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1. input such that when the switch is in the enable position the input is on 3 5 1 SET REJECT SHIFT REGISTERS This menu is activated when the 1 key SET REJECT SHIFT REGISTERS is pressed while the primary set up menu is active The following parameters may then be adjusted or viewed Array Fault Offset 0 Number of Pockets This number is used to correctly display the Bad Array Head number when a Leak Detection Array Fault occurs This is adjusted such that an array fault on head number 1 is correctly displayed on the main screen when an array fault occurs on number 1 Pocket 1 Offset 0 Number of Pockets This number is used to compensate for the number of pockets between the Reject Receiver and discharge location on the tester This is adjusted such that a reject from pocket 1 is counted as a reject from pocket 1 in the Rejects per Pocket screen This number is approximately Total Number of Pockets Leaker Reject Shift plus or minus one pocket Can Presence Shifts 0 15 This is the number of pockets from the Can Presence Sensor to the tester discharge pocket where cans are released from the machine Leaker Reject Shifts 0 15 This is the number of pockets from the Reject Array Receiver pocket to the tester discharge pocket where cans are released from the machine Vision Reject Shifts 0 44 This is the number of pockets from the vision inspection system reject pocket to the tester discharg
2. Can Presence Sensor turns ON With a can in a pocket rotate the machine forward until the Can Presence Sensor just turns ON Record can presence sensor ON position here Determine the position the Reject Receiver turns ON With no cans in the tester rotate the machine forward until INO of the HSMLT M4503 module just turns ON Record reject receiver ON position here SYSTEMS Electronics Group 11 SECTION 2 INSTALLATION HSL LTA LTS User s Manual 7 8 Determine the position the Array Fault Receiver turns ON Rotate the machine forward until INI of the HSMLT M4503 module just turns ON Record array fault ON position here Note A single can could be manually fed into the machine from the infeed through to the discharge of the machine Viewing the Critical Input Positions form the Set up menu will display these three positions as well Set the Sync timing With the previous information the Sync timing is set such that it does not occur within 60 degrees of any of the above positions For instance on the LT 16 the above positions generally occur as follows Can Presence 300 degrees Reject Receiver 45 degrees Array Fault Receiver 45 degrees Thus the default timing for the LT 16 has Sync at 180 degrees since this is furthest from all the signals 9 Set the Pocket 1 timing 90 degrees after the Sync timing 10 Set the Discharge timi
3. Reset Alarms System Message All Faults Normal ONLINE 10 14 2003 3 09PM 4 SYSTEMS Electronics Group 45 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 4 2 3 DOWNLOAD PROGRAM The Set up program allows the user to Download any SYSdev program file to the M4503 amp HSMHLT unnamed Main Display File Edit View Window Help New Ctrl N Open Ctrl O Save Ctrl S Save As Export Shift Data Ctrl Upload save Data Leaker Rejects Vision Rejects Download restore Data 234 165 Print Report CtP frap total Scrap leaker ZScrap vision Exit 0 12 0 07 Bad Can Blow off Alarm Reset Reset Alarms ONLINE 10 14 2003 308PM System Message All Faults Normal Note To Download a SYSdev program to the processor the program must be Online If Online mode cannot be achieved program download will not be executed If the program is currently Offline the user will be prompted to first go Online Once selected and the set up program Online with the processor a dialog box will be displayed allowing the user to select the SYSdev file to download Note Only the files with the sdv file extension will be displayed It is important to keep in mind that only a valid M450
4. key The default screen will now be displayed again The ESC key can also be used at any time to abort the rejects per pocket data display and return back to the default screen SYSTEMS Electronics Group 30 SECTION 3 USING THE KEYPAD DISPLAY 3 3 CURRENT SHIFT KEY The Current Shift key 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 data when the end of shift input transfers from a 0 to a This can be at the end of either an 8 or 12 hour shift or alternatively could be done at label changes such that the data collected would be for label runs rather than complete shifts This data cannot be reset by the operator only at the end of shift input transition Note The Current shift Good Cans and Rejects is displayed as part of the default screen The Current Shift data is defined as follows Good Cans This is the total number of good cans tested so far into the shift This is essentially a can counter Rejects This is the total number of leaker cans rejected from the machine so far into the shift This also is essentially a can counter Vision Inspection Rejects This is the total number of cans rejected by the vision system if used so far into the shift Rejects per Pocket 1 16 This is the total leaker rejects for each pocket A disproportionately high count for a particular pocket indicates a light seal problem
