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1. Previous Pressing this key moves to the previous adjustment field or displays the previous menu or display Holding this key depressed for one second will move to the previous field or display continuously If display selection is returned to the top of the order this key will have no effect SYSTEMS Electronics Group 17 SECTION 3 USING THE KEYPAD DISPLAY HSM DUCTOR User s Manual lt INC gt Increment Pressing this key once increments the currently selected field value by one Holding this key depressed for one second will increment the currently selected field continuously This key is only active in the adjustment mode lt DEC gt Decrement Pressing this key once decrements the currently selected field value by one Holding this key depressed for one second will decrement the currently selected field continuously This key is only active in the adjustment mode lt DISPLAY DATA gt Cycle Counts Pressing this key displays the total number of cycles for each ductor Pressing this key the first time displays the counts for ductors 1 and 2 press the lt NEXT gt to advance to the next display lt PREV gt to retard to the previous display The display will automatically advance to the next display approximately every 7 5 seconds until all cycling counts have been displayed lt RESET COUNTS gt Pressing this key allows the total cycle counts for each ductor to be reset A prompt is displayed asking which ductor
2. folder SYSTEMS Electronics Group 237 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE 4 3 3 EDIT COLOR CONTROL PASSCODE The edit Color Control Passcode is an Online function only This allows the user the ability to directly change the value of the Color Control Passcode Once selected an input box is displayed allowing the user to view the current Passcode setting and to change the value if necessary Please Enter New Passcode 0 65535 Cancel If the passcode is set to zero passcode entry is disabled The operator would then press the Color Control key on the Keypad Display and then press the lt ENTER gt key to gain access to the color control settings without having to enter a zero If the value of the Color Control Passcode is set somewhere between 1 and 65 000 Passcode Entry is enabled This requires the operator to enter in the Correct passcode to gain access to the color control 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 HSM DUCTOR User s Manual SYSTEMS Electronics Group 38 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE 4 4 THE VIEW MENU The View menu allows the user to perform the following functions
3. Duration 0 1 Cans 200 Solenoid Response Time Compensation msec 025 Color Gain ColorGain 100percent per 2000CPM 100 Ductor Feedback Fault Enable Disable Ductor 1 Feedback Fault Enabled N Ductor 2 Feedback Fault Enabled N Ductor 3 Feedback Fault Enabled N Ductor 4 Feedback Fault Enabled N Ductor 5 Feedback Fault Enabled N Ductor 6 Feedback Fault Enabled N Ductor tt Feedback Fault led os Ductor 8 Feedback Fault Sides estas eee 5 1 1 SET MAXIMUM CYCLE DURATION 0 1 CANS The maximum cycle duration is the maximum cycle time in 0 1 cans for one cycle of the ductor This parameter limits the upper value that the operator can enter for the cycle duration If the operator attempts to enter a value higher then this limit the value will default back to the original number The range of this parameter is 140 999 5 1 2 SET MAXIMUM ON DURATION 0 1 CANS This parameter limits the upper value that the operator can enter for the ON duration The cycle duration is the total cycle time in 0 1 cans that the ductor roll is in contact with the fountain roll Ifthe operator attempts to enter a number higher than the maximum ON duration the value will default back to the previous value The range of this parameter is 0 200 SYSTEMS Electronics Group 52 SECTION 5 HSMDCTR DOS B
4. e View the Target Board Interface e View Online Data e View Offline Data amp HSM DUCTOR unnamed Main Display Target Board Interface HSM DUCTOR User s Manual SYSTEMS Electronics Group 39 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE HSM DUCTOR 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 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 M4503 If unsuccessful a warning message will be displayed prompting the user to either Retry or Cancel the op
5. This section describes the features of the HSM DUCTOR package This includes the functional description the user and operator selectable parameters the inputs required and outputs provided etc 1 1 FEATURES e Replaces mechanically cammed ductors on can decorator with pneumatically controlled ductors Controls cyclic ductor solenoids on decorator to a resolution of one tenth of a can at speeds up to 2400CPM e Enables the operator to perform quick label changes by recalling the ductor Cycle and On duration used the last time the particular label was run e Controls cyclic ductor solenoids directly e Incorporates optional ductor feedback sensor inputs to speed compensate for the response time of the solenoid and verify that the ductors are cycling e Keypad adjustment of label parameters Label Number Cycle Duration and On Duration e Stores label parameters for up to 100 labels e User selectable ductor configuration parameters including maximum Cycle duration maximum On duration response time compensation and individual ductor feedback enable e Ductor cycle count data collection allows the viewing of the total number of cycles each ductor has made This is used for life expectancy and predictive maintenance purposes to determine when air cylinders or solenoids should be replaced e Passcode security access for adjusting label parameters e Manual Off Auto modes of operation e Provides control
6. 1 0 Main Menu Set Ductor Parameters Download Program to Module Download Set up data to Module Upload Save Set up data from Module Enter Selection ESC to exit Fon NOTE Before selecting one of the four selections listed above connect an RS 232 cable from COM1 on the computer to the PROG PORT on the M4503 Note The set up program is an on line communications program used to interface with the M4503 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 selections make sure an RS 232 cable is connected from the COM port on the computer to the PROG port on the M4503 The following sections are a complete description of the set up program selections and menus SYSTEMS Electronics Group 51 SECTION 5 HSMDCTR DOS BASED SET UP PROGRAM REFERENCE HSM DUCTOR User s Manual 5 1 SET DUCTOR PARAMETERS This selection is used to set the ductor solenoid control parameters in the M4503 The Set Ductor Parameters menu contains the following selections f HSMDCTR EXE iol x Systems Pneumatic Ductor Set up Menu Version 1 0 Ductor Parameters set up 1 Set Maximum Cycle Duration 2 Set Maximum On Duration 3 Set Solenoid Response Time Compensation 4 Set Color Gain 5 Enable Disable Ductor Feedback Fault Enter Selection ESC to exit Maximum Cycle Duration O Cans oeaan Ob Maximum On
7. 8 N SYSTEMS Electronics Group T22 HSM DUCTOR User s Manual SECTION 2 INSTALLATION 2 7 HSM DUCTOR SET UP The HSM DUCTOR is shipped from the factory with the HSMDCTR application program loaded into the M4503 module This is a standard program used to implement the HSM DUCTOR pneumatic ductor algorithms Once the HSM DUCTOR is installed and the control system is powered up perform the following 1 2 3 4 Modify the existing host PLC program such that the PLC output connected to B100 2 Ductors Auto ON is ON whenever cans are feeding into the decorator Set the desired Maximum Cycle Duration The Maximum Cycle Duration is set to 1 10 of a can resolution The range of this parameter is from 140 to 650 and defines the upper limit or the longest amount of time between ductor cycles Care should be taken not to set this parameter too low as this would restrict the operators range of adjustment The Cycle duration is set individually for each ink station and is the rate at which ink is transferred from the fountain roll Set the desired Maximum On Duration The maximum On duration is set to 1 10 of a can resolution The range of this parameter is from 0 to 200 and defines the upper limit or the longest amount of time the ductor roll can be in contact with the fountain roll The On duration is set individually for each ink station and is the amount of time the ductor roll is in
