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HSM-CUP7 Cupper High Speed Logic Module User`s Manual

1. 2 3 4 5 Select 3 SET MACHINE TIMING and observe the POS field Verify that as the machine is rotated forward either inched or barred that the position increases linearly from 0 through 359 If not swap the S1 and S3 leads of the resolver at the HSM CUP7 resolver connector Then verify that the position then indeed does increase with forward movement Press lt ESC gt to exit back to the primary set up menu Position the machine at machine zero top dead center Auto zero the resolver by selecting 4 ZERO MACHINE from the primary set up menu Enter 0 to zero the resolver The timing set up menu will be displayed now showing the POS at zero The M4500 will calculate the actual offset value required to make this the 000 position and will display this number in the offset field Exit back to the primary set up menu by pressing lt ESC gt Exit back to the default screen by pressing lt ESC gt again SYSTEMS Electronics Group 33 SECTION 3 USING THE KEYPAD DISPLAY HSM CUP7 User s Manual 3 6 SET KEYPAD DISPLAY SET UP PASSCODE The Set Passcode input to the HSM CUP7 is used to set or view the passcode of the set up menu Normally this input should be off To set the passcode jumper this input to 24VDC and press the Set Up key The ENTER PASSCODE prompt will be displayed along with the current passcode This allows the passcode to be viewe
2. 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 from the Edit menu Getting Help The entire 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 HSMCUP7 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 HSM CUP7 User s Manual SYSTEMS Electronics Group 36 SECTION 4 HSMCUP7 WINDOWS BASED SET UP 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 chan
3. Remove the supplied field wiring connectors from the new module and install the new module and replace the 8 32 nuts and lock washers 7ea Install the existing pre wired field wiring connectors on all the I O boards of the module 115VAC power connector I O slots0 and 1 resolver connector and INO IN1 connector Make sure all field wiring connectors are fully mated Apply 115VAC and 24VDC power to the module and verify that the PWR and RUN LEDs on the module are ON and the FLT LED is off Connect an RS 232 cable from the computer COM port to the PROG port on the HSM CUP7 Execute the HSMCUP7 set up program Download the PLS timing set points to the module See section 4 2 4 Windows set up program reference or section 5 2 DOS set up program reference for details Download the previously saved to disk set up data to the module See section 4 2 4 Windows set up program reference or section 5 5 DOS set up program reference for details The HSM CUP7 is now ready to run loaded with the HSMCUP7 timing set points and set up data that was previously saved for the respective cupper SYSTEMS Electronics Group 24 HSM CUP7 User s Manual SECTION 3 USING THE KEYPAD DISPLAY The keypad of the HSM CUP7 contains 24 keys consisting of data display commands set up commands and a numeric keypad The display of the HSM CUP7 is a 2 line by 40 character back lit LCD display which d
4. This can be used to help trouble shoot a die problem on a particular station by observing an excessive number of die jams or cup jams for that station Note The Current shift Stroke Count and Total Die Jams is displayed as part of the default screen see section 3 1 3 4 LAST SHIFT KEY The Last shift data menu displays e The Total Stroke Count e The Total Die Jams Cup Jams Fault Counts Per Station This data is the totals for the last previous shift This is transferred from the current shift when the end of shift input transitions from a 0 to a 1 This can be at the end of either an 8 or 12 hour shift This data cannot be reset by the operator only at the end of shift transition The Last shift data is defined as follows Strokes This is the total number of strokes made for the previous shift This is essentially a counter Die Jams This is the total number of die jam or cup jam faults that occurred for all stations on the previous shift Die Jams Cup Jams per Station This is the number of die jam or cup jam faults that occurred on each station on the previous shift HSM CUP7 User s Manual SYSTEMS Electronics Group IT SECTION 3 USING THE KEYPAD DISPLAY HSM CUP7 User s Manual 3 5 SET UP KEY This selection is used to invoke the primary set up menu This consists of the following four selections 1 SET CUPPER PARAMETERS 2 SET LUBRICATOR PARAMETERS
5. USING THE KEYPAD DISPLAY HSM CUP7 User s Manual 3 1 DEFAULT SCREEN The default screen displayed when no other commands are active contains the following data MACHINE SPEED SPM xxxx POSITION xxx STROKES xxxxxxx DIE JAMS xxxxxx e The Machine Speed is the Current Speed of the Cupper in strokes per minute e The Position is the Current Angular Position of the Cupper Crankshaft in degrees e The Strokes Field is the Total Number of Strokes so far into the current shift e The Die Jams Field is the Total Number of Die Jams or Cup Jams for All Stations so far into the current shift This display effectively replaces a speed meter a position display and two counters This screen is always returned to when no commands are active 3 2 BRAKE RESPONSE KEY This displays the brake response for both Low and High speed stops The response is the number of degrees it takes the press to stop from when the clutch is de activated for a TDC stop to the position that the machine comes to rest This can be used to determine the general condition of the brake and whether servicing of the brake is required To exit back to the default screen simply press the ESC key SYSTEMS Electronics Group 26 SECTION 3 USING THE KEYPAD DISPLAY 3 3 CURRENT SHIFT KEY The Current shift menu displays e The Number of Die Jams Cup Jams Per Station for the Current Shift
6. 5 5 Download Set up Data to Module 72 5 6 Upload save Set up Data from Module 73 6 General Timing Signal Locations 75 7 Recommended Spare Parts 77 HSM CUP7 User s Manual SYSTEMS Electronics Group iii HSM CUP7 User s Manual CONTENTS LIST OF FIGURES Figure 1 HSM CUP7 Recommended Panel Door Cut out 10 Figure 2 Cup Drop Timing Sequence 21 Keypad Display Legend 25 APPENDICES Drawings Appendix A SYSTEMS Electronics Group iv HSM CUP7 User s Manual SECTION 1 GENERAL DESCRIPTION This section describes the features of the HSM CUP7 Cupper High Speed Logic module This includes the functional description alarms detected interlocks between the module and the existing control system etc 1 1 FEATURES e Performs high speed control functions of Cupper to speeds in excess of 300 SPM This includes clutch control air strip control as well as die protection die jam and cup jam detection e Rapid response control of clutch brake system for emergency stops die protection as well as precise TDC stops The clutch solenoid outputs of the HSM CUP7 are not intended as safety contacts for the cupper clutch and must not be the only interrupt to the clutch solenoids e Accurate die jam no cup drop and cup jam detection for up to 16 out presses e Highly repeatable air strip control to reduce die jam problems e Brake Wear compensation Auto TDC timing programming algorithm to stop press at TDC re
7. 60 HSM CUP7 User s Manual SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE 3 Die Jams Cup Jams per Station This is the number of die jam or cup jam faults that occurred on each station on the shift 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 however the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period E HSMCUP unnamed Shift Data PE HEEEER 44414444 SYSTEMS Electronics Group 61 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual 4 5 6 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 HSMCUP unnamed 170 Status SYSTEMS Electronics Group 62 HSM CUP7 User s Manual SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE The DOS based HSMCUP7 set up program is menu driven program allowing the user to easily view data or alter set up variables using a laptop or personal computer In addition to setting the set up variables it can be used to download
8. Enter selection 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 provides a complete description of each timing signal Note Prior to selecting the Machine Timing selection make sure the RS 232 cable is connected from the COM port on the computer to the PROG PORT on the HSM CUP7 HSM CUP7 User s Manual SYSTEMS Electronics Group 66 HSM CUP7 User s Manual SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE 5 2 1 ZERO THE MACHINE To set the machine zero resolver offset perform the following 1 Select the 2 Set Machine Timing selection from the HSM CUP7 set up program main menu 2 Select 1 Online Channel Setpoint Programming from the Main Development menu e hsmcup7 EXE Of x CHANNEL 00 DESCRIPTION TDC HIGH TIMING PROG MODE ONLINE CHANNEL SET POINTS ON OFF ON OFF ON OFF ON OFF ON OFF 0120 0140 u ila 41 1 2 3 4 De 6 e 8 9 E S El ES leal 00 A ES EAE PER SE EA ET pe eed ES EE ane Dela al es 1 O ANA SCALE FACTOR 360 MESSAGE Position 096 Speed RPM 0000 OFFSET 000 3 Select F9 POS RPM and observe the POS field Verify that as the machine is rotated forward either inching or barred that the position in
9. the cupper is running at the speed entered in Lubricator Maximum Speed the analog output will be at 10 volts Lubricator Idle Minimum Speed This parameter determines the speed the lubricator will run at when the cupper is stopped de clutched Note When the cupper is running the lubricator speed reference is proportional as set by the Lubricator Maximum Speed scaling to the speed of the cupper This parameter is used to provide the speed reference when the cupper speed is zero for lubricator jog etc See section 3 5 2 Using the Keypad Display section 4 5 2 Windows set up program reference or section 5 1 4 DOS set up program reference for details on setting the set up parameters HSM CUP7 User s Manual SYSTEMS Electronics Group 20 SECTION 2 INSTALLATION 2 8 4 SET MACHINE ZERO Inch the cupper up to top dead center TDC and set the HSM CUP7 resolver offset See section 3 5 4 Using the Keypad Display section 4 5 4 Windows set up program reference or section 5 2 1 DOS set up program reference for details on setting machine zero 2 8 5 VERIFY LOCATION OF CUP DROP WINDOW CHO06 By inching the machine verify that the Cup Drop Window timing CH06 of the HSM CUP7 first turns on at the point where the cups are first freed from the punches see figure 2 This is the earliest point the sensors might see the cups drop The Cup Drop Window should then be set to stay o