5. no responsibility 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 2001 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description 1 Features Functional Description Leaker Reject Blow off System Vision Inspection System Reject Data Collection Tester Requirements ae ee Xx OoORWN gt aR RWDND 2 Installation 7 2 1 What s Included 7 2 2 Services Required 7 2 3 Pre Installation 8 2 4 Installation Down Day 9 25 Set up 11 2 6 HSMLT Set up Software Installation 15 2 6 4 Windows Installation 15 2 6 2 DOS Installation 16 2 7 SYSdev Program Development Software Installation 17 2 8 HSMLT Application Program Installation 18 2 9 Modify Existing PLC Program 19 2 10 Set up Reference 21 2 10 1 Default Set up Variables LT 10 21 2 10 2 Default Set up Variables LT 12 21 2 10 3 Default Set up Variables LT 16 22 2 10 4 Machine Zero 22 2 10 5 Machine Timing Signals 23 2 10 6 FIFO Error Correction Calibration 23 2 10 7 View Critical Input Positions Menu 26 2 11 HSMLT Module Replacement 26 3 Using the Keypad Display 3 29 31 Default Screen 30 3 2 Rejects per Pocket Key 30 3 3 Current Shift Key 31 3 4 Last Shif
6. reject blow off solenoid e Based on high performance M4503 PLC PLS module allowing easy trouble shooting and user customization using SYSdev DOS based programming package 1 2 FUNCTIONAL DESCRIPTION The HSL LTA LTS Alcoa Borden s Light Tester electronic reject control package is an electronic upgrade for the Borden s Light Tester which replaces the existing mechanical odd even reject mechanism with a tester discharge mounted reject blow off solenoid thus allowing significant increases in speed The package interfaces to the existing leak detection array receiver tracks leaker cans from the receiver to the blow off location in the tester discharge and accurately rejects the leaker cans regardless of machine speed In addition the package can be used to reject cans inspected from vision inspection systems and blow any inspected reject cans from the same reject blow off port Alarm detection is provided including leak detection array fault can jam back up at discharge timing signal failure excessive lo hi FIFO corrections blow off photo eye lenses dirty fault missed reject detection and can presence sensor fail Data collection includes Total number of good cans tested total number of leaker rejects total number of vision rejects rejects per pocket etc both for the current shift and previous last shift The package interfaces directly to the machine mounted resolver existing leak detection array receiver can presence
7. 10 14 2003 312PM 7 1 Can Neck Size in 0 01 inches This parameter is used to calculate when to activate the reject blow off as a function of the can speed The can neck size is simply the diameter of the neck at it s most narrow point in 0 01 inches For example if the neck measures 2 15 at it S most narrow point simply enter 215 for the can neck size The valid range of this value is 180 to 350 The Can Neck Size parameter can be used to compensate for the response time of the blow off solenoids To advance the blow off activate solenoids earlier make the Can Neck Size larger To retard the blow off activate the solenoids later make the Can Neck Size smaller 2 Reject Solenoid Pulse Time msec This is the number of milliseconds that the reject solenoids will be pulsed for when a bad can is rejected This is adjusted to get a strong pulse of air to reject the can Too short of time will result in the can not being fully rejected jamming Too long of time will disturb the following can at high speeds also causing jamming Typically this is set from 10 to 12msec The valid range for this parameter is 8 to 50msec SYSTEMS Electronics Group 59 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 3 4 5 6 7 Diverter Solenoid Pulse Time 01sec This is the amount of time in 01seconds the Leaker Vision diverter solenoid if used is pulsed to diver