8. HSM DUCTOR User s Manual SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE Solenoid Response Time The Solenoid Response time is an indication of the reaction time of pneumatic ductor The response times are only valid when the optional feedback sensors are used The response times for each ink station can be easily viewed by adjusting the station number The following is a description of each of these settings 1 Station Number The ink station mask to view the response time of the ductor solenoid 2 Solenoid On Response Time msec This displays the amount of time msec from first activation of the solenoid to contact with the fountain roll 3 Solenoid Off Response Time msec This displays the amount of time msec from first deactivation of the ductor solenoid to lift off from fountain roll Ductor Status The ductor Status gives the user an indication of the status of the input signals used to control the pneumatic ductor these are as follows 1 Operational Mode A three position selector switch is used to set the operation mode of the ductors auto off manual This display reflects the position of the selector switch 2 Ductors Auto On This displays the state of the ductors Auto On input to the M4503 Ductors Manual Control This allows the user to toggle individual ductor solenoids when the ductors operational mode is Manual and the machine is at Zero speed mai
9. Once Set Up has been enabled the HSM DUCTOR is in a configuration mode and passcode protection is disabled Ductor Feedback Sensors B101 0 B101 7 These inputs are used to verify the ductors for proper operation see section 1 3 Ductor Feedback Machine Mounted Resolver The M4503 module incorporates a built in PLS which interfaces directly with the machine mounted resolver and provides all timing relating to the ductor control system eliminating the need for an external PLS SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSM DUCTOR User s Manual 1 7 OUTPUTS The HSM DUCTOR provides the following DC outputs Ductor Solenoids B110 0 B110 7 These outputs drive the pneumatic ductor solenoids directly The solenoids are cycled at the rate specified by the operator settings Ductor Fault B111 0 B111 7 These outputs are activated whenever the corresponding ductor is detected as failed via the ductor feedback inputs These outputs are also interlocked with the fault FLT relay this relay is energized when all faults are normal The Ductors Run Enable contact should be interlocked with the existing control system to stop the decorator if a fault is detected These faults can be enabled or disabled on an individual basis via Set Up on the keypad display 1 8 MANUAL OFF AUTO CONTROL The HSM DUCTOR contains a MANUAL OFF AUTO selector switch This is used to determine the mod
10. SYSdev PROGRAM DEVELOPMENT SOFTWARE INSTALLATION The SYSdev Program Development software is used to perform on line trouble shooting and program modifications to the M4503 If SYSdev was purchased with the control system and is not already installed on the computer install SYSdev onto the hard drive of your computer following the steps outlined in the SYSdev Program Development Manual 2 5 3 APPLICATION PROGRAM INSTALLATION The application program is a SY Sdev based program loaded into the M4503 module and performs the HSM DUCTOR 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 HSMDCTR 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 PRINTER directories created in section 2 8 2 copy all the files from the disk to each of these subdirectories 2 6 DEFAULT DUCTOR CONFIGURATION SETTINGS As shipped the ductor configuration settings are as follows Maximum Cycle Duration 0 1 cans 500 Maximum ON Duration 0 1 cans 200 Response Time Compensation msec 25 Color Gain CG 100 per 2000CPM 100 Feedback Enable Stations 1
11. a set up Data File This function is accessed from the File menu and the user is given the choice of the following options HSM DUCTOR unnamed Main Display Ol x File Edit View Window Help New Ctrl N Open Ctrl 0 Save Ctrl S Save As Export Shift Data Ctrl Upload save Data Set up Data Alarm Reset Download Program Shift Data Download restore Data gt Label Data Reset Alarms Report Setup l Print Report Ctrl P Exit ONLINE 10 16 2003 4 34PM y System Message All Faults Normal Set up Data This option uploads the ductor cycling parameters data from the M4503 Shift Data This option uploads the Shift Data from the M4503 This is the individual cycling counts for each ductor Label Data This option uploads the Label Data from the M4503 This is the ON duration and CYCLE duration settings for each label The user will be prompted to select a range of labels to upload or select All default This allows the user to upload the label information from one processor and download it to another without altering any of the other set up parameters or shift data registers All This option allows the user to completely upload All of the set up parameters shift data and label data from the M4503 SYSTEMS Electronics Group 3 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 3 DOWNLOAD P
12. counts for the remaining ductors SYSTEMS Electronics Group 24 HSM DUCTOR User s Manual SECTION 3 USING THE KEYPAD DISPLAY 3 8 RESETTING THE TOTAL NUMBER OF CYCLES FOR EACH DUCTOR To reset the total number of cycles for each ductor perform the following Note this procedure should only be performed when replacing a component air cylinder solenoid etc for a particular ductor 1 Press the lt RESET COUNTS gt key The Reset Ductor Cycle Counts screen will be displayed 2 To reset an individual ductor count press the corresponding number of that ductor 1 to 8 and press lt ENTER gt The cycle count for that ductor will be reset 3 To reset the counts for all the ductors press lt 0 gt and then lt ENTER gt 4 To exit out of the screen without resetting any of the ductor counts press lt ESC gt SYSTEMS Electronics Group 25 SECTION 3 USING THE KEYPAD DISPLAY This Page Intentionally Left Blank HSM DUCTOR User s Manual SYSTEMS Electronics Group 26 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE The Windows based set up program is menu driven allowing the user to easily view data alter set up variables or set color control parameters 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 M4503 to match the configuration and performance of the specific printer see section 2 7 HSM Ductor Set
13. cycle the last time the label was run The only additional set up required at label change over is to set the keys open and closed at the required areas on the can The following sections describe the recommended procedure for setting up a label and the recommended procedure for a label change over using a label which has previously been programmed into the color control SYSTEMS Electronics Group 19 SECTION 3 USING THE KEYPAD DISPLAY HSM DUCTOR User s Manual 3 3 SET UP PNEUMATIC DUCTOR PARAMETERS This menu is activated when the Set up key is pressed The following set up parameters may then be adjusted or viewed Note For virtually all the menus the lt NEXT gt and lt PREV gt keys can be used to advance to the next or previous parameter respectively To change the currently displayed parameter simply enter the new value on the numeric keypad and press lt ENTER gt The value will be entered and the next parameter will automatically be displayed When the last parameter in a section is entered the primary set up menu is again displayed Pressing lt ESC gt at anytime will exit back to the main display menu The following parameters are used to define the ductor configuration Maximum Cycle Duration The maximum Cycle duration is set to 1 10 of a can resolution The range of this parameter is from 140 to 650 and defines the upper limit or the longest amount of time between ductor cycles Care sh
14. for inaccuracies In the interests of a commitment to a policy of continuous development and improvement the manufacturer reserves the right to change the specification of the product or it s performance or the contents of the User Manual without notice Copyright 2001 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description 1 Features Functional Description Ductor Feedback Operator Adjustable Parameters User Selectable Ductor Configuration Inputs Outputs Manual Off Auto Control oe ee ee ES ONOORWNH DONA RAON 2 Installation 7 2 1 What s Included 7 2 2 Power Required 8 2 3 Mounting the HSM DUCTOR 8 2 4 Wiring the HSM DUCTOR 9 2 5 HSM DUCTOR Software Installation 9 2 5 1 Windows Based Setup Program Installation __ 10 2 5 2 DOS Based Setup Program Installation 11 2 5 3 SYSdev Program Development Software Installation 12 2 5 4 Application Program Installation 12 2 6 Default Ductor Configuration Settings 12 2 7 HSM DUCTOR Set up 13 2 8 M4503 Module Installation 15 2 9 Download Program and Label Data to M4503 16 3 Using the Keypad Display 17 3 1 Overview of Keypad and Display 17 3 2 Recommended Procedure 19 3 3 Set up Pneumatic Ductor Parameters 20 3 4 Selecting the Label Number 22 3 5 Light Dark Color Adjustment of Ink Station 22 3 6 Change Over using Existing Label 24 3 7 Viewing the Total Number of Cycles for Each Ductor___ 24 3 8 Resetting the Total Number
