advance to the next item of the menu or retard to the previous item on the menu 4 1 DEFAULT SCREEN The default screen displayed when no other commands are active contains the following data MACHINE SPEED SPM xxxx POSITION xxx TOTAL STROKES xxxxxxx Where the Machine Speed is the current speed of the cupper the Position is the current angular position of the cupper crankshaft and the Total Strokes field is the total number of strokes the press has made so far into the current shift This display effectively replaces a speed meter a position display and a counter This screen is always returned to when no commands are active 4 2 BRAKE RESPONSE KEY This key displays the brake response of both low speed and high speed stops The response is the number of degrees it takes the press to stop from when the clutch is de activated for a TDC stop to the position that the machine comes to rest This can be used to determine the general condition of the brake and whether servicing of the brake is required
40. lutch was de activated at the TDC hi timing to where the cupper crankshaft came to rest when a TDC stop was performed at high speed This can be used to determine the general condition of the brake and whether servicing of the brake is required Lo Speed Brake Response degrees This is the number of degrees from the when the clutch was de activated at the TDC Lo timing to where the cupper crankshaft came to rest when a TDC stop was performed at Low speed This can be used to determine the general condition of the brake and whether servicing of the brake is required s Manual SYSTEMS Electronics Group APPENDIX A MODBUS COMMUNICATIONS 401708 TDC Timing On Hi BW Comp This is the on set point of the TDC Hi timing CH00 when modified by the brake wear compensation algorithm This is modified by the M4500 when the brake wear compensation is enabled and CH00 was reprogrammed when the brake response was too long or too short on a high speed TDC stop This is only updated if the brake wear compensation is enabled otherwise it is not used 401709 TDC Timing Off Hi BW Comp This is the off set point of the TDC Hi timing CH00 when modified by the brake wear compensation algorithm This is modified by the M4500 when the brake wear compensation is enabled and CH00 was reprogrammed when the brake response was too long or too short on a high speed TDC stop This is only updated if the brake wear compensation is enabled
41. net door HSL CUP3 User s Manual M4500 User s Manual HSL CUP3 Program Disk 2 1 2 HSL CUP3 ENCL with NEMA 12 ENCLOSURE lea HSL CUP3 NEMA 12 enclosure including the following lea M4500 PLC PLS module lea P4500 Power Supply lea D4591 Display Keypad lea HSL CUP3 User s Manual 1ea M4500 User s Manual lea HSL CUP3 Program Disk HSL CUP3 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 1 3 HSL CUP3 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 lea RSV34 MS1 Resolver lea RSV RSCBLE XX Resolver Cable 2 2 HSL CUP3 INSTALLATION 2 2 1 POWER REQUIRED The HSL CUP3 is powered from 115VAC 230VAC 50 60HZ and 24VDC The 115VAC 230VAC is used to power the M4500 module while the 24VDC is used to power the 24VDC I O clutch solenoids etc Note 24VDC solenoids must be used for all clutch and air strip solenoids These provide a much more consistent and repeatable response time than 115VAC solenoids Assuming 24VDC solenoids were used in the existing system the 24VDC current required by the HSL CUP3 is no more than the existing systems 24VDC current requirement therefore the existing 24VDC power supply should be adequate 2 2 2 MOUNTING AND WIRING THE HSL CUP3 If
42. nting studs of the D4591 install the D4591 in the cut out either in the HSL CUP3 enclosure or the cut out in the user s existing control cabinet Secure the display to the enclosure using 7ea 8 32 nuts and external lock washers 2 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 M4500 only one way HSL CUP3 User s Manual SYSTEMS Electronics Group 16 SECTION 2 INSTALLATION 2 5 4 DOWNLOAD HSLCUP3 PROGRAM AND SET UP DATA TO M4500 Once the M4500 P4500 D4591 are installed perform the following to download the HSLCUP3 application program to the M4500 as well as download the previously saved set up data and timing channel set points 1 Power up the M4500 and the IBM PC or compatible used to interface with the HSL CUP3 2 Connect an RS 232 cable from the computer COM port to the PROG port on the M4500 3 From the computer s menu program select the respective cupper s SET UP CUPPER selection this was set in section 2 3 1 The HSLCUP3 set up program will be invoked with the corresponding HSLCUP3 application program for that cupper 4 Download the HSLCUP3 application program to the M4500 by selecting 4 Download Program to M4500 from the HSL CUP3 main menu A prompt will be displayed verifying the download press the lt ENTER gt key to start the download Once the download is complete press any key to r