10. 3 SET MACHINE TIMING SET POINTS ETC 4 ZERO MACHINE SET RESOLVER OFFSET When selected each of the above selections will bring up a sub menu with the corresponding set up parameters The following sections describe these sub menus and the definitions of the corresponding variables To select the respective set up sub menu simply press the corresponding numeric key 1 thru 4 Note The primary set up menu is passcode protected When the set up key is first depressed an ENTER PASSCODE prompt is displayed At this point a 5 digit passcode must be entered followed by pressing the lt ENTER gt key If the passcode is correct the primary set up menu is displayed and any of the parameters accessed by this menu may be changed If the passcode is incorrect the message INCORRECT PASSCODE will be displayed The passcode may be entered again or the lt ESC gt key can be pressed to return to the main menu When the passcode is entered the digits entered are not displayed Instead characters are displayed as each digit is entered This prevents observation of the passcode as it is entered In addition the ENTER PASSCODE prompt is only displayed for a maximum of 60 seconds The correct passcode must be entered within a 60 second period otherwise the set up mode is aborted and the main menu is displayed Refer to section 3 6 Set Keypad Display passcode for details on setting the passcode as desired A keyed sw
11. 3 5 3 6 Default Screen Brake Response Key Current Shift Key Last Shift Key Set Up Key 3 5 1 Set Cupper Parameters 3 5 2 Set Lubricator Parameters 3 5 3 Set Machine Timing Set Points etc 3 5 4 Zero Machine set resolver offset Set Keypad Display Set Up Passcode HSMCUP7 Windows Based Set up Program Reference 4 1 4 2 4 3 4 4 4 5 General Description The File Menu 4 2 1 The Set Up Data File 4 2 2 Upload save Data 4 23 Download Program 4 2 4 Download restore Data 425 Print Report The Edit Menu 4 3 1 Enable Offline Editing 4 3 2 Setup Comm Port 4 3 3 Set up Passcode The View Menu 4 4 1 Target Board Interface 4 4 2 View Online Data 443 View Offline Data The Window Menu 4 5 1 The Main Display Window 4 5 2 The Setup Parameters Window 4 5 3 The Serial Communications Window 4 5 4 The Machine Timing Window 4 5 5 The Shift Data Window 4 5 6 The I O States Window CONTENTS SYSTEMS Electronics Group Aie CONTENTS 5 HSMCUP7 DOS Based Set up Program Reference ____63 5 1 Set Cupper Lubricator Set up Parameters 64 5 1 1 Enable Disable Brake Wear Compensation 64 5 1 2 Maximum Allowed Stopping Response 65 5 1 3 Set Cupper Running Speeds 65 5 1 4 Set Lubricator Speed References 65 5 2 Set Machine Timing 66 5 2 1 Zero the Machine 67 5 2 2 Adjusting the Timing Channel Set points 68 5 3 Shift Data Brake Response 69 5 4 Download Program to Module 71
12. Date m Internal Fault Code Current Fault Code 00H No Internal Fault has Ocurred Last Fault Code 00H No Internal Fault has Ocurred Corrective Action None 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 still be displayed SYSTEMS Electronics Group 48 HSM CUP7 User s Manual SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE 4 4 2 VIEW ONLINE DATA This function allows the user to place the set up program 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
13. Jam Detection This alarm occurs when the Scrap Jam input is turned on This is generally derived from the grounded scrap discharge and is activated when scrap backs up shorting the discharge The clutch is de activated for a TDC stop at the detection of this fault Timing Signal Fail The timing signal fail occurs when any of the timing signals generated in the PLS section fail to change state periodically while the machine is running Clutch Output Fail No 1 No 2 These alarms occur when the respective clutch output no 1 or no 2 fails either on or off This indicates either a failure in the outputs of the S4568 board that drives the clutch or a short circuit or open circuit in the clutch output wiring HSM CUP7 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSM CUP7 User s Manual No Ram Motion Detected This alarm occurs when the clutch is activated and no ram motion is detected after a time delay This could indicate either the clutch did not activate or that a failure in the resolver coupling has occurred Resolver Fault Motion Detected at Stop This alarm occurs when motion is detected after the clutch has been disengaged for a time delay This indicates either a broken wire in the resolver cable or a failure in the resolver windings Brake Response Too Long The Brake Response Too Long alarm is generated when the actual brake response exceeds a user specified maximum
14. allowed brake response This can be used to indicate that service to the brake should be performed The die jam cup jam and scrap jam alarms are available to the host PLC as discrete outputs The balance of the alarms are summed together into the Not HSM Alarm discrete output If any of the alarms occur the Not HSM Alarm is turned off If all alarms are cleared the Not HSM Alarm is on These outputs should be interlocked to the existing control system to disable the clutch logic In the case of the die jam and cup jam alarms four additional outputs representing the binary station number are also available such that the station that faulted can be read by the host PLC The respective alarm message is displayed on the HSM CUP7 display when the corresponding alarm is active 1 7 DATA COLLECTION The following data is collected for both the current shift and the previous last shift 1 Total number of strokes 2 Total number of Die Jam Cup Jam faults per station This data can be viewed locally on the display by the operator or production control personnel This information is updated current shift transferred to Last shift based on the change of state of the End Of Shift input SYSTEMS Electronics Group HSM CUP7 User s Manual SECTION 2 INSTALLATION The HSM CUP7 module is provided for door mounting on the existing user s control cabinet door or
15. as either condition occurs In general the clutch control as interfaced with the above six interlocks should be implemented as defined in section 1 3 HSM CUP7 User s Manual SYSTEMS Electronics Group 16 SECTION 2 INSTALLATION 5 Add the Coil Stock O Ride output into the PLC program The signal is used to by pass the die jam and cup jam detection when the press is stroked without coil stock Note The HSM CUP7 will produce an COIL STOCK MODE fault if cups are detected dropping while the coil stock override is on This prevents the machine from being run in production with the coil stock override accidentally left on 6 Add the Alarm Reset output This signal should be on as long as the system reset push button is depressed 2 8 HSM CUP7 SET UP The HSM CUP7 is shipped from the factory with the PLC program loaded into the PLC section of the module The PLS channel set point file CUP7TMG loaded in the PLS section In most cases the following user variables and timing channels may have to be altered to tune the HSM CUP7 to the actual cupper it is controlling Once installed and the control system is powered back up perform the following to set up and tune the HSM CUP7 The set up is performed using the Keypad Display or a PC running the HSMCUP7 set up program See section 3 for a description of the Keypad commands and menu displays of the HSM CUP7 Keypad Display See section 4 f
16. in the last previous shift This is essentially a stroke counter Note The current shift data is transferred to the Last shift data when the end of shift input transfers from a 0 to a 1 This can be at the end of either an 8 or 12 hour shift This data cannot be reset either from this menu or by the operator only at the end of shift transition HSM CUP7 User s Manual SYSTEMS Electronics Group 69 SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual Mid Speed Brake Response degrees This is the number of degrees from the when the clutch was de activated at the TDC Mid timing to where the cupper crankshaft came to rest when a TDC stop was performed at mid speed This can be used to determine the general condition of the brake and whether servicing of the brake is required High Speed Brake Response degrees This is the number of degrees from the when the clutch was de activated at the TDC hi timing to where the cupper crankshaft came to rest when a TDC stop was performed at high speed This can be used to determine the general condition of the brake and whether servicing of the brake is required Note The brake response of the brake for both high and mid speeds is updated after each TDC stop SYSTEMS Electronics Group 70 HSM CUP7 User s Manual SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE 5 4 DOWNLOAD PROGRAM TO MODULE This selection is used
17. 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 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 close the Comm port and cease communication with the M4500 SYSTEMS Electronics Group 49 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENC
18. main menu This selection can also be used to verify the program ident revision and checksum without downloading the program Perform steps 1 thru 3 above but instead of initiating the download in step 3 simply press the lt ESC gt key to abort the download once the ident revision and checksum have been displayed SYSTEMS Electronics Group ST SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual 5 5 DOWNLOAD SET UP DATA TO MODULE This selection is used to download the previously uploaded saved set up variables to the HSM CUP7 module This should only be performed when replacing the module Note The set up data consists of the cupper and lubricator set up parameters Timing channel set points are not stored as part of the set up data these are stored in the CUP7TMG file To download the set up data perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the HSM CUP7 2 Select 5 Download Set up data to Module 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 Program execution is not ceased therefore data download can be performed while the machine is running 4 Once download is complete press any key to return to the mai
19. points as well as the PLS configuration and scale factor to the M4500 PLS Shift Data This option downloads the Shift Data to the M4500 This includes the total strokes total die jams and die jams per station for both the current and last shifts All This option allows the user to completely download All of the set up parameters timing channel set points and shift data to the M4500 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 prior 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 document was printed 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 This displays the Print Setup dialog box 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 This function makes use of the windows pri
20. r Port Speed l e Comi 9600 C Com2 19200 C Com3 C Com 4 Cancel Once selected a dialog box requesting the user to select a Comm Port and Baud Rate will be displayed The default setting is COM1 at 9600 baud The option to select the 19200 baud rate is to allow the user to communicate with the processor via the 4516 serial communications board 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 SYSTEMS Electronics Group 45 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual 4 3 3 EDIT SET UP PASSCODE The edit Set up Passcode is an Online function only This allows the user the ability to directly change the value of the Set up Passcode The passcode is not included as part of the setup data file Once selected an input box is displayed allowing the user to view the current Passcode setting and to change the value if necessary If the passcode is set to zero passcode entry is disabled The operator can press the Set up key on the Keypad Display and