8. Good Cans Tested Total Leaker Rejects Total Vision Inspection Rejects Pocket 01 Leaker Rejects Pocket 09 Leaker Rejects Pocket 02 Leaker Rejects Pocket 10 Leaker Rejects Pocket 03 Leaker Rejects Pocket 11 Leaker Rejects Pocket 04 Leaker Rejects Pocket 12 Leaker Rejects Pocket 05 Leaker Rejects Pocket 13 Leaker Rejects Pocket 06 Leaker Rejects Pocket 14 Leaker Rejects Pocket 07 Leaker Rejects Pocket 15 Leaker Rejects Pocket 08 Leaker Rejects Pocket 16 Leaker Rejects Cc ccc ccc 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 HSMLT module Total Good Cans Tested This is the total number of good cans tested so far into the shift This is essentially a can counter Total Leaker Rejects This is the total number of leaker cans rejected by the machine so far into the shift Total Vision Inspection Rejects This is the total number of cans rejected by the vision inspection system if used Pocket Leaker Rejects This is the total leaker rejects for each pocket A disproportionately high count for a particular pocket indicates a light seal problem for that pocket HSL LTA LTS User s Manual SYSTEMS Electronics Group 79 SECTION 5 HSMLT DOS BASED SET UP PROGRAM REFERENCE 5 5 LAST SHIFT DATA The Last Shift data is identical to the current shift data except it is the totals for the previous 8 or 12 h
9. Presence Count 04 System Message All Faults Normal ONLINE 10 14 2008 312PM 7 Can tracking error detection logic is used to determine when a reject FIFO error had occurred This is generally due to the Can Presence sensor missing a can side wall damage on the can or when the Reject Photo Eye misses a can or double clocks a can severe neck damage The error detection logic verifies the reject FIFO is correct This is done by comparing the average number of cans in the FIFO to a calibrated average The error detection logic is calibrated by running the machine at top speed with a continuous flow of cans By clicking on the Calibrate FIFO button the error detection logic is calculated based on the speed of the machine Note Clicking the Calibrate FIFO button when the machine is stopped will disable the can tracking error detection logic SYSTEMS Electronics Group 63 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual To calibrate the FIFO error detection perform the following 1 With the machine stopped select Calibrate FIFO tab in the Set up window 2 Click the Calibrate FIFO button This disables the error detection The Can Check Speed is set at 4800 cpm and the FIFO Min is set to 0 0 and the FIFO Max is set to 9 9 3 With the FIFO error detection disabled run the machine at top speed with a continuous f
10. Revision 47 Program Checksum 82 Program already loaded in module Program Ident HSMLT Program Revision 47 Program Checksum 82 Entire program file will be dumped to M4500 All outputs are turned off while program dump occurs Press ESC to abort program dump or any other key to continue Sending program at address 4520H Note Program download cannot be performed while the tester is running All outputs on the module are turned off and no program execution is performed The tester should therefore be stopped before the download takes place In addition the tester will have to be run without cans after the download is complete in order to reset the can tracking logic Therefore stop the flow of cans to the tester prior to stopping the tester for the program download 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the HSMLT module 2 Select 5 Download Program to Module from the Main Menu The current program ident revision and checksum for both the program on disk and already loaded in the module will be displayed A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key If a prompt stating that the HSMLT file could not be opened is displayed then the HSMLT application program is not installed in the current directory SYSTEMS Electronics Group 81 SECTION 5 HSMLT DOS BASED SET
11. This data is transferred to the Last shift data when the end of shift input transfers from a 0 to a 1 This can be at the end of either an 8 or 12 hour shift or alternatively could be done at label changes such that the data collected would be for label runs rather than complete shifts E HSMLT unnamed Shift Data EDU lal x File Edi View Mindow Helr Rejects Per Pocket Current Shift Last Shift m Current Shift Rejects Per Pocket Total Good Cans 243 730 re 9 13 Leaker Rejects 234 2 zy to Ea Vision Rejects 165 3 ae T 562 Scrap total 0 18 4 393 12 2 577 Scrap leaker 0 12 5 H3 Scrap vision 0 07 I6 a Ha End of Shift i w 5 wj 0 Transfer Data 8 19 6 0 System Message All Faults Normal ONLINE 10 1 4 2003 313 PM Z 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 M4503 The following data is displayed in the Current Shift Totals so far menu SYSTEMS Electronics Group 71 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 1 2 3 4 5 6 7 8 End of Shift Transfer Data This button is used to invoke an end of shift data transfer This will cause the current shift data to be transferred to the last shift and then all counts reset to zero Total Good Cans Tested Th