43. nuous The TDC timing channels will not be modified when single strokes are made or if press is started in continuous and then immediately stopped again Wait about 5 seconds after the press is started before performing the TDC stop to verify the stop position If the brake wear compensation is disabled manually adjust both the TDC High timing CH00 and the TDC Low timing CH01 such that the press stops at top dead center at both respective speeds See section 3 2 2 HSLCUP3 set up program or section 4 4 3 HSL CUP3 keypad for details on adjusting CH00 and CHOI Verify Lubricator Speed References Verify that the coil stock is feed adequately from the lubricator when the machine is running in continuous The lubricator will feed stock proportionally to the speed of the cupper based on the scaling set in Lubricator Maximum Speed Calibration Also verify that the stock is feed satisfactorily in inch and single modes The Lubricator Minimum Speed reference is used to feed stock by hand etc when the cupper is de clutched The machine is now set up and ready to run HSL CUP3 User s Manual SYSTEMS Electronics Group 13 SECTION 2 INSTALLATION 2 5 M4500 P4500 D4591 INSTALLATION The following is provided only as a reference These steps are performed by the factory prior to shipping the HSL CUP3 These steps need only be performed in the event either the M4500 module P4500 power supply or D4591 display need to be replaced Re
44. odically while the machine is running B790 3 Brake Response Too Long The Brake Response Too Long alarm is generated when the actual brake response exceeds a user specified maximum allowed brake response This can be used to indicate that service to the brake should be performed The following data is read from the MODICON PLC MODICON Dest 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 HSL CUP3 User s Manual Data Definition Status Control from MODICON CH00 On CHO00 Off CHOI On CHO01 Off CH02 On CH02 Off CH03 On CH03 Off CH04 On CH04 Off CHOS On CHOS Off CH06 On CH06 Off CH07 On CH07 Off TDC Timing H1 TDC Timing H1 TDC Timing Lo TDC Timing Lo Die Jam Check Timing Die Jam Check Timing Cup Jam Check Timing Cup Jam Check Timing Die Check Reset Timing Die Check Reset Timing Air Strip Timing Air Strip Timing Scrap Jam Timing Scrap Jam Timing Stroke Count Timing Stroke Count Timing BW Comp Desired Stop Lo BW Comp Desired Stop Hi Max Allowed Stop Response BW Alarm Cupper Running Low Speed Cupper Running High Speed Lubricator Maximum Speed Calibrate Lubricator Idle Speed A 3 M4500 Source Address W900 W902 W904 W906 W908 W910 W912 W914 W916 W
45. onse is before the Brake Response Too Long alarm is generated If the actual brake response number of degrees from when the brake is activated to the position where the press ends up at rest when a TDC stop is performed is longer than this number the alarm is generated If the actual brake response is less the alarm is not generated Set this parameter to the value where the brake response is considered too long and service to the brake should be performed typically 270 to 300 degrees Cupper Running Low Speed This is the speed in strokes per minute that the cupper will run when in low speed Cupper Running High Speed This is the speed in strokes per minute that the cupper will run when in high speed HSL CUP3 User s Manual SYSTEMS Electronics Group A4 APPENDIX A MODBUS COMMUNICATIONS 401782 Lubricator Maximum Speed Calibrate The Lubricator Maximum Speed parameter is used to scale the 0 10VDC analog output such that when the cupper is running at the speed entered in Lubricator Maximum Speed the analog output will be at 10 volts This is typically set to the running high speed of the Cupper or slightly higher 401783 Lubricator Idle Speed This parameter determines the speed the lubricator will run at when the cupper is stopped de clutched Note When the cupper is running the lubricator speed reference is proportional as set by the Lubricator Maximum Speed scaling to the speed of the cupper This