21. section 2 6 2 copy all the files from the disk to each of these subdirectories HSM CUP7 User s Manual SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION 2 7 MODIFY EXISTING PLC PROGRAM Modify the existing control system PLC program to interface with the HSM CUP7 by incorporating the following into the existing PLC ladder logic 1 The HSM CUP7 now controls e The Clutch TDC Stop e Air Strip e Die Jam e Cup Jam Detection Defeat the existing Die jam and cup jam detection in the PLC and add both the Die Jam Alarm and Cup Jam Alarm inputs from the HSM CUP7 and the No HSM Alarm interlock Note These alarms must immediately disable the clutch logic in the PLC The Die Jam and Cup Jam alarms are true logic on when alarm detected while the No HSM Alarm is inverted logic off when alarm is detected 2 Add the Clutch On No 1 and Clutch On No 2 outputs into the PLC logic In general these can be derived from the logic that use to drive the clutch solenoids by removing the TDC timing signal from the original logic 3 Add the Continuous Single and Inch Bar Mode outputs to the existing PLC logic The respective output should be on when the corresponding mode is selected 4 Add the Not Immediate Stop output to the PLC logic This should be on when no E stop or immediate stop condition is present and turn off as soon
22. 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 HSMCUP7 setup program can be executed from the Systems folder located in Programs HSM CUP7 User s Manual SYSTEMS Electronics Group 13 SECTION 2 2 6 2 DOS BASED SET UP PROGRAM INSTALLATION To install the DOS based set up software perform the following steps 1 Create one directory off the root directory of the PC for each INSTALLATION 2 3 4 HSM CUP7 User s Manual Cupper the HSM CUP7 will be used on called HSMCUP1 for cupper 1 HSMCUP2 for cupper 2 etc These will be used to store the HSMCUP7 EXE setup programs and HSMCUP7 set up data for each cupper Create these directories by typing the following at the DOS prompt MD HSMCUPI1 lt ENTER gt MD HSMCUP2 lt ENTER gt etc Install the disk labeled HSM CUP7 PROGRAMS into the A drive For each HSMCUP directory you created in the previous step switch to that directory and install the HSM CUP7 set up programs by typing the following at the DOS prompt cupper 1 is shown CD HSMCUP1 lt ENTER gt A INSTALL lt ENTER gt Add each cupper s HSM CUP7 set up program to your computer s menu software by creating a selection for each cupper called SET UP CUPPER 1 for cupper 1 SET UP CUPPER 2 for cupper 2 etc The
23. speed of the Cupper or slightly higher Lubricator Minimum Speed SPM This parameter determines the speed the lubricator will run at when the cupper is stopped de clutched Note When the cupper is running the lubricator speed reference is proportional as set by the Lubricator Maximum Speed scaling to the speed of the cupper This parameter is used to provide the speed reference when the cupper speed is zero for lubricator jog etc SYSTEMS Electronics Group 30 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 zzz OFFSET wwww SCALE 360 Each field is defined as follows Field Definition Chuu Currently selected channel CH00 thru CH17 where uu is the octal channel number SETPOINT xxx Channel on or off set point where xxx is the set point position State of channel set point blank off solid block character on channel name selected channel name CH00 TDC HIGH TIMING CH01 TDC LOW TIMING etc RPM yyyy Current machine speed where yyyy is in SPM 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 di
24. the application program to the module as well as download and up load the set up data and save it to disk The set up variables are used to configure and tune the HSM CUP7 to match the configuration and performance of the specific cupper see section 2 8 The main menu of the HSMCUP7 set up program incorporates the following menu selections hsmeup7 EXE B x Systems HSM CUP Set up Menu Version 1 0 Main Menu Set Cupper Lubricator Set up Parameters Set Machine Timing Shift data Brake Response Download Program to Module Download Set up data to Module Upload Save Set up data from Module ACE CoN Enter Selection ESC to exit NOTE Before selecting one of the nine selections listed above connect an RS 232 cable from COM1 on the computer to the PROG PORT on the HSM CUP Note The HSMCUP7 program is an on line communications program used to interface with the HSM CUP7 module The data displayed in the menus and set in the menus is communicated directly to the module 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 HSMCUP7 to the PROG port on the HSM CUP7 The following sections are a complete description of the HSMCUP7 selections and menus SYSTEMS Electronics Group 63 SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE 5 1 SET CUPPER LUBRICATOR SET UP PARAMETERS This
25. un used stations in order to avoid a die jam Motion Timing This is a pulse train set on for 30 degrees and then set off for 30 degrees through out the entire channel SYSTEMS Electronics Group 76 HSM CUP7 User s Manual SECTION 7 RECOMMENDED SPARE PARTS The following are recommended spares for the HSM CUP7 These parts are available through Systems Engineering Assoc Inc Quantity Part Number Description lea HSM CUP7 Cupper High Speed Logic Module SYSTEMS Electronics Group PE
26. when the brake is activated to the position where the press ends up at rest when a TDC stop is performed is longer than this number the alarm is generated If the actual brake response is less the alarm is not generated Set this parameter to the value where the brake response is considered too long and service to the brake should be performed typically 270 to 300 degrees SYSTEMS Electronics Group 53 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual Cupper Running Speeds This section is used to set the cupper running speeds in the M4500 This section contains the following selections 1 Running Cupper Low Speed SPM This is the speed in strokes per minute the cupper will run when in low speed 2 Running Cupper High Speed SPM This is the speed in strokes per minute the cupper will run when in high speed Lubricator Parameters This section is used to set the lubricator speed references in the M4500 This section contains the following selections HSMCUP unnamed Set Up File Edit View Window Help Cupper Setup Parameters lt r Lubricator Speed References Maximum Speed full scale calibration 250 Idle Speed Cupper Stopped 75 E System Message All Faults Normal ONLINE 10 13 2003 9 52AM y 1 Lubricator Maximum Speed SPM The Lubricator Maximum Speed parameter is used to scale the 0 10VDC analog output such that when the cupper is
27. 0 220 Y Air Strip High Timing CHo3 120 200 Y Air Strip Mid Timing CHO4 140 220 Y Air Strip Low Timing CHOS 150 230 Y Cup Drop Window Timing CHOS 140 120 PLC Timing cHoz 0 20 p PLS Channel EE Recall Channel Clear Channel RPM 0 Position 96 Offset 0 Scale 360 System Message All Faults Normal ONLINE 11041 3 2003 9 52 AM Z 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 resolver Position This is the current Position in degrees of the 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 SYSTEMS Electronics Group 56 SECTION 4 HSMCUP7 WINDOWS BASED SET UP 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 Connect an RS 232 SYSdev cable from the COM port on the computer to the PROG port on the M4500 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 On
28. CTIONAL DESCRIPTION The HSM CUP7 cupper high speed logic module is an electronic upgrade for cuppers and performs the high speed control functions of the cupper including e Rapid Response Clutch Brake Control e Accurate Die Jam Cup Jam Detection e Precise Air Strip Control Included is a Brake Wear Compensation feature that automatically adjusts the TDC timing signal to stop the press at TDC regardless of brake stopping time Alarm detection is provided including e Die Jam Detection e Cup Jam Detection e Scrap Jam Detection e Timing Signal Failure e Clutch Output Failure Detection e No Ram Motion Alarm e Resolver Failure Detection e Brake Response Too Long Alarm SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION Data collection includes for both the current and previous shift e Total Stroke Count e Die Jam Cup Jam Faults Per Station Count Interfaces directly to the machine mounted resolver cup drop sensors clutch brake and air strip solenoids as well as the host PLC via discrete DC I O The HSM CUP7 is not a dedicated black box but is instead implemented using the high performance SYSTEMS M4503 PLC PLS module This allows easy customization by either SEA or the end user The M4503 module is programmed using the SYSdev programming package that 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 troub
29. DOS commands executed for these selections should be cupper 1 shown For the SET UP CUPPER 1 selection CD HSMCUPI1 HSMCUP7 HSMCUP7 CD To execute the respective cupper s set up program simply select the corresponding SET UP CUPPER selection from the menu software s menu SYSTEMS Electronics Group 14 SECTION 2 INSTALLATION 2 6 3 SYSdev PROGRAM DEVELOPMENT SOFTWARE INSTALLATION The SYSdev Program Development software is used to perform on line trouble shooting and program modifications to the HSM CUP7 If SYSdev was purchased with the HSM CUP7 package and is not already installed on the your computer install SYSdev onto the hard drive of your computer following the steps in the SYSdev Program Development manual 2 6 4 HSM CUP7 APPLICATION PROGRAM INSTALLATION The application program is a SYSdev based program loaded into the M4500 module and performs the HSM CUP7 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 HSMCUP7 the 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 HSMCUP7 directories created in
30. E HSM CUP7 User s Manual 4 5 THE WINDOW MENU The Window menu allows the user to select one of 5 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 HSMCUP 7 unnamed Main Display File Edit View Window Help Messages AE 2 Setup Parameters 3 Machine Timing 4 Shift Data 51 0 States Brake Response Low Speed o High Speed 0 Alarm Reset ONLINE 10 13 2003 9 51 AM y System Message All Faults Normal Once a window menu item is selected a check mark is placed next to the selected 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 SYSTEMS Electronics Group 50 HSM CUP7 User s Manual SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE 4 5 1 THE MAIN DISPLAY WINDOW The Main Display window is used to display the general state of t
