SECTION 2 INSTALLATION
Contents
1. 1 Count the number of pins from the spindle wheel to disc transfer location to the bad can pin chain blow off port 2 From the primary setup menu using the Keypad Display select option 2 Set Pin Chain QC Blow off Parameters Press the NEXT key until PINS TO PIN CHAIN BLOW OFF PORT is displayed 3 The number entered is the number counted minus 2 this is still just an approximation 4 Set the CANS TO BLOW OFF FOR EACH MISLOAD press the PREV key equal to five 5 Run the machine at low speed Open the infeed and allow cans to load and be printed After cans have passed the pin chain blow off port close the infeed and observe the number of cans blown off Note Half prints or silver cans may get through the line until this variable is set up properly Adjust the number of pins to pin chain blow off such that whenever the infeed is closed one half printed can is consistently blown off If no cans are blown off the number of pins to pin chain blow off is too high blow off comes on too late Reduce the number of pins to pin chain blow off and repeat this step again If more than one can is blown off the number of pins is too low blow off comes on too early Increase the number of pins to pin chain blow off and repeat this step again 6 Set the CANS TO BLOW OFF FOR EACH MISLOAD equal to 3 Run the machine at low speed with cans and verify that for each miss loaded can three bad cans are blo2. Continue decreasing this time until this can is 1 4 to 1 2 printed press the NEXT key If the can behind the miss load carriage extended on is less than 1 2 printed or silver the Print Carriage extend in response time is too short and the carriage is not extending soon enough Increase the Print Carriage extend in response time by 5 milliseconds and try again Continue increasing this time until this can is 1 2 to 3 4 printed If this can is more than 3 4 printed or fully printed the Print Carriage extend in response time is too long and the carriage is extending too soon Decrease the Print Carriage extend in response time by 5 milliseconds and try again Continue decreasing this time until this can is 1 2 to 3 4 printed Note The extend in time is a function of the retract out time Therefore the retract out time should always be set as desired first before setting the extend in time HSL CD4 User s Manual SYSTEMS Electronics Group 21 SECTION 2 INSTALLATION Prior to setting the varnish unit retract extend response times set the number of shifts to the varnish unit For older generation Rutherford Decorators this is set to 5 For newer decorators this is set to 4 In general this is set such that the varnish unit retracts out on the can ahead of the misloaded spindle Set the varnish extend and retract response times in the same fashion as was done for the carriage In general the mis
3. HAIN BLOW OFF TIMING 1 Set the bad can pin chain blow off timing CH05 such that the timing signal just turns ON when the pin chain blow off port is centered between pins PREVIOUS GOOD CAN BLOW OFF PORT BAD CAN TO BE BLOWN OFF Location of Blow off Timing ON Position channel 05 or 06 2 From the primary setup menu using the Keypad Display select option 3 Set Machine Timing set points etc and perform the following a With the machine stopped view the resolver position b Select timing channel CH05 Pin Chain Blow off c Clear the channel press the CLEAR CHAN key d Enter a new set point press the ENTER SET POINT key The ON SETPOINT should be the current position of the resolver press the ENTER key The OFF SETPOINT should be set 40 degrees after the ON set point press the ENTER key e Search the channel to confirm only one set point one on setting and one off setting HSL CD4 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 10 5 SET OF PINS TO PIN CHAIN BLOW OFF PORT Perform the following to set the of pins to pin chain blow off port Note That the chain take up must be after the bad can pin chain blow off port for reliable pin chain blow off If the take up is before the port the relative position of the port to the blow off timing will vary as the take up moves causing partial blow offs to occur
4. SECTION 2 INSTALLATION 2 10 TUNING THE HSL CD4 The HSL CD4 is shipped from the factory with the PLC application program loaded in the M4500 module PLC section and the PLS channel set point file CD4TMG loaded in the PLS section These standard programs are used to implement the decorator or basecoater algorithms In most cases the following user variables and timing signals may have to be altered to tune the HSL CD4 to the actual decorator it is controlling Once the system is installed and powered back up perform the following to set up and tune the HSL CD4 The set up is performed using either the Keypad Display or a PC running the set up program See the HSM CD4 CD7 Keypad Quick Reference for key depress sequences for entering the following parameters See section 3 of this manual for a description of the Keypad commands and menu displays of the Keypad Display See sections 4 and 5 for a description of menus and variables and how to use the set up programs 2 10 1 DEFAULT SET UP VARIABLES As shipped the user variables for the M4500 are set to the following defaults Print Carriage and Varnish Unit Print Carriage retract response time msec 45 Print Carriage extend response time msec 45 Varnish Unit retract response time msec 60 Varnish Unit extend response time msec 60 Number of Shifts to Varnish Unit 75 Bad Can pin chain Blow off of cans to blow off from infeed open 6 of cans to blow off from prin
