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1. SLOT 0 3 Swi SW2 5 ON m m ON m PLC5 S4516 DF1 PN COMMUNICATIONS CO CPU 1 1 RXD O 2 TX RS 232 TXD 1 3 RX SG 2 7 SG vu wW 3 4 RTS RXD 4 413 ayes 6 DSR RS 422 8 pcp TXD 6 ON DTR TXD 7 ae ee ee ce ee la 0 S3000 NETWORK COMMUNICATIONS 1 IF USED 2 3 S4 Internally the PLC 5 should be set up for RS 232C communication Refer to the dip switch settings guide on the side of the processor HSL CD4 User s Manual SYSTEMS Electronics Group B 1 APPENDIX B DF1 COMMUNICATIONS 4516 DF1 to SLC SLOT 0 3 Swi sw2 m ON my ON m SLC500 4516 DF aon COMMUNICATIONS CO CPU i eee RXD 0 i 2 Rx RS 232 TxD 1 H3 1x SC 2 115 sc vu Ld 3 4 DTR RXD 4 Deen RXD 5 7 RIS RS 422 8 cts TXD 6 L TxD 7 EEEN ECET EEN EE E EENE 0 s3000 NETWORK COMMUNICATIONS 24 iF USED ees S4 E Additionally the S4516 DF1 should be switched for RS 232 communication Dip switch SW1 is the RS 232 RS 422 dip switch should be set to POLE 1 ON POLE 2 OFF Dip switch SW2 is the slot address and is dependent upon the rest of the cards in the M4500 rack For the HSL CD4 or HSM CD7 control system SW2 should be set to POLE 1 ON POLE 2 ON HSL CD4
2. M4500 Mapped PLC Description Add Add Add Function General PLC Status Word 1 from PLC W4900 N7 150 W O Reset Spindle Trips Bit 00 B4900 0 N7 150 0 End of Shift Bit 01 B4900 1 N7 150 1 QC Initiate Bit 02 B4900 2 N7 150 2 Trip Test Bit 03 B4900 3 N7 150 3 Spare Bit 04 B4900 4 N7 150 4 Spare Bit 05 B4900 5 N7 150 5 thru thru thru Spare Bit 14 B4901 6 N7 150 14 Spare Bit 15 B4901 7 N7 150 15 PLC Status Word 2 from PLC N7 151 W O Spare Bit 00 B4902 0 N7 151 0 Spare Bit 01 B4902 1 N7 151 1 thru thru thru Spare Bit 14 B4903 6 N7 151 14 Spare Bit 15 B4903 7 N7 151 15 QC Spindle Number 1 24 25 26 W4904 N7 152 W O Spare W4906 N7 153 W O Spare W4908 N7 154 W O thru thru thru thru Spare W4916 N7 158 W O Spare W4918 N7 159 W O HSL CD4 User s Manual B 16 SYSTEMS Electronics Group
3. SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE This Page Intentionally Left Blank HSL CD4 User s Manual SYSTEMS Electronics Group 68 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE The DOS based HSLCD4 set up program is menu driven allowing the user to easily view data alter set up variables and set the machine timing machine offset timing signal locations etc using a laptop or personal computer The set up variables are used to configure and tune the HSLCD4 to match the configuration and performance of the specific decorator see Tuning the HSL CD4 section 2 10 The main menu of the HSLCD4 set up program incorporates the following menu selections les C HSLCD4 HSLCD4 EXE Systems HSL CD4 Set up Menu Version 2 1 Main Menu Set Carriage Yarnish Response Times Set Pin Chain QC Blow off Parameters Set Machine Timing Number of trips per spindle data Current Shift data Last Shift data Download Program to M4508 Download Set up data to M4508 Upload Save Set up data from M4508 Enter Selection ESC to exit WO IACI CMF NOTE Before selecting one of the nine selections listed above connect an RS 232 cable from COM1 on the computer to the PROG PORT on the M4500 Note The HSLCD4 program is an on line communications program used to interface with the M4500 module The data displayed in the menus and set in the menus is communicated directly to the M4500 Therefore p
4. MODBUS Port PLC address 5 MODBUS Baud MODBUS framing mode Number of start bits Number of data bits Number of stop bits Parity 19 2K RTU 1 8 1 NONE The MODBUS communications driver uses the S4516 communications board to both read and write data to a MODICON PLC DATA WRITTEN TO THE MODICON PLC The following data is written to the MODICON PLC MODICON Dest 4x Address 401700 401701 401702 401703 401704 401705 401706 401707 401708 401709 401710 thru 401733 401734 thru 401757 401758 HSL CD4 User s Manual Data Definition Speed CPM Resolver Position Number of Good Cans Lo 0 to 9 999 Number of Good Cans Hi 10 000 s Total Blow offs Lo 0 to 9 999 Total Blow offs Hi 10 000 s Total Misloads Restart Blow offs Manual Blow offs QC select a can Blow offs Trips per Spindle 1 for Shift thru Trips per Spindle 24 for Shift Trips per Spindle 1 Diagnostics thru Trips per Spindle 24 Diagnostics Status to MODICON M4500 Source Address W182 W180 W1100 W1102 W1104 W1106 W1108 W1112 W1116 W1120 W1124 thru W1170 W1020 thru W1066 W690 SYSTEMS Electronics Group APPENDIX A MODBUS COMMUNICATIONS The definitions of the data sent from the M4500 to the MODICON are as follows 401700 401701 401702 401704 401706 401707 401708 401709 401710 401734 Speed Current strokes per minute of the cupper Resolver
5. unnamed Set Up File Edit View Window Help Print Carriage amish Unit Blow off Parameters i Solenoid Response Times ON OFF msec msec Bad Can Blow off Solenoid 15 a 20 4 GC Blow off Solenoid 15 4f 20 4 System Message All Faults Normal ONLINE 10 6 2003 4 12PM 4 Bad Can Blow off Solenoid ON Response Time This is the time used as the on response time of the pin chain blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid ON this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds Bad Can Blow off Solenoid Off Response Time This is the time used as the off response time of the pin chain blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid OFF this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Q C Can Blow off Solenoid ON Response Time This is the time used as the on response time of the QC blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid ON this amount of time ahead of the QC blow off timing ON position usually set at 15 to 20 millise
6. The HSL CD4 is designed to interface to a resolver not encoder for machine timing If the machine is not already equipped with a resolver then the existing encoder will have to be removed and an RSV34 MSI1 resolver will have to be mounted in it s place If this is the case refer to the RSV34 MS1 data sheet for details on mounting the resolver Note The resolver must make one revolution for each spindle 24 revolutions per spindle wheel revolution Use the RSV RSCBLE cable to connect the resolver to the HSL CD4 Route the resolver cable in a separate conduit away from all other high voltage and control wiring Wire the cable directly to the 8 pin resolver connector on the M4500 see section 2 3 Mounting and Wiring the HSL CD4 2 7 MOUNTING THE SPINDLE 1 I D SENSOR NOT PROVIDED If the machine is not already provided with a spindle 1 I D sensor then one will have to be mounted This sensor is used to determine which spindle is the 1 spindle for both the QC select a can blow off and the trips per spindle count This must see a target once every revolution of the spindle wheel once every 24 spindles Any non discriminating 10 30VDC proximity sensor can be used and it can be mounted anywhere around the periphery of the spindle wheel The target it looks at should be either a large steel bolt head or 1 by 1 square steel target mounted on the spindle wheel in the vicinity of spindle 1 HSL CD4 User s Manual SYSTEMS Electronics
7. Adjust the timing channel set points 3 Download the application program to the M4500 module 4 Download restore or upload save the user setup variables from the M4500 to disk 5 View Shift and Trips per Spindle data To install the DOS based set up software perform the following steps 1 Create a directory off the root for each decorator These will be used to store the HSLCD4 EXE setup program and set up data for each decorator Create these directories by typing the following at the DOS prompt MD HSLDECI lt ENTER gt line 1 Decorator MD HSLDEC2 lt ENTER gt line 2 Decorator MD HSLDEC3 lt ENTER gt line 3 Decorator etc 2 Install the PROGRAMS disk into the drive For each HSLDEC directory you created switch to that directory and install the HSLCD4 set up programs by typing the following at the DOS prompt Line 1 decorator is shown CD HSLDECI lt ENTER gt A INSTALL lt ENTER gt 3 Add each decorator s set up program to your computer s menu software by creating a selection for each decorator called SET UP DECO LINE1 for the line 1 decorator SET UP DECO LINE2 for the line 2 decorator etc The DOS commands executed for these selections should be Line 1 decorator is shown For the SET UP DECO LINE1 selection CD HSLDECI1 HSLCD4 HSLCD4 CD 4 To execute the respective decorator s set up program simply select the corresponding SET UP DECO LINE selection from the menu softw
8. Blow off solenoid off response time msec 020 of bad cans to blow off for misload 003 of cans to blow off from infeed open 006 of cans to blow off from print at restart 004 of cans to blow off from varnish at restart 004 of pins to pin chain blow off port 032 QC_ select a can Blow off Blow off solenoid on response time msec 615 Blow off solenoid off response time msec 020 QC can blow off port shift offset 01 Note Prior to selecting this selection make sure the RS 232 cable is connected from the COM port on the computer to the PROG PORT on the M4500 Bad Can Blow off solenoid on response time This is the time used as the on response time of the pin chain blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the Pin Chain blow off timing CH05 usually set at 15 to 20 milliseconds Bad Can Blow off solenoid off response time This is the time used as the off response time of the pin chain blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the Pin Chain blow off timing CH05 usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids of bad cans to blow off
9. either jogging or barred that the position increases linearly from 0 through 359 If not swap the S1 and S3 leads of the resolver at the M4500 resolver connector Then verify that the position then indeed does increase with forward movement Press ESC to exit the POS RPM update Position the machine at machine zero spindle aligned with V notch at top backside of machine frame see section 2 10 2 Set Machine Zero Auto zero the resolver by selecting F10 Set Offset Enter 0 in the offset field and press lt ENTER gt The M4500 will calculate the actual offset value required to make this the 000 position and will display this number in the offset field The position will now read 0 Exit back to the PLS Main Development menu by pressing lt ESC gt Exit back to the HSLCD4 set up main menu by pressing lt ESC gt again HSL CD4 User s Manual SYSTEMS Electronics Group 75 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE 5 3 2 ADJUSTING THE TIMING CHANNEL SET POINTS To set or alter any of the timing signal set points perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4500 2 Select the 3 Set Machine Timing selection from the HSL CD4 set up program main menu 3 Select 1 Online Channel Setpoint Programming from the Main Development menu 4 Set all channels per section 6 Set points are entered for a particular channel simply by typing in
10. the user will be prompted to first go Online Once selected and the set up program Online with the processor a dialog box will be displayed allowing the user to select the SYSdev file to download Note Only the files with the sdv file extension will be displayed It is important to keep in mind that only a valid M4500 PLC SYSdev file can be downloaded through the set up program Care should be taken when selecting a program to download Once selected a message box is displayed informing the user of the current program revision and checksum of the program loaded in the processor as well as that of the selected program The user must confirm their selection by clicking the Yes command button After the user confirms their choice program download is initiated and the current program download address is displayed When program download is complete the user is prompted to acknowledge Control is passed back to the main program and the set up program remains in an Online edit mode HSL CD4 User s Manual SYSTEMS Electronics Group 44 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 4 DOWNLOAD RESTORE DATA The set up program allows the user to download Set up parameters timing channel set points and shift data to the M4500 from the set up Data File This function is accessed from the File menu and the user is given the choice of the following options amp RTFC
11. BASED SETUP PROGRAM REFERENCE 5 7 DOWNLOAD PROGRAM TO M4500 This selection is used to download the HSLCD4 application program to the M4500 module This should only be performed when replacing the M4500 module see section 2 11 M4500 P4500 D4591 Installation or whenever changes have been made to the source code Note Program download cannot be performed while the machine is running All outputs are turned off and no program execution is performed Any miss loaded cans will not be tripped for resulting in inside litho To download the program perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4500 2 Select 7 Download Program to M4500 A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key Ifa prompt stating that the HSLCD4 REV file could not be opened is displayed then the HSLCD4 application program is not installed in the current directory To install the program perform the steps in section 2 8 4 Application Program Installation 3 Once program download is initiated M4500 program execution will cease the current address being downloaded will be displayed and the RUN LED on the M4500 will flash continuously 4 Once the download is complete the RUN LED on the M4500 will illuminate solid and program execution in the M4500 will resume Press any key to re
12. ENTER SET POINT to enter the new set point The display will then prompt ON SETPOINT Enter the position in degrees where the set point should go on and press lt ENTER gt The display will now prompt OFF SETPOINT Enter the position in degrees where the set point should go off and press lt ENTER gt The channel will now be programmed with a set point that goes on at the on position entered and off at the off position entered Exit back to the primary set up menu by pressing lt ESC gt Exit back to the default screen by pressing lt ESC gt again 3 5 4 SET NUMBER OF SHIFTS TO VARNISH UNIT This is the number of spindles from the Can Sensor to the varnish unit minus 2 In general this is set such that the varnish unit retracts out on the can ahead of the misloaded spindle For older generation Rutherford Decorators this is set to 5 For newer decorators this is set to 4 HSL CD4 User s Manual SYSTEMS Electronics Group 35 SECTION 3 USING THE KEYPAD DISPLAY 3 5 5 ZERO MACHINE SET RESOLVER OFFSET This selection is used to auto zero the resolver To set the machine zero resolver offset perform the following 1 2 3 4 5 Select 3 SET MACHINE TIMING and observe the POS field Verify that as the machine is rotated forward either jogging or barred that the position increases linearly from 0 through 359 If not swap the S1 and S3 leads of the resolver at the M4500 res
13. Group SECTION 2 INSTALLATION 2 8 HSL CD4 SOFTWARE INSTALLATION Follow the steps below to install either the Windows or DOS based setup programs and PLC application program on a PC used to support the HSL CD4 control system 2 8 1 WINDOWS BASED SETUP PROGRAM INSTALLATION The RTFCD7 setup program is compatible with Windows 95 98 ME 2000 XP operating systems and is used to 1 Setup tune the user adjustable variables 2 Adjust the timing channel set points 3 Download the application program to the M4500 module 4 Download restore or upload save the user setup variables from the M4500 5 View Shift and Trips per Spindle data To install the set up software perform the following steps 1 Insert the HSL CD4 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 HSL CD4 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 RTFCD7 setup program can be executed from the Systems folder located in Programs HSL CD4 User s Manual SYSTEMS Electronics Group 10 SECTION 2 INSTALLATION 2 8 2 DOS BASED SETUP PROGRAM INSTALLATION The HSLCD4 set up software is used to 1 Setup tune the user adjustable variables 2
14. If communication problems occur make sure there is a secure connection from the PC to the PLC Then check the Comm port In most cases the user will only need to select a new Comm port If communication problems persist there may be another program causing a conflict with the port Check the port configuration from the Settings folder HSL CD4 User s Manual SYSTEMS Electronics Group 47 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 4 4 THE VIEW MENU The View menu allows the user to perform the following functions e View the Target Board Interface e View Online Data e View Offline Data amp RTFCD unnamed Main Display HSL CD4 User s Manual SYSTEMS Electronics Group 48 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 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 Program Ident Revision Set Network Address Set Time amp Date r Internal Fault Code Current Fault Code 00H No Internal Fault has Ocurred Last Fault Code 00H No Internal Fault has Ocurred Heset Faults Corrective Action None E r Communications Network Error Codes Current