15. for up to 8 ink station machines SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION e Provided with DOS or Windows based Set up program This allows all set up data and label data to be uploaded from the M4503 and saved to disk for back up e Built in 2 Line X 40 character sealed display with 24 key keypad allows setting of all user parameters and local viewing of collected data ductor cycle counts e Interfaces directly with machine mounted resolver e Based on high performance M4503 PLC PLS module that allows easy trouble shooting and user customization using SY Sdev DOS based programming package 1 2 FUNCTIONAL DESCRIPTION The pneumatic ductor color control replaces mechanically cammed ductors with pneumatically controlled ductors The ductors are now activated by air cylinders controlled by solenoids driven by the M4503 This allows the cycle duration number of cans between one complete ductor cycle and the duty cycle the time the ductor is in contact with the fountain roll or On duration to be adjusted independently for each ink station This allows the ink flow rate of each station to be adjusted based on the amount of ink required for each particular color on the label The maximum Cycle duration maximum On duration Response Time compensation and Color Gain are set using either the set up program or Keypad Display These values are used with all labels The operator
16. initiated the current address being downloaded will be displayed Note M4503 program execution is not ceased therefore data download can be performed while the machine is running 4 Once set up data download is complete press any key to return to the main menu SYSTEMS Electronics Group 55 SECTION 5 HSMDCTR DOS BASED SET UP PROGRAM REFERENCE 5 4 UPLOAD SAVE SET UP DATA FROM MODULE This selection is used to save set up variables from the M4503 to the hard drive current directory selected This should be performed periodically to save the label data settings or whenever any of the set up variables are 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 parameters listed in the 1 Set Ductor Parameters menu 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 M4503 2 Select 4 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 M4503 program execution is
17. of the selected program The user must confirm their selection by clicking the Yes command button After the user confirms their choice program download is initiated and the current program download address is displayed When program download is complete the user is prompted to acknowledge Control is passed back to the main program and the set up program remains in an Online edit mode 4 2 4 DOWNLOAD RESTORE DATA The set up program allows the user to download Set up data shift data and Label data to the M4503 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 amp HSM DUCTOR unnamed Main Display Eile Edit View Window Help New Ctrl N Open Ctrl O Save Ctrl S Save As Export Shift Data Ctrl Upload save Data gt Alarm Reset Download Program Download restore Data Set up Data Reset Alarms Shift Data Report Setup Print Report Ctrl P A Exit System Message All Faults Normal ONLINE 10 16 2003 4 34PM 7 HSM DUCTOR User s Manual SYSTEMS Electronics Group 34 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE Set up Data This option downloads the ductor cycling parameters data from the M4503 Shift Data This option downloads the Shift Data from the M4503 This is the individual cycling counts for each
18. only active while Online and displays the current speed of the machine in Cans Per Minute Alarm Reset This function is only available On Line SYSTEMS Electronics Group 43 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE HSM DUCTOR User s Manual 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 amp HSM DUCTOR unnamed Set Up File Edit View Window Help Cycling Parameters Maximum Cycle Duration 0 1 cans 500 el Maximum ON Duration 0 1 cans 200 Response Time Compensation msec 25 Color Gain CG 100 per 2000CPM 100 Feedback Enable HB 8 8 8 8 Bw wt i Enable All Disable All System Message All Faults Normal ONLINE 10 16 2003 4 37 PM y Cycling Parameters This is used to set the ductor solenoid control parameters in the M4503 This section contains the following selections 1 Maximum Cycle Duration 0 1 cans The maximum cycle duration is the maximum cycle time in 0 1 cans for one cycle of the ductor This parameter limits the upper value that the operator can enter for the cycle duration If the operator attempts to enter a value higher then this limit the value will default back to the original number The range of this parameter is 140 999 2 Maximum ON Duration 0 1 cans This
19. parameter limits the upper value that the operator can enter for the ON duration The cycle duration is the total cycle time in 0 1 cans that the ductor roll is in contact with the fountain roll If the operator attempts to enter a number higher than the maximum ON duration the value will default back to the previous value The range of this parameter is 0 200 SYSTEMS Electronics Group 44 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE 3 Response Time Compensation msec This parameter is the difference in msec between the ON and off response times of the ductor solenoid This is used to adjust the ON duration to compensate for the mechanical response time of the whole mechanism As an example if the ON response time was 40 msec and the off response time was 15 msec Then the value entered for this parameter would be 25 msec Note If the optional feedback sensors are used set this parameter to 0 The feedback sensors will automatically adjust the ON duration based on the response time of the solenoids 4 Color Gain This parameter allows the color density to be increased proportionately up or down as a function of machine speed The valid range of this parameter is 50 to 150 per 2000 CPM When set to 100 no increase or decrease as a function of speed will occur When set to 50 the color density will drop 50 from 0 to 2000CPM When set to 150 the colo
20. 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 print manager which allows the user to continue with their work while the document is being printed 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 Edit the Color Control Passcode HSM DUCTOR unnamed Main Display Ol x File Edit View Window Help Comm Port Ctrl M Color Control Passcode m Machine CPM Alarm Reset l 0 Reset Alarms System Message All Faults Normal ONLINE 10 16 2003 4 35PM y SYSTEMS Electronics Group 36 HSM DUCTOR User s Manual SECTION 4 HSMDUCTOR WINDOWS BASED SETUP 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 a
21. 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 30 HSM DUCTOR User s Manual SECTION 4 HSMDUCTOR WINDOWS BASED SETUP 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 31 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE HSM DUCTOR User s Manual 4 2 2 UPLOAD SAVE DATA The Set up program allows the user to upload set up parameters color control settings and shift data from the M4503 into
22. to reset Enter the corresponding number of the ductor to reset that individual ductor count Press lt 0 gt to reset all the ductor counts Press lt ESC gt to reset none of the ductor counts and return to the main menu lt SET UP gt Pressing this key allows the user to set up the ductor configuration parameters This key is only active when set up has been enabled lt ALARM RESET gt Pressing this key resets any active ductor fault alarms feedback detected failure This key is only active when the main default display or fault display is active lt COLOR CONTROL gt Pressing this key allows the operator to select a new label number adjust the Cycle and On durations independently for each ink stations or program a new label from scratch This key is passcode protected when the Set Up switch is not disabled When the Color Control key is depressed the label selection screen is displayed The operator may enter in a new label number or simply press the lt NEXT gt or lt ENTER gt keys to advance to the station adjustment menus SYSTEMS Electronics Group 18 HSM DUCTOR User s Manual SECTION 3 USING THE KEYPAD DISPLAY A number of different screens are shown on the display of the HSM DUCTOR The primary screen displays the machine cpm Other screens displayed include the cycling counts data display reset cycling counts display passcode entry menu and the set up menu 3 2 RECOMMENDED P