5. Set Up key b Press the 5 key Zero Machine set resolver offset c Enter 0 to zero the resolver and set the offset The timing channel set up menu will be displayed showing the position POS at zero HSL CD4 User s Manual SYSTEMS Electronics Group 16 SECTION 2 INSTALLATION 2 10 3 VERIFY LOCATION OF CAN NO CAN SENSOR Verify that the location of the can no can sensor is at the 2nd spindle from 12 o clock when the machine is at zero CAN NO CAN SENSOR CAN NO CAN SENSOR pS CAN Wa MANDREL VARNISH ROLLER Location of Can No Can Sensor Verify the location of the Can No Can sensor Place a can on a spindle and slowly jog it past the sensor The sensor should first see the can at between 300 and 0 degrees If it does the location of the sensor is correct Note The Can No Can sensor ON position can be viewed by selecting option 6 View Critical Input Positions from the primary setup menu using the Keypad Display If the sensor first sees the can between 0 and 30 degrees the system will still function correctly but the Damaged Can Blow off HI CH04 and LOW CH03 timing signals may have to be adjusted If the Can No Can sensor first sees the can outside the 300 to 30 degree range the sensor should be moved to within the 300 to 0 degree range HSL CD4 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 10 4 SET PIN C
6. it still increments another spindle number continue adjusting the Spindle Trip Shift Offset until it does Stop the machine and remove the tape from spindle 1 The machine is now set up and ready to run HSL CD4 User s Manual SYSTEMS Electronics Group 93 2
7. primary setup menu using the Keypad Display select option 2 Set Pin Chain QC Blow off Parameters Press the NEXT key until OF CANS FROM INFEED TO CAN PRX is displayed 2 Initially set this value to 6 If an infeed star wheel is used set this value to 12 3 Run the machine at low speed Open the infeed and allow cans to load and be printed From the default display of the Keypad Display observe the BLOWOFFS field At Infeed Open this number should increment up by the number of cans to blow off at infeed open Observe that this same number of cans are blown off at the bad can pin chain blow off port 4 Ifthe number of cans blown off was less than the number counted increase the number of cans from infeed to can PRX by the difference 5 Ifthe number of cans blown off was more than the number counted decrease the number of cans from infeed to can PRX by the difference HSL CD4 User s Manual SYSTEMS Electronics Group 20 SECTION 2 INSTALLATION 6 Continue to adjust this parameter until the actual number of cans blown off at infeed open is equal to the desired 2 10 8 SET PRINT CARRIAGE AND VARNISH UNIT RETRACT EXTEND RESPONSE TIMES The retract and extend response times is the amount of time the control system will lead the trip point CHO00 for the print carriage CHO1 for the varnish unit to compensate for the mechanical response time of the machine To verify the print carriage and va
8. rnish unit trip control run the machine at high speed induce miss loads and observe the cans blown off at the pin chain blow off Note Pressing the Blank Key on the Keypad Display while the default display is shown will electronically induce a misload into the system The miss loaded can should be completely silver The can ahead of the miss load can the carriage retracted on should be blown off at the pin chain blow off port and should be 1 4 to 1 2 printed The can behind the miss load the can the carriage extended on should be blown off at the pin chain blow off port and should be 1 2 to 3 4 printed Any additional cans blown off following the half print behind the miss load should be fully printed and of good quality print From the primary setup menu using the Keypad Display select option 1 Set Carriage Varnish Response Times If the can ahead of the miss load carriage retracted on is fully printed or more than half printed the Print Carriage retract out response time is too short and the carriage is not retracting soon enough Increase the Print Carriage retract out response time by 5 milliseconds and try again Continue increasing this time until this can is 1 4 to 1 2 printed If this can is less than 1 4 printed or silver the Print Carriage retract out response time is too long and the carriage is retracting too soon Decrease the Print Carriage retract out response time by 5 milliseconds and try again