31. HSM CUP7 Cupper High Speed Logic Module 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 02 2004 HSM CUP7 Cupper High Speed Logic Module User s Manual Copyright 1997 Systems Engineering Associates Inc All Rights Reserved Revised 24 February 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 responsibility is assumed f
32. M CUP7 is first installed it will take a few successive stops for the algorithm to program the TDC timing channels to the correct position Also the compensation is enabled after the press has been running at a fixed speed in continuous The TDC timing channels will not be modified when single strokes are made or if press is started in continuous and then immediately stopped again Wait about 5 seconds after the press is started before performing the TDC stop to verify the stop position If the brake wear compensation is disabled manually adjust both the TDC High timing CH00 and the TDC Mid timing CH01 such that the press stops at back dead center at both respective speeds Note The TDC Low timing must be set manually since it does not incorporate the compensation algorithm See section 3 5 3 Using the Keypad Display section 4 5 4 Windows set up program reference or section 5 2 2 DOS set up program reference for details on adjusting CHOO and CHO1 The Machine Is Now Set Up And Ready To Run SYSTEMS Electronics Group 93 2 SECTION 2 INSTALLATION HSM CUP7 User s Manual 2 9 HSM CUP7 MODULE REPLACEMENT The following is provided only as a reference To replace the module perform the following 1 2 3 4 5 6 7 8 9 Remove all power and field wiring connectors from the module Remove the 8 32 nuts and lock washers 7ea which retain the module in the door and remove the module
33. OWS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual 4 5 5 THE SHIFT DATA WINDOW The Shift Data window is used to view the shift data collected by the M4500 This window is selected from the Window menu Current Shift Last Shift Current Shift l Die Jams per Station Total Strokes 0 10 ION ts 0 Total Die Jams 0 wJ 0 tof Oo ss 0 oe ey 4 0 12 20 us 0 SIEA A we 0 mf 0 End of Shift l e 7 Hs oo Transfer Data e 0 16 EA System Message All Faults Normal ONLINE 10 13 2003 9 52AM y This window utilizes a TAB control to divide the set up parameters into two categories similar to that of the Keypad Display These sections are as follows Current Shift Data This section is used to view the Current Shift data This data is the totals so far into the shift This data is transferred to the Last shift 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 can be reset by the user from this section Note The Transfer Data command button is only active while Online 1 Strokes This is the total number of strokes made for the shift This is essentially a counter 2 Die Jams This is the total number of die jam or cup jam faults that occurred for all stations on the shift SYSTEMS Electronics Group
34. ay lO x Eile Edit View Window Help New Ctrl N Open Ctrl 0l Save Ctrl S Save As Export Shift Data Ctrl x lt Upload save Data gt Machine Position Strokes Die Jams Download Data y 36 o o Print Report Ctrl P Exit High Speed o igh Spee Alarm Reset System Message All Faults Normal ONLINE 10 1 3 2003 9 49AM y 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 HSM CUP7 User s Manual SYSTEMS Electronics Group 4 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual Once selected a message box is displayed informing the user of the current program revision and checksum of the program loaded in the processor as well as that of the selected program The user must confirm their selec
35. console 2 1 WHAT S INCLUDED Verify that the following items are included when unpacking the HSM CUP7 lea HSM CUP7 M4503 Module with required I O boards lea HSM CUP7 User s Manual lea HSM CUP7 Keypad Quick Reference lea M4500 User s Manual lea HSM CUP7 Program Disk The following items are optional items and can be purchased separately as required or desired lea RSV34 MS1 Resolver lea RSV RSCBLE XX Resolver Cable 2 2 POWER REQUIRED The HSM CUP7 is powered from 115 230VAC 50 60HZ and 24VDC The 115 230VAC is used to power the HSM CUP7 module while the 24VDC is used to power the 24VDC I O sensors clutch solenoids etc Note 24VDC solenoids must be used for all clutch and air strip solenoids These provide a much more consistent and repeatable response time than 115VAC solenoids Assuming 24VDC solenoids were used in the existing system the 24VDC current required by the HSM CUP7 is no more than the existing systems 24VDC current requirement therefore the existing 24VDC power supply should be adequate SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 3 MOUNTING THE HSM CUP7 The HSM CUP7 module should be mounted in the door of the existing user s cabinet or console door Perform the following steps to mount the HSM CUP7 module 1 Referring to the recommended cut out in figure 1 cut a cut out in the door of the existing user s control cabinet or console 2 Remove the all the field
36. creases linearly from 0 through 359 If not swap the S1 and S3 leads of the resolver at the HSM CUP7 resolver connector Then verify that the position then indeed does increase with forward movement Press lt ESC gt to exit the POS RPM update 4 Position the machine at Top Dead Center 5 Auto zero the resolver by selecting F10 Set Offset Enter 0 in the offset field and press lt ENTER gt The HSM CUP7 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 SYSTEMS Electronics Group 67 SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE 6 Exit back to the PLS Main Development menu by pressing lt ESC gt Exit back to the HSMCUP7 set up main menu by pressing lt ESC gt again 5 2 2 ADJUSTING THE TIMING CHANNEL SET POINTS To set or alter any of the timing signal set points perform the following 1 2 3 4 HSM CUP7 User s Manual Select the 2 Set Machine Timing selection from the HSM CUP7 set up program main menu Select 1 Online Channel Setpoint Programming from the Main Development menu Set all channels per section 6 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
37. d To change the passcode enter any number between 0 and 64999 and press lt ENTER gt Note Set the passcode to 0 to disable passcode protection When prompted for the passcode press lt ENTER gt to proceed to the set up menu If the passcode protection is used set the passcode to a number between 1 and 64999 A valid passcode will then have to be entered to gain access to the set up menu Once the passcode is set turn the Set Passcode input off SYSTEMS Electronics Group 34 SECTION 4 HSMCUP7 WINDOWS BASED SET UP 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 resolver 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 cupper see HSM CUP7 Set up section 2 8 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 proce
38. d deselect the check box If the compensation is to be enabled select the check box The HSM CUP7 incorporates a brake wear compensation or automatic TDC timing feature which stops the press at TDC regardless of the actual braking response of the clutch brake The stopping compensation is accomplished by automatically adjusting the TDC timing signal based on the previous stop Any overrun is detected and a new TDC timing signal is computed such that the machine will stop at the desired location on the next stop Three TDC signals are provided one for low speed one for mid speed and one for high speed The mid and high speed TDCs incorporate the break wear compensation feature The appropriate TDC timing signal mid or high is adjusted based on the speed of the machine when the TDC stop was initiated Desired TDC Stop Position Low Speed This is the desired stopping location in degrees for a TDC stop at low speed when the brake wear compensation is enabled This is typical set to 000 degrees Back Dead Center Desired TDC Stop Position High Speed This is the desired stopping location in degrees for a TDC stop in high speed when the brake wear compensation is enabled This is typical set to 000 degrees Back Dead Center Maximum Allowed Stopping Response degrees This defines what the maximum allowed brake response is before the Brake Response Too Long alarm is generated If the actual brake response number of degrees from
39. e 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 SYSTEMS Electronics Group 38 HSM CUP7 User s Manual SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE 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 1f the file exists 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 SYSTEMS Electronics Group 39 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual 4 2 2 UPLOAD SAVE DATA The Set up program allows the user to upload set up parameters timing channel set points and shift data
40. ed as long as both inputs are on Both the Continuous and Single mode inputs must be off Bar Mode 1 With both the Inch Bar Mode and Not Immediate Stop inputs on the clutch can be activated by simultaneously turning both the Clutch On No 1 and Clutch On No 2 inputs on The clutch is activated as long as both inputs are on Both the Continuous and Single mode inputs must be off Note In all the above modes the Clutch On No 1 and Clutch On No 2 inputs must be turned on simultaneously within 0 5 seconds in order for the clutch to activate Refer to the schematic at the back of this manual for typical HSM CUP7 clutch connections IMPORTANT SAFETY WARNING The HSM CUP7 is intended as a high speed logic gate to provide consistent and accurate clutch control It is not designed as a redundant dual processor clutch brake safety module The HSM CUP7 must not be the only means of controlling the cupper clutch mechanism Good design practice dictates the use of safety interlocks on any device that starts or stops automatically that can cause personnel injury to operating or maintenance personnel The HSM CUP7 must be used only in conjunction with industry approved safety interlock contacts implemented in accordance with ANSI B11 1 safety requirements otherwise serious personnel injury may result HSM CUP7 User s Manual SYSTEMS Electronic
41. eed SPM The Lubricator Maximum Speed parameter is used to scale the 0 10VDC analog output such that when the cupper is running at the speed entered in Lubricator Maximum Speed the analog output will be at 10 volts This is typically set to the running high speed of the Cupper or slightly higher Lubricator Idle Speed SPM This parameter determines the speed the lubricator will run at when the cupper is stopped de clutched SYSTEMS Electronics Group 65 SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE Note When the cupper is running the lubricator speed reference is proportional as set by the Lubricator Maximum Speed scaling to the speed of the cupper This parameter is used to provide the speed reference when the cupper speed is zero 5 2 SET MACHINE TIMING The Set Machine Timing selection is used to invoke the PLS programming command menus these are the same menus used in SYSdev to program the PLS section of the HSM CUP7 When selected the PLS programming main development menu will be invoked using the default CUP7TMG channel set point file c hsmcup7 EXE Oj x Systems PLS Program Development PLSdev M4500 Version 4 2 Program Name CUP TMG Main Development Menu Online Channel Setpoint Programming Offline Channel Setpoint Programming Edit PLS Configuration Download Channels to PLS Upload Channels from PLS Print Channels File Utilities Return to SYSdev Shell