15. Position Current angular position of the cupper crankshaft in degrees Number of Good Cans This is the total number of good cans printed so far into the shift This is essentially a can counter Total Blow offs This is the total number of cans blown off the machine This includes all types of blow offs the three cans blown off for every miss loaded can infeed open blow offs restart blow offs manual blow offs select a can QC blow offs etc Total Misloads This is the total number of miss loaded cans trips These would be the actual number of damaged cans that did not load properly on the machine This gives an indication of conveying can handling problems Restart Blow offs This is the total number of cans blown off when the infeed opened and from the print station and varnish station at machine restart Manual Blow offs This is the total number of cans blown off by the operator using the Manual Blow off PB or selector switch QC select a can Blow offs This is the total number of cans blown off by the operator with the Select A Can QC station or QC Blow off key on the HSL CD4 keypad for quality verification Trips per Spindle 1 24 for Shift This is the total trips mis loads for each spindle so far into the current shift A disproportionately high count for a particular spindle indicates a loading problem for that spindle Trips per Spindle 1 24 Diagnostics This is the total trips mis loads for each
16. R O thru thru thru thru R O Trips Per Spindle 24 W1066 W4662 N7 31 R O Shift Data Current Shift Good Cans Lo W1100 W4664 N7 32 R O Good Cans Hi W1102 W4666 N7 33 R O Total Blowoffs Lo W1104 W4668 N7 34 R O Total Blowoffs Hi W1106 W4670 N7 35 R O Misload Count Lo W1108 W4672 N7 36 R O Misload Count Hi W1110 W4674 N7 37 R O Restart Blowoffs Lo W1112 W4676 N7 38 R O Restart Blowoffs Hi W1114 W4678 N7 39 R O Manual Blowoffs Lo W1116 W4680 N7 40 R O Manual Blowoffs Hi W1118 W4682 N7 41 R O QC Blowoffs Lo W1120 W4684 N7 42 R O QC Blowoffs Hi W1122 W4686 N7 43 R O Trips Per Spindle 1 W1124 W4688 N7 44 R O thru thru thru thru R O Trips Per Spindle 24 W1170 W4734 N7 67 R O Shift Data Last Shift Good Cans Lo W1200 W4736 N7 68 R O Good Cans Hi W1202 W4738 N7 69 R O Total Blowoffs Lo W1204 W4740 N7 70 R O Total Blowoffs Hi W1206 W4742 N7 71 R O Misload Count Lo W1208 W4744 N7 72 R O Misload Count Hi W1210 W4746 N7 73 R O Restart Blowoffs Lo W1212 W4748 N7 74 R O Restart Blowoffs Hi W1214 W4750 N7 75 R O Manual Blowoffs Lo W1216 W4752 N7 76 R O Manual Blowoffs Hi W1218 W4754 N7 77 R O QC Blowoffs Lo W1220 W4756 N7 78 R O QC Blowoffs Hi W1222 W4758 N7 79 R O Trips Per Spindle 1 W1224 W4760 N7 80 R O thru thru thru thru R O Trips Per Spindle 24 W1270 W4806 N7 103 R O HSL CD4 User s Manual B 13 SYSTEMS Electro
17. REFERENCE 4 2 5 PRINT REPORT The Set up program allows the user to generate a Report printout of all the set up parameters timing channel set points and shift data This function is accessed from the File menu At the top of each page the report displays the name of the set up file being printed At the bottom of each page is the date and time the document was printed as well as the page number To printout a report of the settings contained in the set up Data File perform the following 1 From the File menu select Print Report or press Ctrl P This displays the Print Setup dialog box allowing the user to select a printer as well as the paper size and orientation Once the user selects OK the report is generated and sent to the specified printer device This function makes use of the windows 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 amp RTFCD unnamed Main Display 5 x File Edit View Window Help Machine CPM Good Cans Q C Blow off Spindle Number en 400 148 Blanket Blow off a 4163 k _ Mandel Biwott Bad Can Blow off Test Trip Blow off System Messa
18. UNIT RETRACT OUT RESPONSE TIME msec This is the time used to lead the trip point to retract the varnish unit time from solenoid actuation to first break with varnish wheel in milliseconds The M4500 will activate the extend solenoid this amount of time ahead of the varnish unit trip timing CH01 usually set at 60 milliseconds VARNISH UNIT EXTEND IN RESPONSE TIME msec This is the time to lead the trip point to extend the varnish unit time from solenoid actuation to first contact with varnish wheel in milliseconds The M4500 will activate the extend solenoid this amount of time ahead of the varnish unit trip timing CHO1 usually set at 60 milliseconds The NEXT and PREV keys can be used to advance to the next response time or the previous time respectively To change the currently displayed response time simply enter the new value on the numeric keypad and press lt ENTER gt The value will be entered and the next response time variable will automatically be displayed When the last response time Varnish extend time is entered the primary set up menu is again displayed Pressing lt ESC gt at anytime will also exit you back to the primary set up menu Note All response times entered must be in the range of 5 to 80 milliseconds HSL CD4 User s Manual SYSTEMS Electronics Group 3 SECTION 3 USING THE KEYPAD DISPLAY 3 5 2 SET PIN CHAIN QC BLOW OFF PARAMETERS This menu is activated when the 2 key SET PIN
19. User s Manual SYSTEMS Electronics Group B 2 APPENDIX B DF1 COMMUNICATIONS SOFTWARE PLC5 The following sample RSLogix5 code is used to execute the message control function to allow a PLCS processor to communicate with the S4516 DF1 serial communications board MG Read Write Message Control MG20 0 Setup Screen MSG Read Virite Message Control MG22 0 Setup Screen WRITE DATA 0006 END HSL CD4 User s Manual SYSTEMS Electronics Group B 3 APPENDIX B DF1 COMMUNICATIONS SLC500 The following sample RSLogix500 code is used to execute the message control function to allow a SLC500 processor to communicate with the S4516 DF1 serial communications board Trmsnitt N12 40 MSG Read Write Message 10 Type Peer To Peer Read Write Read Target Device S00CPU Local Remote Local Control Block 12 0 Control Block Length 14 Setup Screen MSG Read Write Message Type Peer To Peer Read Write Read Target Device S500CPU Local Remote Local Control Block 12 20 Control Block Length 14 Setup Screen MSG 0002 Read Write Message Type Peer To Peer Read Write Write Target Device S00CPU Local Remote Local Control Block N12 40 Control Block Length 14 Setup Screen 0003 0004 0005 0006 HSL CD4 User s Manual SYSTEMS Electronics Group B 4 APPENDIX B DF1 COMMUNICATIONS USING THE MSG INSTRUCTION READ INSTRUCTION PLC5 The read message MSG comman
20. W4846 N7 123 R O CH02 Can No Can Clock on W4848 N7 124 R O CH02 Can No Can Clock off W4850 N7 125 R O CHO03 Damaged Can Blowoff Low Speed on W4852 N7 126 R O CH03 Damaged Can Blowoff Low Speed off W4854 N7 127 R O CH04 Damaged Can Blowoff High Speed on W4856 N7 128 R O CH04 Damaged Can Blowoff High Speed off W4858 N7 129 R O CH05 Pin Chain Blowoff Timing on W4860 N7 130 R O CH05 Pin Chain Blowoff Timing off W4862 N7 131 R O CH06 QC Blowoff Timing on W4864 N7 132 R O CHO06 QC Blowoff Timing off W4866 N7 133 R O CHO7 Can Gate Timing on W4868 N7 134 R O CHO7 Can Gate Timing off W4870 N7 135 R O CH10 PLC Clock Timing on W4872 N7 136 R O CH10 PLC Clock Timing off W4874 N7 137 R O HSL CD4 User s Manual B 14 SYSTEMS Electronics Group APPENDIX B DF1 COMMUNICATIONS M4500 Mapped PLC Description Add Add Add Function Setup Infeed Open Number of Shifts B1019 W4876 N7 138 R O Number of Segments on Blanket wheel B1018 W4878 N7 139 R O Spare Registers Spare W4880 N7 140 R O Spare W4882 N7 141 R O thru thru thru thru Spare W4896 N7 148 R O Spare W4898 N7 149 R O HSL CD4 User s Manual B 15 SYSTEMS Electronics Group APPENDIX B DF1 COMMUNICATIONS Data Written To The M4500 10 Elements Is Defined As Follows
21. exit you back to the primary set up menu HSL CD4 User s Manual SYSTEMS Electronics Group 33 SECTION 3 USING THE KEYPAD DISPLAY 3 5 3 SET MACHINE TIMING SET POINTS ETC This selection brings up the timing set point menu which displays the following fields CHuu SETPOINT xxx channel name RPM yyyy POS zzz OFFSET wwww SCALE 360 Each field is defined as follows Field Definition Chuu Currently selected channel CH00 thru CH17 where uu is the octal channel number SETPOINT xxx Channel on or off set point where xxx is the set point position State of channel set point blank off solid block character on channel name selected channel name CH00 PRINT CARRIAGE TRIP CH01 VARNISH UNIT TRIP etc RPM yyyy Current machine speed where yyyy is in CPM POS zzz Current resolver position where zzz is in degrees OFFSET wwww Resolver offset where Wwww is the offset in degrees SCALE 360 Resolver SCALE FACTOR 360 degrees per revolution In addition to displaying the timing set point menu the following keys are also enabled ENTER SET POINT CLEAR CHANNEL SELECT CHANNEL and SEARCH CHANNEL The ENTER SET POINT key is used to enter a new set point both on and off set points in the selected channel The CLEAR CHANNEL key is used to clear all set points from the selected channel The SELECT CHANNEL key is used to select a new channel for programming The SEARCH CHANNEL is u
22. iv CONTENTS LIST OF FIGURES APPENDICES Appendix A A 1 A 1 A 4 Appendix B B 1 B 3 B 5 B 9 B 12 Appendix C SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 1 FEATURES Performs high speed control functions of Rutherford Decorator Basecoater to speeds in excess of 2000 CPM This includes speed compensated print carriage and varnish unit trip which eliminates inside deco and varnish problems and three can pin chain bad can blow off which reduces scrap High speed front end upgrade package which interfaces with existing control system Performs the following control functions 1 Detection of miss loaded cans 2 Damaged can blow off 3 Speed compensated print carriage trip control 4 Speed compensated varnish unit trip control 5 Three can bad can pin chain blow off 6 Single select a can QC pin chain blow off 7 Can gate open close control 8 Alarm detection infeed track jam no can transfer can on mandrel and timing signal fail detection 9 Data Acquisition Total number of good cans printed total number of blow offs trips per spindle etc for both current shift and last shift 10 Automatic Form Roll Throw off at infeed track jam or can gate closed Built in 2 Line X 40 character sealed display with 24 key membrane keypad allows local viewing of collected data can count blow off count trips per spindle by operator and set up of all user variables key switch enable
23. or Cancel the operation If the operation is canceled and communication with the processor cannot be established the system will be placed in an Offline edit mode Note Anytime while the set up program is Online with the processor and communication is interrupted a warning message will be displayed prompting the user to either Retry or Cancel the operation 4 4 3 VIEW OFFLINE DATA This function allows the user to place the set up program in an Offline mode This is accessed by the View menu by selecting Offline Data or by simply pressing the F4 function key This allows the user to perform Offline editing All values displayed in Offline edit mode reflect the actual values contained in the currently loaded set up data file Note The program can be toggled between Online and Offline by simply double clicking on the Online or Offline panel displayed in the status bar at the bottom of the window Once invoked the set up program will close the Comm port and cease communication with the M4500 HSL CD4 User s Manual SYSTEMS Electronics Group 50 SECTION 4 RTFCD7 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 2 RT
24. respective setup program RTFCD7 for Windows systems HSLCD4 exe for DOS systems 4 Download the HSLCD4 application program to the M4500 See section 4 2 3 for Windows based systems see section 5 7 for DOS 5 Download the PLS timing set points to the M4500 See section 4 2 4 for Windows based systems section 5 3 for DOS 6 Download the previously saved set up data to the M4500 See section 4 2 4 for Windows based systems section 5 8 for DOS 7 The M4500 is now ready to run loaded with HSLCD4 application program timing set points and set up data Note Double check the machine zero position and re zero the resolver if necessary prior to running the machine HSL CD4 User s Manual SYSTEMS Electronics Group 26 SECTION 3 USING THE KEYPAD DISPLAY The keypad display of the HSL CD4 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 or activate the select a can QC blow off to adjust the timing and all set up parameters z SYSTEMS ELECTRONICS _ GROUP INC 7 MACHINE SPEED CPM 0000 GOOD CANS 0O BLOW OFFS 0 TRIPS ENTE SPINDLE UP ae CHAN 1 2 3S ENTER Qc emeena seer 4 5 6 esc NEXT vst a1 7 8 9 o J TS The keypad display allows th
25. the above selections will bring up a sub menu with the corresponding set up parameters The following sections describe these sub menus and the definitions of the corresponding variables To select the respective set up sub menu simply press the corresponding numeric key 1 thru 6 HSL CD4 User s Manual SYSTEMS Electronics Group 30 SECTION 3 USING THE KEYPAD DISPLAY 3 5 1 SET CARRIAGE VARNISH RESPONSE TIMES This menu is activated when the 1 key SET CARRIAGE VARNISH RESPONSE TIMES is pressed while the primary set up menu is active See section 2 10 8 for a complete description of how to adjust the print carriage and varnish unit response times The following four set up parameters may then be adjusted or viewed PRINT CARRIAGE RETRACT OUT RESPONSE TIME msec This is the time used to lead the trip point to retract the print carriage time from solenoid actuation to first break with blanket in milliseconds The M4500 will activate the retract solenoid this amount of time ahead of the print carriage unit trip timing CH00 usually set at 40 to 50 milliseconds PRINT CARRIAGE EXTEND IN RESPONSE TIME msec This is the time used to lead the trip point to extend the carriage unit time from solenoid actuation to first contact with blanket in milliseconds The M4500 will activate the extend solenoid this amount of time ahead of the print carriage unit trip timing CH00 usually set at 40 to 50 milliseconds VARNISH
26. the main menu the total trips per spindle is displayed and updated continuously in fields that read Spindle xx trips for each spindle To exit back to the main menu press lt ESC gt A disproportionately high count for a particular spindle indicates a loading problem for that spindle C HSLCD4 HSLCD4 EXE _ amp L _E_ tts ol x Systems HSL CD4 Set up Menu Version 2 1 Trips per Spindle Menu 1 Set Spindle 1 trip offset 2 Reset Spindle trip counts Enter Selection ESC to exit Spindle 1 trip offset 00 Spindle 01 trips 36 Spindle 13 trips 4 Spindle 02 trips 23 Spindle 14 trips 15 Spindle 03 trips 10 Spindle 15 trips 3 Spindle 04 trips 9 Spindle 16 trips 13 Spindle 05 trips 2 Spindle 1 trips 5 Spindle 06 trips 1 Spindle 18 trips 3 Spindle 07 trips 4 Spindle 19 trips 4 Spindle 08 trips 1 Spindle 20 trips 2 Spindle 09 trips 2 Spindle 21 trips 16 Spindle 10 trips 4 Spindle 22 trips 29 Spindle 11 trips 14 Spindle 23 trips 7 Spindle 12 trips 11 Spindle 24 trips 19 Note Prior to selecting this selection make sure the RS 232 cable is connected from the COM port on the computer to the PROG port on the M4500 The menu selections on the Trips Per Spindle menu allow you to reset the trips per spindle counts or set the Spindle Trip Shift Offset The selections are listed below 1 Set Spindle 1 trip offset 2 Reset Spindle trip counts To se
27. the set point in the form XXX Y YY lt ENTER gt in the first set point of the given channel Note Up to 50 set points may be entered for any channel However for the decorator only one set point is used per channel and should be entered in the number set point The XXX is the location the set point will turn on while YYY is the location where the set point will turn off Use the PgUp PgDn F1 Next Chan or F2 Prev Chan keys to select the desired channel for programming 5 Once all channels are programmed press lt ESC gt to exit back to the PLS Main Development Menu Press lt ESC gt again to exit back to the HSLCD4 set up main menu The new channels will be saved both in the M4500 and in the CD4TMG file on the hard drive HSL CD4 User s Manual SYSTEMS Electronics Group 76 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE 5 4 NUMBER OF TRIPS PER SPINDLE DATA The Number of trips per spindle menu is provided to aid in the trouble shooting of a loading problem with a spindle or spindles The total number of trips for each spindle since the last reset or end of shift is displayed The operator can reset these counts at any time to aid in the trouble shooting process In addition the Spindle Trip Offset can be entered from this menu This is used to compensate for the location of the can no can sensor and the spindle 1 I D sensor location When the 4 Number of Trips per Spindle selection is selected from
28. variables have been changed Note When the set up variables are changed they are changed directly in the M4500 not on the file in the computer By uploading saving the set up variables to disk they can be downloaded to the M4500 in the event the module must be replaced The set up data consists of the carriage varnish response times pin chain QC blow off parameters and the spindle trip shift offset Timing channel set points are not stored as part of the set up data To upload the set up data perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4500 2 Select 9 Upload Save Set up data from M4500 A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key 3 Once data upload is initiated the current address being uploaded will be displayed Note Program execution is not ceased therefore data upload can be performed while the machine is running 4 Once set up data upload is complete press any key to return to the HSLCD4 main menu HSL CD4 User s Manual SYSTEMS Electronics Group 81 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE This Page Intentionally Left Blank HSL CD4 User s Manual SYSTEMS Electronics Group 82 SECTION 6 GENERAL TIMING SIGNAL LOCATIONS The following is a general description of the timing signals and the locations they should
29. 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 varnish 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 syst