46. p the machine and indicate the problem when any one of the alarms occurs 1 7 DATA COLLECTION The following data is collected for both the current shift and the previous last shift 1 Total strokes made 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 bit set via the MODBUS or DF1 communications This bit can be activated on an 8 or 12 hour shift basis HSL CUP3 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION The standard HSL CUP3 package is provided for back panel mounting inside the existing user s control cabinet In addition the HSL CUP3 can be purchased in a self contained NEMA 12 enclosure for mounting adjacent to the existing control cabinet by specifying part number HSL CUP3 ENCL 2 1 WHAT S INCLUDED Depending on which package is purchased verify that the following items are included when unpacking the HSL CUP3 2 1 1 HSL CUP3 for back panel mounting lea lea lea lea lea HSL CUP3 back panel for mounting in the existing user s control cabinet including the following lea M4500 PLC PLS module lea P4500 Power Supply D4591 Display with ribbon cable for mounting in the existing user s control cabi
47. s 3 Brake Wear compensation Auto TDC timing programming algorithm to stop press at TDC regardless of brake response 4 Brake response determination allows displaying of actual brake response in degrees 5 Brake response alarm to indicate when brake stopping response in degrees has exceeded user preset limit 6 Lubricator speed reference 0 10volt analog output provides reference to lubricator proportional to speed of cupper user scalable 7 Alarm detection timing signal fail detection and brake response too long alarm 8 Data Acquisition Total number of strokes for both current shift and last shift e Built in 2 Line X 40 character sealed display with 24 key membrane keypad allows local viewing of collected data stroke count brake response by operator and set up of all user variables e Interfaces directly with machine mounted resolver and all clutch and air strip solenoids e Based on high performance M4500 PLC PLS module which allows easy trouble shooting and user customization using SYSdev DOS based programming package e Built in PLS provides all machine timing eliminating need for an additional PLS 1 2 GENERAL DESCRIPTION The HSL CUP3 Cupper high speed control package is an electronic upgrade package for cuppers which performs the high speed control functions of the cupper including rapid response clutch brake control and precise air strip control In addition the package provides a brake wear compens
48. start bits Number of data bits Number of stop bits Parity HSL CUP3 User s Manual 5 19 2K RTU 1 8 1 NONE SYSTEMS Electronics Group A 7
49. the shift data this screen also shows the brake response of the brake for both high and low speeds This data is updated after each TDC stop To exit back to the main menu press lt ESC gt 3 3 1 SHIFT DATA DEFINITIONS Total Strokes This is the total number of strokes the press has made for the shift This is essentially a can counter Low Speed Brake Response degrees This is the number of degrees from the when the clutch was de activated at the TDC Lo timing to where the cupper crankshaft came to rest when a TDC stop was performed at Low speed This can be used to determine the general condition of the brake and whether servicing of the brake is required High Speed Brake Response degrees This is the number of degrees from the when the clutch was de activated at the TDC hi timing to where the cupper crankshaft came to rest when a TDC stop was performed at high speed This can be used to determine the general condition of the brake and whether servicing of the brake is required HSL CUP3 User s Manual SYSTEMS Electronics Group 24 SECTION 3 USING THE HSLCUP3 SET UP PROGRAM 3 4 DOWNLOAD PROGRAM TO M4500 This selection is used to download the HSLCUP3 application program to the M4500 module This should only be performed when either replacing the M4500 module see section 2 5 or when the program has been changed To download the program perform the following Note Program download cannot be perform
50. ting this bit to a 1 enables the set up parameters 401777 thru 401783 in the MODICON to be used in the M4500 If this bit is set to a 0 the values in 401777 thru 401783 in the MODICON are not used as the set up parameters the M4500 instead uses the values set up thru the HSL CUP3 keypad or the HSLCUP3 set up program Timing Channel Program Enable Setting this bit to a 1 enables the CHOO thru CH07 On and Off set points 401761 thru 401776 from the MODICON to be used as the set points for CHO0 thru CHO7 in the PLS section of the M4500 If this bit is set to a 0 the values in 401761 thru 401776 in the MODICON are not used as the set points the M4500 instead uses the values set up thru the HSL CUP3 keypad or the HSLCUP3 set up program Set Resolver Zero Auto Zero Setting this bit sets the PLS offset such that the current position is 0 To set the resolver zero position the machine at Top Dead Center and then set this bit to a 1 The resolver position will now read 000 Reset this bit back to 0 when done Alarm Reset Setting this bit to a 1 resets the timing signal fail alarm and the brake response too long alarm HSL CUP3 User s Manual SYSTEMS Electronics Group A 6 APPENDIX A MODBUS COMMUNICATIONS The MODBUS driver uses the following data format and parameters the MODBUS port on the MODICON PLC must be set to match these MODBUS Port PLC address MODBUS Baud MODBUS framing mode Number of