12. and accurately rejects leaker cans at all speeds e Performs high speed control functions of Alcoa Light Tester to speeds in excess of 3000 CPM machine mechanically permitting This includes detection of leaker cans interfaces with existing Leak detection arrays rejection of leaker cans alarm detection as well as data acquisition e Optionally excepts reject input from Vision inspection systems to incorporate rejection of inspected cans with leaker reject blow off solenoid as well e High speed front end upgrade package which interfaces with existing control system e Alarm detection leak detection array fault tester discharge can jam back up timing signal fail can presence sensor fail photo eye lenses dirty fault and missed reject detection e Data Acquisition Total number of good cans tested total number of leaker rejects total number of vision rejects total rejects per pocket etc for both current shift and last shift SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSL LTA LTS User s Manual e Built in 2 Line X 40 character sealed display with 24 key membrane keypad allows local viewing of collected data can count reject count rejects per pocket by operator and set up of all user variables passcode protected or key switch enabled by authorized personnel e Interfaces directly with machine mounted resolver existing leak detection array receiver can presence sensor reject photo eye and
13. as well as clock the data from the Can Presence sensor The Sync Timing should be as far as possible from the occurrence of the above four signals For the LT 10 this is at 0 degrees for the LT 16 the is at 180 degrees Pocket 1 Timing CH01 The Pocket 1 Timing is used to reset the pocket count to pocket 1 Set the Pocket 1 Timing 90 degrees following the Sync Timing SYSTEMS Electronics Group Sai SECTION 5 HSMLT DOS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 3 Discharge Timing CH02 The Discharge Timing CH02 should be set about 30 degrees before the location that the can is released from the tester With cans in the machine rotate the tester by hand to the location where the can is just released Set the Discharge Timing CH02 to the position 30 degrees before this can release position 4 PLC Timing CH03 The PLC Timing is provided as an extra timing signal which can be used by the existing host control system Set this timing as desired 5 3 NUMBER OF REJECTS PER POCKET DATA The number of leaker rejects per pocket menu is provided to aid in the trouble shooting of a light seal problem with a pocket or pockets The total number of rejects for each pocket since the last reset or end of shift is displayed Systems HSM LT Set up Menu Version 2 1 Leaker Rejects per Pocket Menu Press ESC to return to main menu Pocket 01 Leaker Rejects Pocket 02 Leaker Rejects Pocket 03 Le
14. by selecting Offline Data or by simply pressing the F4 function key This allows the user to perform Offline editing All values displayed in Offline edit mode reflect the actual values contained in the currently loaded set up data file Note The program can be toggled between Online and Offline by simply double clicking on the Online or Offline panel displayed in the status bar at the bottom of the window Once invoked the set up program will close the Comm port and cease communication with the M4503 SYSTEMS Electronics Group 54 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE 4 5 THE WINDOW MENU The Window menu allows the user to select one of five different Display Set up windows to modify set up parameters view shift data or receive feedback about the current status of the control system amp HSMHLT unnamed Main Display File Edi View window Help 2 Set up Parameters 3 Serial Communications 4 Shift Data 51 0 States Machine CPM r Good Cans Leaker Rejects Vision Rejects 0 243 730 294 165 r Scrap total Scrap leaker ZScrap vision 0 18 0 12 0 07 Bad Can Blow off Alarm Reset Reset Alarms System Message All Faults Normal ONLINE 10 14 2003 3 12PM 7 Once a window menu item is selected a check mark is placed next to
15. for the number of pockets between the Reject Receiver and discharge location on the tester This is adjusted such that a reject from pocket 1 is counted as a reject from pocket 1 in the Rejects per Pocket screen This number is approximately Total Number of Pockets Leaker Reject Shift plus or minus one pocket 5 Rejected Pocket This is the number of the last pocket that generated a vision reject This is only available in the online mode 6 Array Fault Offset 0 Number of Pockets This number is used to properly display a faulted array head when a Leak Detection Array Fault alarm occurs 7 Faulted Array Head This displays the faulted array head when a Leak Detection Array Fault alarm occurs HSL LTA LTS User s Manual SYSTEMS Electronics Group 58 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE Blow off Parameters HSMHLT unnamed Set Up File Edit View Window Help lal x Reject Shift Registers iB Machine Timing Calibrate FIFO Critical Input Postions r Reject Blow off Parameter Set up Bad Can Blow off Can Neck Size 0 01 in 215 4 Test Blow off Solenoid NS Reject Solenoid Pulse Time msec 10 7 Diverter Solenoid Pulse Time 0 01sec 100 a Can Time msec 23 0 Blow off Solenoid ON Time msec 10 0 Blow off Solenoid Delay Time msec 135 System Message All Faults Normal ONLINE