23. up Note The set up program is an on line communications program used to interface with the M4503 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 M4503 The variables displayed while in the Online edit mode are read directly from the processor Data is saved to a Set up Data file sdt whenever changes are made to a parameter or if the data is uploaded from the processor HSM DUCTOR unnamed Messages Machine CPM i Alarm Reset D Reset Alarms System Message All Faults Normal i ONLINE 1041 6 2003 4 33 PM Ui HSM DUCTOR User s Manual SYSTEMS Electronics Group 07 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE HSM DUCTOR User s Manual 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 1f 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 on
24. ASED SET UP PROGRAM REFERENCE 5 1 3 SET SOLENOID RESPONSE TIME COMPENSATION msec This parameter is the difference in msec between the ON and off response times of the ductor solenoid This is used to adjust the ON duration to compensate for the mechanical response time of the whole mechanism As an example if the ON response time was 40 msec and the off response time was 15 msec Then the value entered for this parameter would be 25 msec Note If the optional feedback sensors are used set this parameter to 0 The feedback sensors will automatically adjust the ON duration based on the response time of the solenoids 5 1 4 SET COLOR GAIN This parameter allows the color density to be increased proportionately up or down as a function of machine speed The valid range of this parameter is 50 to 150 per 2000 CPM When set to 100 no increase or decrease as a function of speed will occur When set to 50 the color density will drop 50 from 0 to 2000CPM When set to 150 the color density will increase by 50 from 0 to 2000CPM This parameter is used to compensate for ink atomization misting as a function of speed higher speed proportionately higher ink misting 5 1 5 ENABLE DISABLE DUCTOR FEEDBACK FAULT This selection is used to enable or disable the feedback fault detection When the optional feedback sensors are installed the ductor feedback faults should be enabled The fe
25. DOS Setup Program Reference for details on downloading the program to the M4503 6 The M4503 is now ready to run loaded with application program ductor configuration and label data that was previously saved for the respective decorator Exit back to the DOS prompt by pressing lt ESC gt HSM DUCTOR User s Manual SYSTEMS Electronics Group 16 HSM DUCTOR User s Manual SECTION 3 USING THE KEYPAD DISPLAY The Keypad Display of the HSM DUCTOR contains 24 keys consisting of 12 function keys and a numeric keypad and a 2 line by 40 character back lit LCD display The Keypad Display can be used to view data modify all set up parameters or adjust the color control settings SYSTEMS K ELECTRONICS GROUP INC PEA TAZA q N PNEUMATIC DUCTOR CONTROL MACHINE CPM 0000 sols e ler 2 s es aaa also DEC NEXT Zy eel Zell sbe Note For virtually all the menus the NEXT and PREV keys can be used to advance to the next item of the menu or return to the previous item on the menu 3 1 OVERVIEW OF KEYPAD AND DISPLAY lt NEXT gt Pressing this key moves to the next adjustment field or displays the next menu or display Holding this key depressed for one second will move to the next field or display continuously If all displays have been shown the system will exit to the main default display lt PREV gt
26. HSM DUCTOR Pneumatic Ductor Control System 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 DUCTOR Pneumatic Ductor Control System User s Manual Copyright O 2001 Systems Engineering Associates Inc All Rights Reserved Revised 18 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
27. HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE HSM DUCTOR User s Manual 2 3 4 On Duration The On duration can be individually set for each ink station for each label The On duration is the amount of time cans the ductor roll is in contact with the fountain roll Follow the procedure outlined in section 3 5 Light Dark Color Adjustment of Ink Station to properly adjust the On duration Note The user cannot adjust the On duration to within 14 cans 140 tenths of the Cycle duration To disable a ductor from cycling set this variable to zero Cycle Duration The Cycle duration can be individually set for each ink station for each label The Cycle duration is the frequency at which the ductor is activated This is the duration number of cans between one complete cycle Follow the procedure outlined in section 3 5 Light Dark Color Adjustment of Ink Station to properly adjust the Cycle duration Note The user cannot adjust the Cycle duration to within 14 cans 140 tenths of the On duration Color Density The Color Density display is used as an indication of the amount of ink being transferred by the ductor Different settings of the On and Cycle durations will achieve the same Color Density Follow the procedure outlined in section 3 2 Recommended Procedure for using the color control SYSTEMS Electronics Group 48
28. ROCEDURE FOR USING THE HSM DUCTOR On the original mechanically cammed ductor the keys on the fountain were used both to control the areas on the can that the ink was to be applied as well as the color quality light dark of the color Thus the keys were adjusted proportionally to where on the can the color was located as well as how much area the color covered and how dark the color was With the pneumatic ductor the color quality is now controlled by the frequency and duty cycle of the ductor as set by the operator through the Keypad Display The fountain keys are simply used to define the locations top bottom middle etc the color is located on the can The keys should not be adjusted proportional as before but should be either closed at areas where there will be no color on the can or opened a predefined number of turns on areas where the color is located on the can This allows label changes to occur quicker by simply setting the keys open or closed at the locations required on the can and selecting the label number for the respective label on the Keypad Display thus setting the color quality to the same level as previously set for that label The M4503 is capable of saving the settings for up to 100 labels As different labels are run the labels programmed are added to the internal data base When a programmed label is run again simply recall the label number and the ductors will oscillate at the same frequency and duty
29. ROGRAM The Set up program allows the user to Download any SY Sdev program file to the M4503 2 HSM DUCTOR unnamed Main Display File Edit View Window Help New Ctrl N Open Ctrl Ol Save Ctrl S Save As Export Shift Data Ctrl Upload save Data gt Alarm Reset Download restore Data gt Reset Alarms Report Setup Print Report Ctrl P Exit System Message All Faults Normal ONLINE 11041 6 2003 4 34PM 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 M4503 PLC SY Sdev file can be downloaded through the set up program Care should be taken when selecting a program to download HSM DUCTOR User s Manual SYSTEMS Electronics Group 33 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE 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
30. TER PASSCODE is displayed enter the corresponding 1 to 5 digit passcode on the numeric keypad and press lt ENTER gt If the prompt ENTER PASSCODE INCORRECT PASSCODE is displayed enter the correct passcode and press lt ENTER gt 3 The LABEL field is displayed Enter a new label 0 99 on the numeric keypad and press lt ENTER gt or press the lt NEXT gt key to use the existing label Note The decorator must be stopped in order to change the label number 4 Ifno further changes are to be made to the ink stations settings press lt ESC gt to exit 3 5 LIGHT DARK COLOR ADJUSTMENT OF INK STATION The On duration and Cycle duration for each ink station can be set individually for each label number The On duration can be viewed as a Course adjustment and the Cycle duration can be viewed as a Fine adjustment Observe how changing either the On duration or Cycle duration changes the relative Color Density Note If an ink station is not used simply set its On duration to zero to disable the cycling operation Use the Color Density display as an indication of the amount of ink being transferred by the ductor Different settings of the On and Cycle durations will achieve the same Color Density SYSTEMS Electronics Group 22 SECTION 3 USING THE KEYPAD DISPLAY Note To reduce Light and Dark variations in print betwee
