Home

User`s manual complete - Sea

1. 3 3 Spare CHO RPM 0 Position 358 Offset 215 Scale 360 s ystem Message All Faults Normal i ONLINE 11041 2 2003 212 PM P In addition the following parameters are displayed at the bottom of this window RPM This is the current speed in Revolutions per Minute of the main crank resolver Position This is the current Position in degrees of the main crank resolver Offset This is the current resolver offset set in degrees Scale This is the scale factor of the resolver or the number of divisions in one revolution HSL ANCNF User s Manual SYSTEMS Electronics Group 43 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE Note The General Timing Signal Locations section provides a complete description of each timing channel signal Zeroing the Machine setting the resolver offset To set machine zero perform the following 1 2 3 4 5 6 7 Connect an RS 232 SYSdev cable from the COM port on the computer to the PROG port on the M4500 From the Window menu select Machine Timing From the View menu select Online Data The set up program will attempt to communicate with the processor and place the system into an Online mode of operation Observe the Position field at the bottom of the window Verify that as the machine is rotated forward that the position increases linearly from 0 th
2. to exit back to the primary set up menu 2 Position the machine at machine zero 3 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 4 The M4500 will calculate the actual offset value required to make this the 000 position and will display this number in the offset field 5 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 3 5 5 CALIBRATE NUMBER SHIFTS TO STATIONS This selection is used to enter the calibration mode see section 2 4 4 Calibrate Number of Shifts to each Station for details on performing the calibration When selected the display will prompt for 0 to enter the calibrate mode or ESC to return back to the primary set up menu Press 0 to enter the calibration mode The Calibrate Counts will be reset and Calibration In Progress Current Shift Count From Infeed will be displayed As the machine is run with the can feed open the Current Shift Count From Infeed will display the number of shifts that the first can fed in is past the infeed screw sensor When the first can reaches the flanger transfer sensor the calibration is complete and the display will return to the primary set up menu The Calibration Counts will now be set and can be used to enter t
3. Colorado 80007 USA AMIA Phone 303 421 0484 Fax 303 321 8108 HSL ANCNF User s Manual SYSTEMS Electronics Group 28 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 THE FILE MENU The File menu allows the user to perform the following functions e Create a New set up Data File e Open an existing Data File e Save any changes made to the current Data File to disk e Upload save Data from the Processor e Download a SYSdev sdv program to the processor e Download restore Data from the current set up Data File to the processor e Print a Report of the current set up parameters e Exit the set up program RE S pi unnamed Main Display O x File Edit View Window Help Open Ctrl O Save Ctrl S Save As Export Shift Data Ctrl X Upload save Data Machine CPM Download Program Download Data ift Last Shift Jams Station Transfer Jam 0 234 567 Print Report Ctrl P 34 567 Exit 111 50 normal STOTT OZ 112 51 normal Station 03 113 53 normal Station 04 114 53 normal Station 05 115 55 normal Station O6 116 56 normal Station 07 117 56 normal Station 08 118 57 normal Station 09 119 59 normal Station 10 120 59 normal Reset Jams Station Station 11 121 60 normal _ Flanger 122 62 normal End of Shift System Message All Faults Normal ONLINE 10 12 2003 2 05 PM A HSL ANCNF U
4. ao HSL ANCNF User s Manual SYSTEMS Electronics Group 46 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 5 THE I O STATES WINDOW The I O States window is provided to display states of the inputs and outputs The control boards the states of the timing channels as well as states of the M4500 are shown This includes the interrupt inputs INO and IN1 the analog I O and the resolver These values are displayed as read by the M4500 processor E ANCNF unnamed 1 0 Status HSL ANCNF User s Manual SYSTEMS Electronics Group 47 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE This Page Intentionally Left Blank HSL ANCNF User s Manual SYSTEMS Electronics Group 48 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE The DOS based HSLANCNF set up program is menu driven allowing the user to easily view data alter set up variables or set the machine timing machine offset timing signal locations etc using a laptop or personal computer The set up variables are used to configure and tune the HSL ANCNE to match the configuration and performance of the specific necker flanger see section 2 4 Tuning the HSL ANCNF The main menu of the HSLANCNF set up program incorporates the following menu selections e HSLANF EXE lol x Systems HSL ANCNF Set up Menu Version 2 0 Main Menu Set Number of Shifts to Necker Stations Flanger Set Transfer Jam Al
5. 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 9 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 HSLANCNF main menu HSL ANCNF User s Manual SYSTEMS Electronics Group 60 SECTION 6 GENERAL TIMING SIGNAL LOCATIONS The following is a general description of the timing signals and the locations they should be set at CH00 TRANSFER TIMING This signal should transition from off to on when cans are centered in the middle of the transfer sensors and infeed sensor This signal should be at least 40 degrees wide CH01 PLC CLOCK TIMING This signal is not used by the HSL ANCNF internally but is instead provided for the host PLC as a general timing signal to clock once per can shift CHO01 should be programmed on for 180 degrees and off for 180 degrees but can otherwise be programmed to start anywhere as desired HSL ANCNF User s Manual SYSTEMS Electronics Group 61 SECTION 6 GENERAL TIMING SIGNAL LOCATION
6. addition the transfer jam detection can be disabled by setting the number of shifts for the respective station to 0 This would be done on machines not equipped with all stations Calibration Count Stations 1 thru 10 and Flanger These are the actual number of shifts from the infeed screw sensor to the transfer sensor for each respective station These numbers are determined when the calibration is performed HSL ANCNF User s Manual 4 SYSTEMS Electronics Group SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE Number of Missing Cans for Transfer Jam Alarm Stations 1 thru 10 and Flanger These variables are the number of consecutive missing cans once cans should be at the transfer sensor for that station as set in the Number of Shifts that will cause a transfer jam for each respective station Each station can be set independently If the Number of missing cans is set to 4 for a particular station a transfer jam will be generated when four or more consecutive missing cans are detected at that station If three or less consecutive missing cans occurred the transfer jam would not be generated Transfer Jam Enable This allows the user to disable the jam detection for a particular station without setting the number of shifts to 0 Jam detection cannot be enabled if the number of shifts to the station is set to zero Calibrate Number of Shifts reset calibration counts This is used to initiate the calibration mod
7. adjusted or viewed for each station see section 2 4 4 Calibrate Number of Shifts to each Station for more details CALIBRATION COUNT Stations 1 thru 10 and Flanger These are the actual number of shifts from the infeed screw sensor to the transfer sensor for each respective station These numbers are determined when the calibration is performed These numbers cannot be changed in this menu only viewed NUMBER OF SHIFTS Stations 1 thru 10 and Flanger This is the number of shifts from the infeed screw sensor to the transfer sensor for each station These numbers can be determined using the calibration mode or they could be counted manually if desired The range of values for these numbers is 1 to 319 In addition the transfer jam detection for stations 6 thru 10 can be disabled by setting the number of shifts for the respective station to 0 stations 1 thru 5 and the flanger cannot be disabled This would be done on machines not equipped with these stations HSL ANCNF User s Manual SYSTEMS Electronics Group 22 SECTION 3 USING THE KEYPAD DISPLAY The NEXT and PREV keys can be used to advance to the next station or the previous station respectively To change the displayed Number of Shifts for the current station simply enter the new value on the numeric keypad and press lt ENTER gt The value will be entered and the next station will automatically be displayed When the number of shifts for the
8. operation can be changed by simply double clicking the online offline mode panel Hot Keys Hot keys are activated by holding down the ALT key and simultaneously pressing the underlined letter of the desired function Almost every function can be activated by either pressing a series of hot keys or using the TAB key to move between fields Online Offline Modes The set up program allows the user to make changes while Online with the processor The Offline mode is used to preset parameters prior to download All functions are available to the user while Online however specific Online functions are disabled in the Offline edit mode Note Offline changes can only be made by enabling Offline Editing accessed under the Edit menu Getting Help The entire contents of the user s manual is contained within the help file Pressing Ctrl H will display the help file window Pressing the F1 key will display the contents file Hot spots allow jumps to other topics to display additional information as desired Selecting About ANCNE from the Help menu will display a dialog box listing information about the current revision of the setup program and how to obtain technical support is Version 1 0 0 Systems Electronics Group Copyright 2003 Systems Engineering Associates Inc All Rights Reserved Technical Support Systems Engineering Associates Inc 14989 West 69th Avenue System Inf Arvada