30. CHAIN QC BLOW OFF PARAMETERS is pressed while the primary set up menu is active The following blow off set up parameters may then be adjusted or viewed CANS TO BLOW OFF AT INFEED OPEN This is the number of cans which will be blown off when the infeed is first opened Valid range 0 to 99 TO BLOW OFF FROM PRINT AT RESTART This is the number of cans which will be blown off from the print station when the machine is restarted Valid range 0 to 99 CANS TO BLOW OFF FROM VARNISH AT RESTART This is the number of cans which will be blown off from the varnish station when the machine is restarted Valid range 0 to 99 CANS TO BLOW OFF FOR EACH MISLOAD This is the number of cans blown off at the pin chain port when one miss loaded can is detected typically set at 3 cans PINS TO PIN CHAIN BLOW OFF PORT This is the number of pins from the spindle wheel to disk transfer location to the first can blown off at the Pin Chain blow off port minus two This can be a number from 0 to 999 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 PIN CHAIN BAD CAN SOLENOID ON RESPONSE TIME msec This is the time used as the on response time of the pin chain blow off port time from on soleno
31. Comm Error Code 00H No Network Comm Error Last Comm Error Code 00H No Network Comm Error Once invoked the set up program will prompt the user to select a program to compare with the one existing in the processor Whether a program is selected or the user cancels the setup program will attempt to communicate with the M4500 If unsuccessful a warning message will be displayed prompting the user to either Retry or Cancel the operation If the operation is canceled and communication with the processor cannot be established the system will be placed in an Offline mode however the Target Board Interface window will be displayed HSL CD4 User s Manual SYSTEMS Electronics Group 49 SECTION 4 RTFCD7 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 M4500 If the set up program is unsuccessful a warning message will be displayed prompting the user to either Retry
32. D unnamed Main Display File Edit View Window Help New Ctrl N Open Ctl 0 Save Ctl S Save As Export Shift Data Ctr Upload save Data gt Good Cans Q C Blow off Download Program e Spindle Number Download Data Set up Parameters EH Blanket Blow off Print Report Ctrl P Timing Channels k Shift Data jz i Mandrel Blowoff Bad Can Blow off Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 3 14PM Set up Parameters This option downloads the Set up data to the M4500 This includes print carriage and varnish unit response times and blow off parameters Timing Channels This option downloads the Machine Timing channel set points as well as the PLS configuration and scale factor to the M4500 PLS Shift Data This option downloads the Shift Data to the M4500 This includes the Trips per Spindle data the Current Shift and the Last Shift data All This option allows the user to completely download All of the set up parameters timing channel set points and shift data to the M4500 Note Only the values contained within the current data file are used If the validity of the current data file is questionable review the data in an Offline mode prior to download HSL CD4 User s Manual SYSTEMS Electronics Group 45 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM
33. DF1 COMMUNICATIONS READ WRITE DATA DEFINITIONS Data Read From The M4500 150 Elements Is Defined As Follows M4500 Mapped PLC Description Add Add Add Function General M4500 Status Word 1 to PLC W4600 N7 0 R O Zero Speed Bit 00 F119 B4600 0 N7 0 0 Spare Bit 01 B4600 1 N7 0 1 Spare Bit 02 B4600 2 N7 0 2 thru thru thru Spare Bit 14 B4601 6 N7 0 14 Spare Bit 15 B4601 7 N7 0 15 M4500 Status Word 2 to PLC W4602 N7 1 R O Zero Speed Output Bit 00 B121 4 B4602 0 N7 1 0 Infeed Track Jam Bit 01 B121 5 B4602 1 N7 1 1 No Can Transfer Bit 02 B121 6 B4602 2 N7 1 2 Timing Signal Fail Bit 03 F124 B4602 3 N7 1 3 Spare Bit 04 B4602 4 N7 1 4 Spare Bit 05 B4602 5 N7 1 5 thru thru thru Spare Bit 14 B4603 6 N7 1 14 Spare Bit 15 B4603 7 N7 1 15 Resolver Pos W180 W4604 N7 2 R O Resolver RPM W182 W4606 N7 3 R O Resolver Period W184 W4608 N7 4 R O Resolver Scale Factor W186 W4610 N7 5 R O Resolver Offset W188 W4612 N7 6 R O HSL CD4 User s Manual B 12 SYSTEMS Electronics Group APPENDIX B DF1 COMMUNICATIONS M4500 Mapped PLC Description Add Add Add Function Shift Data Trips Per Spindle Last Spindle Tripped B598 W4614 N7 7 R O Trips Per Spindle 1 W1020 W4616 N7 8
34. ECTION 2 INSTALLATION 5 Install S4516 SLOTO 3 OPTIONAL Set the slot address dip switches SW2 on the S4516 to the following positions slot3 S4516 SW2 switch ON SW switch2 ON Set the RS 232 RS 422 select dip switches SW1 on the S4516 to the following positions RS 232 selected S4516 SWI switch ON SWI switch2 OFF Install the 4516 in Slot0 3 slot next to 4573 of the M4500 chassis 6 Install the cover back over the M4500 making sure all the board connectors protrude the slots in the cover Tighten the three captive screws on the lower front of the cover and the two captive screws on each side of the M4500 chassis 7 Connect the display ribbon cable to the connector on the back of the M4500 the connector on the cable is polarized and should mate with the connector on the M4500 only one way 8 Mount the M4500 chassis to the HSL CD4 back panel using four 8 32 screws 9 With power to the P4500 off install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4500 the connector on the cable is polarized and should mate with the connector on the M4500 only one way 10 Install the respective field wiring arms on all the I O boards of the M4500 I O slots0 thru 2 serial communications connector on USER PORT resolver connector and INO IN1 connector Make sure all field wiring connectors are fully mated in the M4500 2 11 2 P4500 POWER SUPPLY INSTALLATION To install
35. Ean Bal wa Bua js aaa HSL CD4 User s Manual SYSTEMS Electronics Group ee SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 5 THE SHIFT DATA WINDOW The Shift Data window is used to view the shift data collected by the M4500 This window is selected from the Window menu RTFCD unnamed Shift Data File Edit View Window Help Trips Per Spindle Current Shift Last Shift M Spindle Tri pindle Trip a H3 a Spindle 1 Trip Offs 0 wI 23 4a 15 Tripped Spindle 11 3 10 15 l 3 Total Trips 237 4 16 13 Reset Trips 5 7 5 me 3 System Message All Faults Normal ONLINE 10 6 2003 4 38PM _ A This window utilizes a TAB control to divide the set up parameters into three categories similar to that of the Keypad Display These sections are as follows Trips per Spindle The Number of trips per spindle display is provided to aid in the trouble shooting of a loading problem with a spindle or spindles The total number of trips for each spindle since the last reset or end of shift is displayed The operator can reset these counts at anytime to aid in the trouble shooting process The following data is displayed in the Trips per Spindle section 1 Spindle 1 Trip Offset The Spindle Trip Offset can be entered from this section This is used to compensate for the location of the can no can sensor and the spindle 1 I D s
36. FCD7 unnamed Main Display 0 x File Edit View Window Help v 1 Main Display Messages 2 Set up Parameters 3 Serial Communications 4 Machine Timing 5 Shift Data E E T E 6 1 0 States Machine CPHM Good Cans r Q C Blow off m 4 169 Spindle Number a 400148 E F Blanket Blow off j Mandrel Blowoff Bad Can Blow off Test Trip Blow off System Message All Faults Normal ONLINE 1 0 6 2003 3 49PM 4 Once a window menu item is selected a check mark is placed next to the selected item and the selected window is displayed with the name changed in the title bar of the main window Note Read only variables are displayed in blue with a gray background Any variables that can be altered by the user are displayed in black with a white background In most cases a parameter that can be changed by the user will have associated with it increment and decrement controls The user can either click on the desired parameter to adjust and enter in a new value or use the increment or decrement controls to change the value by 1 unit HSL CD4 User s Manual SYSTEMS Electronics Group 5 SECTION 4 RTFCD7 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 alo x M
37. H02 off to on transition CH03 DAMAGED CAN BLOW OFF LO TIMING This signal is used to activate the damaged can blow off solenoid at low speeds below 1000CPM The damaged can blow off on solenoid will actually be on for the duration of CH03 when a miss loaded can is detected This signal should be set on 10 degrees before air starts to leave the damaged can port and set off 20 degrees before air stops leaving the port CH04 DAMAGED CAN BLOW OFF HI TIMING This signal is used to activate the damaged can blow off solenoid at high speeds above 1000CPM The damaged can blow off on solenoid will actually be on for the duration of CH04 when a miss loaded can is detected This signal should be set on 25 degrees before CH03 turns on and set off 50 degrees before CH03 turns off Note The can no can sensor must normally first see a good can at least 30 degrees prior to the off to on transition of CH04 if not retard both CH03 and CH04 as necessary CH04 is the timing channel that actually clocks in the good can bad can data from the can no can sensor CH05 PIN CHAIN BAD CAN BLOW OFF TIMING This should turn on when the chain blow off port is centered between pins on the chain see section 2 10 4 Set Pin Chain Blow off Timing This signal should be 40 degrees wide CHO06 QC SELECT A CAN BLOW OFF TIMING This should turn on when the select a can chain blow off port is centered between pins on the chain
38. HSL CD4 Rutherford Decorator High Speed Front End User s Manual Systems Engineering Associates Inc 14989 West 69th Avenue Arvada Colorado 80007 U S A Telephone 303 421 0484 Fax 303 421 8108 www sea seg com 02 2004 HSL CD4 Rutherford Decorator High Speed Front End User s Manual Copyright 1995 Systems Engineering Associates Inc All Rights Reserved Revised 25 March 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 respon
39. INS 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 blown 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 Electroni
40. ION 2 INSTALLATION 2 11 M4500 P4500 D4591 INSTALLATION The following is provided only as a reference These steps are performed by the factory prior to shipping the HSL CD4 These steps need only be performed in the event either the M4500 module P4500 power supply or D4591 display need to be replaced Refer to the M4500 User s Manual for general details on installing the M4500 P4500 and D4591 2 11 1 M4500 MODULE INSTALLATION To install the M4500 module perform the following 1 2 3 4 Remove the cover from the M4500 chassis retained with three captive screws on the lower front of the cover and two captive screws on each side of the M4500 chassis Install S4563 SLOTO 0 Set the slot address dip switches SW1 on the S4563 to the following positions slot0 S4563 SWI switch OFF SWI switch2 OFF Install the 4563 in Slot0 0 furthest left slot of the M4500 chassis Install S4568 SLOTO 1 Set the slot address dip switches SW1 on the S4568 to the following positions slot1 S4568 SWI switch ON SWI switch2 OFF Install the 4568 in Slot0 1 slot next to 4563 of the M4500 chassis Install S4573 SLOTO 2 Set the slot address dip switches SW1 on the S4573 to the following positions slot2 S4573 SW1 switch OFF SWI switch2 ON Install the 4573 in Slot0 2 slot next to S4568 of the M4500 chassis HSL CD4 User s Manual SYSTEMS Electronics Group 24 S
41. MS Electronics Group SECTION 2 INSTALLATION The standard HSL CD4 package is provided for back panel mounting inside the existing user s control cabinet In addition the HSL CD4 can be purchased in a self contained NEMA 12 enclosure for mounting adjacent to the existing control cabinet by specifying part number HSL CD4 ENCL 2 1 WHAT S INCLUDED Depending on which package is purchased verify that the following items are included when unpacking the HSL CD4 2 1 1 HSL CD4 for back panel mounting lea lea lea lea lea lea lea HSL CD4 back panel for mounting in the existing user s control cabinet including the following M4500 PLC PLS module P4500 Power Supply D4591 Display with ribbon cable for mounting in the existing control cabinet door HSL CD4 User s Manual M4500 User s Manual HSL CD4 Program Disk 2 1 2 HSL CD4 ENCL with NEMA 12 ENCLOSURE lea HSL CD4 NEMA 12 enclosure including the following lea M4500 PLC PLS module lea P4500 Power Supply lea D4591 Display Keypad lea HSL CD4 User s Manual lea M4500 User s Manual lea HSL CD4 Program Disk HSL CD4 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 1 3 HSL CD4 OPTIONS PURCHASED SEPARATELY The following items can be purchased separately as required or desired All items are compatible with both the back panel mountable package or the NEMA 12 enclosed package lea 4516 Data Communications Board MODBUS and DF1
42. Restart Blow offs e Manual Blow offs e QC Blow offs e Trips Mis loads per Spindle 1 24 Note The Current shift Good Cans and Blow offs are displayed as part of the default screen This data is the totals so far into the current shift This data is transferred to the Last shift data when the end of shift input transfers from a 0 to a 1 This can be at the end of either an 8 or 12 hour shift or alternatively could be done at label changes such the data collected would be for label runs rather than complete shifts This data cannot be reset by the operator only at the end of shift input transition Good Cans This is the total number of good cans printed so far into the shift This is essentially a can counter Blow offs This is the total number of cans blown off the machine This includes all types of blow offs the three cans blown off for every miss loaded can infeed open blow offs restart blow offs manual blow offs select a can QC blow offs etc Mis loads This is the total number of miss loaded cans trips These would be the actual number of damaged cans that did not load properly on the machine This gives an indication of conveying can handling problems Restart Blow offs This is the total number of cans blown off when the infeed opened and from the print station and varnish station at machine restart Manual Blow offs This is the total number of cans blown off by the operator using the Manual Blow off PB or
43. System Message All Faults Normal ONLINE 10 6 2003 2 43PM 4 HSL CD4 User s Manual SYSTEMS Electronics Group 41 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 1 THE SET UP DATA FILE The set up Data File sdt is a binary access file designed for fast file I O operation When the set up program is first invoked the default set up parameters are loaded into memory If changes are made to any of the set up parameters either online or offline as well as shift data the user will be flagged to Save Changes upon exit of the program Note Any windows based Set up program can open a set up Data File however the data tables will not be properly aligned The user will be alerted to the problem if a set up data file has been created by either a different set up program or a different revision of the software The set up Data File is similar to that of a word processing file When the program first starts a default file is loaded and the user is able to make any changes as desired The set up program is unaware of the settings and parameters that exist within the M4500 Therefore to normalize the set up program with the processor the user should define or open an existing file then upload All variables from the processor This allows the user to either create a backup of the data or maintain an existing file The user can even open a data file for another decorator save the file to a
44. Total Good Cans This is the total number of good cans printed so far into the shift This is essentially a can counter Total Blow offs This is the total number of cans blown off the machine This includes all types of blow offs the can s blown off for each mis load infeed open blow offs restart blow offs manual blow offs select a can QC blow offs etc Total Bad Cans or Mis loads This is the total number of mis loaded cans trips These would be the actual number of damaged cans that did not load properly on the machine This gives an indication of conveying can handling problems Manual Blow offs This is the total number of cans blown off by the operator using the Manual Blow off PB or selector switch QC Blow offs This is the total number of cans blown off by the operator with the Select A Can QC station or QC Blow off key on the M4500 keypad for quality verification HSL CD4 User s Manual SYSTEMS Electronics Group 65 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 6 Restart Blow offs This is the total number of cans blown off when the infeed opened and from the print station and varnish station at machine restart 7 Total Trips This is the total number of trips sum of the individual trips per spindle for the shift 8 Spindle 01 through 24 This is the total trips mis loads for each spindle A disproportionately high count for a particular spindle indicates a loading problem for that spind