51. ts 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 1996 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description 1 1 1 Features 1 1 2 General Description 1 1 3 Clutch Brake Control 2 1 3 1 Control of Clutch Via Host PLC 2 1 4 Air Strip Control 3 1 5 Brake Wear Compensation 3 1 6 Alarm Detection 4 1 7 Data Collection 4 2 Installation 5 2 1 What s Included 5 2 1 1 HSL CUP3 for back panel mounting 5 2 1 2 HSL CUP3 ENCL with NEMA 12 Enclosure 5 2 1 3 HSL CUP3 Options 6 2 2 HSL CUP3 Installation 6 2 2 1 Power Required 6 2 2 2 Mounting and Wiring the HSL CUP3 6 2 2 3 Mounting the RSV34 MS1 Resolver 7 2 3 HSL CUP3 Software Installation 7 2 3 4 HSL CUP3 Set up Software Installation 8 2 3 2 SYSdev Program Development Software Installation 9 2 3 3 HSL CUP3 Application Program Installation 9 24 Tuning the HSL CUP3 10 2 4 1 Set Cupper Set up Parameters 11 2 4 2 Set Lubricator Speed References 12 2 4 3 Set Machine Zero 13 2 4 4 Verify Machine Operation 13 2 5 M4500 P4500 D4591 Installation 14 2 5 1 M4500 Module Installation 14 2 5 2 P4500 Power Supply Installation 16 2 5 3 D4591 Keypad Display Installation 16 2 5 4 Download HSLCUP3 Program and Set up Data to M4500 17 HSL CUP3 User s Manual SYSTEMS
52. tware s menu The main development menu of SYSdev will be initiated with the HSLCUP3 program See the SYSdev Program Development manual and the M4500 Program Development manual for complete details on on line monitoring and program development with SYSdev HSL CUP3 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 4 TUNING THE HSL CUP3 The HSL CUP3 is shipped from the factory with the PLC program HSLCUP3 loaded in the M4500 module PLC section and the PLS channel set point file CUP3TMG loaded in the PLS section of the M4500 module These are the standard programs used to implement the standard HSL CUP3 cupper algorithm In addition as shipped the user variables for the M4500 are set the following defaults Brake Wear Compensation Enabled DON Desired TDC Stop Position Low Speed 000 Desired TDC Stop Position High Speed 000 Maximum Allowed Stopping Response degrees 300 Cupper Running Speeds Low Speed SPM 120 High Speed SPM 220 Lubricator Speed Reference Maximum Speed 250 Idle Speed Cupper stopped 100 The CUP3TMG timing channel file as shipped contains the following default timing set points CHAN CHOO CH01 CH02 CHO3 CH04 CHO05 CHO6 CHO7 CH10 CH11 CH12 CH13 CH14 CH15 CH16 CH17 ON 140 180 120 300 000 120 020 180 000 OFF HSL CUP3 User s Manual DESCRIPTION TDC High timing TDC Low timing Die Jam Check timing
53. when in low speed Running Cupper High Speed SPM This is the speed in strokes per minute that the cupper will run when in high speed Lubricator Maximum Speed CPM The Lubricator Maximum Speed parameter is used to scale the 0 10VDC analog output such that when the cupper is running at the speed entered in Lubricator Maximum Speed the analog output will be at 10 volts This is typically set to the running high speed of the Cupper or slightly higher Lubricator Idle Speed CPM This parameter determines the speed the lubricator will run at when the cupper is stopped de clutched Note When the cupper is running the lubricator speed reference is proportional as set by the Lubricator Maximum Speed scaling to the speed of the cupper This parameter is used to provide the speed reference when the cupper speed is zero HSL CUP3 User s Manual SYSTEMS Electronics Group 20 SECTION 3 USING THE HSLCUP3 SET UP PROGRAM 3 1 2 CUPPER LUBRICATOR SET UP PARAMETER SELECTIONS The menu selections on the Cupper Lubricator Set Up Parameters menu allow you to set the set up variables listed under the following menu selections 1 Enable Disable Brake Wear Compensation Enable Disable Brake wear compensation Desired TDC Stop Position Low speed Desired TDC Stop Position High speed 2 Maximum Allowed Cupper Stopping Response Maximum Allowed Cupper Stopping Response 3 Set Cupper Running Speeds Low Spee

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