9. to the host PLC via the transfer jam alarm outputs HSL ANCNF User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 5 TIMING SIGNAL FAILURE DETECTION 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 This alarm is available to the host PLC via a discrete output This should be used to stop the machine and indicate the problem when the alarm occurs 1 6 DATA COLLECTION The following data is collected for both the current shift and the previous last shift 1 Total number of good cans necked and flanged 2 Total number of transfer jams 3 Total number of transfer jams for each station This data is viewed locally on the Keypad Display or can be sent to the host PLC via RS 232 communications MODBUS protocol 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 or alternatively could be activated manually on a label run basis depending on the user s preference In addition to the shift data collection a separate buffer is available to collect transfer jams per station counts as a diagnostics aid to the operator for trouble shooting a transfer jam problem for a specific station Unlike the shift data these counts can be reset manu
10. user to specify the serial communications port and rate to talk to the M4500 The programming port of the M4500 is set to 9600 baud C Com2 C 19200 C Com3 C Com4 i i x Comm Port Port Speed 1 Com1 e 9600 Cancel Once selected a dialog box requesting the user to select a Comm Port and Baud Rate will be displayed The default setting is COMI at 9600 baud In most cases the user will only need to specify the communications port and leave the baud rate at 9600 If communication problems occur make sure there is a secure connection from the PC to the PLC Then check the Comm port In most cases the user will only need to select a new Comm port If communication problems persist there may be another program causing a conflict with the port Check the port configuration from the Settings folder HSL ANCNF User s Manual SYSTEMS Electronics Group 34 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 4 THE VIEW MENU The View menu allows the user to perform the following functions e View the Target Board Interface e View Online Data e View Offline Data a8 ANCNF unnamed Main Display Target Board Interface h S8ggssesssscgss HSL ANCNF User s Manual SYSTEMS Electronics Group 35 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 4 1 TARGET BOARD INTERFACE This function allows th
11. 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 blank HSL ANCNF User s Manual SYSTEMS Electronics Group 24 SECTION 3 USING THE KEYPAD DISPLAY Entering or Adjusting Set point To set or adjust a timing channel perform the following 1 2 3 4 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 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 h
12. HSL ANCNF ANCC Necker Flanger 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 ANCNF ANCC Necker Flanger High Speed Front End User s Manual Copyright 1995 Systems Engineering Associates Inc All Rights Reserved Revised 26 January 2004 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 r
13. Lo 0 to 9 999 401705 Total Xfer Jams Hi 10 000 s 401706 Xfer Jams Station 1 401707 Xfer Jams Station 2 401708 Xfer Jams Station 3 401709 Xfer Jams Station 4 401710 Xfer Jams Station 5 401711 Xfer Jams Station 6 401712 Xfer Jams Station 7 401713 Xfer Jams Station 8 401714 Xfer Jams Station 9 401715 Xfer Jams Station 10 401716 Xfer Jams Station 11 401717 Xfer Jams Flanger 401718 Status to MODICON 401719 Xfer Check Enables shifts to Stations HSL ANCNF User s Manual M4500 Source Address W182 W180 W1100 W1102 W1104 W1106 W1108 W1110 W1112 WI1114 W1116 W1118 W1120 W1122 W1124 W1126 W1128 W1130 W790 W34 SYSTEMS Electronics Group APPENDIX A MODBUS COMMUNICATIONS The bits of the Status register to the MODICON from the M4500 are mapped as follows W790 Status to MODICON 4x address 401718 in MODICON B790 0 Transfer Jam Station 1 B790 1 Transfer Jam Station 2 B790 2 Transfer Jam Station 3 B790 3 Transfer Jam Station 4 B790 4 Transfer Jam Station 5 B790 5 Transfer Jam Station 6 B790 6 Transfer Jam Station 7 B790 7 Transfer Jam Station 8 B791 0 Transfer Jam Station 9 B791 1 Transfer Jam Station 10 B791 2 Transfer Jam Station 11 B791 3 Transfer Jam Flanger B791 4 Transfer Jam any station Alarm B791 5 PLC Clock Timing B791 6 Timing Signal Fail Alarm B791 7 Not Used The bits of the Xfer Check Enables shifts to each Station register to the MODICON fr
14. M ALARM COUNT PRESETS The Transfer Jam Alarm Count set up menu is used to set the Number of Missing Cans for Transfer Jam Alarm for each station in the M4500 This menu is invoked by selecting 2 Set Transfer Jam Alarm Count Presets from the Main Menu le HSLANF EXE loj x Systems HSL ANCNF Set up Menu Version 2 0 Number of Missing Cans for Transfer Jam Alarm each station 1 Set Number of Missing Cans for Transfer Jam Alarms 2 Help Screen Enter Selection ESC to exit Number of Missing Cans for Transfer Jam Alarm Station 1 005 Station 2 005 Station 3 005 Station 4 005 Station 5 005 Station 6 005 Station 7 005 Station 8 005 Station 9 005 Station 10 005 Station 11 005 Flanger 005 Number of Missing Cans for Transfer Jam Alarm Stations 1 thru 10 and Flanger These variables are the number of consecutive missing cans once cans should be at the transfer sensor for that station as set in the Number of Shifts that will cause a transfer jam for each respective station Each station can be set independently If the Number of missing cans is set to 4 for a particular station a transfer jam will be generated when four or more consecutive missing cans are detected at that station If three or less consecutive missing cans occurred the transfer jam would not be generated The menu selection on the Number of Missing Cans for Transfer Jam Alarm menu allows
15. NCNFTMG timing channel file as shipped contains the following default timing set points CHAN ON OFF DESCRIPTION CH00 180 240 Transfer Timing CH01 090 270 PLC Clock Timing In most cases the above user variables and timing channels will have to be altered to tune the HSL ANCNE to the actual necker flanger it is controlling HSL ANCNF User s Manual SYSTEMS Electronics Group 11 SECTION 2 INSTALLATION Once installed and the control system is powered back up perform the following to set up and tune the HSL ANCNF The set up is performed using either the Keypad Display or a PC running the set up program See section 3 of this manual for a description of the Keypad commands and menu displays of the Keypad Display See sections 4 and 5 for a description of menus and how to use the set up programs 2 4 1 SET MACHINE ZERO Zero machine set resolver offset Using the Keypad Display perform the following 1 Select 3 SET MACHINE TIMING and observe the POS field Verify that as the machine is rotated forward 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 2 Position the machine at machine zero 3 Auto zero the resolver by selecting 4 ZERO MACHINE from the primary set up menu E
16. ND SET UP DATA TO M4500 Once the M4500 P4500 D4591 are installed perform the following to download the HSLANCNF 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 ANCNF 2 Connect an RS 232 cable from the computer COM port to the PROG port on the M4500 3 Using the setup program download the application program to the M4500 A prompt will be displayed verifying the download See section 4 2 3 Windows setup program reference or section 5 7 DOS setup program reference for complete details 4 Download the previously saved to disk set up data to the See section 4 2 4 Windows setup program reference or section 5 8 DOS setup program reference for complete details 5 Download the PLS timing set points to the M4500 6 Zero the machine set the resolver offset 7 The M4500 is now ready to run loaded with the application program timing set points and set up data that was previously saved for the respective necker flanger HSL ANCNF User s Manual SYSTEMS Electronics Group 18 SECTION 3 USING THE KEYPAD DISPLAY The keypad of the HSL ANCNF contains 24 keys consisting of data display commands set up commands and a numeric keypad The display of the HSL ANCNF is 2 line by 40 character back lit LCD display which displays the selected data and set up menus The keypad dis
17. S This Page Intentionally Left Blank HSL ANCNF User s Manual SYSTEMS Electronics Group 62 SECTION 7 RECOMMENDED SPARE PARTS The following are recommended spares for the HSL ANCNF These parts are available through Systems Engineering Assoc Inc Quantity Part Number lea M4500 1ea P4500 1ea 4563 lea S4573 lea D4591 Description PLC PLS Processor Chassis 4 Slot Power Supply 16 point 10 30VDC Input Board 16 point 10 30VDC Output Board Display Keypad HSL ANCNF User s Manual SYSTEMS Electronics Group 63 SECTION 7 RECOMMENDED SPARE PARTS This Page Intentionally Left Blank HSL ANCNF User s Manual SYSTEMS Electronics Group 64 APPENDIX A MODBUS COMMUNICATIONS MODBUS PORT CONFIGURATION 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 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 The MODBUS communications driver uses the S4516 communications board to both read and write data to a MODICON PLC DATA WRITTEN TO THE MODICON PLC The following data is written to the MODICON PLC MODICON Dest 4x Address Data Definition 401700 Speed CPM 401701 Resolver Position 401702 Number of Good Cans Lo 0 to 9 999 401703 Number of Good Cans Hi 10 000 s 401704 Total Xfer Jams
18. S Print Channels File Utilities Return to SVSdev Shell Enter selection e HSLANF EXE Bl x CHRNNEL 00 DESCRIPTION TRRNSFER TIMING PROG MODE ONLINE CHANNEL SET POINTS ON OFF ON OFF ON OFF ON OFF Pals 31 41 ON OFF 0180 0240 11 ies LES pt Pd Ern OR En och et INT Le RS Poe Js Bes S PES CST LOS E Lisa ESL roce EJE ES pen cue et BSWO ANDU FONE SCALE FRCTOR 360 MESSAGE Position 358 Speed RPM 0000 HSL ANCNF User s Manual SYSTEMS Electronics Group 53 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE 5 3 1 ZEROING THE MACHINE To set the machine zero resolver offset perform the following 1 2 3 4 5 6 Select the 3 Set Machine Timing selection from the HSL ANCNF set up program main menu Select 1 Online Channel Set point Programming from the Main Development menu Select F9 POS RPM and observe the POS field Verify that as the machine is rotated forward 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 machine zero Auto zero the resolver by selecting F10 Set Offset Enter 0 in the offset fiel
19. SLNFI HSLANCNF HSLANCNF CD 4 To execute the respective necker flanger s set up program simply select the corresponding SET UP N F LINE selection from the menu software s menu HSL ANCNF User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 3 3 APPLICATION PROGRAM INSTALLATION The HSLANCNF application program is a SYSdev based program loaded into the M4500 module and performs the HSL ANCNF logic The 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 HSLANCNF program will have to be loaded onto the hard drive of the PC used to support the system The SYSdev Program Development Software will also have to be loaded on the PC To install this program perform the following 1 Install the PROGRAMS disk into the drive 2 For each of the HSLNF1 directories created in section 2 3 2 DOS Setup Program Installation copy all the files from the disk to each of these subdirectories 2 3 4 SYSdev PROGRAM DEVELOPMENT SOFTWARE INSTALLATION The SYSdev Program Development software is used to perform on line trouble shooting and program modifications to the HSL ANCNF If SYSdev was purchased with the control system and is not already installed on the your computer install SYSdev onto the hard drive of your computer following the steps outlined in the SYSdev Pro