42. em is occurring adjust the respective Air Strip timing CH03 High Speed CH04 Mid Speed CH05 Low Speed until the problem is corrected See section 3 5 3 Using the Keypad Display section 4 5 4 Windows set up program reference or section 5 2 2 DOS set up program reference for details on adjusting CH03 thru and CHOS la HSM CUP7 User s Manual SECTION 2 INSTALLATION Verify Cup Drop Timing With the machine running with the coil stock verify that no false die jam or cup jam faults are occurring If false die jams or cup jams are occurring verify that the cup drop sensors are detecting the cups when they drop If the sensors are detecting the cups adjust the Cup Drop Window timing as necessary to eliminate the false die jam or cup jam faults The cups must drop inside the Cup Drop Window in order to avoid a die jam and must not be detected outside the Cup Drop Window in order to avoid a cup jam Verify that the die jam detection is working correctly by removing the coil stock from the press and then stroking the press with the coil stock override off The press should stop with a die jam alarm for station 1 displayed die jams for all stations actually occur but 1 is displayed since it is the lowest numbered station to fault Verify TDC Stops If the brake wear compensation is enabled verify that the press does stop at the desired location in both the high and the mid speeds Note When the HS
43. for the cupper 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 Once all channels are programmed press lt ESC gt to exit back to the PLS Main Development Menu Press lt ESC gt again to exit back to the HSMCUP7 set up main menu The new channels will be saved both in the module and in the CUP7TMG file on the hard drive SYSTEMS Electronics Group 68 SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE 5 3 SHIFT DATA BRAKE RESPONSE This selection is used to view the Current Shift data Last Shift data and the Low and High Speed Brake Responses When selected the Shift Data Brake Response menu is invoked The following data is displayed in the Shift Data Brake Response menu e hsmcup7 EXE Of x Systems HSM CUP Set up Menu Version 1 0 Shift Data Brake Response Press ESC to return to main menu Current Shift Total Strokes Last Shift Total Strokes Brake Response Low Speed High Speed Current Shift Total Strokes This is the total number of strokes made so far into the current shift This is essentially a stroke counter Last Shift Total Strokes This is the total number of strokes made
44. from the M4500 into a set up Data File This function is accessed from the File menu and the user is given the choice of the following options HSMCUP unnamed Main Display File Edit View Window Help iol x New Ctri N Open Ctrl O Save Ctrl S Save As Export Shift Data Ctil X Set up Parameters Timing Channels Shift Data Upload save Data Download Program Download Data gt Print Report Ctrl P Exit High Speed 0 Alarm Reset System Message All Faults Normal ONLINE 10 13 2003 9 49AM y Set up Parameters This option uploads the Set up data from the M4500 This includes cupper and lubrication set up parameters Timing Channels This option uploads the Machine Timing channel set points as well as the PLS configuration and scale factor Shift Data This option uploads the Shift Data from the M4500 This includes the total strokes total die jams and die jams per station for both the current and last shifts All This option allows the user to completely upload All of the set up parameters timing channel set points and shift data from the M4500 SYSTEMS Electronics Group AQ SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE 4 2 3 DOWNLOAD PROGRAM The Set up program allows the user to Download any SYSdev program file to the M4500 HSMCUP unnamed Main Displ
45. gardless of brake response Brake response determination allows displaying of actual brake response in degrees Brake response alarm to indicate when brake stopping response in degrees has exceeded user preset limit e Lubricator speed reference 0 10volt analog output provides reference to lubricator proportional to speed of cupper user scalable e Alarm detection die jam detection cup jam detection scrap jam detection timing signal fail detection clutch output failure detection no ram motion alarm resolver failure detection and brake response too long alarm e Data Acquisition Total number of strokes and total number of die jam cup jam faults for each station for both current shift and last shift SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSM CUP7 User s Manual e Built in 2 Line X 40 character sealed display with 24 key membrane keypad allows local viewing of collected data stroke count die jams per station brake response by operator and set up of all user variables passcode protected or key switch enabled by authorized personnel e Interfaces directly with machine mounted resolver cup drop sensors and all clutch and air strip solenoids e Based on high performance M4503 PLC PLS module that allows easy trouble shooting and user customization using SY Sdev DOS based programming package e Built in PLS provides all machine timing eliminating need for an additional PLS 1 2 FUN
46. ges 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 amp HSMCUP unnamed Main Display File Edit View Window Help Open Ctrl O Save Ctrl S Save As Export Shift Data Ctrl x lt Upload save Data Machine Position Strokes Die Jams Download Program oe a _ Download Data gt i 2 Print Report Ctrl P Exit HighSpeed i Alarm Reset System Message All Faults Normal ONLINE 11011 3 2003 3 48AM 7 HSM CUP7 User s Manual SYSTEMS Electronics Group 37 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual 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 t
47. he control system This window is selected from the Window HSMCUP unnamed Main Display File Edit View Window Help Messages Machine Speed sekis r oo Strokes Die Jams Brake Response Low Speed 0 High Speed 0 Alarm Reset System Message All Faults Normal ONLINE 10 13 2003 9 36AM y 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 Speed This display is only active while Online and displays the current speed of the machine in Strokes Per Minute Position This display is only active while Online and displays the current angular position of the cupper crankshaft Strokes This display is the Current Shift total number of strokes into the current shift SYSTEMS Electronics Group 51 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE Die Jams This display is the Current Shift total number of die jams or cup jams for all stations that the machine has had so far into the current shift Brake Response This is
48. he 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 Al 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 cupper save the file to a new name make the necessary changes and simply download the new parameters 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 fil
49. ics Group 73 SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE This Page Intentionally Left Blank HSM CUP7 User s Manual SYSTEMS Electronics Group 74 HSM CUP7 User s Manual SECTION 6 GENERAL TIMING SIGNAL LOCATIONS The following is a general description of the timing signals and the locations they should be set at CHOO CHO01 CH02 CH03 CH04 CHO5 TDC High Timing This signal is used to de activate the clutch for a TDC stop at high speed Note The leading edge is used to de activate the clutch thus the width of the signal is not critical generally set 20 degrees wide When the brake wear compensation is enabled this signal is adjusted automatically by the HSM CUP7 If the brake wear compensation is disabled this signal must be set manually In this case it should be set such that the press stops at top dead center for a TDC stop at high speed TDC Mid Timing Same as the TDC High timing CH00 except used when the machine is running in mid speed TDC Low Timing Same as the TDC High timing CH00 except used when the machine is running in low speed The TDC Low timing does not incorporate the brake wear compensation feature and must therefore be set manually Air Strip High Timing This signal is used to activate the air strip solenoid when the machine is running in high speed The air strip is on for the entire window that CH03 is on while the machi
50. ine timing If the machine is not already equipped with a resolver then the existing encoder will have to be removed and an RSV34 MS 1 resolver will have to be mounted in it s place If this is the case refer to the RSV34 MS1 data sheet for details on mounting the resolver Use the RSV RSCBLE cable to connect the resolver to the HSM CUP7 Route the resolver cable in a separate conduit away from all other high voltage and control wiring Wire the cable directly to the 8 pin resolver connector on the HSM CUP7 see section 2 4 SYSTEMS Electronics Group 12 SECTION 2 INSTALLATION 2 6 HSM CUP7 SOFTWARE INSTALLATION The HSM CUP7 set up software is used to e Download the Program to the HSM CUP7 Module e Tune Set Up the User Adjustable Variables of the HSM CUP7 e Download and Upload Save the User Set Up Variables to Disk e View Shift Data Follow the steps below to install either the Windows or DOS based setup programs and PLC application program on a PC used to support the HSM CUP7 control system 2 6 1 WINDOWS BASED SET UP PROGRAM INSTALLATION The HSMCUP7 setup program is compatible with Windows 95 98 ME 2000 XP operating systems To install the set up software perform the following steps 1 Insert the HSM CUP7 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 HSM CUP7 CD Select the
51. isplays the selected data and set up menus The keypad display can be used by the operator to view data or can be used to adjust the timing and all set up parameters SYSTEMS BS ELECTRONICS GROUP INC bs MACHINE SPEED SPM 0000 POSITION 000 STROKES 0 DIE_JAMS 0 pa BRAKE ser ENTER cea as sponse UP point CHAN 1 2 T A eaaa e NEXT AAA IS The display keypad allows the following to be viewed or adjusted 1 Set the Cupper Set Up Parameters 2 Set the Lubricator Set Up Parameters 3 Set Machine Timing 4 Set Machine Zero 5 View the Actual Brake Response in degrees 6 View the Current Shift Data 7 View the Last Shift Data The definitions of the keypad commands and menus are described in the following sections Note For virtually all the menus the NEXT and PREV keys can be used to advance to the next item of the menu or retard to the previous item on the menu To change a set up parameter simply enter the new value on the numeric keypad and press lt ENTER gt The value will be entered and the next parameter will automatically be displayed When the last parameter is entered the primary set up menu will be displayed Pressing lt ESC gt at anytime will also exit you back to the primary set up menu SYSTEMS Electronics Group 25 SECTION 3