16. sensor reject photo eye and reject blow off solenoid as well as the host PLC via discrete DC I O SYSTEMS Electronics Group HSL LTA LTS User s Manual SECTION 1 GENERAL DESCRIPTION The package is not a dedicated black box but is instead implemented using the high performance SYSTEMS M4503 PLC PLS module allowing easy customization by either SEA or the end user The M4503 module is programmed using the DOS based SYSdev programming package allowing 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 M4503 module incorporates a built in PLS which interfaces directly with the machine mounted resolver and provides all machine timing eliminating the need for an external PLS 1 3 LEAKER REJECT BLOW OFF SYSTEM The package incorporates a reject blow off assembly which is mounted in the discharge of the tester to reject detected leak cans This replaces the existing mechanical odd even reject mechanism thus allowing significant increases in speed The package interfaces to the existing leak detection array receiver tracks leaker cans from the receiver to the blow off location in the discharge and accurately rejects the leaker cans regardless of machine speed By eliminating the existing mechanical reject mechanism limitations of machine speed relating to the response time of the mechanical reject are eliminated The blow off reject
17. system is capable of accurately rejecting cans at speeds in excess of 3000 CPM The discharge reject blow off assembly consists of a bracket equipped with two high speed blow off solenoids and a fiber optic photo eye This is mounted at the discharge of the tester immediately following the discharge star wheel The existing encoder is replaced with a resolver to provide the additional timing required A can presence sensor mounted in the discharge starwheel along with the resolver and existing leak detection array receiver are used to track the cans to the discharge of the machine The leaker cans are then rejected from the machine using the blow off photo eye to accurately activate the reject solenoid regardless of machine speed SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSL LTA LTS User s Manual 1 4 VISION INSPECTION SYSTEM REJECT The package can except a reject signal from a vision inspection system and reject these cans with the same reject blow off solenoid The vision system reject signal must occur between the infeed load location on the tester and the discharge of the tester The vision reject signal must also be in sync with the machine 1 5 DATA COLLECTION The following data is collected for both the current shift and the previous last shift 1 Total number of good cans tested 2 Total number of leaker rejects 3 Total number of vision inspection rejects 4 Total leaker rejects per po
18. the FIFO such that the correct bad cans are always rejected An error is generally due to the Can Presence Sensor missing a can side wall damage on the can or when the Reject Photo Eye misses a can or double clocks neck damage The error correction logic verifies the reject FIFO is correct by comparing the average number of cans in the FIFO to a calibrated average number of cans that should be in the FIFO The FIFO is corrected if the average falls below a min threshold or above a max threshold See section 2 10 6 FIFO Error Correction Calibration HSL LTA LTS User s Manual SYSTEMS Electronics Group 36 HSL LTA LTS User s Manual SECTION 3 USING THE KEYPAD DISPLAY 3 5 6 VIEW CRITICAL INPUT POSITIONS The View Critical Input Positions menu is used to view the position in degrees that the Reject Receiver Array Fault Receiver Can Presence Sensor and Vision Reject signals are coming in at while the machine is running Primarily this is to verify that none of these signals are coming in within 60 degrees of the Sync timing If any of them do the system could potentially miss clock the FIFO causing the wrong can to be intermittently rejected The 6 View Critical Input Positions menu is accessed from the main set up menu when the SET UP key has been depressed 3 5 7 SET KEYPAD DISPLAY SET UP KEY PASSCODE The Set Passcode input to the HSL LTA LTS is used to actuall