31. able the particular stations that have feedback If the ductor feedback is not used disable all stations This parameter enables the individual feedback faults and should only be enabled when the optional feedback sensors are used Once enabled the M4503 will verify that the ductor is cycling properly If a ductor is not detected as cycling properly the Ductor Feedback Fault is energized indicating a problem with the ductor cycling control Ifa Ductor Feedback Fault does occur the ductors should be manually activated to verify proper cycling operation as well as the sensor for proper feedback operation The feedback sensor should be set such that it is only ON when the ductor is in contact with the fountain roll Enable Set Passcode and select Color Control to enter a new passcode If Set Up is enabled the user will not be prompted to enter a new passcode Factory default is set to zero Once set up is complete upload this data to disk using the Set up program software This allows the data to be downloaded to the module again if the module is replaced This data should be backed up on a periodic basis as labels are added or changed SYSTEMS Electronics Group 14 HSM DUCTOR User s Manual SECTION 2 INSTALLATION 2 8 M4503 MODULE INSTALLATION The following is provided as a reference These steps are performed by the factory prior to shipping the HSM DUCTOR These steps need on
32. 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 is first started the default parameters are 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 M4503 Therefore to normalize the set up program with the processor the user should define or open an existing file then upload All variables from the processor This allows the user to either create a backup of the data or maintain an existing file The user can even open a data file for another printer 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 file will be displayed in
33. bility 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 M4503 The programming port of the M4503 is set to 9600 baud Once selected a dialog box requesting the user to select a Comm Port and Baud Rate will be displayed iL Settings 3 xj Comm Port m Port Speed e Comi 9600 C Com2 C 19200 C Com3 C Com Cancel 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 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
34. can perform quick label changes by recalling the settings used the last time a particular label was run Thus when a label change is made the corresponding label number is selected and settings for each ink station used for that label previously are used again HSM DUCTOR User s Manual SYSTEMS Electronics Group HSM DUCTOR User s Manual SECTION 1 GENERAL DESCRIPTION When the machine first starts up the ductors are staged ON in one can increments At the beginning of each cycle the ductor solenoid is activated and the ductor roll comes in contact with the fountain roll Once the On duration is complete the solenoid is deactivated and the ink is transferred to the first steel roll At the completion of the cycle there is a 5 can dwell period before the next cycle starts During this dwell period ductor cycling operation is checked and adjustments made to the On duration for the response time of the solenoids 1 3 DUCTOR FEEDBACK Sensors mounted on the machine sense the actuation of the ductor arm verifies that the ductor is cycling and compensates for the response time of the solenoid As the speed of the machine changes the feedback sensor is used to adjust the amount of time the ductor is in contact with the fountain roll This allows consistent ink transfer throughout the entire speed range of the machine If a ductor is not detected as cycling an output is activated to indicate a fault in the ductors cycli
35. contact with the fountain roll Set the Response Time Compensation The response time compensation parameters is used to adjust the On duration based on the difference between the ON and off response time of the ductor solenoid As and example if the ON response time were 40 msec and the off response time was 15 msec then this parameter would need to be set to 25 msec The ON response time is defined as the time ductor is activated to the time it comes in contact with the fountain roll The off response time is the time the ductor is deactivated to the time it lifts off of the fountain roll If the optional feedback sensors are to be used this parameter should be set to zero SYSTEMS Electronics Group 13 SECTION 2 INSTALLATION HSM DUCTOR User s Manual 5 6 7 8 Set the Color Gain parameter This parameter allows the color density to be increased proportionately up or down as a function of machine speed The valid range of this parameter is 50 to 150 per 2000 CPM When set to 100 no increase or decrease as a function of speed will occur When set to 50 the color density will drop 50 from 0 to 2000CPM When set to 150 the color density will increase by 50 from 0 to 2000CPM This parameter is used to compensate for ink atomization misting as a function of speed higher speed proportionately higher ink misting If the ductor feedback sensors are to be used en
36. ductor Label Data This option downloads the Label Data from the M4503 This is the ON duration and CYCLE duration settings for each label The user will be prompted to select a range of labels to download or select Al default This allows the user to upload the label information from one processor and download it to another without altering any of the other set up parameters or shift data registers All This option allows the user to completely upload All of the set up parameters shift data and label data from the M4503 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 label data and shift data This function is accessed from the File menu Prior to selecting Print Report the user should select Report Setup to set the following report printout options Report Set up xi Report Options IV Print Set up Parameters IV Print Shift Data Counts IV Print Label Set up Data All Labels 0 99 Labels from to Cancel Eull Report HSM DUCTOR User s Manual SYSTEMS Electronics Group 35 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE HSM DUCTOR User s Manual At the top of each page the
37. e of operation These are as follows Manual Ductors cycle normally while the decorator is running Ductor Auto On input from host PLC ignored Ductors turn off rest on first steel roll when the decorator reaches zero speed While the decorator is stopped each individual ductor can be toggled on and off by pressing the keypad number corresponding to it s station This provides a test method to verify the operation of each ductor Off Ductors always off resting against first steel roll Auto Ductors cycle normally while decorator is running and the Ductor Auto On input from the host PLC is on Ductors turn off when decorator reaches zero speed or when Ductor Auto On input from host PLC is off SYSTEMS Electronics Group SECTION 2 INSTALLATION The standard control package is provided in a self contained NEMA 12 enclosure for mounting in the vicinity of the ink stations In addition the HSM DUCTOR can be purchased for mounting in the existing user s control cabinet door by specifying HSM DUCTOR UB 2 1 WHAT S INCLUDED Depending on which package is purchased verify that the following items are included when unpacking the HSM DUCTOR HSM DUCTOR With NEMA 12 ENCLOSURE lea HSM DUCTOR NEMA 12 enclosure including the M4503 PLC PLS Module lea HSM DUCTOR User s Manual lea HSM DUCTOR Keypad Quick Reference lea M4500 User s Manual lea HSM DUCTOR Program Disk HSM DUCTOR UB For Mounting I
38. ections are use to install the set up software and application program files on an IBM PC or compatible used to support the M4503 The set up software is used to download the application program to the M4503 module tune the user adjustable set up variables download and upload save user set up variables to disk and view shift data on a PC used to support the M4503 SYSTEMS Electronics Group SECTION 2 INSTALLATION HSM DUCTOR User s Manual 2 5 1 WINDOWS BASED SET UP PROGRAM INSTALLATION The HSMDUCTOR setup program is compatible with Windows 95 98 ME 2000 XP operating systems and is used to 1 Setup tune the user adjustable variables 2 Adjust the color control ON duration and CYCLE duration for each ductor 3 Download the application program to the M4503 module 4 Download restore or upload save the user setup variables from the M4503 5 View Shift data To install the set up software perform the following steps 1 Insert the HSM DUCTOR 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 DUCTOR CD Select the setup exe file and Click Open and then Ok 5 This will initiate the installation process Follow the instructions that appear on the screen to complete the installation process The HSMDUCTOR setup program can be executed from the Systems folder l