52. itch can then be wired to the Set Up Enable input such that when the switch is in the enable position the input is on When this input is on the passcode prompt is bypassed and access to the primary set up menu is provided immediately If the Set Up Enable input is off then the normal passcode prompt is displayed SYSTEMS Electronics Group 28 SECTION 3 USING THE KEYPAD DISPLAY 3 5 1 SET CUPPER PARAMETERS This menu is activated when the 1 key SET CUPPER PARAMETERS is pressed while the primary set up menu is active The following set up parameters may then be adjusted or viewed Brake Wear Comp Enable 0 No 1 Yes This prompt is used to enable or disable the brake wear compensation If the compensation is to be disabled enter 0 and press lt ENTER gt If the compensation is to be enabled enter 1 and press lt ENTER gt Desired TDC Stop POS Mid Speed This is the desired stopping location in degrees for a TDC stop in mid speed when the brake wear compensation is enabled This is typical set to 000 degrees Top Dead Center This prompt is only displayed when the brake wear compensation is enabled Desired TDC Stop POS High Speed This is the desired stopping location in degrees for a TDC stop in high speed when the brake wear compensation is enabled This is typical set to 000 degrees Top Dead Center This prompt is only displayed when the brake wear compensatio
53. le shooting The M4503 module incorporates a built in PLS that interfaces directly with the machine mounted resolver and provides all machine timing eliminating the need for an external PLS 1 3 CLUTCH BRAKE CONTROL The clutch brake solenoids are activated by the HSM CUP7 through the electro mechanical two hand control circuitry provided externally by the user The throughput of the HSM CUP7 is 0 5 milliseconds This fast throughput along with the fact that the PLS is fully integrated with the processor allows extremely fast and repeatable de clutching and braking response to be achieved Normally the clutch is controlled via inputs on the HSM CUP7 that are controlled from outputs on the host PLC However detection of any of the alarms die jam fault cup jam fault etc results in an immediate de clutch of the solenoids HSM CUP7 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSM CUP7 User s Manual 1 3 1 CONTROL OF CLUTCH VIA HOST PLC Six discrete DC inputs to the HSM CUP7 from the host PLC are used to control the clutch e Clutch On No 1 e Clutch On No 2 e Continuous Mode e Single Mode e Inch Bar Mode e Not Immediate Stop The HSM CUP7 is essential a high speed gate which implements the TDC stop single inch and bar clutch control all based the states of the six inputs listed above The following description of operation defines the requirements of the host PLC logic to activate the c
54. line mode of operation 4 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 through 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 5 Position the machine at machine zero inch the cupper to top dead center TDC 6 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 7 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 HSM CUP7 User s Manual SYSTEMS Electronics Group 57 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE Adjusting the Timing Channel Setpoints To set any of the timing signal setpoints perform the following Note Any changes made to the timing channel setpoints 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 attemp
55. lutch through the HSM CUP7 Continuous Mode 1 To activate the clutch in continuous mode turn both the Clutch On No 1 and Clutch On No 2 inputs on simultaneously while the Continuous Mode and Not Immediate Stop inputs are on The Single and Inch Bar inputs must be off 2 To perform a TDC stop turn both the Clutch On No 1 and Clutch On No 2 inputs off while leaving the Not Immediate Stop input on 3 To perform an immediate emergency stop turn both the Clutch On No 1 and Clutch On No 2 as well as the Not Immediate Stop inputs off simultaneously The Not Immediate Stop input is used to indicate to the HSM CUP7 that the clutch should be disengaged immediately not waiting for the TDC timing signal Single Mode 1 To single stroke the press with the Single Mode and Not Immediate Stop inputs on turn the Clutch On No 1 and Clutch On No 2 inputs on simultaneously for 5 to 50 milliseconds The press will make one stroke Both the Continuous and Inch Bar mode inputs must be off SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION Inch Mode 1 To inch the press with the Inch Bar mode and Not Immediate Stop inputs on simultaneously turn on and off both the Clutch On No 1 and Clutch On No 2 inputs The clutch is activat
56. n all the way up to about 20 degrees before this location this is almost one complete stroke This allows the greatest amount of time for the cups to drop The Die Jam alarm is generated if a cup from any station fails to drop within the Cup Drop Window timing CH06 The Cup Jam alarm is generated if any cup is detected when the Cup Drop Window is off cups must be clear by this time See section 3 5 3 Using the Keypad Display section 4 5 4 Windows set up program reference or section 5 2 2 DOS set up program reference for details on setting the location of the cup drop window CH06 HSM CUP7 User s Manual SYSTEMS Electronics Group 21 SECTION 2 INSTALLATION CUP DROP CUP DROPS WINDOW CDW WITHIN CDW CH06 gt CDW ON EXAMPLE 1 NO DIE JAM NORMAL GOOD OR CUP JAM CUP DROP EXAMPLE 2 9 p DIE JAM NO CUP DROP ALARM EXAMPLE 3 CUP JAM CUP JAMED ALARM AT SENSOR 0 180 360 CUP DETECTED OUTSIDE CDW CDW OFF Figure 2 Cup Drop Check Timing Sequence 2 8 6 VERIFY MACHINE OPERATION Once steps 2 8 2 thru 2 8 5 are complete run the machine in normal production at all speeds where practical and verify the following Verify Air Strip Timing With the machine running with the coil stock verify that the cups are dropped with out any problems verify at low medium and high speed If a probl
57. n menu SYSTEMS Electronics Group 72 SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE 5 6 UPLOAD SAVE SET UP DATA FROM MODULE This selection is used to save the set up variables from the HSM CUP7 module 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 module not on the file in the computer By uploading saving the set up variables to disk they can be downloaded to the module in the event the module must be replaced The set up data consists of the cupper and lubricator set up parameters Timing channel set points are not stored as part of the set up data these are stored in the CUP7TMG file To upload the set up data perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the HSM CUP7 2 Select 6 Upload Save Set up data from Module 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 Program execution is not ceased therefore data upload can be performed while the machine is running 4 Once upload is complete press any key to return to the main menu HSM CUP7 User s Manual SYSTEMS Electron
58. n is enabled Maximum Allowed Stopping Response This defines what the maximum allowed brake response is before the Brake Response Too Long alarm is generated If the actual brake response number of degrees from when the brake is activated to the position where the press ends up at rest when a TDC stop is performed is longer than this number the alarm is generated If the actual brake response is less the alarm is not generated Set this parameter to the value where the brake response is considered too long and service to the brake should be performed typically 270 to 300 degrees Running Cupper Low Speed SPM This is the speed the cupper will run when in low speed Running Cupper High Speed SPM This is the speed in strokes per minute that the cupper will run when in high speed HSM CUP7 User s Manual SYSTEMS Electronics Group 29 SECTION 3 USING THE KEYPAD DISPLAY HSM CUP7 User s Manual 3 5 2 SET LUBRICATOR PARAMETERS This menu is activated when the 2 key SET LUBRICATOR PARAMETERS is pressed while the primary set up menu is active The following lubricator set up parameters may then be adjusted or viewed Lubricator Maximum Speed SPM The Lubricator Maximum Speed parameter is used to scale the 0 10VDC analog output such that when the cupper is running at the speed entered in Lubricator Maximum Speed the analog output will be at 10 volts This is typically set to the running high
59. nd Air Strip solenoids 5 Cup Drop Sensors using three conductor shielded cable The shields of the sensor cables should be tied to earth ground at a terminal inside the existing control cabinet and left floating at the sensors Any un used cup drop inputs on the HSM CUP7 should be jumpered to the PLC Timing output B110 7 This defeats the die jam detection for the un used stations by simulating a cup drop 6 Set Up Enable passcode by pass key switch if desired 7 Resolver cable from resolver or existing PLS to RO S4 connector on HSM CUP7 using a three pair two conductor shielded cable The shield of the resolver cable should be tied to the SHLD terminal of the HSM CUP7 resolver input connector Make sure the resolver cable shield is left floating at the resolver HSM CUP7 User s Manual SYSTEMS Electronics Group y SECTION 2 INSTALLATION HSM CUP7 User s Manual 8 Lubricator Speed reference 0 10V analog from HSM CUP7 to lubricator drive if used Note In some applications it may be necessary to use an analog isolation amplifier not provided to isolate the drive from the HSM CUP7 module to prevent damage to the HSM CUP7 module In general when wiring the HSM CUP7 keep all 24VDC wiring resolver cable and lubricator speed reference wiring away from high voltage wiring 2 5 MOUNTING THE RSV34 MS1 RESOLVER if required The HSM CUP7 is designed to interface to a resolver not encoder for mach
60. ne is running This signal is generally set on about 120 degrees and then set off at about 200 Air Strip Mid Timing Same as the Air Strip High timing CH03 except used when the machine is running in mid speed This is generally set on about 140 degrees and then off at about 220 Air Strip Low Timing Same as the Air Strip High timing CH03 except used when the machine is running in low speed This is generally set on about 150 degrees and then off at about 230 SYSTEMS Electronics Group 75 SECTION 6 GENERAL TIMING SIGNAL LOCATIONS HSM CUP7 User s Manual CHO06 CHO CH10 Cup Drop Window Timing This signal is used to verify that the cups do drop correctly from the die The cups must drop inside this window to avoid a die jam fault and the cups must not be detected outside this window in order to avoid a cup jam fault The signal is generally set on at 140 degrees or the point where the cups are first freed from the punches and set off at 120 degrees almost one stroke later to allow the maximum amount of time for the cups to drop PLC Timing This is a general purpose timing signal provided as an output which can be input to the host PLC and used for whatever purpose desired by the host PLC In addition this signal can be used to jumper out un used die stations on machines that are less than 16 out In this case this signal simulates the cup drop for the