45. ain Blow off Timing 18 2 10 5 Set of Pins to Pin Chain Blow off Port 19 2 10 6 Set of Cans to Blow off at Restart 20 2 10 7 Set of Cans from Infeed to Can PRX 20 2 10 8 Set Print Carriage and Varnish Unit Retract Extend Response Times 21 2 10 9 Set QC Blow off Shift Offset 22 2 10 10 Set Blanket Wheel Segments 23 2 10 11 Set Spindle Trip Shift Offset 23 2 11 M4500 P4500 D4591 Installation 24 2 11 1 M4500 Module Installation 24 2 11 2 P4500 Power Supply Installation 25 2 11 3 D4591 Keypad Display Installation 26 2 11 4 Download HSLCD4 Program and Set up Data to M4500 26 HSL CD4 User s Manual SYSTEMS Electronics Group HSL CD4 User s Manual 3 Using the Keypad Display 3 1 3 2 3 3 3 4 3 5 3 6 Default Screen Trips per Spindle Key Current Shift Key Last Shift Key Set up Key 3 5 1 Set Carriage Varnish Response Times 3 5 2 Set Pin Chain QC Blow off Parameters 3 5 3 Set Machine Timing set points etc 3 5 4 Set Number of Shifts to Varnish Unit 3 5 5 Zero Machine set resolver offset 3 5 6 View Critical Input Positions QC Blow off Key RTFCD7 Windows Based Set up Program Reference 4 1 4 2 4 3 4 4 4 5 General Description The File Menu 4 2 1 The Set Up Data File 4 2 2 Upload save Data 4 2 3 Download Program 4 2 4 Download restore Data 4 2 5 Print Report The Edit Menu 4 3 1 Enable Offline Editing 4 3 2 Setup Comm Port The View Menu 4 4 1 Tar
46. alarms occurs 1 7 DATA COLLECTION The following data is collected for both the current shift and the previous last shift 1 Total number of good cans printed 2 Total number of cans blown off 3 Total number of miss loaded cans bad cans 4 Total number of restart blow offs 5 Total number of manual blow offs 6 Total number of select a can QC blow offs 7 Total trips per spindle for each spindle This data can be viewed locally on the display sent to the host PLC via RS 232 communications MODBUS or Allen Bradley DF1 protocols using the optional 4516 serial communications board This information is updated current shift transferred to Last shift based on the change of state of a discrete input This input can be activated on an 8 or 12 hour shift basis or alternatively could be activated manually on a label run basis depending on the user s preference In addition to the shift data collection a separate buffer is available to collect trips per spindle counts as a diagnostics aid to the operator for trouble shooting a loading problem on a specific mandrel Unlike the shift data these counts can be reset manually by the operator at will This allows the operator to note an abnormally high count on a specific mandrel attempt to correct the problem reset the counts and then check the counts at a latter time to determine if the problem is corrected This data can be viewed on the Keypad Display HSL CD4 User s Manual SYSTE
47. amaged can blow off print carriage trip varnish unit trip and pin chain blow off will be controlled by the HSL CD4 If the existing host PLC was previously controlling these functions this logic can optionally be removed from the existing host PLC In most cases this logic can be left in the program as connecting the respective solenoids to the HSL CD4 will effectively defeat the logic 2 Add the Infeed Track Jam and Can On Mandrel no transfer alarms as inputs to the host PLC These should stop the machine anytime either of these alarms are on 3 Add the Carriage Auto Mode and Carriage Manual In outputs into the PLC logic When both are off the carriage will be retracted When the Manual In is on the carriage will be extended print position When the Auto Mode is on the carriage is controlled by the can no can sensor HSL CD4 User s Manual SYSTEMS Electronics Group 12 4 5 6 7 8 9 SECTION 2 INSTALLATION Add the Varnish Auto Mode and Vanish Manual In outputs into the PLC logic When both are off the varnish unit will be retracted When the Manual In is on the varnish will be extended varnish position When the Auto Mode is on the varnish unit is controlled by the can no can sensor Add the Damaged Can Auto Mode and Damaged Can Manual On outputs into the PLC logic When both are off the damaged can blow off is disabled When the Manual On is on the damage
48. and tune the M4500 to match the configuration and performance of the specific decorator see Tuning the HSL CD4 section 2 10 Note The set up program is an on line communications program used to interface with the M4500 module The data displayed and set in the windows is communicated directly to the module while in the Online edit mode Therefore prior to going online with the processor make sure an RS 232 cable is connected from the COM port on the computer to the PROG port on the M4500 The variables displayed while in the Online edit mode are read directly from the processor Data is saved to a Set up Data file sdt whenever changes are made to a parameter or if the data is uploaded from the processor RTFCD7 unnamed E E ioj xj File Edit View Window Help Messages Machine CPM ___ Good Cans r Q C Blow off Spindle Number 0 400 148 ns Blanket Blow off I L EN r Blow offs l 4169 Single Blow off Mandrel Blowoff Bad Can Blow off Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 238PM_ HSL CD4 User s Manual SYSTEMS Electronics Group 39 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 4 1 GENERAL DESCRIPTION Title Bar At the top of the window is the Title Bar The title bar is used to display the name of the working Set up Data file as well as t
49. anual SYSTEMS Electronics Group APPENDIX B DF1 COMMUNICATIONS The Local Station Address is only necessary to define if communications with the 4516 DF1 is executed over a Data Highway network via a DataLink Module WRITE INSTRUCTION SLC500 The write message MSG command for a SLC500 is setup as follows MSG N12 40 14 Elements Note The Data Table Address can be any integer file address The 10 elements written to the M4500 PLC are defined in the last section Read Write Data Definitions HSL CD4 User s Manual SYSTEMS Electronics Group B 8 APPENDIX B DF1 COMMUNICATIONS CHANNEL 0 SETUP PLC5 The Channel 0 Serial Port should be setup as follows Edit Channel Properties oeoo sl Paigo E fe Z EnorDetect ecc Z n E Full Duplex Modem Note The Communication Mode is setup for System Point to Point HSL CD4 User s Manual B 9 SYSTEMS Electronics Group APPENDIX B DF1 COMMUNICATIONS The Channel 0 Options are setup as follows Edit Channel Properties The Detect Duplicate Messages should be unchecked HSL CD4 User s Manual SYSTEMS Electronics Group B 10 APPENDIX B DF1 COMMUNICATIONS SLC500 The Channel 0 Serial Port should be setup as follows Channel Configuration The Duplicate Packet Detect should be unchecked HSL CD4 User s Manual SYSTEMS Electronics Group B 11 APPENDIX B
50. are s menu HSL CD4 User s Manual SYSTEMS Electronics Group ll SECTION 2 INSTALLATION 2 8 3 SYSdev PROGRAM DEVELOPMENT SOFTWARE INSTALLATION The SYSdev Program Development software is used to perform on line trouble shooting and program modifications to the HSL CD4 If SYSdev was purchased with the HSL CD4 package and is not already installed on the your computer install SYSdev onto the hard drive of your computer following the steps in outlined in the SYSdev Program Development manual 2 8 4 APPLICATION PROGRAM INSTALLATION The application program is a SYSdev based program loaded into the M4500 module and performs the HSL CD4 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 HSLCD4 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 HSLDEC directories created in section 2 8 2 copy all the files from the disk to each of these subdirectories 2 9 MODIFY EXISTING PLC PROGRAM Modify the existing control system PLC program to interface with the HSL CD4 by incorporating the following into the existing PLC ladder logic 1 The d
51. at 15 to 20 milliseconds QC Can Blow off solenoid off response time This is the time used as the off response time of the QC blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the QC blow off timing CH06 usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids QC Can Blow off port shift offset This is the number of spindles difference from detection of the spindle 1 flag to the QC blow off port This is a number between 1 and 24 and is empirically set by selecting spindle 1 for blow off and adjusting this value until the can from spindle 1 is the can that is blown off HSL CD4 User s Manual SYSTEMS Electronics Group 73 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE 5 3 SET MACHINE TIMING The Set Machine Timing selection is used to invoke the PLS programming command menus these are the same menus used in SYSdev to program the PLS section of the M4500 C HSLCD4 HSLCD4 EXE BE 2n Systems PLS Program Development PLSdev ion 4 2 Program Name CD amp THG Main Development Menu Online Channel Setpoint Programming Offline Channel Setpoint Programming Edit PLS Configuration Download Channels to PLS Upload Channels from PLS Print Channels File Utilities Return to S Y Sdev Shell Enter selection Note Prior to selec
52. ata is read from the MODICON PLC MODICON Dest 4x Address 401760 401761 401762 401763 401764 401765 401766 401767 401768 401769 401770 401771 401772 401773 401774 401775 401776 401777 401778 401779 401780 Data Definition Status Control from MODICON CH00 On Carriage Trip Timing CHO00 Off Carriage Trip Timing CH01 On Varnish Trip Timing CHO01 Off Varnish Trip Timing CH02 On Can No Can Clock Timing CH02 Off Can No Can Clock Timing CH03 On Damaged Can Blow off Lo CH03 Off Damaged Can Blow off Lo CH04 On Damaged Can Blow off Hi CH04 Off Damaged Can Blow off Hi CH05 On Pin Chain Blow off Timing CH05 Off Pin Chain Blow off Timing CH06 On QC Blow off Timing CH06 Off QC Blow off Timing CH07 On Can Gate Timing CHO07 Off Can Gate Timing Print Carriage Retract Response Time Print Carriage Extend Response Time Varnish Unit Retract Response Time Varnish Unit Extend Response Time Bad Can Pin Chain Blow off 401781 401782 401783 401784 401785 401786 401787 Blow off Solenoid On Response Time Blow off Solenoid Off Response Time of bad cans to blow off for misload of cans blow off from infeed open of cans blow off from print at restart of cans blow off from varnish at restart of pins to pin chain blow off port QC Can Select a can Blow off 401788 401789 401790 401791 HSL CD4 User s Manual Blow off Solenoi
53. be set at CH00 PRINT CARRIAGE TRIP This signal should just turn on when a spindle is at the midpoint of a blanket For a bad can the carriage is retracted midway of the can previous to the bad can and extended midway on the can following the bad can This signal should be 40 degrees wide SPINDLE WHEEL BLANKET a WHEEL Location of Print Carriage Trip Timin CH00 ON Set point CH01 VARNISH UNIT TRIP This signal should just turn on when a spindle is centered on the varnish wheel For a bad can the varnish unit is retracted midway on the can previous to the bad can and extended midway on the can following the bad can This signal should be 40 degrees wide VARNISH ROLLER Location of Varnish Unit Trip Timing CH01 ON Set point HSL CD4 User s Manual SYSTEMS Electronics Group 83 SECTION 6 GENERAL TIMING SIGNAL LOCATIONS CH02 CAN NO CAN CLOCK This signal is used to clock the bad can shift register which activates the carriage varnish and pin chain blow off for miss loaded cans It is also used as a general purpose clock for all shift registers counters etc The can no can clock is generally set on at 180 degrees and off at 000 degrees The off to on transition of CH02 cannot however coincide with either the CH0O Carriage trip CHO1 Varnish trip or CH05 Pin Chain Blow off timing signals These timing signals must be set at least 30 degrees ahead or behind the C
54. ch is used to match the actual mandrel number to the selected mandrel number e Number of blankets on blanket wheel e Both the ON and off solenoid response times 1 5 AUTOMATIC FORM ROLL THROW OFF Automatic form roll throw off is incorporated to throw off the form rolls in the event of an infeed track jam or when the can gate is closed This prevents the blankets from over inking when no cans are printed under these conditions which in turn reduces the number of cans which have to be blown off once the jam is cleared or the infeed is opened This can also be incorporated into the ductor rolls to prevent the transfer of ink into the station under these same conditions HSL CD4 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 6 ALARM DETECTION The package detects the following alarms INFEED TRACK JAM The infeed track jam alarm occurs when 6 consecutive empty mandrels are detected by the can no can sensor after the can gate is opened NO CAN TRANSFER The no can transfer alarm occurs when the no can transfer sensor detects a can on a mandrel after the disk transfer location TIMING SIGNAL FAIL The timing signal fail occurs when any of the timing signals generated in the PLS section fail to change state periodically while the machine is running The above alarms are available to the host PLC via discrete outputs These should be used to stop the machine and indicate the problem when any one of the
55. conds Q C Can Blow off Solenoid Off Response Time This is the time used as the off response time of the QC blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid OFF this amount of time ahead of the QC blow off timing ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids HSL CD4 User s Manual SYSTEMS Electronics Group 57 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 3 THE SERIAL COMMUNICATIONS WINDOW The Serial Communications window is used to view the configuration status of the S4516 serial communications board if installed as well as view the status of the Allen Bradley DF1 communication protocol and set up the Allen Bradley PLC communication parameters From this window the user can view or adjust the following parameters e View the 4516 configuration status e View the S4516 DF1 serial communication status e View the Allen Bradley Link Layer serial communication status e Select the Allen Bradley PLC type PLCS or SLC500 to communicate to e View Set the Allen Bradley PLC destination node e Select the starting Allen Bradley PLC destination file number r 4516 DF1 Communication Status DFI Communication Set up 4516 Configuration Status 2 Success a PLC5 X Transmit Data Status 0 Unknown Statu
56. cs 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 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
57. ction make sure the RS 232 cable is connected from the COM port on the computer to the PROG PORT on the M4500 Print Carriage retract response time This is the time used as the retract response time of the carriage unit time from solenoid actuation to first break with blanket in milliseconds The M4500 will activate the retract solenoid this amount of time ahead of the Carriage unit trip timing CH00 usually set at 40 to 50 milliseconds Print Carriage extend response time This is the time used as the extend response time of the carriage unit time from solenoid actuation to first contact with blanket in milliseconds The M4500 will activate the extend solenoid this amount of time ahead of the Carriage unit trip timing CHO00 usually set at 40 to 50 milliseconds HSL CD4 User s Manual SYSTEMS Electronics Group 70 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE Varnish Unit retract response time This is the time used as the retract response time of the varnish unit time from solenoid actuation to first break with varnish wheel in milliseconds The M4500 will activate the extend solenoid this amount of time ahead of the Varnish unit trip timing CH01 usually set at 60 milliseconds Varnish Unit extend response time This is the time used as the extend response time of the varnish unit time from solenoid actuation to first contact with varnish wheel in milliseconds The M4500 will activate the extend solenoid this a
58. d On Response Time Blow off Solenoid Off Response Time QC can blow off port shift offset Spindle Trip Offset A 4 M4500 Source Address W900 W902 W904 W906 W908 W910 W912 W914 W916 W918 W920 W922 W924 W926 W928 W930 W932 W934 W936 W938 W940 W942 W944 W946 W948 W950 W952 W954 W956 W958 W960 W962 SYSTEMS Electronics Group APPENDIX A MODBUS COMMUNICATIONS The definitions of the data read from the MODICON to the M4500 are as follows 401761 thru 401776 401777 401778 401779 401780 401781 CH00 On Carriage Trip Timing CH07 Off Can Gate Timing Variables 401761 thru 401776 are the On and Off timing set points for CH00 thru CH07 respectively This allows the MODICON to program these timing channels when the Timing Channel Program Enable bit 401760 3 from the MODICON is set to a 1 These are the same On and Off set points that would normally be set through the HSL CD4 keypad see section 3 5 3 Set Machine Timing or set through the HSLCD4 set up program See section 4 5 4 The Machine Timing Window or section 5 3 Set Machine Timing See section 6 for the definitions of the CH00 through CH07 timing channels Print Carriage Retract Response Time This is the time used as the retract response time of the carriage unit time from solenoid actuation to first break with blanket in milliseconds The M4500 will activate the retract solenoid this amount
59. d by authorized personnel Interfaces directly with machine mounted resolver can no can sensor and all trip and blow off solenoids Based on high performance M4500 PLC PLS module which allows easy trouble shooting and user customization using SYSdev DOS or Windows based programming package Built in PLS provides all machine timing eliminating need for an additional PLS Can be used on all Rutherford Basecoaters both carriage trip models and two coater roll models as well as all Rutherford Decorator models HSL CD4 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 2 FUNCTIONAL DESCRIPTION The HSL CD4 Decorator Basecoater high speed control package is an electronic upgrade package for the Rutherford decorator basecoater which detects miss loaded cans performs speed compensated print trip varnish trip and three can bad can blow off at speeds in excess of 2000 CPM In addition the package provides 1 Select A Can Pin Chain Blow off for print quality verification 2 Alarm Detection including e Infeed Track Jam e No Can Transfer can on mandrel e Timing Signal Failure 3 Data Collection both for the current shift and previous last shift including e Total Good Can Count e Blow off Counts e Trips per Spindle The package interfaces directly to the machine mounted resolver can no can sensor trip and blow off solenoids as well as the host PLC via discrete DC I O The CD4 co