20. adjusted by using the increment decrement controls Note Only one set point is used per channel 5 Ifa channel needs to be Recalled or Cleared enter the desired channel number into the PLS Channel field Click the Recall Channel command button to recall the set points Click the Clear Channel command button the completely clear all set points for the selected channel Note Ifa channel has been cleared or the On and Off set points have the same setting the set point will be displayed as Resetting the PLS Configuration As an aid to the user the current PLS configuration is displayed in the PLS Configuration tab of this window The PLS configuration should only be reset if a new module has been installed To reset the PLS configuration click the Reset PLS Config command button This function only resets the PLS configuration to the default settings HSL ANCNF User s Manual SYSTEMS Electronics Group 45 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 4 THE SERIAL COMMUNICATIONS WINDOW The Serial Communications window is used to view the configuration and communication status of the S4516 serial communications board if installed From this window the user can view the following e 4516 configuration status e S4516 serial communication status E ANCNF unnamed 4516 Serial Communications Ese 766 e pes ped wie Bem f e00 pra Ee
21. ally by the operator at will This allows the operator to note an abnormally high count on a specific station attempt to correct the problem reset the counts and then check the counts at a latter time to determine if the problem is corrected This data can also be viewed on the Keypad Display display HSL ANCNF User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION This Page Intentionally Left Blank HSL ANCNF User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION The standard HSL ANCNF package is provided for back panel mounting inside the existing user s control cabinet In addition a self contained NEMA 12 enclosure can be purchased in for mounting adjacent to the existing control cabinet by specifying part number HSL ANCNF ENCL 2 1 WHAT S INCLUDED Depending on which package is purchased verify that the following items are included when unpacking the HSL ANCNF 2 1 1 HSL ANCNF for back panel mounting lea lea lea lea lea HSL ANCNF 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 cabinet door HSL ANCNF User s Manual M4500 User s Manual HSL ANCNF Program Disk 2 1 2 HSL ANCNF ENCL with NEMA 12 ENCLOSURE lea HSL ANCNF NEMA 12 enclosure including the following lea M4500 PLC PLS module lea P4500 Pow
22. am The transfer jam detection for stations 6 through 10 can be individually disabled by setting the Number of Shifts for the respective station to 0 This is provided for machines that are not equipped with these stations Setting a number between to 319 enables the transfer jam detection for that respective station with the shift number equal to the number entered The transfer jam detection for stations 1 through 5 and the flanger cannot be disabled The numbers entered for the Number of Shifts should be the same as the Calibration Counts See section 3 5 1 using the Keypad Display section 4 5 2 Windows setup program reference or section 5 1 DOS setup program reference for details on setting the Number of Shifts 2 4 6 SET NUMBER OF MISSING CANS FOR TRANSFER JAM ALARM These variables are the number of consecutive missing cans once cans should be at the transfer sensor for that station as set in the Number of Shifts that will cause a transfer jam for each respective station Each station can be set independently If the Number of missing cans is set to 4 for a particular station a transfer jam will be generated when four or more consecutive missing cans are detected at that station If three or less consecutive missing cans occurred the transfer jam would not be generated See section 3 5 2 using the Keypad Display section 4 5 2 Windows setup program reference or section 5 2 DOS setup progr
23. am reference for details on setting the Number of Missing Cans for Transfer Jam Alarm The HSL ANCNF Is Now Set Up And Ready To Run HSL ANCNF User s Manual SYSTEMS Electronics Group 4 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 ANCNF These steps need only be performed in the event either the M4500 module P4500 power supply or D4591 display need to be replaced Refer 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 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 4563 to the following positions slot0 S4563 SWI switch OFF SWI switch2 OFF Install the 4563 in Slot0 0 furthest left slot of the M4500 chassis 3 Install S4573 SLOTO 1 Set the slot address dip switches SW1 on the S4573 to the following positions slot 84573 SWI switchl ON SWI switch2 OFF Install the 4573 in Slot0 1 slot next to 4563 of the M4500 chassis 4 Install S4573 SLOTO 2 Set the slot address dip switches SW1 on the S4573 to the following posit
24. arm Count Presets Set Machine Timing Number of Transfer Jams per Station data Current Shift data Last Shift data Download Program to M4500 Download Set up data to M4500 Upload Save Set up data from M4500 Enter Selection ESC to exit WOIACTIE Conor NOTE Before selecting one of the nine selections listed above connect an RS 232 cable from COM on the computer to the PROG PORT on the M4500 Note The HSLANCNF 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 HSLANCNF to the PROG port on the M4500 The following sections are a complete description of the HSLANCNF selections and menus HSL ANCNF User s Manual SYSTEMS Electronics Group 49 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE 5 1 SET NUMBER OF SHIFTS TO NECKER STATIONS FLANGER The Number of Shifts set up menu is used to set the number of shifts from the infeed screw sensor to each necker station and the flanger in the M4500 This menu is invoked by selecting 1 Set Number of Shifts to Necker Stations Flanger from the Main Menu See section 2 4 4 Calibrate Number of Shifts to Each Station for more details Systems HSL ANCNF Set up Menu Versi
25. computer to the PROG port on the M4500 2 Select 7 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 HSLANCNF REV file could not be opened is displayed then the HSLANCNF application program is not installed in the current directory To install the program perform the steps in section 2 3 3 Application Program Installation 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 to the HSLANCNF main menu HSL ANCNF User s Manual SYSTEMS Electronics Group 58 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE 5 8 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 when replacing the M4500 module Note The set up data consists of the number of shifts to each station and the number of missing cans for transfer jam alarm for each station Timing channel set points are not stored as part of the set up data To download the set up data
26. d 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 HSLANCNF set up main menu by pressing lt ESC gt again HSL ANCNF User s Manual SYSTEMS Electronics Group 54 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE 5 3 2 ADJUSTING THE TIMING CHANNEL SET POINTS To set or alter any of the timing signal set points perform the following 1 Select the 3 Set Machine Timing selection from the HSL ANCNF set up program main menu 2 Select 1 Online Channel Set point Programming from the Main Development menu 3 Set all channels per section 6 General Timing Signal Locations Set points are entered for a particular channel simply by typing in the set point in 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 necker flanger only one set point is used per channel and this should be entered in the number 1 set point The XXX is the location the set point will turn on while Y Y Y 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 4 Once all channels are programmed press lt ESC gt
27. d sensor should be located to see the cans at the same time as well If this is not the case adjust each sensor accordingly or the Transfer Timing Signal CH00 2 4 4 CALIBRATE NUMBER OF SHIFTS TO EACH STATION The HSL ANCNF control system incorporates a feature to automatically determine the number of shifts from the Infeed Screw sensor to each stations transfer sensor These Calibration Counts can then be entered in as the Number of Shifts for each station To determine the number of shifts to each station perform the following 1 Close the Infeed and run the machine completely empty of cans Note The machine must be empty of cans prior to initiating the calibration otherwise the calibration count numbers determined will be incorrect 2 From the Keypad Display select Set Up then 5 CALIBRATE NUMBER SHIFTS TO STATIONS and press 0 to start the calibration 3 While slowly running the machine open the infeed The Calibration Counts will start incrementing once the first can has passed the infeed screw sensor Each count will continue to increase until the first can has reached the corresponding transfer sensor at that station This is the exact number of shifts from the infeed screw sensor to that station 4 Continue running the machine until the cans have reached the flanger transfer sensor flanger calibration count stopped incrementing The number of shifts to each station has now been determined and
28. e The calibration mode automatically determines the Calibration Count registers See section 2 4 4 Calibrate Number of Shifts to Stations for more details Auto Set Shifts Shifts set to Calibration Counts This selection copies the Calibration Count registers to the Number of Shifts registers when selected This would be done after the calibration has been performed and the Calibration counts have been determined This is the quickest and easiest way to set the Number of Shifts variables HSL ANCNF User s Manual SYSTEMS Electronics Group 42 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 3 THE MACHINE TIMING WINDOW The Machine Timing window is used to invoke the PLS programming command menus From this window the user can view or adjust the following parameters e Adjust Timing Channel set points e Set the resolver offset e Clear or Recall a PLS timing channel e View the current PLS configuration e Reset the PLS configuration to default settings amp ANCNF unnamed Machine Timing File Edi View Window Help Timing Channels PLs Configuration Timing Channels Resolver Offset ON OFF Po y Transfer Timing CH00 180 34 240 Y PC Clock Timing CHOW so 270 Sega Spae cHO2y E 3 PLS Channel Spare CH03 EA 1 fo Spare cosy 7 3 77 3 Recall Channel Clear Channel Spare CHO5 E Spare cHoS