39. ectronics Group 035 SECTION 3 USING THE KEYPAD DISPLAY HSM DUCTOR User s Manual 3 6 CHANGE OVER USING AN EXISTING LABEL IN THE HSM DUCTOR When a label is to be run again perform following to set up the label at change over 1 Select the respective label number on the Keypad Display 2 Set the keys open predefined number of turns a number which is used for all ink stations on all labels on the areas of the can that will have ink and closed on areas that will not have ink 3 Run the machine and verify that ink is being distributed on the can correctly The ink will be metered at the same rate as previously set the last time the label was run Thus only minor adjustments to the keys may be necessary to assure that ink is not distributed to areas where no color is applied resulting in slinging due to ink build up 3 7 VIEWING THE TOTAL NUMBER OF CYCLES FOR EACH DUCTOR The total number of cycles for each ductor is accumulated in the M4503 This is used for life expectancy and predictive maintenance purposes to determine when air cylinders or solenoids should be replaced To view the number of cycles for each ductor perform the following 1 Press the lt DISPLAY DATA gt key The total number of cycles for ductors 1 and 2 will be displayed 2 To view the counts for ductors 3 and 4 press lt NEXT gt key The counts for ductors 3 and 4 will be displayed 3 Continue pressing the lt NEXT gt key to view the
40. edback sensor verifies the cycling of the ductor and resets the ON duration as the speed of the machine changes based on the response time of the solenoid HSM DUCTOR User s Manual SYSTEMS Electronics Group 53 SECTION 5 HSMDCTR DOS BASED SET UP PROGRAM REFERENCE HSM DUCTOR User s Manual 5 2 DOWNLOAD PROGRAM TO MODULE This selection is used to download the application program to the M4503 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 should not be performed while the decorator is running All outputs on the M4503 are turned off and no program execution is performed The decorator should therefore be stopped before the download takes place To download the program perform the following 1 2 3 4 5 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4503 Select 2 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 Ifa prompt stating that the file could not be opened is displayed then the application program is not installed in the current directory O
41. eration If the operation is canceled and communication with the processor cannot be established the system will be placed in an Offline mode however the Target Board Interface window will be displayed SYSTEMS Electronics Group AQ HSM DUCTOR User s Manual SECTION 4 HSMDUCTOR WINDOWS BASED SETUP 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 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 M4503 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 p
42. he color density to be increased proportionately up or down as a function of machine speed The valid range of this parameter is 50 to 150 per 2000 CPM When set to 100 no increase or decrease as a function of speed will occur When set to 50 the color density will drop 50 from 0 to 2000CPM When set to 150 the color density will increase by 50 from 0 to 2000CPM This parameter is used to compensate for ink atomization misting as a function of speed higher speed proportionately higher ink misting Feedback Enable stations 1 8 This parameter enables the individual feedback faults and should only be enabled when the optional feedback sensors are used Once enabled the M4503 will verify that the ductor is cycling properly If a ductor is not detected as cycling properly the Ductor Feedback Fault is energized indicating a problem with the ductor cycling control If a Ductor Feedback Fault does occur the ductors should be manually activated to verify proper cycling operation as well as the sensor for proper feedback operation The feedback sensor should be set such that it is only ON when the ductor is in contact with the fountain roll SYSTEMS Electronics Group 21 SECTION 3 USING THE KEYPAD DISPLAY HSM DUCTOR User s Manual 3 4 SELECTING THE LABEL NUMBER To select a label perform the following 1 Press the lt COLOR CONTROLS key to enter the adjustment mode 2 If the prompt EN
43. in 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 HSM DUCTOR User s Manual SYSTEMS Electronics Group 42 HSM DUCTOR User s Manual SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 1 THE MAIN DISPLAY WINDOW The Main Display window is used to display the general state of the control system This window is selected from the Window File Edit Vies Window Help Messages j Machine CPM i Alarm Reset D Reset Alarms System Message All Faults Normal ONLINE 10 16 2003 4 33 PM 7 The following is a list of the functions of the Main Display window Messages The Messages display is continuously updated It displays alarm and status messages specific to the M4503 as well as the current Online or Offline status of the set up program By simply scrolling the display the user is able to view all active alarm and status messages If no alarm or status messages are active a default message is displayed Machine CPM This display is
44. lace 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 M4503 SYSTEMS Electronics Group 4 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 THE WINDOW MENU The Window menu allows the user to select one of six 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 HSM DUCTOR unnamed Main Display File Edit View Window Help Messages MEE y 2 Setup Parameters 3 Shift Data 4 Color Control 51 0 States m Machine CPM Alarm Reset l 0 Reset Alarms System Message All Faults Normal ONLINE 11041 6 2003 437 PM 7 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 ma
45. line 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 Hot Keys Hot keys are activated by holding down the ALT key and simultaneously pressing the underlined letter of the desired function Almost every function can be activated by either pressing a series of hot keys or using the TAB key to move between fields Online Offline Modes The set up program allows the user to make changes while Online with the processor The Offline mode is used to preset parameters prior to download All functions are available to the user while Online however specific Online functions are disabled in the Offline edit mode Note Offline changes can only be made by enabling Offline Editing accessed under the Edit menu Getting Help The entire 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 RTFCD7 from the Help menu will display a dialog box listing information about the current revision of the se
46. ly be performed in the event the M4503 module needs to be replaced Refer to the M4500 User s Manual for general details on installing the M4503 To install the M4503 module perform the following 1 Mount the M4503 in the cut out of the enclosure 2 Install the respective field wiring arms in the M4503 I O slots 0 and 1 INO IN1 connector and resolver connector Make sure all the field wiring connectors are fully mated in the M4503 SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION 2 9 DOWNLOAD HSMDUCTR PROGRAM AND LABEL DATA TO M4503 The following is provided only as a reference These steps are performed by the factory prior to shipping the HSM DUCTOR These steps need only be performed in the event the M4503 module needs to be replaced Once the M4503 is installed perform the following to download the HSMDCTR application program to the M4503 as well as download the previously saved set up 1 Power up the M4503 and the IBM PC or compatible used to interface with the HSM DUCTOR 2 Connect an RS 232 cable from the computer COM port to the PROG port on the M4503 3 Invoke the set up program 4 Download the program to the M4503 See section 4 2 3 Windows Setup Program Reference or section 5 2 DOS Setup Program Reference for details on downloading the program to the M4503 5 Download the previously saved data to the M4503 See section 4 2 4 Windows Setup Program Reference or section 5 3