60. d can blow off is on When the Auto Mode is on the damaged can blow off is controlled by the can no can sensor and infeed open Add the Pin Chain Manual Blow off output to the PLC logic This can be used as a manual blow off When on the bad can pin chain blow off is on When off the pin chain blow off functions normally blowing off detected bad cans restart cans etc Add the Can Feed Open output to the PLC logic When turned on while running the infeed is timed open with the can feed timing signal When turned off while running the infeed is timed closed with the can feed timing signal When the machine is stopped turning this input on and off will respectively open and close the can stop Add the Main Drive On output to the PLC logic This should be on when the drive is enabled running and should be off when the drive is disabled this includes auto stop conditions This is true for jog modes as well Add the Alarm Reset output This signal should be on as long as the system reset push button is depressed HSL CD4 User s Manual SYSTEMS Electronics Group 13 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 m
61. d for a PLCS is setup as follows MSG MG20 0 1 Elements PLC 3 Word Range Read INGO 00 _ o MSG MG21 0 1 Elements PLC 3 Word Range Read 10 100 Note The Communication Command is PLC3 Word Range Read The Data Table Address can be any integer file address The 150 elements total read from the M4500 PLC are defined in the last section Read Write Data Definitions HSL CD4 User s Manual SYSTEMS Electronics Group B 5 APPENDIX B DF1 COMMUNICATIONS The Local Station Address is only necessary to define if communications with the S4516 DF1 is executed over a Data Highway network via a DataLink Module WRITE INSTRUCTION PLC5 The write message MSG command for a PLCS is setup as follows MSG MG22 0 1 Elements PLC 3 Word Range Write 10 150 Note The Communication Command is PLC3 Word Range Write The Data Table Address can be any integer file address The 10 elements written to the M4500 PLC are defined in the last section Read Write Data Definitions HSL CD4 User s Manual SYSTEMS Electronics Group B 6 APPENDIX B DF1 COMMUNICATIONS READ INSTRUCTION SLC500 The read message MSG command for a SLC500 is setup as follows MSG N12 0 14 Elements Note The Data Table Address can be any integer file address The 150 elements total read from the M4500 PLC are defined in the last section Read Write Data Definitions HSL CD4 User s M
62. d 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 setup program and how to obtain technical support HSL CD4 User s Manual SYSTEMS Electronics Group 40 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 THE FILE MENU The File menu allows the user to perform the following functions e Create a New set up Data File e Open an existing Data File 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 amp RTFCD unnamed Main Display O x File Edit View Window Help Open N Ctrl O Save Ctl S Save As Export Shift Data Ctrl lt Upload save Data gt ood Cans r Q C Blow off Download Program 100145 Spindle Number Download Data 2 Blanket Blow off E aj Print Report Ctrl P G Mandel Blowoff Exit Bad Can Blow off Test Trip Blow off
63. ding 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 miss 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 o
64. e following to be viewed or adjusted 1 Set Carriage Varnish Response Times 2 Set Pin Chain QC Blow off Parameters 3 Set Machine Timing 4 Set Number of Shifts to Varnish Unit 5 Set Machine Zero 6 View Can No Can ON Position 7 View the Number of Trips per Spindle 8 View the Shift Data 9 Activate the select a can QC blow off 10 Test Print Carriage and Varnish Unit Trip Control The definitions of the keypad commands and menus are described in the following sections Note For virtually all the menus the NEXT and PREV keys can be used to advance to the next item of the menu or return to the previous item on the menu HSL CD4 User s Manual SYSTEMS Electronics Group OTs SECTION 3 USING THE KEYPAD DISPLAY 3 1 DEFAULT SCREEN The default screen displayed when no other commands are active contains the following data MACHINE SPEED CPM xxxx GOOD CANS xxxxxxx BLOW OFFS xxxxxx Where the Machine Speed is the current speed of the decorator the Good Cans field is the total number of good cans printed so far into the current shift and the Blow offs field is the total number of cans blown off the machine scrap so far into the current shift This display effectively replaces a speed meter and two can counters This screen is always returned to when no commands are active 3 2 TRIPS PER SPINDLE KEY The Number of trips per spindle menu is provided to aid in the trouble shooting of a loading probl
65. e from PLCS or SLC500 Note This parameter should be set prior to communicating with an A B processor Destination Node This is used to set the node number of the A B PLC to send and receive data from This also displays the node number of the A B PLC that send a Command message packet HSL CD4 User s Manual SYSTEMS Electronics Group 59 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE Destination File Number This is the file number the M4500 will read and write data from See Appendix B for a description of the data read from and written to an Allen Bradley PLC 4 5 4 THE MACHINE TIMING WINDOW The Machine Timing window is used to invoke the PLS programming command menus From this window the user can view or adjust the following parameters e Adjust Timing Channel setpoints e Set the Main Crank resolver offset e Clear or Recall a PLS timing channel e View the current PLS configuration e Reset the PLS configuration to default settings RTFCD unnamed Machine Timing File Edit View Window Help Timing Channels PLs Configuration Timing Channels Resolver Offset ON OFF D Carriage Trip Timing cH 20 60 4 Set Offset Vamish Trip Timing CHO 10 H f so af Can No Can Clock Timing CH02 180 4 0 _ pis channel Damaged Can Blow off Low CH0 60 250 4 EE Damaged Can Blow off High CH04 30 2 200 EA eet Bad Can Blow off Tim
66. e of the data packet transmission and will typically display either Busy or Done If there are problems delivering the message packet the response code along with a description will be displayed Note The Transmit Data Status prev is used to view the last or previous status Current Transaction This is the Transaction number delivered to the Allen Bradley PLC Active Command This displays either Read or Write This is used to view the command type of the current transaction Number of BYTES Received This displays the current number of bytes received from either a Command or Reply message packet Received Command BIT Status This displays the state of the command received If this displays a Reply then the command was sent from the M4500 If this displays Command then a command action was received by the M4500 A B Link Layer Status This displays the status of the receipt of the message packet sent to the Allen Bradley PLC If the delivery is not successful an error code along with a description is displayed Refer the to the Allen Bradley Communication Protocol and Command Set reference manual for more information on Link Layer error codes AIB Link Layer Current Transaction Received This is the Transaction number received from the Allen Bradley PLC PLC Type This is used to specify the Type of PLC the M4500 will communicate to The user can choos
67. ed can on spindle 1 increments the spindle 1 count in the Trips per spindle menu Note The above parameters 401777 thru 401791 are effective only when the Set Up Parameters Enable bit 401760 2 from the MODICON is set to a 1 Otherwise these variables are not updated in the M4500 The bits of the Status Control register from the MODICON to M4500 are mapped as follows W900 Status Control from MODICON 4x address 401760 in MODICON B900 0 End of Shift B900 1 Spindle Trip Reset B900 2 Set Up Parameters Enable B900 3 Timing Channel Program Enable B900 4 Set Resolver Zero Auto Zero B900 5 Alarm Reset B900 6 Not Used thru B901 7 Not Used The Status Control bits sent from the MODICON PLC are defined as follows B900 0 B900 1 B900 2 End of Shift Setting this bit to a 1 transfers the current shift data in the M4500 to the last shift data and clears the current shift data to start data collection for the next shift The current shift data in the MODICON should be saved to the last shift data stack prior to setting this bit Spindle Trip Reset Setting this bit to a 1 resets the Trips per Spindle 1 24 counts stored in MODICON 4x variables 401734 thru 401757 Set Up Parameters Enable Setting this bit to a 1 enables the set up parameters 401777 thru 401791 in the MODICON to be used in the M4500 If this bit is set to a 0 the values in 401777 thru 401791 in the MODICON are not used as
68. em 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 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 exten
69. em with a spindle or spindles The total number of trips for each spindle since the last reset or end of shift is displayed The operator can reset these counts at any time to aid in the trouble shooting process The data can be viewed simply be pressing this key The display shows a series of screens each with four spindles from 1 through 24 as shown below TRIPS MIS LOADS PER SPINDLE 1 XXXX 2 XXXX 3 XXXX 4 XXXX Where the numbers 1 through 4 are the first 4 spindles and the xxxx would be the actual counts for the respective spindles Screens for spindles 5 thru 8 9 thru 12 etc are shown in this fashion each for a time delay of 10 seconds In addition the user can advance to the next screen or retard to the previous screen by pressing the NEXT or PREV key respectively The final screen of this menu prompts the user to reset the counts by pressing 0 or not to by pressing ESC This provides the operator with the opportunity to reset the counts if desired for trouble shooting If the counts are to be reset press the 0 key if not press the ESC key The default screen will now be displayed again The ESC key can also be used at any time to abort the trips per spindle data display and return to the default screen HSL CD4 User s Manual SYSTEMS Electronics Group 28 SECTION 3 USING THE KEYPAD DISPLAY 3 3 CURRENT SHIFT KEY The Current shift data menu displays the following information e Mis loads e
70. ensor location Use the Tripped Spindle display to adjust the offset value Follow the procedure outlined in section 2 10 11 Set Spindle Trip Shift Offset 2 Spindle xx Trips This is the total number of trips for each spindle This data is displayed and updated continuously in the respective field for each spindle A disproportionately high count for a particular spindle indicates a loading problem for that spindle HSL CD4 User s Manual SYSTEMS Electronics Group 64 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE Current Shift Data This section is used to view the Current Shift data This data is the totals so far into the shift This data is transferred to the Last shift at the end of either an 8 or 12 hour shift or alternatively could be done at label changes such that the data collected would be for label runs rather than complete shifts This data can be reset by the user from this section amp RTFCD7 unnamed Shift Data Ioj x Fie Edit View Window Help Last Shift Current Shift Total Good Cans 400148 Total Blow offs 4c Bad Can Blow offs ers Manual Blow offs 640 Q C Blow offs 176 Restart Blow offs 558 Total Trips 1 078 m End of Shift Transfer Data System Message All Faults Normal ONLINE 10 6 2003 4 39PM _ Note The Transfer Data command button is only active while Online 1 2 3 4 5
71. er s Manual SYSTEMS Electronics Group A 5 APPENDIX A MODBUS COMMUNICATIONS 401782 401783 401784 401785 401786 401787 401788 401789 401790 Blow off Solenoid Off Response time This is the time used as the off response time of the pin chain blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the Pin Chain blow off timing CH05 usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Valid range 5 to 60 msec of bad cans to blow off for misload This is the number of cans blown off at the pin chain port when one miss loaded can is detected typically set at 3 cans of cans blow off from infeed open This is the number of cans which will be blown off when the infeed is first opened Valid range 0 to 99 of cans blow off from print at restart This is the number of cans which will be blown off from the print station when the machine is restarted Valid range 0 to 99 of cans blow off from varnish at restart This is the number of cans which will be blown off from the varnish station when the machine is restarted Valid range 0 to 99 of pins to pin chain blow off port This is the number of pins from the spindle wheel to disk transfer location to the first can blown off at the Pin Chain blow off port mi
72. ess 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 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 SECT
73. essages m Machine CPM Good Cans r Q C Blow off Spindle Number es Blanket Blow off r Blow offs 4163 Single Blow off Mandrel Blowoff Bad Can Blow off Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 2 38PM The following is a list of the functions of the Main Display window Messages The Messages display is continuously updated It displays alarm and status messages specific to the M4500 as well as the current Online or Offline status of the set up program By simply scrolling the display the user is able to view all active alarm and status messages If no alarm or status messages are active a default message is displayed Machine CPM This display is only active while Online and displays the current speed of the machine in Cans Per Minute Good Cans This display is the Current Shift good can count Blow offs This display is the Current Shift total blow off count HSL CD4 User s Manual SYSTEMS Electronics Group 52 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE Q C Blow off This display is only active while Online and it allows the operator to perform a QC Select A Can blow off e The operator can perform a Single blow off by entering in the desired spindle number and clicking the Single Blow off command button e The operator can perform a Bla
74. etc HSL CD4 User s Manual SYSTEMS Electronics Group 55 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 5 Number of Cans to Blow off from Print at Restart This is the number of cans which will be blown off from the print station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc 6 Number of Cans to Blow off from Varnish at Restart This is the number of cans which will be blown off from the varnish station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc 7 Q C Can Blow off Port Shift Offset This is the number of spindles difference from detection of the spindle 1 flag to the QC blow off port This is a number between 1 and 24 and is empirically set by selecting spindle 1 for blow off and adjusting this value until the can from spindle 1 is the can that is blown off 8 Number of Segments on Blanket Wheel The blanket wheel segments is the value used to blow off a consecutive number of cans starting with blanket 1 whenever a Blanket QC Blow off is initiated QC blow off code 25 HSL CD4 User s Manual SYSTEMS Electronics Group 56 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE Blow off Solenoids This section is used to adjust the response times of the Bad Can and QC blow off solenoid in the M4500 1 2 3 4 amp RTFCD
75. f Cans to Blow off at Infeed Open ics Number of Cans to Blow off from Print at Restart Em Number of Cans to Blow off from Varnish at Restart Em Q C Can Blow off Port Shift Offset 1 Number of Segments on Blanket Wheel is System Message All Faults Normal ONLINE 10 6 2003 4 01PM Note The Bad Can Blow off command button will electronically induce a mis loaded can into the system as well as the Q C Can Blow off will blow off a can printed on spindle 1 at the QC blow off port 1 2 3 4 Number of Pins to Pin Chain Blow off Port This is the number of pins from the spindle wheel to disk transfer location to the first can blown off at the Pin Chain blow off port minus two This can be a number from 0 to 999 Number 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 Number of Cans to Blow off for Each Mis load This is the number of cans blown off at the pin chain port when one mis loaded can is detected typically set at 1 can Number of Cans to Blow off at Infeed Open This is the number of cans which will be blown off when the infeed is first opened To blow off no cans at infeed open set equal to 0 to blow off one can set equal to 1
76. for misload This is the number of cans blown off at the pin chain port when one miss loaded can is detected typically set at 3 cans HSL CD4 User s Manual SYSTEMS Electronics Group 92 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE of cans to blow off from infeed open This is the number of cans which will be blown off when the infeed is first opened To blow off no cans at infeed open set equal to 0 to blow off one can set equal to 1 etc of cans to blow off from print at restart This is the number of cans which will be blown off from the print station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc of cans to blow off from varnish at restart This is the number of cans which will be blown off from the varnish station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc of pins to pin chain blow off port This is the number of pins from the spindle wheel to disk transfer location to the first can blown off at the Pin Chain blow off port minus two This can be a number from 0 to 999 QC Can Blow off solenoid on response time This is the time used as the on response time of the QC blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the QC blow off timing CH06 usually set