29. e shooting If the counts are to be reset press the 0 key if not press the ESC key The default screen will now be displayed again The ESC key can also be used at any time to abort the jams per station data display and return back to the default screen HSL ANCNF User s Manual SYSTEMS Electronics Group 20 SECTION 3 USING THE KEYPAD DISPLAY 3 3 CURRENT SHIFT KEY The Current shift data menu displays the following information e Good Cans e Total Jams e Transfer Jams per Station 1 Flanger This data is the totals so far into the shift This 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 or alternatively could be done at label changes such the data collected would be for label runs rather than complete shifts This data cannot be reset by the operator only at the end of shift input transition Note The Current shift Good Cans and Total Jams is displayed as part of the default screen Good Cans This is the total number of good cans necked and flanged so far into the shift This is essentially a can counter Total Jams This is the total number of transfer jams for all stations of the machine Transfer Jams per Station 1 Flanger This is the total transfer jams for each station A disproportionately high count for a particular station indicates a transfer jam probl
30. e user of the current program revision and checksum of the program loaded in the processor as well as that of the selected program Program Download x 9 Program to be loaded into module on disk 2 Program Ident HSLANF Program Revision 63 Program Checksum 61 Target Board M4500 PLC Program currently loaded in module Program Ident HSLANF Program Revision 63 Program Checksum 61 Entire program file will be dumped to the PLC All outputs are off while program dump occurrs Do You Wisth to Continue E No Cancel The user must confirm their selection by clicking the Yes command button After the user confirms their choice program download is initiated and the current program download address is displayed When program download is complete the user is prompted to acknowledge Control is passed back to the main program and the set up program remains in an Online edit mode HSL ANCNF User s Manual SYSTEMS Electronics Group 31 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 4 DOWNLOAD RESTORE DATA The set up program allows the user to download Set up parameters timing channel set points and shift data to the M4500 from the set up Data File This function is accessed from the File menu Note Only the values contained within the current data file are used If the validity of the current data file is questionable review the data in an Offline mode prio
31. e user to view fault codes S3000 network communication error codes and review the current Ident and Revision of the application program This is accessed by the View menu by selecting Target Board Interface Target Board Interface Program Ident Revision Set Network Address Set Time amp Date Internal Fault Code Current Fault Code 00H No Internal Fault has Ocurred Last Fault Code 00H No Internal Fault has Ocurred Corrective Action None Heset Faults r Communications Network Error Codes Current Comm Error Code 00H No Network Comm Error Last Comm Error Code 00H No Network Comm Error Once invoked the set up program will prompt the user to select a program to compare with the one existing in the processor Whether a program is selected or the user cancels the setup program will attempt to communicate with the M4500 If unsuccessful a warning message will be displayed prompting the user to either Retry or Cancel the operation If the operation is canceled and communication with the processor cannot be established the system will be placed in an Offline mode however the Target Board Interface window will be displayed HSL ANCNF User s Manual 36 SYSTEMS Electronics Group SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 4 2 VIEW ONLINE DATA This function allows the user to place the set up pr
32. em for that station 3 4 LAST SHIFT KEY The Last Shift data is identical to the current shift data except it is for the previous 8 or 12 hour shift or previous label run how ever the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period HSL ANCNF User s Manual SYSTEMS Electronics Group 21 SECTION 3 USING THE KEYPAD DISPLAY 3 5 SET UP KEY This selection is used to invoke the primary set up menu This consists of the following five selections 1 SET NUMBER OF SHIFTS TO STATIONS 2 SET TRANSFER JAM COUNT PRESETS 3 SET MACHINE TIMING SET POINTS ETC 4 ZERO MACHINE SET RESOLVER OFFSET 5 CALIBRATE NUMBER SHIFTS TO STATIONS The set up menu is key switch protected such that 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 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 5 3 5 1 SET NUMBER OF SHIFTS TO STATIONS This menu is activated when the 1 key SET NUMBER OF SHIFTS TO STATIONS is pressed while the primary set up menu is active The following set up parameters may then be
33. er Supply lea D4591 Display Keypad lea HSL ANCNF User s Manual lea M4500 User s Manual lea HSL ANCNF Program Disk HSL ANCNF User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 1 3 HSL ANCNF 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 MSI Resolver lea RSV RSCBLE XX Resolver Cable 2 2 HSL ANCNF INSTALLATION 2 2 1 POWER REQUIRED The HSL ANCNF is powered from 115VAC 230VAC 50 60HZ and 24VDC The 115VAC 230V AC is used to power the M4500 module while the 24VDC is used to power the 24VDC I O sensors transfer jam outputs and Calefi valves The 24VDC current required by the HSL ANCMF is no more than the existing system s 24VDC current requirement therefore the existing 24VDC power supply should be adequate 2 2 2 MOUNTING AND WIRING THE HSL ANCNF If installing the HSL ANCNF package mounted in the NEMA 12 enclosure mount the HSL ANCNF NEMA 12 enclosure in proximity to the existing control cabinet If installing the HSL ANCNF back panel mounted 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
34. ers to another processor The following functions can be accessed any time from any set up or display windows New To create a New data file select New from the File menu or press Ctrl N This creates a completely new file loaded with the default variables and the word unnamed is displayed in the title bar If any changes were made to the existing file the user is prompted to save changes to the existing file Open To Open and existing data file select Open from the File menu or press Ctrl O This displays a dialog box allowing the user to select an existing data file to open The name of the file will be displayed in the title bar If any changes were made to the existing file the user will be prompted to save any changes before terminating the program Save To Save data file to disk select Save from the File menu or press Ctrl S This displays a dialog box allowing the user to select a folder and enter a name for the file The user will be notified if the file already exists and the extension sdt will automatically be added to the file name If this is a New file the user will be prompted to enter a file name Save As To save the data file to a new name select Save As from the File menu This displays a dialog box allowing the user to select a folder and enter in a new name for the file The user will be notified if the file exis
35. esponsibility is 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 1995 Systems Engineering Associates Inc All Rights Reserved HSL ANCNF User s Manual CONTENTS 1 General Description 2 5 1 2 5 2 2 5 3 2 5 4 1 1 Features 1 2 Functional Description 1 3 Transfer Jam Detection 1 4 Can Jam Detection 1 5 Timing Signal Failure Detection 1 6 Data Collection 2 Installation 2 1 What s Included 2 1 1 HSL ANCNF for back panel mounting 2 1 2 HSL ANCNF ENCL with NEMA 12 Enclosure _ 2 1 3 HSL ANCNF Options 2 2 HSL ANCNF Installation 2 2 1 Power Required 2 2 2 Mounting and Wiring the HSL ANCNF 2 2 3 Mounting the RSV34 MS1 Resolver 2 3 HSL ANCNF Software Installation 2 3 4 Windows Based Setup Program Installation 2 3 2 DOS Based Setup Program Installation 2 3 8 Application Program Installation 2 3 4 SYSdev Program Development Software Installation 2 4 Tuning the HSL ANCNF 2 4 4 Set Machine Zero 2 4 Set Machine Timing 2 4 3 Verify Location of Infeed and Transfer Sensors _ 2 4 4 Calibrate Number of Shifts to each Station 2 4 5 Set Number of Shifts to Stations 2 4 6 Set Number of Missing Cans for Transfer Jam Alarm 2 5 M4500 P4500 D4591 Installation M4500 Module Installation P4500 Power Supp
36. ew sensor to the transfer sensor for each respective station These numbers are determined when the calibration is performed HSL ANCNF User s Manual SYSTEMS Electronics Group 50 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE The menu selections in this set up menu allow you to set the Number of Shifts variables as well as perform the calibration The menu incorporates the following selections 1 Calibrate Number of Shifts reset calibration counts Used to initiate the calibration mode The calibration mode automatically determines the Calibration Count registers 2 Set Number of Shifts to each Station This allows each station to be individually and manually set When selected prompts for each station are displayed Enter the corresponding Number of Shifts for that station and press enter 3 Auto Set Shifts Shifts set to Calibration Counts This selection copies the Calibration Count registers to the Number of Shifts registers when selected This would be done after the calibration has been performed and the Calibration counts have been determined This is the quickest and easiest way to set the Number of Shifts variables 4 Help Screen This help screen provides a description of the calibration procedure and the definitions of each menu selection HSL ANCNF User s Manual SYSTEMS Electronics Group 5 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE 5 2 SET TRANSFER JA
37. 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 ANCNF User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION Wire the HSL ANCNE 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 M4500 resolver input connector as shown on the electrical schematic 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 The HSL ANCNE 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 and a resolver RSV34 MS1 will have to be mounted in it s place If this is the case refer to the RSV34 MSI resolver data sheet for details on mounting the resolver Note The resolver must make one revolution for each can Use the RSV RSCBLE cable to connect the resolver to the HSL ANCNF Route the resolver cable in a separate conduit away from all other high voltage and control wiring Wire the cable d