61. ng the Desired Mid and High Speed Stopping Points if the brake wear compensation is enabled e Setting the Maximum Allowed Stopping Response e Setting the Cupper Running Low and High Speeds Brake Wear Compensation If the brake wear compensation is used enable it by setting the Brake Wear Compensation Enable to Y and set the Desired TDC Stop Position Mid and High The Desired TDC Stop positions is the location of the ram when it comes to rest after a TDC stop Both the Mid and High desired stopping positions are generally set to 000 degrees Enabling the brake wear compensation allows the HSM CUP7 to automatically adjust the TDC timing channels CH00 High and CH01 Mid as necessary such that the press will stop at the desired stopping position regardless of the actual brake response If the brake wear compensation is not used disable it by setting the Brake Wear Compensation Enable to N Disabling the brake wear compensation requires the TDC High timing CH00 and the TDC Mid timing CHO1 signals to be set manually such that the press stops at TDC Note If the brake response then changes the press will not stop at the desired position if the brake wear compensation is disabled Maximum Allowed Stopping Response This parameter defines the maximum allowed brake response before a Brake Response Too Long alarm is generated If the actual brake response number of degree
62. nt manager which allows the user to continue with their work while the document is being printed HSM CUP7 User s Manual SYSTEMS Electronics Group 43 SECTION 4 HSMCUP7 WINDOWS BASED SET UP 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 e Set the Set up Passcode amp HSMCUP 7 unnamed Main Display Enable Offline Editing F2 h M1 gt 0 111 fate HSM CUP7 User s Manual SYSTEMS Electronics Group HSM CUP7 User s Manual SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE 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 4 3 2 SETUP COMM PORT This function allows the user to specify the serial communications port and baud rate to talk to the M4500 The programming port of the M4500 is set to 9600 baud Setting x Comm Port
63. on of the brake A Brake Response Too Long alarm is also generated when the actual brake response exceeds a user specified maximum allowed brake response This can be used to indicate that service to the brake should be performed HSM CUP7 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 6 ALARM DETECTION The package detects the following alarms Die Jam Detection The Cup Drop Window timing signal CH06 along with the machine mounted cup drop sensors are used to verify that the cups drop correctly each stroke The cups for each station must drop inside the Cup Drop Window in order to avoid a die jam alarm If a cup from any station fails to drop inside the Cup Drop Window a Die Jam Alarm is generated for that station The clutch is then de activated for a TDC stop and the station number that failed is displayed on the Keypad Display Die jam protection is provided for up to 16 stations Cup Jam Detection The Cup Drop Window timing signal CH06 along with the machine mounted cup drop sensors are used to verify that the cups do not jam in front of the cup drop sensors If a cup for any station is detected outside the Cup Drop Window timing a cup jam alarm is generated for that station The clutch is then de activated for a TDC stop and the station number that failed is displayed on the HSM CUP7 display Cup jam protection is provided for up to 16 stations Scrap
64. or a description of the menus variables and how to use the Windows based set up program See section 5 for a description of the menus variables and how to use the DOS based set up program HSM CUP7 User s Manual SYSTEMS Electronics Group 17 SECTION 2 INSTALLATION 2 8 1 DEFAULT SET UP VARIABLES As shipped the user variables for the HSM CUP7 are set to the following defaults Brake Wear Compensation Enabled N Desired TDC Stop Position Mid Speed 000 Desired TDC Stop Position High Speed 000 Maximum Allowed Stopping Response degrees 300 Cupper Running Speeds Low Speed SPM 100 High Speed SPM 250 Lubricator Speed Reference Maximum Speed 250 Idle Speed Cupper stopped 075 The CUP7TMG timing channel file as shipped contains the following default timing set points CHAN ON OFF DESCRIPTION CHO0 120 140 TDC High timing CH01 160 180 TDC Mid timing CHO2 200 220 TDC Low timing CHO3 120 200 Air Strip High timing CH04 140 220 Air Strip Mid timing CHO5 150 230 Air Strip Low timing CHO6 140 120 Cup Drop Window timing CHO7 000 020 PLC Timing CH10 CH11 2 _ CH12 2 CH13 gt CH14 _ CH15 _ CH16 _ CH17 oe HSM CUP7 User s Manual SYSTEMS Electronics Group 18 SECTION 2 INSTALLATION 2 8 2 SET CUPPER SET UP PARAMETERS The Cupper set up parameters include e Enabling or Disabling The Brake Wear Compensation e Setti
65. or 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 1997 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description III 1 1 Features 1 1 2 Functional Description 2 1 3 Clutch Brake Control 3 1 3 1 Control of Clutch via Host PLC 4 1 4 Air Strip Control 6 1 5 Brake Wear Compensation 6 1 6 Alarm Detection 7 1 7 Data Collection 8 2 Installation _ 9 2 1 What s Included 9 2 2 Power Required 9 2 3 Mounting the HSM CUP7 10 2 4 Wiring the HSM CUP7 11 2 5 Mounting the RSV34 MS1 Resolver if required 12 2 6 HSM CUP7 Software Installation 13 2 6 1 Windows Based Setup Program Installation __ 13 2 6 2 DOS Based Setup Program Installation 14 2 6 3 SYSdev Program Development Software Installation 15 2 6 4 HSM CUP7 Application Program Installation ___ 15 2 7 Modify Existing PLC Program 16 2 8 HSM CUP7 Set Up 17 2 8 1 Default Set Up Variables 18 2 8 2 Set Cupper Set Up Parameters 19 2 8 3 Set Lubricator Speed References 20 2 8 4 Set Machine Zero 21 2 8 5 Verify Location of Cup Drop Window CHO06 ___ 21 2 8 6 Verify Machine Operation 22 2 9 HSM CUP7 Module Replacement 24 HSM CUP7 User s Manual SYSTEMS Electronics Group HSM CUP7 User s Manual 3 Using the Keypad Display 31 3 2 3 3 3 4
66. p in mid speed when the brake wear compensation is enabled This is typical set to 000 degrees Back Dead Center HSM CUP7 User s Manual SYSTEMS Electronics Group 64 HSM CUP7 User s Manual SECTION 5 HSMCUP7 DOS BASED SET UP PROGRAM REFERENCE Desired TDC Stop Position High Speed This is the desired stopping location in degrees for a TDC stop in high speed when the brake wear compensation is enabled This is typical set to 000 degrees Back Dead Center 5 1 2 MAXIMUM ALLOWED STOPPING RESPONSE Maximum Allowed Stopping Response degrees This defines what the maximum allowed brake response is before the Brake Response Too Long alarm is generated If the actual brake response number of degrees from when the brake is activated to the position where the press ends up at rest when a TDC stop is performed is longer than this number the alarm is generated If the actual brake response is less the alarm is not generated Set this parameter to the value where the brake response is considered too long and service to the brake should be performed typically 270 to 300 degrees 5 1 3 SET CUPPER RUNNING SPEEDS Running Cupper Low Speed SPM This is the speed in strokes per minute that the cupper will run when in low speed Running Cupper High Speed SPM This is the speed in strokes per minute that the cupper will run when in high speed 5 1 4 SET LUBRICATOR SPEED REFERENCES Lubricator Maximum Sp
67. r 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 however may be extended by programming another set point onto an existing set point using either the existing on or off set point as the starting position for the new set point This will result in one larger set point 3 Press ENTER SET POINT to enter the new set point The display will then prompt ON SETPOINT Enter the position in degrees where the set point should go on and press lt ENTER gt The display will now prompt OFF SETPOINT Enter the position in degrees where the set point should go off and press lt ENTER gt The channel will now be programmed with a set point that goes on at the on position entered and off at the off position entered 4 Exit back to the primary set up menu by pressing lt ESC gt Exit back to the default screen by pressing lt ESC gt again SYSTEMS Electronics Group 339 HSM CUP7 User s Manual 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
68. running at the speed entered in Lubricator Maximum Speed the analog output will be at 10 volts This is typically set to the running high speed of the Cupper or slightly higher 2 Lubricator Idle Speed SPM This parameter determines the speed the lubricator will run at when the cupper is stopped de clutched SYSTEMS Electronics Group 54 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE 4 5 3 THE SERIAL COMMUNICATIONS WINDOW The Serial Communications window is used to view the configuration status of the S4516 serial communications board This option is not available for the HSMCUP7 amp HSMCUP unnamed 4516DF1 HSM CUP7 User s Manual SYSTEMS Electronics Group 55 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual 4 5 4 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 setpoints 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 File Edit View Window Help Timing Channels PLs Configuration Timing Channels p Resolver Offset ON OFF Po y TDC High Timing CHOO 120 140 Y TDC Mid Timing CHo1 160 180 4 Soma TDC Low Timing CHo2 20
69. s Group SECTION 1 GENERAL DESCRIPTION 1 4 AIR STRIP CONTROL The HSM CUP7 provides a repeatability of 0 5 milliseconds for the air strip thus reducing die jam problems Air Strip Low Air Strip Mid and Air Strip High timing signals are provided to activate the air strip when the press is running in the respective speeds 1 5 BRAKE WEAR COMPENSATION The HSM CUP7 incorporates a brake wear compensation or automatic TDC timing feature which stops the press at TDC regardless of the actual braking response of the clutch brake The stopping compensation is accomplished by automatically adjusting the TDC timing signal based on the previous stop Any overrun is detected and a new TDC timing signal is computed such that the machine will stop at the desired location on the next stop Three TDC signals are provided one for low speed one for mid speed and one for high speed The mid and high speed TDCs incorporate the break wear compensation feature The appropriate TDC timing signal mid or high is adjusted based on the speed of the machine when the TDC stop was initiated In addition to the brake wear compensation the HSM CUP7 also calculates the actual brake response in degrees This is the number of degrees from where the clutch was de activated TDC timing location to where the crankshaft actually ended up stopping This can then be displayed by the operator or maintenance personnel to determine the conditi