9. s loaded can should have no varnish on it the can ahead and behind should be approximately 2 3 varnished 2 10 9 SET QC BLOW OFF SHIFT OFFSET If the QC Can select a can feature is used set the QC can blow off port shift offset as follows 1 Dial in spindle 1 on the Select A Can thumbwheel switch This function can also be performed from the Keypad Display utilizing the QC BLOW OFF key and entering 1 2 With the machine running slowly mark cans printed on spindle 1 so they can be identified while on the pin chain 3 Press the Select A Can pushbutton and compare the can that was actually blown off with the location of a can marked on spindle 1 4 From the primary setup menu using the Keypad Display select option 2 Set Pin Chain QC Blow off Parameters Press the NEXT key until QC BLOW OFF SHIFT OFFSET 1 24 is displayed Add the difference between the can actually blown off and the marked can on spindle 1 to the QC blow off shift offset and enter this as the new offset number 5 Continue to adjust the offset number until a can marked on spindle 1 is blown off Note This variable must be a number between 1 and 24 as there is always a can printed on spindle 1 every 24 cans HSL CD4 User s Manual SYSTEMS Electronics Group wD se SECTION 2 INSTALLATION 2 10 10 SET BLANKET WHEEL SEGMENTS The blanket wheel segments is the value used to blow off a consecutive number of cans star
10. t at restart 4 of cans to blow off from varnish at restart 4 of cans to blow off for each misload 13 of pins to pin chain blow off port 5 of cans from infeed to can PRX 6 Blow off solenoid on response time msec 15 Blow off solenoid off response time msec 20 QC Can select a can Blow off Blow off solenoid on response time msec 15 Blow off solenoid off response time msec 20 QC can blow off port shift offset A Blanket wheel segments 8 Spindle Trip Offset 0 HSL CD4 User s Manual SYSTEMS Electronics Group 14 SECTION 2 INSTALLATION The CD4TMG timing channel file as shipped contains the following default timing set points CHAN ON CH00 020 CHO1 010 CHO2 180 CHO3 060 CH04 030 CH05 250 CH06 255 CH07 000 CH10 000 CH1 CH12 CH13 CH14 CH15 CH16 CH17 OFF HSL CD4 User s Manual DESCRIPTION Carriage trip timing Varnish trip timing Can No Can clock Damaged Can Blow off Low speed Damaged Can Blow off High speed Pin Chain Blow off bad can timing Select A Can QC Blow off timing Can Gate Timing PLC Clock Timing SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION 2 10 2 SET MACHINE ZERO 1 Position the machine at machine zero MANDREL CENTERED IN NOTCH OR HOLE BLANKET WHEEL Machine Zero Position as seen from back of machine 2 Set the resolver offset Using the Keypad Display perform the following a Press the
11. ting with blanket 1 whenever a Blanket QC Blow off is initiated QC blow off code 25 Set the number of Blanket Wheel Segments as follows 1 From the primary setup menu using the Keypad Display select option 2 Set Pin Chain QC Blow off Parameters Press the NEXT key until BLANKET WHEEL SEGMENTS 4 12 is displayed last setup parameter in this menu 2 Enter the number of segments on the blanket wheel 2 10 11 SET SPINDLE TRIP SHIFT OFFSET Set the Spindle Trip Shift Offset as follows 1 From the primary setup menu using the Keypad Display select option 2 Set Pin Chain QC Blow off Parameters Press the NEXT key until SPINDLE TRIP SHIFT OFFSET 0 23 is displayed last setup parameter in this menu 2 Initially set the Spindle Trip Offset to zero 3 Wrap a piece of tape around spindle 1 such that cans will not load on this spindle With the machine running slowly open the can gate and verify that cans do not load on spindle 1 and that the print carriage is tripped for that spindle 4 Observe the Trips per Spindle data and determine which spindle number is being incremented The spindle number that should be incrementing is spindle 1 If it is not subtract 1 from the spindle number that is being incremented and enter this value as the Spindle Trip Shift Offset 5 Verify that the spindle 1 count is incremented every time the carriage trips for spindle 1 If
12. wn off miss loaded silver can blown off at damaged can blow off port half print cans ahead and behind miss loaded can blown off at pin chain port If not adjust of pins to pin chain blow off port accordingly until they are HSL CD4 User s Manual SYSTEMS Electronics Group 19 SECTION 2 INSTALLATION Note Once this variable is set it may be desirable to set the of cans to blow off for each misload equal to 4 or 5 until the print carriage and varnish unit response times are set in steps 5 and 6 This is done so that the cans following the miss load can be verified for proper print Once this is done the of cans to blow off for each misload can be set back to 3 2 10 6 SET OF CANS TO BLOW OFF AT RESTART From the primary setup menu using the Keypad Display select option 2 Set Pin Chain QC Blow off Parameters Set the following infeed open restart blow off parameters as desired a of Cans to Blow off at Infeed Open b of Cans to Blow off from Print at Restart c of Cans to Blow off from Varnish at Restart 2 10 7 SET OF CANS FROM INFEED TO CAN PRX This parameter is used to adjust the number of stations from the can gate solenoid to can no can sensor Default value is set to 6 stations Some Rutherford decorators utilize an infeed star wheel adding an additional 6 total 12 stations from infeed to can PRX Perform the following to set the of Cans from Infeed to Can PRX 1 From the
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