47. module into the cut out from the front Attach the M4503 to the door with the supplied hardware Once the module is installed a lugged earth ground wire should be installed on one of the mounting screws to insure that the module is grounded 4 Re Install all terminal connectors on the module to begin terminating wires HSM DUCTOR User s Manual SYSTEMS Electronics Group HSM DUCTOR User s Manual SECTION 2 INSTALLATION 2 4 WIRING THE HSM DUCTOR Refer to the electrical control schematic at the back of this manual wire the HSM DUCTOR to the existing control system Note Keep all 24VDC wiring away from high voltage wiring 1 Wire the resolver input per sheet 1 of the electrical control schematic 2 Wire input terminals 628 Ductors Auto ON 629 Set Passcode 630 Alarm Reset and 631 Set Up Enable from outputs of the host PLC 3 Wire output terminals 610 thru 617 from the M4503 to the respective ductor solenoids as shown on the schematic at the back of this manual 4 Wire FLT1 and FLT2 Ductors Feedback Fault M4503 Fault interlock to an input on the host PLC 5 If the ductor feedback sensors are to be used wire these sensors to input terminals 634 thru 641 Note The sensors should be PNP sourcing type sensors Wire output terminals 618 thru 625 from the M4503 to the host PLC 1f desired for individual Ductor Feedback Fault detection 2 5 HSM DUCTOR SOFTWARE INSTALLATION The following s
48. n cycle times adjust both the On duration and Cycle duration down to achieve the same Color Density For a new label or existing label that needs color adjustment perform the following 1 Press the lt COLOR CONTROLS key to enter the adjustment mode if not already in adjustment mode 2 To select the desired ink station for adjustment press the lt NEXT gt or lt PREV gt keys until the desired ink station is displayed 3 To lighten the color start by decreasing the On duration or increasing the Cycle duration Watch the Color Density to see how your adjustments change this value Remember think of the On duration as a Course adjustment and the Cycle duration as a Fine adjustment 4 To darken the color start by increasing the On duration or decreasing Cycle duration Watch the Color Density to see how your adjustments change this value Once again think of the On duration as a Course adjustment and the Cycle duration as a Fine adjustment 5 Check the color quality and continue to increase or decrease the Color Density until the desired color quality is achieved 6 Perform steps 2 through 4 above for all ink stations used as necessary 7 Once the label quality is satisfactory press the lt ESC gt key to exit the adjustment mode and save the changes for the selected label HSM DUCTOR User s Manual SYSTEMS El
49. n Existing Enclosure lea M4503 PLC Module lea HSM DUCTOR User s Manual lea HSM DUCTOR Keypad Quick Reference lea M4500 User s Manual lea HSM DUCTOR Program Disk Note The HSM DUCTOR package comprises only the controls portion PLC PLS module enclosure program etc of the pneumatic ductor system The mechanical portion of the pneumatic system air cylinders solenoids actuation arms etc are not supplied HSM DUCTOR User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 2 POWER REQUIRED The HSM DUCTOR is powered from 115VAC 50 60HZ and 24VDC The 115VAC is used to power the M4503 module while the 24VDC is used to power the ductor solenoids and ductor feedback sensors if used The 24VDC current required is 2 Amps for six stations and 2 75 Amps for eight stations 2 3 MOUNTING THE HSM DUCTOR If installing the HSM DUCTOR package mounted in the NEMA 12 enclosure mount the enclosure in proximity to the ink stations of the decorator It should be mounted to provide the maximum convenience to the operator when performing a label change If installing the HSM DUCTOR UB package mount the M4503 in the existing control cabinet door 1 Remove all terminal connectors so that the module can easily slide into the recommended cutout 2 Refer to drawing 14 4515 15 sheet 1 create a cut out in the existing control cabinet door 3 With the gasket installed on the M4503 mounting studs slide the
50. n drive off machine not in motion The individual solenoids can be toggled On and Off by clicking on the individual stations The user may also toggle All the ink stations On by clicking the Ductors ON All command or toggle all Off by clicking the Ductors OFF All command button SYSTEMS Electronics Group 49 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE HSM DUCTOR User s Manual 4 5 5 THE I O STATES WINDOW The I O States window is provided to display states of the inputs and outputs The control boards as well as states of the M4503 are shown This includes the interrupt inputs INO and IN 1 the analog I O and the resolver These values are displayed as read by the M4503 processor E HSM DUCTOR unnamed 170 Status SYSTEMS Electronics Group 50 HSM DUCTOR User s Manual SECTION 5 HSMDCTR DOS BASED SET UP PROGRAM REFERENCE The DOS based HSMDCTR set up program is menu driven allowing the user to easily view data alter set up variables and set color control parameters using a laptop or personal computer The set up variables are used to configure and tune the HSMDCTR to match the configuration and performance of the specific printer see section 2 7 HSM Ductor Set up The main menu of the HSMDCTR set up program incorporates the following menu selections HSMDCTR EXE 101 x Systems Pneumatic Ductor Set up Menu Version
51. nce program download is initiated 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 M4503 will resume Press any key to return back to the main menu This selection can also be used to verify the program ident revision and checksum without downloading the program Perform steps 1 through 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 54 HSM DUCTOR User s Manual SECTION 5 HSMDCTR DOS BASED SET UP PROGRAM REFERENCE 5 3 DOWNLOAD SET UP DATA TO MODULE This selection is used to download the previously uploaded saved set up variables to the M4503 module This should only be performed when replacing the module Note The set up data consists of the parameters listed in the 1 Set Ductor Parameters menu 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 M4503 2 Select 3 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
52. ndow is used to view and adjust any of the color control settings This window is selected from the Window menu A unnamed Color Control File Edit View Window Help Color Control Solenoid Response Time Label Number 0 el Station Number 1 ON CYCLE Solenoid ON Response Time msec 25681 Duration Duration Color 0 1 cans 0 1 cans Density Solenoid OFF Response Time msec 0 a 40 31 20 327 2 zi ga z Hz 5 y 20 5 34 0 Ductor Status 3 60 250 40 8 Operational Mode OFF 4 70 250 47 6 Ductors Auto ON OFF ws e 250 4 544 _ 6 90 250 61 2 Ductors Manual Control ez 100 lt 250 lt lt 680 Ei ois bea e a ala ml ll a al a 7 we no S 20 748 Ductors GER AI System Message All Faults Normal ONLINE 10 16 2003 4 38PM y Color Control Parameters The label number On duration and Cycle duration are used to adjust the color control settings in the M4503 The following is a description of each of these settings 1 Label Number The M4503 is capable of storing the settings for up to 100 labels 0 99 Select desired label number to adjust the On and Cycle duration settings Note The user can only adjust the Label Number when the machine is at Zero Speed main drive off and no motion detected SYSTEMS Electronics Group 47 SECTION 4
53. ng operation Note The feedback sensor must go ON when the ductor is in contact with the fountain roll SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSM DUCTOR User s Manual 1 4 OPERATOR ADJUSTABLE PARAMETERS The following parameters can be adjusted by the decorator operator through the Color Control key on the Keypad Display e Label Number 0 99 e Ink Station On Duration e Ink Station Cycle Duration Note The above values are passcode protected to prevent unauthorized personnel from making adjustments Also the On duration and Cycle duration cannot be set within 14 cans 140 counts of one another Passcode protection can be enabled or disabled via the passcode itself If the passcode is set to zero or the Set Up Enable input is ON then passcode protection is disabled otherwise passcode protection is enabled If passcode protection is enabled the operator must enter the proper passcode in order to make adjustments to the color control parameters If the Set Passcode input is ON then a new passcode can be entered If a passcode is not entered the value is reset to zero 1 5 USER SELECTABLE DUCTOR CONFIGURATION The following parameters are used to define the HSM DUCTOR configuration 1 Maximum Cycle Duration 2 Maximum On Duration 3 Response Time Compensation 4 Color Gain 5 Feedback Enable stations 1 8 The above parameters are