77. ge All Faults Normal ONLINE 10 6 2003 3 22PM HSL CD4 User s Manual SYSTEMS Electronics Group 46 SECTION 4 RTFCD7 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 ability to make any necessary changes to the set up parameters while not online with the processor If offline editing is not enabled the user is only able to view the set up parameters and shift data When the program is first invoked the default setting is offline editing disabled The user will need to specifically select Enable Offline Editing from the edit menu or press function key F2 to enable disable this feature 4 3 2 SETUP COMM PORT This function allows the user to specify the serial communications port and rate to talk to the M4500 The programming port of the M4500 is set to 9600 baud ob y ge r Comm Port Port Speed Com 9600 C Com2 C 19200 C Com3 C Com 4 Cancel Once selected a dialog box requesting the user to select a Comm Port and Baud Rate will be displayed The default setting is COM1 at 9600 baud The option to select the 19200 baud rate is to allow the user to communicate with the processor via the 4516 serial communications board In most cases the user will only need to specify the communications port and leave the baud rate at 9600
78. get Board Interface 4 4 2 View Online Data 4 4 3 View Offline Data The Window Menu 4 5 1 The Main Display Window 4 5 2 The Setup Parameters Window 4 5 3 The Serial Communications Window 4 5 4 The Machine Timing Window 4 5 5 The Shift Data Window 4 5 6 The I O States Window CONTENTS SYSTEMS Electronics Group Siis CONTENTS 5 HSLCD4 DOS Based Set up Program Reference 69 5 1 Set Carriage Varnish Response Times 70 5 2 Set Pin Chain QC Blow off Parameters 72 5 3 Set Machine Timing 74 5 3 1 Zeroing the Machine 75 5 3 2 Adjusting the Timing Channel Set points 76 5 4 Number of Trips per Spindle Data 77 5 5 Current Shift Data 78 5 6 Last Shift Data 79 5 7 Download Program to M4500 80 5 8 Download Set up Data to M4500 80 5 9 Upload save Set up Data from M4500 81 6 General Timing Signal Locations 83 7 Recommended Spare Parts 85 HSL CD4 User s Manual SYSTEMS Electronics Group iii HSL CD4 User s Manual D4591 Recommended Panel Door Cut out Machine Zero Position Location of Can No Can Sensor Location of Blow off Timing ON Position Keypad Display Legend Location of Print Carriage trip timing CHOO Location of Varnish Unit Trip Timing CH01 MODBUS Communications MODBUS Port Configuration Data Written to the MODICON PLC Data Read from the MODICON PLC Allen Bradley DF1 Communications Hardware Software Using the MSG Instruction Channel 0 Setup Read Write Data Definitions Drawings
79. he name of the active Window The title bar is dark if the window is active and grayed if another window is active The color depends on the settings of the Display Properties of the Control Panel Status Bar At the bottom of the window is the Status Bar The status bar is used to display system messages online or offline mode as well as the current time and date as set by the operating system The system messages panel displays general information about operation of the system The Online Offline mode panel displays the status of the current set up program mode of operation The mode of operation can be changed by simply double clicking the online offline mode panel Hot Keys Hot keys are activated by holding down the ALT key and simultaneously pressing the underlined letter of the desired function Almost every function can be activated by either pressing a series of hot keys or using the TAB key to move between fields Online Offline Modes The set up program allows the user to make changes while Online with the processor The Offline mode is used to preset parameters prior to download All functions are available to the user while Online however specific Online functions are disabled in the Offline edit mode Note Offline changes can only be made by enabling Offline Editing accessed under the Edit menu Getting Help The entire contents of the user s manual is containe
80. her than complete shifts This data cannot be reset either from this menu or by the operator only at the end of shift input transition To exit back to the main menu press lt ESC gt Total Good Cans This is the total number of good cans printed so far into the shift This is essentially a can counter Total Blow offs This is the total number of cans blown off the machine This includes all types of blow offs the three cans blown off for every miss loaded can infeed open blow offs restart blow offs manual blow offs select a can QC blow offs etc Total Mis loads This is the total number of miss loaded cans trips These would be the actual number of damaged cans that did not load properly on the machine This gives an indication of conveying can handling problems Restart Blow offs This is the total number of cans blown off when the infeed opened and from the print station and varnish station at machine restart Manual Blow offs This is the total number of cans blown off by the operator using the Manual Blow off PB or selector switch HSL CD4 User s Manual SYSTEMS Electronics Group 78 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE QC Blow offs This is the total number of cans blown off by the operator with the Select A Can QC station or QC Blow off key on the HSL CD4 keypad for quality verification Spindle 01 trips thru Spindle 24 trips This is the total trips mis loads for each spindle A disproportio
81. id actuation to first air out port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the Pin Chain blow off timing CH05 usually set at 15 to 20 milliseconds Valid range 5 to 60 msec PIN CHAIN BAD CAN SOLENOID OFF RESPONSE TIME msec This is the time used as the off response time of the pin chain blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the Pin Chain blow off timing CH05 usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Valid range 5 to 60 msec QC BLOW OFF SOLENOID ON RESPONSE TIME msec This is the time used as the on response time of the QC blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the QC blow off timing CH06 usually set at 15 to 20 milliseconds Valid range 5 to 60 msec HSL CD4 User s Manual SYSTEMS Electronics Group 339 SECTION 3 USING THE KEYPAD DISPLAY QC BLOW OFF SOLENOID OFF RESPONSE TIME msec This is the time used as the off response time of the QC blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the QC blow off timing CH06 usually set at 15 to 20 m
82. illiseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Valid range 5 to 60 msec QC BLOW OFF SHIFT OFFSET This is the number of spindles difference from detection of the spindle 1 flag to the QC blow off port This is a number between 1 and 24 and is empirically set by selecting spindle 1 for blow off and adjusting this value until the can from spindle 1 is the can that is blown off BLANKET WHEEL SEGMENTS 4 12 The blanket wheel segments is the value used to blow off a consecutive number of cans starting with blanket 1 whenever a Blanket QC Blow off is initiated QC blow off code 25 SPINDLE TRIP SHIFT OFFSET This is the number of spindle difference from the detection of the spindle 1 flag to the Can No Can sensor This is a number between 0 and 23 and is empirically such that a miss loaded can on spindle 1 increments the spindle 1 count in the Trips per spindle menu see section 2 10 11 Set Spindle Trip Shift Offset The NEXT and PREV keys can be used to advance to the next parameter or the previous parameter respectively To change the currently displayed parameter simply enter the new value on the numeric keypad and press lt ENTER gt The value will be entered and the next parameter will automatically be displayed When the last parameter Spindle trip shift offset is entered the primary set up menu is again displayed Pressing lt ESC gt at anytime will also
83. ing CHOS 250 230 4 Q C Blow off Timing CHOG 255 295 Test Blow off Can Gate Timing Timing CHO 0 140 44 Bad Can Biwott PLC Clock Timing CH10 0 180 Can No Can Sensor ON Position 0 G C Can Blow off 4 ct RPM 0 Position 85 Offset 333 Scale 360 System Message All Faults Normal ONLINE 1 0 6 2003 4 36PM 4 In addition the following parameters are displayed at the bottom of this window RPM This is the current speed in Revolutions per Minute of the main crank resolver Position This is the current Position in degrees of the main crank resolver Offset This is the current resolver offset set in degrees HSL CD4 User s Manual SYSTEMS Electronics Group 60 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE Scale This is the scale factor of the resolver or the number of divisions in one revolution Note The General Timing Signal Locations section provides a complete description of each timing channel signal Zeroing the Machine setting the resolver offset To set machine zero perform the following 1 2 3 4 5 6 7 Connect an RS 232 SYSdev cable from the COM port on the computer to the PROG port on the M4500 From the Window menu select Machine Timing From the View menu select Online Data The set up program will attempt to communicate with
84. le Last Shift Data The Last Shift data is identical to the current shift data except it is for the previous 8 or 12 hour shift or previous label run however the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period amp RTFCD unnamed Shift Data File Edit View Window Help Trips Per Spindle Current Shift m Last Shift j Total Good Cans 765 533 Total Blow offs E Bad Can Blow offs 366 Manual Blow offs ee Q C Blow offs 394 Restart Blow offs 999 Total Trips 2 666 a 2 122 on EA 4 80 oh E ne 70 S ee 3 E 59 Ho sk at er 2 143 _ maj 74 map 187 ms 115 me 137 mz 104 maf a maf 70 woj 81 21 p mo 22 134 3 85 24 1233 gt 10 x System Message All Faults Normal ONLINE 10 6 2003 4 40PM 7 HSL CD4 User s Manual 66 SYSTEMS Electronics Group SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 6 THE I O STATES WINDOW The I O States window is provided to display states of the inputs and outputs The control boards the states of the timing channels as well as states of the M4500 are shown This includes the interrupt inputs INO and IN1 the analog I O and the resolver These values are displayed as read by the M4500 processor amp RTFCD unnamed I O Status HSL CD4 User s Manual SYSTEMS Electronics Group 67
85. mount of time ahead of the Varnish unit trip timing CH01 usually set at 60 milliseconds Number of Shifts to Varnish Unit This is the number of spindles from the Can Sensor to the varnish unit minus 2 In general this is set such that the varnish unit retracts out on the can ahead of the misloaded spindle For older generation Rutherford Decorators this is set to 5 For newer generation decorators this is set to 4 HSL CD4 User s Manual SYSTEMS Electronics Group ST SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE 5 2 SET PIN CHAIN QC BLOW OFF PARAMETERS The Pin Chain QC Can Blow off set up menu is used to set the Pin Chain QC Blow off parameters in the M4500 This menu is invoked by selecting 2 Set Pin Chain QC Blow off Parameters from the Main Menu The menu selections on the Pin Chain QC blow off set up menu allow the user to set the Pin Chain QC Blow off variables listed under the following menu selections To set a particular variable select the corresponding menu selection and follow the prompts as they occur le C AHSLCD4 HSLCD4 EXE o x Systems HSL CD4 Set up Menu Version 2 1 Pin Chain QC Blow off set up Set Bad Can pin chain blow off response times Set number of cans to blow off pin chain Set number of pins to pin chain blow off port Setup QC select a can blow off Enter Selection ESC to exit Pin Chain Bad Can Blow off Fone Blow off solenoid on response time msec 015
86. n 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 starting 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 Pr
87. nately high count for a particular spindle indicates a loading problem for that spindle 5 6 LAST SHIFT DATA The Last Shift data is identical to the current shift data except it is for the previous 8 or 12 hour shift or previous label run how ever the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period Refer to section 5 5 Current Shift Data for definitions of the data fields in the Last Shift data menu c gt C HSLCD4 HSLCD4 EXE O tt a 5 x Systems HSL CD4 Set up Menu Version 2 1 Last Shift Total for shift Press ESC to return to main menu Total Good Cans 765533 Total Blow offs 14113 Total Misloads 9696 Restart Blow offs 999 Manual Blow offs 3026 QC Blow offs 394 Spindle 01 trips 259 Spindle 13 trips 74 Spindle 02 trips 122 Spindle 14 trips 181 Spindle 03 trips 121 Spindle 15 trips 115 Spindle 04 trips 80 Spindle 16 trips 191 Spindle 05 trips 99 Spindle 17 trips 104 Spindle 06 trips 70 Spindle 18 trips 84 Spindle 07 trips 58 Spindle 19 trips 70 Spindle 08 trips 65 Spindle 20 trips 81 Spindle 09 trips 59 Spindle 21 trips 110 Spindle 10 trips 91 Spindle 22 trips 194 Spindle 11 trips 87 Spindle 23 trips 85 Spindle 12 trips 143 Spindle 24 trips 123 HSL CD4 User s Manual SYSTEMS Electronics Group 79 SECTION 5 HSLCD4 DOS
88. nd enter in a new name for the file The user will be notified if 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 HSL CD4 User s Manual SYSTEMS Electronics Group 42 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 2 UPLOAD SAVE DATA The Set up program allows the user to upload blow off parameters timing channel set points and shift data from the M4500 into a set up Data File This function is accessed from the File menu and the user is given the choice of the following options amp RTFCD unnamed Main Display File Edit View Window Help New Ctrl N Open Ctl O Save Ctl S Save As Export Shift Data Ctrl lt Upload save Data Set up Parameters Q C Blow off Download Program Timing Channels Spindle Number Download Data b Shift Data En _ Blanket Blow off Print Report Ctrl P Exit i Mandrel Blowoff Bad Can Blow off Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 3 05 PM Set up Parameters This option uploads the Set up data from the M4500 This includes the print carriage and varnish unit response times as well as blow off pa
89. 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 the title bar If any changes were made to the existing file the user will be prompted to save any changes before terminating the program Save To Save data file to disk select Save from the File menu or press Ctrl S This displays a dialog box allowing the user to select a folder and enter a name for the file The user will be notified if the file already exists and the extension sdt will automatically be added to the file name If this is a New file the user will be prompted to enter a file name Save As To save the data file to a new name select Save As from the File menu This displays a dialog box allowing the user to select a folder a
90. nics Group APPENDIX B DF1 COMMUNICATIONS M4500 Mapped PLC Description Add Add Add ___ Function Setup Print Carriage Varnish Unit Print Carriage Retract out Response Time B1012 W4808 N7 104 R O Print Carriage Extend in Response Time B1013 W4810 N7 105 R O Varnish Unit Retract out Response Time B1014 W4812 N7 106 R O Varnish Unit Extend in Response Time B1015 W4814 N7 107 R O Setup Bad Can Pin Chain Blowoff to Blowoff from Infeed Open B1000 W4816 N7 108 R O to Blowoff from Print at Restart B1001 W4818 N7 109 R O to Blowoff from Varnish at Restart B1002 W4820 N7 110 R O to Blowoff for each Misload B1003 W4822 N7 111 R O Pins to Pinchain Blowoff Port W1004 W4824 N7 112 R O Blowoff Solenoid ON Response Time B1006 W4826 N7 113 R O Blowoff Solenoid off Response Time B1007 W4828 N7 114 R O Setup QC Pin Chain Blowoff Blowoff Solenoid ON Response Time B1008 W4830 N7 115 R O Blowoff Solenoid off Response Time B1009 W4832 N7 116 R O QC Can Blowoff Port Shift Offset B1010 W4834 N7 117 R O Spindle Trip Shift Offset B1011 W4836 N7 118 R O Setup Passcode W1070 W4838 N7 119 R O Timing Channel Setpoints CHOO Carriage Trip Timing on W4840 N7 120 R O CHOO Carriage Trip Timing off W4842 N7 121 R O CHO01 Varnish Trip Timing on W4844 N7 122 R O CH01 Varnish Trip Timing off
91. nket blow off by clicking the Blanket Blow off command button The blanket blow off will initiate a blow off sequence such that a can printed by each blanket is blown off at the QC blow off port starting with a can printed by blanket 1 e The operator can perform a Mandrel Blow off by clicking the Mandrel Blow off command button The mandrel blow off will initiate a blow off sequence such that a can printed on each mandrel will be consecutively blown off at the QC blow off port starting with mandrel 1 Bad Can Blow off This display is only active while Online and it allows the operator to test the action of the control system by electronically inducing a mis loaded or Bad Can into the system By clicking on the Test Trip Blow off command button a Bad Can will be electronically induced into the system to test the response of the control system due to a Mis Loaded can 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 RTFCD unnamed Set Up File Edit View Window Help Print Carriage Varnish Unit Blow off Parameters Blow off Solenoids Print Carriage Retract out Response Time msec 45 Extend in Response Time msec 45 Varnish Unit Retract out Response Time msec oo g Extend in Response Time msec o 4 Numbe