38. flanged so far into the current shift and the Total Jams field is the total number of transfer jams for all stations so far into the current shift This display effectively replaces a speed meter and two can counters This screen is always returned to when no commands are active 3 2 JAMS PER STATION KEY The number of transfer jams per station menu is provided to aid in the trouble shooting of a transfer jam problem with a particular station The total number of transfer jams for each station since the last reset or end of shift is displayed The operator can reset these counts at any time to aid in the trouble shooting process The data can be viewed simply be pressing this key The display shows a series of screens each with four stations from 1 through 10 and the flanger as shown below TRANSFER JAMS PER STATION 1 XXxx 2 XXXX 3 XXXX 4 XXXX Where the numbers 1 through 4 are the first 4 stations and the xxxx would be the actual counts for the respective stations Screens for stations 5 thru 8 9 thru flanger are shown in this fashion each for a time delay of 10 seconds In addition the user can advance to the next screen or retard to the previous screen by pressing the NEXT or PREV key respectively The final screen of this menu prompts the user to reset the counts by pressing 0 or not to by pressing ESC This provides the operator with the opportunity to reset the counts if desired for troubl
39. flanger 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 Note All number of shifts entered must be in the range of 1 to 319 except stations 6 thru 10 which may be disabled by entering 0 3 5 2 SET TRANSFER JAM COUNT PRESETS This menu is activated when the 2 key SET TRANSFER JAM COUNT PRESETS is pressed while the primary set up menu is active The following set up parameters may then be adjusted or viewed NUMBER OF MISSING CANS FOR TRANSFER JAM Stations 1 thru 10 and Flanger These variables are the number of consecutive missing cans once cans should be at the transfer sensor for that station as set in the Number of Shifts that will cause a transfer jam for each respective station Each station can be set independently If the Number of missing cans is set to 4 for a particular station a transfer jam will be generated when four or more consecutive missing cans are detected at that station If three or less consecutive missing cans occurred the transfer jam would not be generated The NEXT and PREV keys can be used to advance to the next station or the previous station respectively To change the currently displayed parameter simply enter the new value on the numeric keypad and press ENTER The value will be entered and the next station will automatically be displayed When the number of missing cans for the fla
40. gram Development manual HSL ANCNF User s Manual SYSTEMS Electronics Group 10 SECTION 2 INSTALLATION 2 4 TUNING THE HSL ANCNF The HSL ANCNF is shipped from the factory with the PLC program HSLANF loaded in the M4500 module PLC section and the PLS channel set point file ANCNFTMG loaded in the PLS section These are the standard programs used to implement the standard necker flanger algorithms In addition as shipped the user variables are set to the following defaults Number of Shifts to each station Station 21 020 Station Z2 040 Station Z3 060 Station H4 080 Station 5 100 Station Z6 120 Station Z7 140 Station H8 160 Station Z9 180 Station H10 200 Flanger 220 Number of Missing Cans for Transfer Jam Alarm Station 21 DOS Station Z2 DOS Station Z3 DOS Station H4 005 Station 5 005 Station H6 DOS Station Z7 005 Station Z8 005 Station Z9 DOS Station 210 DOS Flanger 005 The A
41. he Number of Shifts to each sensor see section 3 5 1 Set Number of Shifts to Stations HSL ANCNF User s Manual SYSTEMS Electronics Group 26 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE The Windows based set up program is menu driven allowing the user to easily view data alter set up variables or set machine timing machine offset timing signal locations etc using a PC running the Windows 95 98 ME 2000 XP NT operating system The set up variables are used to configure and tune the M4500 to match the configuration and performance of the specific necker flanger see section 2 4 Tuning the HSL ANCNF Note The set up program is an on line communications program used to interface with the M4500 module The data displayed and set in the windows is communicated directly to the module while in the Online edit mode Therefore prior to going online with the processor make sure an RS 232 cable is connected from the COM port on the computer to the PROG port on the M4500 The variables displayed while in the Online edit mode are read directly from the processor Data is saved to a Set up Data file sdt whenever changes are made to a parameter or if the data is uploaded from the processor amp ANCNF unnamed Main Display O x File Edi View Window Help Messages l Shift Data Machine CPM Current S
42. hift Last Shift Jams Station Transfer Jam 0 Good Cans 123 456 234 567 Total Jams 23 800 34 567 Station 01 11 111 50 normal Station 02 12 112 51 normal Station 03 14 113 53 normal Station 04 14 114 53 normal Station 05 16 115 55 normal Station 06 17 116 56 normal Station 07 17 117 56 normal Station 08 18 118 57 normal Station 09 20 119 59 normal Station 10 20 120 59 normal Fleset Jams Station Station 11 22 121 60 normal Flanger 122 normal End of Shift System Message All Faults Normal ONLINE 4 0 12 2003 2 05 PM Z HSL ANCNF User s Manual SYSTEMS Electronics Group 2 23 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 1 GENERAL DESCRIPTION Title Bar At the top of the window is the Title Bar The title bar is used to display the name of the working Set up Data file as well as the name of the active Window The title bar is dark if the window is active and grayed if another window is active The color depends on the settings of the Display Properties of the Control Panel Status Bar At the bottom of the window is the Status Bar The status bar is used to display system messages online or offline mode as well as the current time and date as set by the operating system The system messages panel displays general information about operation of the system The Online Offline mode panel displays the status of the current set up program mode of operation The mode of
43. ions slot2 84573 SWI switchl OFF SWI switch2 ON Install the 4573 in Slot0 2 slot next to the other 4573 of the M4500 chassis HSL ANCNF User s Manual SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION 5 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 S4516 to the following positions RS 232 selected 4516 SWI switchl ON SW1 switch2 OFF Install the 4516 in Slot0 3 slot next to 4573 of the M4500 chassis 6 Install the cover back over the M4500 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 M4500 chassis 7 Connect the display ribbon cable to the connector on the back of the M4500 Note The connector on the cable is polarized It will only mate with the connector on the M4500 in only one way 8 Mount the M4500 chassis to the HSL ANCNF back panel using four 8 32 screws 9 With power to the P4500 off install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4500 Note The connector on the cable is polarized It will only mate with the connector on the M4500 in only one way 10 Install the respective field wiring a
44. irectly to the 8 pin resolver connector on the M4500 Refer to the electrical control schematic at the back of this manual for details HSL ANCNF User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 3 HSL ANCNF SOFTWARE INSTALLATION Follow the steps below to install either the Windows or DOS based setup programs and PLC application program on a laptop or personal computer used to support the HSL ANCNF control system 2 3 1 WINDOWS BASED SETUP PROGRAM INSTALLATION The Windows based ANCNF setup program is compatible with Windows 95 98 ME 2000 XP operating systems and is used to 1 Setup tune the user adjustable variables 2 Adjust the timing channel set points 3 Download the application program to the M4500 module 4 Download restore or upload save the user setup variables from the M4500 5 View Shift production data and station transfer jams To install the set up software perform the following steps 1 Insert the CD into the drive 2 From the Windows desktop Click Start and then select run 3 From the Run dialog box Click the Browse button 4 Select the drive with CD Select the setup exe file and Click Open and then Ok 5 This will initiate the installation process Follow the instructions that appear on the screen to complete the installation process The ANCNF setup program can be executed from the Systems folder located in Programs HSL ANCNF User s Man
45. lecet Jams Station Station 11 22 121 60 normal Flanger 122 normal End of Shift System Message All Faults Normal ONLINE 10 12 2003 2 05 PM 7 The following is a list of the functions of the Main Display window Messages The Messages display is continuously updated It displays alarm and status messages specific to the M4500 as well as the current Online or Offline status of the set up program By simply scrolling the display the user is able to view all active alarm and status messages If no alarm or status messages are active a default message is displayed Machine CPM This display is only active while Online and displays the current speed of the machine in Cans Per Minute HSL ANCNF User s Manual SYSTEMS Electronics Group 39 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE Current Shift Data This data is the totals so far into the shift This 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 or alternatively could be done at label changes such that the data collected would be for label runs rather than complete shifts This data cannot be reset either from this menu or by the operator only at the end of shift input transition To exit back to the main menu press lt ESC gt 1 Good Cans This is the total number of good cans necked and flanged so fa
46. lp h Comm Port Ctrl M Shift Data Machine CPM Current Shift Last Shift Jams Station Transfer Jam 0 Good Cans 123 456 234 567 Total Jams 23 800 34 567 Station 01 11 111 50 normal 12 112 51 normal Station 03 14 113 53 normal Station 04 14 114 53 normal Station 05 16 115 55 normal Station 06 17 116 56 normal Station 07 17 117 56 normal Station 08 18 118 57 normal Station 09 20 119 59 normal Station 10 20 120 59 normal Reset Jams Station Station 11 22 121 60 normal Flanger 122 normal End of Shift System Message All Faults Normal ONLINE 10 12 2003 2 09 PM 7 4 3 1 ENABLE OFFLINE EDITING This function allows the user to perform Offline editing on the currently loaded set up data file This allows the user the ability to make any necessary changes to the set up parameters while not online with the processor If offline editing is not enabled the user is only able to view the set up parameters and shift data When the program is first invoked the default setting is offline editing disabled The user will need to specifically select Enable Offline Editing from the edit menu or press function key F2 to enable disable this feature HSL ANCNF User s Manual SYSTEMS Electronics Group 33 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 3 2 SETUP COMM PORT This function allows the