19. the machine at machine zero see section 2 10 4 From the 3 Set Machine Timing selection of the Set up menu verify the position reads 000 degrees 20 degrees If not re zero the resolver HSL LTA LTS User s Manual SYSTEMS Electronics Group 87 SECTION 6 TROUBLE SHOOTING 7 Verify 360 degrees per pocket Position the machine at 0 degrees A pocket should be aligned with the reset lamp centered in the reset photo diode of a pocket By hand move the machine forward one pocket such that the next pocket is centered on the reset lamp the position should count up thru 359 and again be at 0 degrees Do this for all the pockets Note The position may deviate 20 degrees from pocket to pocket This is normal and is not a problem If it does deviate significantly more than 20 degrees perform the following a Using a DVM in AC mode measure the voltage between R1 and R2 on the HSMLT M4503 resolver connector This should read 1 0 to 1 5 VRMS AC voltage If no voltage is read replace the HSMLT M4503 module see section 2 11 Be sure the DVM is in AC mode this is not a DC voltage b Again using the DVM in AC mode verify the voltage between S1 and S3 on the HSMLT M4503 module resolver connector while slowing rotating the machine forward one pocket The voltage should vary between 0 and 2 0 VRMS If the voltage always stays at zero as the machine is moved forward check the resolver wiring for a loose connec
20. the neck of the can breaks the beam of the Reject Photo Eye is used to calculate the speed of the can and thus lead the blow off solenoid correctly at all speeds In addition the Reject Photo Eye is used to clock the cans out of the FIFO so the set up of the Reject Photo Eye is critical Verify the following a Verify the fiber optic lenses see the neck of the can With two cans side by side the lenses must be able to see thru the valley created by the two necks b Verify the lenses cannot see over the top of the can when the can is pushed or tilted toward the dome c Verify the gain potentiometer on the body of the Q23SP6 Photo Eye is fully clockwise max gain This is a turn pot 10 With the machine running in normal production verify the positions that the critical inputs come in see section 2 10 7 These inputs include the Reject Receiver Array Fault Receiver Can Presence Sensor and Vision Reject signal None of these signals should come in within 60 degrees of the Sync timing otherwise FIFO errors may occur SYSTEMS Electronics Group 89 SECTION 6 TROUBLE SHOOTING HSL LTA LTS User s Manual 11 For aluminum can installations Verify that the can flow from the discharge is smooth and that the cans are not intermittently bouncing back into the discharge Since the Reject Photo Eye is used to calculate the speed of the can as it is rejected and thus lead the blow off based on
21. the selected item and the selected window is displayed and the name is 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 LTA LTS User s Manual SYSTEMS Electronics Group 55 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 4 5 1 THE MAIN DISPLAY WINDOW The Main Display window is used to display the general state of the control system This window is selected from the Window menu Messages r Machine CPM Good Cans m Leaker Rejects r Mision Rejects 0 249 730 294 165 r Scrap total r Scrap leaker ZScrap vision 0 18 0 12 0 07 m Bad Can Blow off Alarm Reset Test Blow off Solenoid Reset Alarms System Message All Faults Normal ONLINE 10 14 2003 307 PM 4 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 mes
22. 0 PLC SYSdev file can be downloaded through the set up program Care should be taken when selecting a program to download SYSTEMS Electronics Group 46 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE Once selected a message box is displayed informing the user of the current program revision and checksum of the program loaded in the processor as well as that of the selected program The user must confirm their selection by clicking the Yes command button Program Download xi 9 Program to be loaded into module on disk 2 Program Ident HSMLT Program Revision Program Checksum 82 Target Board M4500 PLC Program currently loaded in module Program Ident HSMLT Program Revision 47 Program Checksum 82 Entire program file will be dumped to the PLC All outputs are off while program dump occurrs Do You Wisth to Continue Yes No Cancel 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 SYSTEMS Electronics Group 47 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 4 2 4 DOWNLOAD RESTORE DATA The set up program allows the user to download Set up parameter
23. HSL LTA LTS ALCOA Light Tester Pneumatic Reject Control 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 LTA LTS ALCOA Light Tester Pneumatic Reject Control User s Manual Revised 16 February 2004 Copyright 2001 Systems Engineering Associates Inc All Rights Reserved 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
24. HSMLT unnamed Main Display Target Board Interface i m S gt sy gg gg Pe mtr ect HSL LTA LTS User s Manual SYSTEMS Electronics Group 152 SECTION 4 HSMLT WINDOWS BASED SET UP 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 from the View menu by selecting Target Board Interface Target Board Interface E X Fault Codes Status Program Ident Revision Set Network Address Set Time amp Date m Internal Fault Code Current Fault Code 00H No Internal Fault has Ocurred Last Fault Code 00H No Internal Fault has Ocurred Corrective Action None iri r Communications Network Error Codes Current Comm Error Code 00H No Network Comm Error Last Comm Error Code 00H No Network Comm Error Once invoked the set up program will prompt the user to select a program to compare with the one existing in the processor Whether a program is selected or the user cancels the setup program will attempt to communicate with the M4503 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 b