92. ntrol system is not a dedicated black box but is instead implemented using the high performance SYSTEMS M4500 PLC PLS module This allows easy customization by either SEA or the end user The M4500 module is programmed using the SYSdev programming package DOS or Windows based which allows the module to be programmed in any combination of Ladder or High level subset of C as well as perform on line monitoring and trouble shooting The M4500 module incorporates a built in PLS which interfaces directly to the machine mounted resolver and provides all machine timing eliminating the need for an external PLS 1 3 SPEED COMPENSATED PRINT CARRIAGE TRIP AND VARNISH UNIT CONTROL Speed compensated print carriage and varnish unit trip at speeds in excess of 2000 CPM is incorporated to compensate for the response time of the carriage or varnish unit The print carriage or varnish unit is always extended or retracted such that a miss loaded mandrel is not printed or varnished regardless of machine speed The package achieves this by implementing a speed compensation algorithm that leads the trip point by the response time of the carriage or varnish unit The control is capable of leading the trip point by up to two stations 60msec at 2000 CPM HSL CD4 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION Note A single mandrel trip is possible at speeds up to 1200 CPM a two station trip is recommended for speed
93. nus two This can be a number from 0 to 999 Blow off Solenoid On Response time This is the time used as the on response time of the QC blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the QC blow off timing CH06 usually set at 15 to 20 milliseconds Valid range 5 to 60 msec Blow off Solenoid Off Response time This is the time used as the off response time of the QC blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the QC blow off timing CH06 usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Valid range 5 to 60 msec QC can blow off port shift offset This is the number of spindles difference from detection of the spindle 1 flag to the QC blow off port This is a number between 1 and 24 and is empirically set by selecting spindle 1 for blow off and adjusting this value until the can from spindle 1 is the can that is blown off HSL CD4 User s Manual SYSTEMS Electronics Group A 6 401791 APPENDIX A MODBUS COMMUNICATIONS Spindle Trip Offset This is the number of spindle difference from the detection of the spindle 1 flag to the Can No Can sensor This is a number between 0 and 23 and is empirically such that a miss load
94. of time ahead of the Carriage unit trip timing CH00 usually set at 40 to 50 milliseconds Print Carriage Extend Response Time This is the time used as the extend response time of the carriage unit time from solenoid actuation to first contact with blanket in milliseconds The M4500 will activate the extend solenoid this amount of time ahead of the Carriage unit trip timing CH00 usually set at 40 to 50 milliseconds Varnish Unit Retract Response Time This is the time used as the retract response time of the varnish unit time from solenoid actuation to first break with varnish wheel in milliseconds The M4500 will activate the extend solenoid this amount of time ahead of the Varnish unit trip timing CH01 usually set at 60 milliseconds Varnish Unit Extend Response Time This is the time used as the extend response time of the varnish unit time from solenoid actuation to first contact with varnish wheel in milliseconds The M4500 will activate the extend solenoid this amount of time ahead of the Varnish unit trip timing CH01 usually set at 60 milliseconds Blow off Solenoid On Response time This is the time used as the on response time of the pin chain blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the Pin Chain blow off timing CH05 usually set at 15 to 20 milliseconds Valid range 5 to 60 msec HSL CD4 Us
95. olenoid 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 CHOO CH01 CH02 CHO3 CH04 CHO5 CHO6 CHO7 CH10 CH11 CH12 CH13 CH14 CH15 CH16 CH17 ON 020 010 180 060 030 250 255 000 OFF 060 050 000 250 200 290 295 140 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 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 Gro
96. olver connector Then verify that the position then indeed does increase with forward movement Press ESC to exit back to the primary set up menu Position the machine at machine zero spindle aligned with V notch at top backside of the machine frame see section 2 10 2 Set Machine Zero Auto zero the resolver by selecting 4 ZERO MACHINE from the primary set up menu Enter 0 to zero the resolver The timing set up menu will be displayed now showing the POS at zero The M4500 will calculate the actual offset value required to make this the 000 position and will display this number in the offset field Exit back to the primary set up menu by pressing lt ESC gt Exit back to the default screen by pressing lt ESC gt again 3 5 6 VIEW CRITICAL INPUT POSITIONS This selection is used to view the On position of the Can No Can sensor To view critical input positions perform the following 1 2 Select 6 VIEW CRITICAL INPUT POSITIONS and observe the can no can PRX POS field 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 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 sens
97. or Cut out Note The D4591 must be located within 6 feet of the M4500 module to avoid EMI pick up on the Display ribbon cable Connect the ribbon cable from the M4500 module to the D4591 module HSL CD4 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION Referring to the electrical control schematic at the back of this manual wire the HSL CD4 to the existing control system as follows Note Keep all 24VDC wiring resolver cable and sensor cable wiring away from high voltage wiring Wire the machine mounted resolver directly to the 8 pin resolver input connector on the M4500 1 Incoming Power 115VAC 230VAC to FU1 neutral to 900 and ground to GND 24VDC to 501 and common to 500 2 Interlocks from existing control system to HSL CD4 terminals I10 through 119 3 Interlocks to existing control system from HSL CD4 terminals O22 through O25 4 Carriage Trip Varnish Unit Trip Damaged Can Blow off Pin Chain Blow off and Can Feed solenoids terminals O10 through O21 5 Can No Can Sensor Spindle No 1 I D Sensor and No Transfer Sensor terminals 108 109 121 using three conductor shielded cables The shields of the sensor cables should be tied to earth ground at a terminal inside the existing control cabinet and left floating at the sensors 6 Set Up Enable key switch if desired to allow entry to set up variables through Keypad Display 7 Resolver cable from resolver or existing PLS to 8 pin resolver inp
98. or first sees the can outside the 300 to 30 degree range the sensor should be moved to within the 300 to 0 degree range Press ESC to exit back to the primary set up menu HSL CD4 User s Manual SYSTEMS Electronics Group 36 SECTION 3 USING THE KEYPAD DISPLAY 3 6 QC BLOW OFF KEY This key is used to blow off a can from a selected spindle at the Pin Chain QC Blow off port To blow off a can press the QC BLOW OFF key The display will then prompt Enter Spindle to Blow Can off Enter the desired spindle number 1 24 and press enter One can from that spindle will be blown off at the Pin Chain QC blow off port Note Entering in a 25 or 26 will initiate a consecutive can blow off Code 25 will initiate a Blanket blow off one can from each blanket starting with blanket 1 Code 26 will initiate a Mandrel blow off one can from each mandrel starting with mandrel 1 HSL CD4 User s Manual SYSTEMS Electronics Group 37 SECTION 3 USING THE KEYPAD DISPLAY This Page Intentionally Left Blank HSL CD4 User s Manual SYSTEMS Electronics Group 38 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE The Windows based set up program is menu driven allowing the user to easily view data alter set up variables or set machine timing machine offset timing signal locations etc using a PC running the Windows 95 98 ME 2000 XP NT operating system The set up variables are used to configure
99. ost 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 print 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 s
100. protocols lea HSL QCSTA Remote Select A Can PB station lea HSL DSP Remote RPM Position Display lea RSV34 MSI1 Resolver lea RSV RSCBLE XX Resolver Cable 2 2 POWER REQUIRED The HSL CD4 is powered from 115VAC 230VAC 50 60HZ and 24VDC The 11SVAC 230VAC is used to power the M4500 module while the 24VDC is used to power the 24VDC I O sensors trip and blow off solenoids Note 24VDC solenoids must be used for all trip and blow off solenoids These provide a much more consistent and repeatable response time than 115VAC solenoids Assuming 24VDC solenoids were used in the existing system the 24VDC current required by the HSL CD4 is no more than the existing systems 24VDC current requirement therefore the existing 24VDC power supply should be adequate HSL CD4 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 3 MOUNTING AND WIRING THE HSL CD4 If installing the HSL CD4 package mounted in the NEMA 12 enclosure mount the HSL CD4 NEMA 12 enclosure in proximity to the existing control cabinet If installing the HSL CD4 BP package mount the back panel in the existing control cabinet Referring to the figure below create a cut out in the existing control cabinet door and mount the D4591 display 4 475 re 4 475 m 0 250 ss TER p 8 090 3 500 ve 6 lt __ 0 218 DIA HOLE 0 475 _ 1 775 piles es 4 450 TYPICAL 7 PLACES D4591 Recommended Panel Do
101. r of Shifts to Varnish Unit 5 Test Blow off Bad Can Blow off System Message All Faults Normal ONLINE 10 6 2003 3 58PM This window utilizes a TAB control to divide the set up parameters into three categories similar to that of the Keypad Display HSL CD4 User s Manual SYSTEMS Electronics Group 53 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE Print Carriage Varnish Unit This section is used to set the print carriage Retract Extend response times and the varnish unit Retract Extend response times in the M4500 This section contains the following selections 1 2 3 4 5 Print Carriage Retract out Response Time msec This is the time used as the retract response time of the carriage unit time from solenoid actuation to first break with blanket in milliseconds This will activate the retract solenoid this amount of time ahead of the Carriage unit trip timing CH00 usually set at 40 to 50 milliseconds Print Carriage Extend in Response Time msec This is the time used as the extend response time of the carriage unit time from solenoid actuation to first contact with blanket in milliseconds This will activate the extend solenoid this amount of time ahead of the Carriage unit trip timing CH00 usually set at 40 to 50 milliseconds Varnish Unit Retract out Response Time msec This is the time used as the retract response time of the varni
102. rameters Timing Channels This option uploads the Machine Timing channel set points as well as the PLS configuration and scale factor Shift Data This option uploads the Shift Data from the M4500 This includes the Trips per Spindle data the Current Shift and the Last Shift data All This option allows the user to completely upload Al of the set up parameters timing channel set points and shift data from the M4500 HSL CD4 User s Manual SYSTEMS Electronics Group 43 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 3 DOWNLOAD PROGRAM The Set up program allows the user to Download any SYSdev program file to the M4500 RTFCD7 unnamed Main Display 5 x File Edit View Window Help New Ctrl N Open Ctl O Save Ctri S Save As Export Shift Data Ctrl lt Upload save Data Download Data gt Print Report Ctrl P ood Cans Q C Blow off Spindle Number _ 400 148 Blanket Blow off ul low offs i i Mandrel Blowoff Bad Can Blow off 4 169 Test Trip Blow off Exit System Message All Faults Normal ONLINE 10 6 2003 3 05PM 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
103. rior to selecting any of the above selections make sure an RS 232 cable is connected from the COM port on the computer running HSLCD4 to the PROG port on the M4500 The following sections are a complete description of the HSLCD4 selections and menus HSL CD4 User s Manual SYSTEMS Electronics Group 69 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE 5 1 SET CARRIAGE VARNISH RESPONSE TIMES The Carriage Varnish Unit set up menu is used to set the print carriage and varnish unit response times in the M4500 This menu is invoked by selecting 1 Set Carriage Varnish Response Times from the Main Menu The menu selections on the Print Carriage Varnish Unit set up menu allow the user to set the Carriage Varnish variables listed under the following menu selections To set a particular variable select the corresponding menu selection and follow the prompts as they occur C HSLCD4 HSLCD4 EXE Systems HSL CD4 Set up Menu Version 2 1 Print Carriage Varnish Unit set up Set Print Carriage extend retract response times Set Varnish Unit extend retract response times Set number of shifts to Varnish Unit Enter Selection ESC to exit _ Print Carriage Print Carriage retract response time msec Print Carriage extend response time msec Varnish Unit Varnish Unit retract response time msec Varnish Unit extend response time msec Number of shifts to Varnish Unit Note Prior to selecting this sele
104. s Destination Node 1 al Transmit Data Status prev 0 Unknown Status D TE esination File Number Current Transaction 1 a Active Command Read Number of BYTES Received 0 Received Command BIT Status Command AZB Link Layer Status Status 00 Success No Error Current Transaction Received l 0 System Message All Faults Normal ONLINE 10 6 2003 4 15PM 7 4516 Configuration Status This displays the current state of the configuration of the 4516 serial communications board System function sfunc19 54516 configuration is used to set the S4516 configuration network node address network baud rate and USER port baud rate This must be executed prior to executing ether system functions 10 11 or 13 System function 19 is generally executed in the Initialization file of the user program HSL CD4 User s Manual SYSTEMS Electronics Group 58 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE The following values are returned from a system function 19 call 1 Busy 2 Done S4516 Successfully configured 3 Invalid Parameter either network node address network baud rate or USER port baud rate is invalid 4 Timeout no response form S4516 32 Hardware ACK error from 4516 34 Invalid S4516 Slot Address W8156 must be loaded with the slot address of the 4516 prior to executing system function 19 II Transmit Data Status This represents the stat
105. s above 1200 CPM 1 4 BAD CAN AND SELECT A CAN PIN CHAIN BLOW OFF Both the Bad Can pin chain blow off and Select A Can pin chain blow off incorporate speed compensation to compensate for the response time of the blow off solenoids regardless of machine speed This allows accurate rejection of a single can from the pin chain at speeds in excess of 2000 CPM The bad can blow off is activated automatically to reject miss loaded cans from the pin chain The Select A Can feature allows the user to dial in a mandrel number either at a remote PB station or from the Keypad Display and blow off one can printed on that mandrel Mandrels 1 through 24 can be individually blown off this way to verify the print quality of each mandrel Two other select a can blow off modes are also available blanket and mandrel The blanket mode blows off consecutive cans printed on each blanket starting with blanket 1 The mandrel blow off mode blows off 24 consecutive cans printed on all 24 mandrels starting with mandrel 1 The following variables can be set by the user for the bad can blow off e Number of pins to the pin chain blow off port up to 999 e Number of cans to blow off for each bad can three is usually required when varnish is used e Both the ON and off solenoid response time used by the speed compensation algorithm The following variables can be set by the user for the select a can blow off e QC shift offset 1 to 24 whi
106. sed to view both the on and off set points in the selected channel Searching Channel To view the set points in a channel simply press the SEARCH CHANNEL key The next off to on or on to off position is shown in the SETPOINT field If the transition was off to on the state character will be a solid block If the transition was on to off the state character will be blank HSL CD4 User s Manual SYSTEMS Electronics Group 34 SECTION 3 USING THE KEYPAD DISPLAY Entering or Adjusting Set point To set or adjust a timing channel perform the following 1 2 3 4 Select the channel to be adjusted by pressing the SELECT CHANNEL key entering the channel number 00 to 17 and pressing enter In addition the NEXT and PREV keys can be used to advance to the next channel or retard to the previous channel Press CLEAR CHANNEL to clear the existing set point out Note Entering a new set point does not automatically clear the old set point out If the two set points are not in the same place the channel will simply have two set points in it if the old one is not cleared out first Therefore always clear the channel before entering a new set point A set point may however be extended by programming another set point onto an existing set point using either the existing on or off set point as the starting position for the new set point This will result in one larger set point Press