47. ly Installation D4591 Keypad Display Installation Download Application Program and Set up Data to M4500 SYSTEMS Electronics Group WWNNN a o 0 O al NOOO OD HSL ANCNF User s Manual 3 Using the Keypad Display 4 3 1 3 2 3 3 3 4 3 5 Default Screen Jams per Station Key Current Shift Key Last Shift Key Set Up Key 3 5 1 Set Number of Shifts to Stations 3 5 2 Set Transfer Jam Count Presets 3 5 3 Set Machine Timing Set Points etc 3 5 4 Zero Machine Set Resolver Offset 3 5 5 Calibrate Number of Shifts to Stations ANCNF Windows Based Set up Program Reference 4 1 4 2 4 3 44 4 5 General Description The File Menu 4 2 1 The Set Up Data File 4 2 2 Upload save Data 4 2 3 Download Program 4 2 4 Download restore Data 4 2 5 Print Report The Edit Menu 4 3 1 Enable Offline Editing 4 3 2 Setup Comm Port The View Menu 4 4 1 Target Board Interface 4 4 2 View Online Data 4 4 3 View Offline Data The Window Menu 4 5 1 The Main Display Window 4 5 2 The Setup Parameters Window 4 5 3 The Machine Timing Window 4 5 4 The Serial Communications Window 4 5 5 Thel O States Window CONTENTS SYSTEMS Electronics Group ii CONTENTS 5 HSLANCNF DOS Based Set up Program Reference 49 5 1 Set Number of Shifts to Necker Stations Flanger 50 5 2 Set Transfer Jam Alarm Count Presets 52 5 3 Set Machine Timing 53 5 3 1 Zeroing the Machine 54 5 3 2 Adjusting
48. ly double clicking on the Online or Offline panel displayed in the status bar at the bottom of the window Once invoked the set up program will close the Comm port and cease communication with the M4500 HSL ANCNF User s Manual SYSTEMS Electronics Group 37 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 THE WINDOW MENU The Window menu allows the user to select one of five different Display Set up windows to modify set up parameters view shift data or receive feedback about the current status of the control system amp _ANCNF unnamed Main Display ml xl File Edi View window Help Set up Parameters 3 Machine Timing 4 Serial Communications 51 0 States Shift Data Machine CPM Current Shift Last Shift Jams Station Transfer Jam 0 Good Cans 123 456 234 567 Total Jams 23 800 34 567 Station 01 11 111 50 normal Station 02 12 112 51 normal Station 03 14 113 53 normal Station 04 14 114 53 normal Station 05 16 115 55 normal Station B 17 116 56 normal Station 07 17 117 56 normal Station 08 18 118 57 normal Station 09 20 119 59 normal Station 10 20 120 59 normal an Station 11 22 121 60 normal Flanger 122 normal End of Shift System Message All Faults Normal ONLINE 1 0 12 2003 21 PM 7 Once a window menu item is selected a check mark is placed next to the selec
49. nger 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 ANCNF User s Manual SYSTEMS Electronics Group 2203 SECTION 3 USING THE KEYPAD DISPLAY 3 5 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 zz OFFSET wwww SCALE 360 Each field is defined as follows Field Definition Chuu Currently selected channel CH00 thru CH07 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 TRANSFER TIMING CH01 PLC CLOCK 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
50. nter 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 4 Exit back to the primary set up menu by pressing lt ESC gt Press lt ESC gt again to exit back to the default screen 2 4 2 SET MACHINE TIMING Set the Transfer Jam timing signal CH00 such that it transitions from off to on when cans are centered in the middle of the transfer sensors and infeed sensor Although only the leading edge off to on transition is used CH00 should still be programmed ON for at least 40 degrees The PLC Can Clock CHO1 is provided for the host PLC as a general timing signal to clock once per can and is not used by the control system CHO1 should be programmed on for 180 degrees and off for 180 degrees but can otherwise be programmed to start anywhere as desired HSL ANCNF User s Manual SYSTEMS Electronics Group 12 SECTION 2 INSTALLATION 2 4 3 VERIFY LOCATION OF INFEED AND TRANSFER SENSORS The infeed and Transfer sensors must turn on at least 50 degrees before the off to on transition of the Transfer Timing signal CH00 and must be on at least 20 degrees after this same location This guarantees that the cans will be clocked in properly by each sensor All the transfer sensors and infee
51. of good cans necked and flanged so far into the shift This is essentially a can counter Total Transfer Jams This is the total number of transfer jams for all stations of the machine Station 01 jams thru Flanger Jams This is the total transfer jams for each station A disproportionately high count for a particular station indicates a transfer jam problem for that station HSL ANCNF User s Manual SYSTEMS Electronics Group 57 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE 5 6 LAST SHIFT DATA The Last Shift data is identical to the current shift data except it is for the previous 8 or 12 hour shift or previous label run how ever the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period 5 7 DOWNLOAD PROGRAM TO M4500 This selection is used to download the HSLANCNF application program to the M4500 module This should only be performed when replacing the M4500 or when the program has been changed To download the program perform the following Note Program download cannot be performed while the necker flanger is running All outputs on the M4500 are turned off and no program execution is performed Transfer jam detection would not take place such that if a jam did occur the machine would not be stopped The necker flanger should therefore be stopped while the download takes place 1 Connect the RS 232 cable from the COM port on the
52. of transfer jams number of transfer jams per station 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 can count total jams transfer jams per station by operator and set up of all user variables key switch enabled by authorized personnel e Interfaces directly with machine mounted resolver infeed screw sensor transfer sensors all stations and Calefi 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 HSL ANCNF User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 2 FUNCTIONAL DESCRIPTION The HSL ANCNF Necker Flanger high speed control package is an electronic upgrade package for the ANC necker flanger which detects transfer jams all stations can jams all stations and Calefi valve control In addition the package provides timing signal failure detection and data collection including Total good can count total number of transfer jams and transfer jams per station both for the current shift and previous last shift The package interfaces directly to the machine mounted resolver infeed screw sensor transfer sensors and Calefi solenoids as well as the host PLC via discrete DC I O The package is n
53. ogram in an Online mode with the processor This is accessed by the View menu by selecting Online Data or by simply pressing the F3 function key Note The program can be toggled between Offline and Online by simply double clicking on the Online or Offline panel displayed in the status bar at the bottom of the window Once invoked the set up program will attempt to open the Comm port and communicate with the M4500 If the set up program is unsuccessful a warning message will be displayed prompting the user to either Retry or Cancel the operation If the operation is canceled and communication with the processor cannot be established the system will be placed in an Offline edit mode Note Anytime while the set up program is Online with the processor and communication is interrupted a warning message will be displayed prompting the user to either Retry or Cancel the operation 4 4 3 VIEW OFFLINE DATA This function allows the user to place the set up program in an Offline mode This is accessed by the View menu by selecting Offline Data or by simply pressing the F4 function key This allows the user to perform Offline editing All values displayed in Offline edit mode reflect the actual values contained in the currently loaded set up data file Note The program can be toggled between Online and Offline by simp
54. om the M4500 are mapped as follows W34 Xfer Check Enables to MODICON 4x address 401719 in MODICON B34 0 F16 thru B34 7 F23 B35 0 F24 B35 1 F25 B35 2 F26 B35 3 F27 B35 4 F28 Station 1 Xfer Check shift to Station 1 Station 8 Xfer Check shift to Station 8 Station 9 Xfer Check shift to Station 9 Station 10 Xfer Check shift to Station 10 Station 11 Xfer Check shift to Station 11 Flanger Xfer Check shift to Flanger Infeed Shift In first bit of shift register HSL ANCNF User s Manual SYSTEMS Electronics Group A 2 APPENDIX A MODBUS COMMUNICATIONS DATA READ FROM THE MODICON PLC The following data is read from the MODICON PLC MODICON Dest M4500 Source 4x Address Data Definition Address 401760 Status from MODICON W792 The bits of the Status Control register from the MODICON to M4500 are mapped as follows W792 Status from MODICON 4x address 401760 in MODICON B792 0 End of Shift 1 End of Shift B792 1 Not Used thru B793 7 Not Used Note Setting Bit0 above to a 1 will reset the Current shift data in the M4500 passed to MODICON addresses 401702 thru 401717 Prior to setting BitO save this data to the previous shift buffer in the MODICON if desired Bit0 would be set to a 1 for at least 5 seconds at the end of shift then set back to a 0 HSL ANCNF User s Manual SYSTEMS Electronics Group A 3
55. on 2 0 Number of Shifts to Each Necker Station Flanger 1 Calibrate Number of Shifts reset calibration counts 2 Set Number of Shifts to each Station 3 Auto Set Shifts Shifts set to Calibration Counts 4 Help Screen Enter Selection ESC to exit Number of Shifts Calibration Count Station H1 025 Station H1 020 Station H2 040 Station H2 040 Station 3 060 Station 3 060 Station 4 080 Station 4 080 Station H5 100 Station H5 100 Station H6 120 Station H6 120 Station 7 140 Station 7 140 Station 8 160 Station 8 160 Station 9 180 Station H9 180 Station H10 200 Station H10 200 Station 11 220 Station 11 220 Flanger 240 Flanger 240 Total Count 240 Number of Shifts Stations 1 thru 10 and Flanger This is the number of shifts from the infeed screw sensor to the transfer sensor for each station These numbers can be determined using the calibration mode or they could be counted manually 1f desired The range of values for these numbers is 1 to 319 In addition the transfer jam detection for stations 6 thru 10 can be disabled by setting the number of shifts for the respective station to 0 stations 1 thru 5 and the flanger cannot be disabled This would be done on machines not equipped with these stations Calibration Count Stations 1 thru 10 and Flanger These are the actual number of shifts from the infeed scr