54. not ceased therefore data upload can be performed while the machine is running 4 Once set up data upload is complete press any key to return to the main menu HSM DUCTOR User s Manual SYSTEMS Electronics Group 56 HSM DUCTOR User s Manual SECTION 6 RECOMMENDED SPARES The following is a recommended spare parts list for the HSM DUCTOR These parts are available through Systems Engineering Associates Inc Quantity Part Number Description l ea HSM DUCTOR Decorator Cyclic Ductor Control Module M4503 SYSTEMS Electronics Group 57
55. ocated in Programs SYSTEMS Electronics Group 10 SECTION 2 INSTALLATION 2 5 2 DOS BASED SET UP PROGRAM INSTALLATION Follow the steps below to install the DOS based set up software on a PC used to support the M4503 1 Create one directory off the root directory for each decorator ductor system called PRINTER1 for the line 1 decorator PRINTER2 for the line 2 decorator PRINTER3 for the line 3 decorator etc These will be used to store the setup programs and set up data for each decorator Create these directories by typing the following at the DOS prompt MD PRINTER1 lt ENTER gt MD PRINTER2 lt ENTER gt MD PRINTER3 lt ENTER gt 2 Install disk1 into the A drive For each PRINTER directory you created in the previous step switch to that directory and install the set up programs by typing the following commands at the DOS prompt Line 1 decorator is shown CD PRINTER I lt ENTER gt A INSTALL lt ENTER gt 3 If using a menu program add each decorator s ductor set up program to your computer s menu software The DOS commands executed for these selections should be line 1 printer shown For Line 1 Decorator CD PRINTERI1 HSMDCTR CD 4 To execute the respective decorator s ductor set up program simply select the corresponding selection from the menu software s menu HSM DUCTOR User s Manual SYSTEMS Electronics Group 11 SECTION 2 INSTALLATION HSM DUCTOR User s Manual 2 5 3
56. of Cycles for Each Ductor__ 25 HSM DUCTOR User s Manual SYSTEMS Electronics Group CONTENTS 4 HSMDUCTOR Windows Based Set up Program Reference 27 4 1 General Description 28 4 2 The File Menu 29 4 2 1 The Set Up Data File 30 4 2 2 Upload save Data 32 4 2 3 Download Program 33 42 4 Download restore Data 34 42 5 Print Report 35 4 3 The Edit Menu 36 4 3 1 Enable Offline Editing 37 4 3 2 Setup Comm Port 37 4 3 3 Edit Color Control Passcode 38 44 The View Menu 39 4 4 1 Target Board Interface 40 44 2 View Online Data 41 443 View Offline Data 41 45 The Window Menu 42 4 5 1 The Main Display Window 43 4 5 2 The Setup Parameters Window 44 4 5 4 The Shift Data Window 46 4 5 5 The Color Control Window 47 4 5 6 The I O States Window 50 5 HSMDCTR DOS Based Set Up Program Reference 51 5 1 Set Ductor Parameters 52 5 1 1 Set Maximum Cycle Duration 52 5 1 2 Set Maximum ON Duration 52 5 1 3 Set Solenoid Response Time Compensation _ s s 53 5 1 4 Set Color Gain 53 5 1 5 Enable Disable Ductor Feedback Fault 53 5 2 Download Program to Module 54 5 3 Download Set up Data to Module 55 5 4 Upload save Set up Data from Module 56 6 Recommended Spare Parts 57 HSM DUCTOR User s Manual SYSTEMS Electronics Group Aie CONTENTS DRAWINGS Electrical Control Schematic 14 4515 10 Mechanical Layout 14 4515 15 HSM DUCTOR User s Manual SYSTEMS Electronics Group iii HSM DUCTOR User s Manual SECTION 1 GENERAL DESCRIPTION
57. ould be taken not to set this parameter too low as this would restrict the operators range of adjustment The Cycle duration is set individually for each ink station and is the rate at which ink is transferred from the fountain roll Maximum On Duration The maximum On duration is set to 1 10 of a can resolution The range of this parameter is from 0 to 200 and defines the upper limit or the longest amount of time the ductor roll can be in contact with the fountain roll The On duration is set individually for each ink station and is the amount of time the ductor roll is in contact with the fountain roll Response Time Compensation The response time compensation parameters is used to adjust the On duration based on the difference between the ON and off response time of the ductor solenoid As and example if the ON response time were 40 msec and the off response time was 15 msec then this parameter would need to be set to 25 msec The ON response time is defined as the time ductor is activated to the time it comes in contact with the fountain roll The off response time 1s the time the ductor is deactivated to the time it lifts off of the fountain roll Ifthe optional feedback sensors are to be used this parameter should be set to zero SYSTEMS Electronics Group 20 HSM DUCTOR User s Manual SECTION 3 USING THE KEYPAD DISPLAY Color Gain This parameter allows t
58. r density will increase by 50 from 0 to 2000CPM This parameter is used to compensate for ink atomization misting as a function of speed higher speed proportionately higher ink misting 5 Enable Disable Ductor Feedback Fault This selection is used to enable or disable the feedback fault detection When the optional feedback sensors are installed the ductor feedback faults should be enabled The feedback sensor verifies the cycling of the ductor and resets the ON duration as the speed of the machine changes based on the response time of the solenoid HSM DUCTOR User s Manual SYSTEMS Electronics Group 45 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE HSM DUCTOR User s Manual 4 5 3 THE SHIFT DATA WINDOW The Shift Data window is used to view the shift data collected by the M4503 This window is selected from the Window menu E HSM DUCTOR unnamed Shift Data EHEEEEEE Cycle Counts This displays the total number of cycles for each ductor Reset Counts Pressing this key allows the total cycle counts for each ductor to be reset The user can also choose to reset an individual ductor by setting or incrementing the Ductor Number and then pressing the Reset Counts command button SYSTEMS Electronics Group 46 HSM DUCTOR User s Manual SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 4 THE COLOR CONTROL WINDOW The Color Control wi
59. set either using the set up program or the Keypad Display See section 3 for the definitions of these parameters and the procedure for setting these parameters using the Keypad Display SYSTEMS Electronics Group HSM DUCTOR User s Manual SECTION 1 GENERAL DESCRIPTION 1 6 INPUTS The HSM DUCTOR interfaces with the existing PLC using discrete I O as well as the existing PLS These are as follows Ductors Auto ON B100 2 This signal is used to enable and disable the ductors when the MANUAL OFF AUTO switch is in the AUTO mode This is derived from the existing host PLC and should be programmed to enable the ductors when the canfeed is open etc Set Passcode B100 3 This signal is used to reset the existing passcode value This signal should be derived from a keyed selector switch located within the host PLC control cabinet Once Set Passcode has been enabled a new passcode can be entered when entering the Color Control configuration menu The passcode cannot be set if Set Up has been enabled Alarm Reset B100 4 This input is used to clear the ductor feedback fault based on an alarm reset derived from the existing host PLC The keypad display has an alarm reset as well to clear a ductor feedback fault Set Up Enable B100 5 This signal is used to enable the setup of the ductor configuration parameters This signal should be derived from a selector switch located within the host PLC control cabinet
60. tup program and how to obtain technical support SYSTEMS Electronics Group 28 HSM DUCTOR User s Manual SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 THE FILE MENU The File menu allows the user to perform the following functions Create a New set up Data File Open an existing Data File Save any changes made to the current Data File to disk Upload save Data from the Processor Download a SYSdev sdv program to the processor Download restore Data from the current set up Data File to the processor Print a Report of the current set up parameters e Exit the set up program EG HSM DUCTOR unnamed Main Display Eie New Ctrl R SYSTEMS Electronics Group 29 SECTION 4 HSMDUCTOR WINDOWS BASED SETUP PROGRAM REFERENCE HSM DUCTOR 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 the problem if a set up data file has

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