70. s from when the brake is activated to the position where the press ends up at rest when a TDC stop is performed is longer than this number the alarm is generated If the actual brake response is less the alarm is not generated Set this parameter to the value where the brake response is considered too long and service to the brake should be performed typically 270 to 300 degrees HSM CUP7 User s Manual SYSTEMS Electronics Group 19 SECTION 2 INSTALLATION Cupper Running Speeds Set the Cupper running Low Speed and High Speed to the speeds that the cupper will actually run at when the respective speed is selected Note This is not a speed reference but is instead parameters used by the HSM CUP7 to know when to switch between the TDC Low TDC Mid and TDC High timing as well as the Air Strip Low Air Strip Mid and High timing etc See section 3 5 1 Using the Keypad Display section 4 5 2 Windows set up program reference or section 5 1 3 DOS set up program reference for details on setting the set up parameters 2 8 3 SET LUBRICATOR SPEED REFERENCES Set the Lubricator Maximum Speed and Lubricator Idle Speed as desired These parameters are used to control the speed of the lubricator via the 0 10Volt lubricator speed reference output of the HSM CUP7 module Lubricator Maximum Speed The Lubricator Maximum Speed parameter is used to scale the 0 10VDC analog output such that when
71. selection is used to set the various set up parameters in the HSM CUP7 When selected the Cupper Lubricator Set up Parameters menu is invoked The Cupper Lubricator Set up Parameters menu contains the following selections hsmcup EXE Systems HSM CUP Set up Menu Version 1 0 Cupper Lubricator Set up Parameters Enable Disable Brake Wear Compensation Maximum Allowed Cupper Stopping Response Set Cupper Running Speeds Set Lubricator Speed References Enter Selection ESC to exit Fon Brake Wear a Enabte NM A attire ern Sr ee N Desired TDC Stop Position Low Speed 000 Desired TDC Stop Position High Speed 000 Maximum Allowed Stopping Response degrees 300 Cupper Running Speeds Lon Speed SPH isan enna es ee ee ce eee OB HighSpeed SPH ga ik ae Oe Lubricator Speed References Maximum Speed Full Scale Calibration 250 Idle Speed Cupper Stopped 075 The following selections set the corresponding parameters 5 1 1 ENABLE DISABLE BRAKE WEAR COMPENSATION Brake Wear Compensation Enable 0 No 1 Yes This prompt is used to enable or disable the brake wear compensation If the compensation is to be disabled enter 0 and press lt ENTER gt If the compensation is to be enabled enter 1 and press lt ENTER gt Desired TDC Stop Position Mid Speed This is the desired stopping location in degrees for a TDC sto
72. simply press the lt ENTER gt key to gain access to the set up parameters without having to enter a zero If the value of the passcode is a value between 1 and 65 000 Passcode Entry is enabled This requires the operator to enter in the Correct passcode to gain access to the set up parameters Note Passcode entry is only in effect when the Set up Enable selector switch is in the Disable position If an invalid value is entered the passcode value will not be reset and a message box notifying the user of the error is displayed SYSTEMS Electronics Group 46 SECTION 4 HSMCUP7 WINDOWS BASED SET UP 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 amp HSMCUP unnamed Main Display HSM CUP7 User s Manual SYSTEMS Electronics Group 47 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE HSM CUP7 User s Manual 4 4 1 TARGET BOARD INTERFACE This function allows the 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 S g xi Fault Codes Status Program Ident Revision Set Network Address Set Time amp
73. splaying the timing set point menu the following keys are also enabled ENTER SET POINT CLEAR CHANNEL SELECT CHANNEL and SEARCH CHANNEL HSM CUP7 User s Manual SYSTEMS Electronics Group 31 SECTION 3 USING THE KEYPAD DISPLAY HSM CUP7 User s Manual The ENTER SET POINT key is used to enter a new set point both on and off set points in the selected channel The CLEAR CHANNEL key is used to clear all set points from the selected channel The SELECT CHANNEL key is used to select a new channel for programming The SEARCH CHANNEL is used to view both the on and off set points in the selected channel Searching Channel To view the set points in a channel simply press the SEARCH CHANNEL key The next off to on or on to off position is shown in the SETPOINT field If the transition was off to on the state character will be a solid block If the transition was on to off the state character will be blank Entering or Adjusting Set point To set or adjust a timing channel perform the following 1 Select the channel to be adjusted by pressing the SELECT CHANNEL key entering the channel number 00 to 17 and pressing lt ENTER gt In addition the NEXT and PREV keys can be used to advance to the next channel or retard to the previous channel 2 Press CLEAR CHANNEL to clea
74. ssor 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 HSMCUP unnamed Main Display Ioj x Fie Edit View Window Help Messages Machine Speed Machine Position Strokes Die Jams 0 100 0 0 Brake Response Low Speed 0 High Speed o Alarm Reset System Message All Faults Normal ONLINE 10 13 2003 3364M 4 HSM CUP7 User s Manual SYSTEMS Electronics Group 35 SECTION 4 HSMCUP7 WINDOWS BASED SET UP 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 operation can be changed by simply double clicking the online offline mode panel
75. t to communicate with the processor and place the system into an Online mode of operation 4 Set all channels per the General Timing Signal Locations section Setpoints for a particular channel are either entered in the field or 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 setpoints Click the Clear Channel command button the completely clear all setpoints for the selected channel Note Ifa channel has been cleared or the On and Off setpoints have the same setting the set point will be displayed as EEE HSM CUP7 User s Manual SYSTEMS Electronics Group 58 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE 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 E HSMCUP unnamed Machine Timing a E ES ES asi ESI ES ESI a HSM CUP7 User s Manual SYSTEMS Electronics Group 59 SECTION 4 HSMCUP7 WIND
76. the brake response of both the low and high speed stops The response is the number of degrees it takes the press to stop from when the clutch is de activated for a TDC stop to the position that the machine comes to rest 4 5 2 THE SETUP PARAMETERS WINDOW The Set up Parameters window is used to view and adjust any of the set up parameters This window is selected from the Window menu HSMCUP7 unnamed Set Up Of x File Edit View Window Help Lubrication Parameters Brake Wear Compensation Brake Wear Compensation Enable I TDC Stop Position Low Speed 0 TDC Stop Position High Speed 0 Maximum Allowed Stopping Response deg 300 r Cupper Running Speeds Low Speed SPM 100 lt High Speed SPM 250 System Message All Faults Normal ONLINE 10 13 2003 9 52AM y This window utilizes a TAB control to divide the set up parameters into two categories similar to that of the Keypad Display HSM CUP7 User s Manual SYSTEMS Electronics Group 52 HSM CUP7 User s Manual SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE Brake Wear Compensation This section is used to set the brake wear compensation parameters in the M4500 This section contains the following selections 1 2 3 4 Brake Wear Compensation Enable This prompt is used to enable or disable the brake wear compensation If the compensation is to be disable
77. tion 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 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 and the user is given the choice of the following options E HSMCUP unnamed Main Display Eile Edit View Window Help New Ctrl Open Ctrl O Save Ctrl S Save As Export Shift Data Ctrl x lt Upload save Data Machine Position r Strokes Die Jams Download Program m aaa MEE Download Data Set up Parameters Timing Channels Shift Data Print Report Ctrl P Exit High Speed O Alarm Reset System Message All Faults Normal ONLINE 10 13 2003 9 49AM y Set up Parameters This option downloads the Set up data to the M4500 This includes cupper and lubrication set up parameters SYSTEMS Electronics Group 42 SECTION 4 HSMCUP7 WINDOWS BASED SET UP PROGRAM REFERENCE Timing Channels This option downloads the Machine Timing channel set
78. to download the HSMCUP7 application program to the HSM CUP7 module This should only be performed when either replacing the module or when the program has been changed To download the program perform the following Note Program download cannot be performed while the cupper is running All outputs on the HSM CUP7 are turned off and no program execution is performed The cupper should therefore be stopped before the download takes place 1 2 3 4 5 Connect the RS 232 cable from the COM port on the computer to the PROG port on the HSM CUP7 Select 4 Download Program to Module from the Main Menu The current program ident revision and checksum for both the program on disk and already loaded in the module will be displayed 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 If a prompt stating that the HSMCUP7 file could not be opened is displayed then the HSMCUP7 application program is not installed in the current directory Once program download is initiated HSM CUP7 program execution will cease the current address being downloaded will be displayed and the RUN LED on the module will flash continuously Once the download is complete the RUN LED on the module will illuminate solid and program execution in the HSM CUP7 will resume Press any key to return back to the HSMCUP7
79. wiring connectors from the top of the HSM CUP7 module With the gasket installed on the HSM CUP7 module mounting studs slide the HSM CUP7 module into the cut out from the front Attach the HSM CUP7 module to the door using the supplied hardware 3 Once the module is installed a lugged earth ground wire should be installed on one of the module mounting screws to insure that the HSM CUP7 is well grounded 3 500 8 000 1 875 0 218 0 475 w 1 775 4 450 Figure 1 HSM CUP7 Recommended Panel Door Cut out HSM CUP7 User s Manual SYSTEMS Electronics Group 10 SECTION 2 INSTALLATION 2 4 WIRING THE HSM CUP7 Referring to the electrical control schematic at the back of this manual wire the HSM CUP7 as follows Note The HSM CUP7 contains removable field wiring connectors for ease of maintenance It is generally easier to perform the wiring described below with the connectors removed from the module and then installing the connectors to the module once all wiring is complete 1 Incoming Power 115VAC 230VAC to L N and G of HSM CUP7 power connector and 24VDC to I O connectors 2 Interlocks from existing control system to HSM CUP7 inputs B100 0 B100 1 B100 2 B100 3 B100 4 B100 5 B100 6 and B100 7 3 Interlocks to existing control system from HSM CUP7 outputs B110 6 B110 7 B111 0 B111 3 B111 4 B111 5 and B111 6 4 Clutch a

HSM-CUP7 Cupper High Speed Logic Module User`s Manual

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