56. on on the Transfer Jams Per Station menu allows you to reset the transfer jams per station counts The selection is listed below 1 Reset Jams per Station Counts To reset the station jam counts simply press 1 The counts will be reset in the M4500 To exit back to the main menu press lt ESC gt HSL ANCNF User s Manual SYSTEMS Electronics Group 56 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE 5 5 CURRENT SHIFT DATA The Current shift data menu displays the following information e HSLANF EXE inl xi Systems HSL ANCNF Set up Menu Version 2 0 Current Shift Totals so far Press ESC to return to main menu Total Good Cans Processed Total Transfer Jams for all stations 23800 Number of Transfer Jams for each station Station 1 Station Station Station Station Station Station Station Station Station Station Flanger This data is the totals so far into the shift This 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 or alternatively could be done at label changes such that the data collected would be for label runs rather than complete shifts This data cannot be reset either from this menu or by the operator only at the end of shift input transition To exit back to the main menu press lt ESC gt Total Good Cans Processed This is the total number
57. ot a dedicated black box but is instead implemented using the high performance SYSTEMS M4500 PLC PLS module This allows easy customization by either SEA or the end user The M4500 module is programmed using the DOS based SYSdev programming package This 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 TRANSFER JAM DETECTION The transfer jam detection is implemented as follows Transfer jam detection for each station is enabled a user settable number of shifts after the infeed screw sensor has detected the first can fed into the machine At this point if a user settable number of missing cans is detected a transfer jam is generated for that station This is signaled to the host PLC via discrete I O and the machine stopped This detection is performed for necking stations 1 thru 10 and the flanger The transfer jam detection can individually be disabled for machines not equipped with these stations 1 4 CAN JAM DETECTION The can jam detection is implemented as follows If the transfer sensor for a corresponding station is covered for a time delay once the machine is running a can jam alarm is generated for that station These alarms are available
58. owever 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 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 ENTER The channel will now be programmed with a set point that goes on at the on position entered and off at the off position entered 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 ANCNF User s Manual SYSTEMS Electronics Group 25 SECTION 3 USING THE KEYPAD DISPLAY 3 5 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 Select 3 SET MACHINE TIMING and observe the POS field Verify that as the machine is rotated forward 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
59. 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 8 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 HSLANCNF main menu HSL ANCNF User s Manual SYSTEMS Electronics Group 59 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE 5 9 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 The set up data consists of the number of shifts to each station and the number of missing cans for transfer jam alarm for each station Timing channel set points are not stored as part of the set up data To upload the set up data
60. play can be used by the operator to view data and can be used by authorized personnel key switch protected to adjust the timing and all set up parameters SYSTEMS XQ ELECTRONICS GROUP INC MACHINE SPEED CPM 0000 GOOD CANS O TOTAL JAMS O JAMS ENTER STATION up EUN CHAN 1 2 5 ENTER cune m 4 5 6 s NEXT in em zlselej o The display keypad allows the following to be viewed or adjusted 1 Set Number of Shifts to Stations 2 Set Transfer Jam Count Presets 3 Set Machine Timing 4 Set Machine Zero 5 View the Number of Transfer Jams per Station 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 HSL ANCNF User s Manual SYSTEMS Electronics Group 19 SECTION 3 USING THE KEYPAD DISPLAY 3 1 DEFAULT SCREEN The default screen displayed when no other commands are active contains the following data MACHINE SPEED CPM xxxx GOOD CANS xxxxxxx TOTAL JAMS xxxxxx Where the Machine Speed is the current speed of the necker flanger the Good Cans field is the total number of good cans necked and
61. r into the current shift This is essentially a can counter 2 Total Jams This is the total number of transfer jams for all stations of the machine 3 Station 01 Jams thru Flanger Jams This is the total transfer jams for each station A disproportionately high count for a particular station indicates a transfer jam problem for that station Last Shift Data The Last Shift data is identical to the current shift data except it is for the previous 8 or 12 hour shift or previous label run how ever the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period Jams Per Station Data The number of transfer jams per station is provided to aid in the trouble shooting of a transfer jam problem with a particular station The total number of jams for each station since the last reset or end of shift is displayed The user can reset these counts at any time by clicking on the Reset Jams Station button to aid in the trouble shooting process Transfer Jam Alarms The state of the station transfer jam alarm status is indicated here If a station is in alarm the text will display ALARM otherwise the text will display normal This data is only available while the setup program is Online HSL ANCNF User s Manual SYSTEMS Electronics Group 40 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 2 THE SETUP PARAMETERS WINDOW The Set up Parame
62. r to download 4 2 5 PRINT REPORT The Set up program allows the user to generate a Report printout of all the set up parameters timing channel set points and shift data This function is accessed from the File menu At the top of each page the report displays the name of the set up file being printed At the bottom of each page is the date and time the data was uploaded as well as the page number To printout a report of the settings contained in the set up Data File perform the following 1 From the File menu select Print Report or press Ctrl P If the user is currently Online with the processor the current values inside the processor will be automatically uploaded 2 The Print Setup dialog box will then be displayed allowing the user to select a printer as well as the paper size and orientation Once the user selects OK the report is generated and sent to the specified printer device Note This function makes use of the windows print manager which allows the user to continue with their work while the document is being printed HSL ANCNF User s Manual SYSTEMS Electronics Group 332 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 3 THE EDIT MENU The Edit menu allows the user to perform the following functions e Enable Disable Offline Editing e Set up the Comm Port amp ANCNF unnamed Main Display Ol x File Edit View Window He
63. rms on all the I O boards of the M4500 I O slotsO thru 2 MODBUS connector on USER PORT resolver connector and INO IN1 connector Make sure all the field wiring connectors are fully mated HSL ANCNF User s Manual SYSTEMS Electronics Group 16 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 ANCNF 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 Note The connector on the cable is polarized It will only mate with the connector on the M4500 in 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 mounting studs of the D4591 install the D4591 in the cut out either in the HSL ANCNF enclosure or the cut out in the user s existing control cabinet refer to the mechanical layout drawing at the back of the manual 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 ANCNF User s Manual SYSTEMS Electronics Group 17 SECTION 2 INSTALLATION 2 5 4 DOWNLOAD APPLICATION PROGRAM A
64. rough 359 degrees If not swap the S1 and S3 leads at the resolver connector on the M4500 Then verify that the position does indeed increase with forward movement Position the machine at machine Auto zero the resolver by entering 0 in the Resolver Offset field and clicking the Set Offset command button A message box will appear prompting the user to confirm their choice Select Yes to set the resolver offset The M4500 will calculate the actual offset value required to make this the 0 position The new offset value will be displayed in the Offset field and the position will then read zero HSL ANCNF User s Manual SYSTEMS Electronics Group 44 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE Adjusting the Timing Channel Set points To set any of the timing signal set points perform the following Note Any changes made to the timing channel set points will be saved as part of the setup data file 1 Connect an RS 232 SYSdev cable from the COM port on the computer to the PROG port on the M4510 2 From the Window menu select Machine Timing 3 From the View menu select Online Data The set up program will attempt to communicate with the processor and place the system into an Online mode of operation 4 Set all channels per the section 6 General Timing Signal Locations Set points for a particular channel are either entered in the field or
65. ser s Manual SYSTEMS Electronics Group 29 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 1 THE SET UP DATA FILE The set up Data File sdt is a binary access file designed for fast file I O operation When the set up program is first invoked the default set up parameters are loaded into memory If changes are made to any of the set up parameters either online or offline as well as shift data the user will be flagged to Save Changes upon exit of the program Note Any windows based Set up program can open a set up Data File however the data tables will not be properly aligned The user will be alerted to the problem if a set up data file has been created by either a different set up program or a different revision of the software The set up Data File is similar to that of a word processing file When the program first starts a default file is loaded and the user is able to make any changes as desired The set up program is unaware of the settings and parameters that exist within the M4500 Therefore to normalize the set up program with the processor the user should define or open an existing file then upload All variables from the processor This allows the user to either create a backup of the data or maintain an existing file The user can even open a data file for another necker flanger save the file to a new name make the necessary changes and simply download the new paramet