107. see section 2 10 4 Set Pin Chain Blow off Timing This signal should be 40 degrees wide CH07 CAN GATE TIMING This signal is used to open and close the can gate Set as necessary for proper can gating CH10 PLC CLOCK TIMING This signal is provided to the PLC via a discrete DC output This is used for whatever purpose required by the host PLC to clock once per spindle data In general this should be set on for 180 degrees and off for 180 degrees Otherwise set as desired This signal is not used by the HSL CD4 package internally in any way HSL CD4 User s Manual SYSTEMS Electronics Group 84 SECTION 7 RECOMMENDED SPARE PARTS The following are recommended spares for the HSL CD4 These parts are available through Systems Engineering Assoc Inc Quantity lea lea lea lea lea lea HSL CD4 User s Manual Part Number M4500 P4500 54563 54568 54573 D4591 Description PLC PLS Processor Chassis 4 Slot Power Supply 16 Point 10 30VDC Input Board 8 input 8 output 10 30VDC I O Board 16 point 10 30VDC Output Board Display Keypad SYSTEMS Electronics Group 85 SECTION 7 RECOMMENDED SPARE PARTS This Page Intentionally Left Blank HSL CD4 User s Manual SYSTEMS Electronics Group 86 APPENDIX A MODBUS COMMUNICATIONS MODBUS PORT CONFIGURATION The MODBUS driver uses the following data format and parameters the MODBUS port on the MODICON PLC must be set to match these
108. select Machine Timing e From the View menu select Online Data The set up program will attempt to communicate with the processor and place the system into an Online mode of operation Set all channels per the section 6 General Timing Signal Locations Set points for a particular channel are either entered in the field or adjusted by using the increment decrement controls Note Only one set point is used per channel If a channel needs to be Recalled or Cleared enter the desired channel number into the PLS Channel field Click the Recall Channel command button to recall the setpoints Click the Clear Channel command button the completely clear all setpoints for the selected channel Note Ifa channel has been cleared or the On and Off setpoints have the same setting the set point will be displayed as HSL CD4 User s Manual SYSTEMS Electronics Group 62 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE Resetting the PLS Configuration As an aid to the user the current PLS configuration is displayed in the PLS Configuration tab of this window The PLS configuration should only be reset if a new module has been installed To reset the PLS configuration click the Reset PLS Config command button This function only resets the PLS configuration to the default settings amp RTFCD 7 unnamed Machine Timing ual Ega oa
109. selector switch QC Blow offs This is the total number of cans blown off by the operator with the Select A Can QC station or QC Blow off key on the HSL CD4 keypad for quality verification Trips Mis loads per Spindle 1 24 This is the total trips mis loads for each spindle A disproportionately high count for a particular spindle indicates a loading problem for that spindle HSL CD4 User s Manual SYSTEMS Electronics Group 29 SECTION 3 USING THE KEYPAD DISPLAY 3 4 LAST SHIFT KEY The Last Shift data is identical to the current shift data except it is for the previous 8 or 12 hour shift or previous label run how ever the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period Refer to section 3 3 Current Shift Key for definitions of the data fields in the Last Shift data menu 3 5 SET UP KEY This selection is used to invoke the primary set up menu This consists of the following four selections SET CARRIAGE VARNISH RESPONSE TIMES SET PIN CHAIN QC BLOW OFF PARAMETERS SET MACHINE TIMING SET POINTS ETC SET NUMBER OF SHIFTS TO VARNISH UNIT ZERO MACHINE SET RESOLVER OFFSET VIEW CRITICAL INPUT POSITIONS Ne ee The set up menu can be key switch protected such that only authorized personnel those with the key can activate the selection The Set up Enable input must be ON to invoke the set up menu When selected each of
110. sh unit time from solenoid actuation to first break with varnish wheel in milliseconds This will activate the extend solenoid this amount of time ahead of the Varnish unit trip timing CH01 usually set at 60 milliseconds Varnish Unit Extend in Response Time msec This is the time used as the extend response time of the varnish unit time from solenoid actuation to first contact with varnish wheel in milliseconds This will activate the extend solenoid this amount of time ahead of the Varnish unit trip timing CH01 usually set at 60 milliseconds Number of Shifts to Varnish Unit This is the number of spindles from the Can Sensor to the varnish unit minus 2 In general this is set such that the varnish unit retracts out on the can ahead of the misloaded spindle For older generation Rutherford Decorators this is set to 5 For newer decorators this is set to 4 HSL CD4 User s Manual SYSTEMS Electronics Group 54 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE Blow off Parameters This section is used to set the Pin Chain QC Blow off parameters in the M4500 amp RTFCD7 unnamed Set Up O x File Edit View Window Help Print Carriage Varnish Unit i Blow off Solenoids Blow off Set up Test Blow off Number of Pins to Pin Chain Blow off Port 32 z Bad Can Blow off Number of Cans from Infeed to Can PRX ics Number of Can to Blow off for Each Mis load 3 OB Nollie Number o
111. sibility is assumed for inaccuracies In the interests of a commitment to a policy of continuous development and improvement the manufacturer reserves the right to change the specification of the product or it s performance or the contents of the User Manual without notice Copyright 1995 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description 1 Features Functional Description Speed Compensated Print Carriage Trip and Varnish Unit Control Bad Can and Select A Can Pin Chain Blow off Automatic Form Roll Throw off Alarm Detection Data Collection _ Q Na ha oe l HM NOOR RRWWHNY 2 Installation 5 2 1 Whaf s Included 5 2 1 1 HSL CD4 for back panel mounting 5 2 1 2 HSL CD4 ENCL with NEMA 12 Enclosure ss 5 2 1 3 HSL CD4 Options 6 2 2 Power Required 6 2 3 Mounting and Wiring the HSL CD4 7 2 4 Mounting the HSL QCSTA 8 2 5 Mounting the HSL DSP Remote Display 9 2 6 Mounting the RSV34 MS1 Resolver 9 2 7 Mounting the Spindle 1 I D Sensor 9 2 8 HSL CD4 Software Installation 10 2 8 1 Windows Based Setup Program Installation ___ 10 2 8 2 DOS Based Setup Program Installation 11 2 8 3 SYSdev Program Development Software Installation 12 2 8 4 Application Program Installation 12 2 9 Modify Existing PLC Program 12 2 10 Tuning the HSL CD4 14 2 10 1 Default Set up Variables 14 2 10 2 Set Machine Zero 16 2 10 3 Verify Location of Can No Can Sensor 17 2 10 4 Set Pin Ch
112. spindle These counts can be reset by the operator whenever desired A disproportionately high count for a particular spindle indicates a loading problem for that spindle HSL CD4 User s Manual SYSTEMS Electronics Group A 2 The bits of the APPENDIX A MODBUS COMMUNICATIONS Status register to the MODICON from the M4500 are mapped as follows W690 Status to MODICON 4x address 401758 in MODICON B690 0 B690 1 B690 2 B690 3 B690 4 thru B691 7 Zero Speed Infeed Track Jam Alarm Transfer Jam Alarm Timing Signal Fail Alarm Not Used Not Used The Status bits sent to the MODICON PLC are defined as follows B690 0 Zero Speed This bit is set to a 1 when the decorator speed is below 30CPM This bit is set to a 0 when the speed is greater than 30CPM B690 1 Infeed Track Jam Alarm The infeed track jam alarm occurs when 6 consecutive empty mandrels are detected by the can no can sensor after the can gate is opened B690 2 Transfer Jam Alarm The no can transfer alarm occurs when the no can transfer sensor detects a can on a mandrel after the disk transfer location B690 3 Timing Signal Fail Alarm The timing signal fail occurs when any of the timing signals generated in the PLS section fail to change state periodically while the machine is running HSL CD4 User s Manual SYSTEMS Electronics Group A 3 APPENDIX A MODBUS COMMUNICATIONS DATA READ FROM THE MODICON PLC The following d
113. t the spindle trip offset select 1 and enter the required offset see section 2 10 11 Set Spindle Trip Shift Offset and press lt ENTER gt To reset the spindle trip counts simply press 2 The counts will be reset in the M4500 To exit back to the main menu press lt ESC gt HSL CD4 User s Manual SYSTEMS Electronics Group 97 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE 5 5 CURRENT SHIFT DATA The Current shift data menu displays the following information Systems HSL CDA Set up Menu Version 2 1 Current Shift Totals so far Press ESC to return to main menu Total Good Cans 400148 Total Blow offs Total Misloads 2795 Restart Blow offs Manual Blow offs 640 QC Blow offs Spindle trips Spindle 13 Spindle trips Spindle 14 trips Spindle trips Spindle 15 trips Spindle trips Spindle 16 trips Spindle trips Spindle 17 trips Spindle trips Spindle 18 trips Spindle trips Spindle 19 trips Spindle trips Spindle 20 trips Spindle trips Spindle 21 trips Spindle trips Spindle 22 trips Spindle trips Spindle 23 trips Spindle trips Spindle 24 trips This data is the totals so far into the shift This data is transferred to the Last shift data when the end of shift input transfers from a 0 to a 1 This can be at the end of either an 8 or 12 hour shift or alternatively could be done at label changes such that the data collected would be for label runs rat
114. the P4500 perform the following steps 1 Mount the P4500 to the HSL CD4 in the mounting holes next to the M4500 left side using two 8 32 screws 2 With power to the P4500 off install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4500 the connector on the cable is polarized and should mate with the connector on the M4500 only one way HSL CD4 User s Manual SYSTEMS Electronics Group 25 SECTION 2 INSTALLATION 2 11 3 D4591 KEYPAD DISPLAY INSTALLATION To install the D4591 perform the following steps 1 With the gasket installed on the mounting studs of the D4591 install the D4591 in the cut out either in the HSL CD4 enclosure or the cut out in the user s existing control cabinet Secure the display to the enclosure using 7ea 8 32 nuts and external lock washers 2 Connect the display ribbon cable to the connector on the lower back of the display the connector on the cable is polarized and should mate with connector on the M4500 only one way 2 11 4 DOWNLOAD HSLCD4 PROGRAM AND SET UP DATA TO M4500 Once the M4500 P4500 D4591 are installed perform the following to download the HSLCD4 application program to the M4500 as well as download the previously saved set up data and timing channel set points 1 Power up the M4500 and the IBM PC or compatible used to interface with the HSL CD4 2 Connect an RS 232 cable from the computer COM port to the PROG port on the M4500 3 Initiate the
115. the processor and place the system into an Online mode of operation Observe the Position field at the bottom of the window Verify that as the machine is rotated forward that the position increases linearly from 0 through 359 degrees If not swap the S1 and S3 leads at the resolver connector on the M4500 Then verify that the position does indeed increase with forward movement Position the machine at machine zero spindle aligned with V notch at top backside of machine frame see section 2 10 2 Set Machine Zero Auto zero the resolver by entering 0 in the Resolver Offset field and clicking the Set Offset command button A message box will appear prompting the user to confirm their choice Select Yes to set the resolver offset The M4500 will calculate the actual offset value required to make this the 0 position The new offset value will be displayed in the Offset field and the position will then read zero HSL CD4 User s Manual SYSTEMS Electronics Group 61 SECTION 4 RTFCD7 WINDOWS BASED SETUP PROGRAM REFERENCE Adjusting the Timing Channel Setpoints To set any of the timing signal setpoints perform the following Note Any changes made to the timing channel setpoints will be saved as part of the setup data file 1 2 3 4 5 Connect an RS 232 SYSdev cable from the COM port on the computer to the PROG port on the M4510 From the Window menu
116. the set up parameters the M4500 instead uses the values set up thru the HSL CD4 keypad or the HSLCD4 set up program HSL CD4 User s Manual SYSTEMS Electronics Group A 7 APPENDIX A MODBUS COMMUNICATIONS B900 3 B900 4 B900 5 Timing Channel Program Enable Setting this bit to a 1 enables the CHOO thru CH07 On and Off set points 401761 thru 401776 from the MODICON to be used as the set points for CH0O0 thru CH07 in the PLS section of the M4500 If this bit is set to a 0 the values in 401761 thru 401776 in the MODICON are not used as the set points the M4500 instead uses the values set up thru the HSL CD4 keypad or the HSLCD4 set up program Set Resolver Zero Auto Zero Setting this bit sets the PLS offset such that the current position is 0 To set the resolver zero position the machine at machine zero and then set this bit to a 1 The resolver position will now read 000 Reset this bit back to 0 when done Alarm Reset Setting this bit to a 1 resets the Infeed Track Jam alarm Transfer Jam alarm and the Timing Signal Fail alarm HSL CD4 User s Manual SYSTEMS Electronics Group A 8 APPENDIX B DF1 COMMUNICATIONS HARDWARE DF1 communication takes place via the Channel 0 port of the Allen Bradley PLC The RS 232 cable should be constructed and connected as shown below 4516 DF1 to PLC5
117. ting the Machine Timing selection make sure the RS 232 cable is connected from the COM port on the computer to the CHAN PORT on the M4500 When selected the PLS programming main development menu will be invoked using the default CD4TMG channel set point file C HSLCD4 HSLCD4 EXE _ ME CHANNEL 00 DESCRIPTION Carriage Trip Timing PROG MODE ONLINE CHANNEL SET POINTS ON OFF ON OFF ON OFF ON OFF ON OFF 0020 0060 n 2i 31 41 T J SCALE FACTOR 36 MESSAGE Position 085 Speed RPM 0000 OFFSET 333 PULSE TRAIN NO ON gt ORE gt START HSL CD4 User s Manual SYSTEMS Electronics Group 74 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE From this menu the user can zero the machine set the resolver offset and adjust the timing signal set points Note Section 6 provides a complete description of each timing signal 5 3 1 ZEROING THE MACHINE To set the machine zero resolver offset perform the following 1 2 3 4 5 6 7 8 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4500 Select the 3 Set Machine Timing selection from the HSL CD4 set up program main menu Select 1 Online Channel Setpoint Programming from the Main Development menu Select F9 POS RPM and observe the POS field Verify that as the machine is rotated forward
118. turn back to the HSLCD4 main menu 5 8 DOWNLOAD SET UP DATA TO M4500 This selection is used to download the previously uploaded saved set up variables to the M4500 This should only be performed when replacing the M4500 module see section 2 11 M4500 P4500 D4591 Installation Note The set up data consists of the carriage varnish response times pin chain QC blow off parameters and the spindle trip shift offset Timing channel set points are not stored as part of the set up data To download the set up data perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4500 HSL CD4 User s Manual SYSTEMS Electronics Group 80 SECTION 5 HSLCD4 DOS BASED SETUP PROGRAM REFERENCE 2 Select 8 Download Set up data to M4500 A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key 3 Once data download is initiated the current address being downloaded will be displayed Note 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 HSLCD4 main menu 5 9 UPLOAD SAVE SET UP DATA FROM M4500 This selection is used to save the set up variables from the M4500 to the hard drive current directory selected This should be performed anytime any of the set up
119. up 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 CHAIN 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 Blo
120. ut connector on the M4500 using a three pair two conductor shielded cable The shield of the resolver cable should be tied to the SHLD terminal of the M4500 resolver input connector Make sure the resolver cable shield is left floating at the resolver 2 4 MOUNTING THE HSL QCSTA The HSL QCSTA is used to blow off a can from a selected spindle or blanket from the pin chain for quality verification If the optional HSL QCSTA remote select a can PB station was purchased mount it in the vicinity of the pin chain QC blow off port in a convenient location for the operator Wire the HSL QCSTA to the HSL CD4 panel referring to the electrical control schematic at the back of this manual HSL CD4 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 5 MOUNTING THE HSL DSP REMOTE DISPLAY The HSL DSP is a remote 4 digit BCD display which displays either the current CPM or resolver position as selected by the operator If the optional HSL DSP remote RPM Position display was purchased make a cut out in the operator s control console for the display where desired Prior to mounting remove the back cover of the display and set the dip switches as outlined on the electrical control schematic at the back of this manual Mount the display and wire per the schematic at the back of this manual A selector switch can also be mounted and wired as shown to select either CPM or position 2 6 MOUNTING THE RSV34 MS1 RESOLVER IF REQUIRED
121. w 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 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 P

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