66. ted item and the selected window is displayed with the name changed in the title bar of the main window Note Read only variables are displayed in blue with a gray background Any variables that can be altered by the user are displayed in black with a white background In most cases a parameter that can be changed by the user will have associated with it increment and decrement controls The user can either click on the desired parameter to adjust and enter in a new value or use the increment or decrement controls to change the value by 1 unit HSL ANCNF User s Manual SYSTEMS Electronics Group 38 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 1 THE MAIN DISPLAY WINDOW The Main Display window is used to display the general state of the control system This window is selected from the Window menu amp ANCNF unnamed Main Display Ol xl File Edi View Window Help Messages Shift Data i Machine CPM Current Shift Last Shift Jams Station Transfer Jam 0 Good Cans 123 456 234 567 Total Jams 23 800 34 567 Station 01 11 111 50 normal Station 02 12 112 51 normal Station 03 14 113 53 normal Station 04 14 114 53 normal Station 05 16 115 55 normal Station B 17 116 56 normal Station 07 17 117 56 normal Station 08 18 118 57 normal Station 09 20 119 59 normal Station 10 20 120 59 normal F
67. ters window is used to view and adjust any of the set up parameters This window is selected from the Window menu amp ANCNF unnamed Set Up File Edit View Window Help loj xi Station 01 Number of Shifts to Station a 4 Station 02 40 a Station 03 60 a Station 04 80 a Station 05 100 lt Station 06 120 a Station 07 140 a Station 8 Station 09 Station 10 Station 11 Flanger S 160 fd a 180 d 200 2d 220 Ir 2 240 I Total Count Calibration Count E s e EEEE 40 rl nfl 2 N Sj cof m oo Ol O 3 Le 240 s ystem Message All Faults Normal Number of Missing Cans for Transfer Jam Alarm 5 E M Transfer Jam Enable 5 M Transfer Jam Enable 5 a M Transfer Jam Enable 5 5 M Transfer Jam Enable 5 M Transfer Jam Enable 5 E M Transfer Jam Enable 5 E M Transfer Jam Enable 5 q M Transfer Jam Enable 5 E M Transfer Jam Enable 5 E v Transfer Jam Enable 5 E M Transfer Jam Enable Number of Shifts to Station Calibrate Number of Shifts Auto Set Shifts ONLINE 10 12 2003 2 11PM y Number of Shifts Stations 1 thru 10 and Flanger This is the number of shifts from the infeed screw sensor to the transfer sensor for each station These numbers can be determined using the calibration mode or they could be counted manually if desired The range of values for these numbers is 1 to 319 In
68. the Timing Channel Set points 55 5 4 Number of Transfer Jams per Station Data 56 5 5 Current Shift Data 57 5 6 Last Shift Data 58 5 7 Download Program to M4500 58 5 8 Download Set up Data to M4500 59 5 9 Upload Save Set up Data from M4500 60 6 General Timing Signal Locations 61 7 Recommended Spare Parts 63 HSL ANCNF User s Manual SYSTEMS Electronics Group iii HSL ANCNF User s Manual Keypad Display Legend MODBUS Communications MODBUS Port Configuration Data Written to the MODICON PLC Data Read from the MODICON PLC Drawings iv CONTENTS LIST OF FIGURES 19 APPENDICES Appendix A A 1 A 1 A 3 Appendix B SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 1 FEATURES e Performs high speed control functions of ANC Necker Flanger This includes transfer jam detection can jam detection and Calefi valve control e High speed front end upgrade package which interfaces with existing control system e Performs the following control functions 1 Detection of transfer jams Stations 1 thru 10 and Flanger 2 Detection of can jams Stations 1 thru 10 and Flanger 3 Auto Calibration mode to determine number of stations from infeed screw sensor to transfer sensors of each station 4 Individually adjusted number of missing cans for transfer jam alarm for each station 5 Timing signal fail detection 6 Data Acquisition Total number of good cans necked and flanged total number
69. the calibration mode will be exited The Calibration Count numbers are saved in battery backed RAM and can be used at a latter time if desired They are only reset when the calibration mode is entered Note The calibration counts are only accurate if the following conditions are true e All the transfer sensors are fully functional and located properly e Nocans fail to transfer properly transfer jam while the calibration takes place If a jam does occur or any sensor fails to operate properly the problem will need to be corrected and the calibration performed again HSL ANCNF User s Manual SYSTEMS Electronics Group 13 SECTION 2 INSTALLATION 5 The Calibration Counts are not automatically copied to the Number of Shifts to each station variables at the end of the calibration The user must copy the Calibration Counts over to the Number of Shifts manually This allows the user to review the Calibration Counts for reasonableness prior to setting the Number of Shifts variables 2 4 5 SET NUMBER OF SHIFTS TO STATIONS The Number of Shifts to each necker flanger station are the presets used in the transfer shift register to enable the transfer jam detection When the infeed screw sensor first sees cans each station will then expect to see cans the corresponding number of shifts latter These numbers can be set from the set up menu of the HSL ANCNF Keypad Display or using the set up progr
70. to exit back to the PLS Main Development Menu Press lt ESC gt again to exit back to the HSLANCNF set up main menu The new channels will be saved both in the M4500 and in the ANCNFTMG file on the hard drive HSL ANCNF User s Manual SYSTEMS Electronics Group 55 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE 5 4 NUMBER OF TRANSFER JAMS PER STATION DATA The number of transfer jams per station menu is provided to aid in the trouble shooting of a transfer jam problem with a particular station The total number of jams for each station since the last reset or end of shift is displayed The operator can reset these counts at any time to aid in the trouble shooting process This menu is invoked by selecting 4 Number of Transfer Jams per Station from the Main Menu HSLANF_EXE m x Systems HSL ANCNF Set up Menu Version 2 0 Transfer Jams per Station Menu 1 Reset Jams per Station counts Enter Selection ESC to exit Number of Transfer Jams for each station Station 1 90 Station 2 91 Station ooo Station i4 O Station nO Station 6 96 Station Has DO Statron oaeo o N Station Hoc 99 Station 10 59 Station 11 Elangersie ees ace 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 The menu selecti
71. ts and the extension sdt will automatically be added to the file name Export Shift Data This function allows the user to export the shift data to a Tab Delimited text file This allows the user to easily use the shift data to produce production reports HSL ANCNF User s Manual SYSTEMS Electronics Group 30 SECTION 4 ANCNF WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 2 UPLOAD SAVE DATA The Set up program allows the user set up parameters timing channel set points and shift data from the M4500 into a set up Data File This function is accessed from the File 4 2 3 DOWNLOAD PROGRAM The Set up program allows the user to Download any SYSdev program file to the M4500 Note To Download a SYSdev program to the processor the program must be Online If Online mode cannot be achieved program download will not be executed If the program is currently Offline the user will be prompted to first go Online Once selected and the set up program Online with the processor a dialog box will be displayed allowing the user to select the SYSdev file to download Note Only the files with the sdv file extension will be displayed It is important to keep in mind that only a valid M4500 PLC SYSdev file can be downloaded through the set up program Care should be taken when selecting a program to download Once selected a message box is displayed informing th
72. ual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 3 2 DOS BASED SET UP PROGRAM INSTALLATION The DOS based HSLANF set up software is used to 1 Download the application program to the M4500 module 2 Tune set up the user adjustable variables of the HSL ANCNF 3 Download and upload save the user setup variables from the M4500 to disk 4 View jams per station and shift data To install the set up software perform the following steps 1 Create a directory off the root for each necker flanger These will be used to store the HSLANCNF EXE setup programs and HSLANCNF set up data for each machine Create these directories by typing the following at the DOS prompt MD HSLNF1 lt ENTER gt MD HSLNF2 lt ENTER gt MD HSLNF3 lt ENTER gt etc 2 Install the PROGRAMS into the drive For each HSLNF directory you created switch to that directory and install the HSL ANCNF set up programs by typing the following at the DOS prompt Line 1 necker flanger is shown CD HSLNF1 lt ENTER gt A INSTALL lt ENTER gt 3 Add each necker flanger s HSL ANCNF set up program to your computer s menu software by creating a selection for each necker flanger called SET UP N F LINE1 for the line 1 necker flanger SET UP N F LINE2 for the line 2 necker flanger etc The DOS commands executed for these selections should be Line necker flanger is shown For the SET UP N F LINE1 selection CD MH
73. you to set the presets for each station 1 Set Number of Missing Cans for Transfer Jam Alarms This allows each station to be individually and manually set When selected prompts for each station are displayed Enter the corresponding Number of Missing Cans for Transfer Jam Alarm for that station and press enter 2 Help Screen This is a help screen for the Number of Missing Cans for Transfer Jam Alarm menu providing a description of the these parameters HSL ANCNF User s Manual SYSTEMS Electronics Group 52 SECTION 5 HSLANCNF DOS BASED SETUP PROGRAM REFERENCE 5 3 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 ANCNFTMG 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 6 General Timing Signal Locations provides a complete description of each timing signal HSLANF EXE Of x Systems PLS Program Development PLSdev M4500 Version 4 2 Program Name ANCNFTMG Main Development Menu Online Channel Setpoint Programming Offline Channel Setpoint Programming Edit PLS Configuration Download Channels to PLS Upload Channels from PL

User`s manual complete - Sea

Contents

Download Pdf Manuals

Related Search

Related Contents