25. LTA LTS User s Manual SYSTEMS Electronics Group E e EIS APPENDIX A DF1 COMMUNICATIONS Data Written To The M4503 5 Elements Is Defined As Follows M4503 Mapped PLC Description Add Add Add Function General PLC Status Word 1 from PLC W3900 N7 0 W O End of Shift Bit 00 B3900 0 N7 0 0 Test Blow off Bit 01 B3900 1 N7 0 1 Spare Bit 02 B3900 2 N7 0 2 Spare Bit 03 B3900 3 N7 0 3 thru Thru Thru Spare Bit 14 B3901 6 N7 0 14 Spare Bit 15 B3901 7 N7 0 15 Spare W3902 N7 1 W O Spare W3904 N7 2 W O Spare W3906 N7 3 W O Spare W3908 N7 4 W O HSL LTA LTS User s Manual A 14 SYSTEMS Electronics Group
26. MLT WINDOWS BASED SET UP PROGRAM REFERENCE 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 About HSMLT EN HSMLT Version 2 0 1 Systems Electronics Group Copyright 2000 Systems Engineering Associates Inc All Rights Reserved Technical Support Systems Engineering Associates Inc 14883 West 69th Avenue Arvada Colorado 80007 USA gremio Phone 303 421 0484 Fax 303 321 8108 HSL LTA LTS User s Manual SYSTEMS Electronics Group 42 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE 4 2 THE FILE MENU The File menu allows the user to perform the following functions Create a New set up Data File e Open an existing Data File e Save any changes made to the current Data File to disk e Export Shift Data to a Text File e Upload save Data from the Processor e Download a SYSdev sdv program to the processor e the processor Download restore Data from the current set up Data File to e Print a Report of the current set up parameters e Exit the set up program S HSMLT unnamed Main Display File Edit View Window Help 15 x Open Ctrl O
27. MS Electronics Group HSL LTA LTS User s Manual SECTION 2 INSTALLATION The HSL LTA LTS enclosure is provided for wall mounting in the vicinity of the existing user s control cabinet or tester 2 1 WHAT S INCLUDED Verify that the following items are included when unpacking the HSL LTA LTS lea HSL LTA LTS Enclosure 14 X 12 X 8 with HSMLT Reject Control Module lea BRK LTB SOL Reject Blow off Assembly with blow off solenoid and Fiber Optic Photo Eye lea BRK LTB PRX Can Presence Sensor Assembly lea BRK LTB HD Hardware Kit lea RSV34 MSI Resolver lea RSV RSCBLE 100 Resolver Cable lea HSL LTA LTS User s Manual lea M4500 User s Manual lea HSL LTA LTS Program Disk 2 2 SERVICES REQUIRED Electrical Power The HSL LTA LTS is powered from 115VAC 230VAC 50 60HZ at 2 0 1 0 Amps and 24VDC at 2 0 Amps The 115VAC 230VAC is used to power the HSMLT module while the 24VDC is used to power the 24VDC I O sensors and blow off solenoid The 24VDC current required by the HSL LTA LTS is no more than the existing systems 24VDC current requirement therefore the existing 24VDC power supply should be adequate Compressed Air Compressed Air is used for the reject blow off Clean dry air at 90 to 110 psi 0 25 SCFM is required SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 3 PRE INSTALLATION The following should be performed by the customer prior to the maintenance down day Mec
28. PROGRAM INSTALLATION The HSMLT application program is a SYSdev based program which is loaded into the HSMLT module and performs the HSL LTA LTS logic The HSMLT 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 HSMLT program will have to be loaded onto the hard drive of the PC which is used to support the HSL LTA LTS The SYSdev Program Development Software will also have to be loaded on the PC To install this program perform the following 1 Ifnot already done perform steps 1 through 3 of section 2 6 2 This creates the directories and menu selections which will be used to store and select the HSMLT application programs 2 Install the program disk into either the 3 1 2 floppy or compact disk drive Copy the HSMLT application program into each of the HSMLT directories 3 The HSMLT application programs can be added to your computer s menu software or Windows desktop The DOS commands executed for these selections should be Line tester shown CD SYSDEV HSLT1 HSMLT 4 To initiate SYSdev with the HSMLT program simply select the respective HSMLT PROGRAM The main development menu of SYSdev will be initiated with the HSMLT program See the SYSdev Program Development manual and the M4500 Program Development manual for complete details on on line monitoring and program dev
29. Receiver Can Presence Sensor and Vision Reject signals are coming in at while the machine is running Primarily this is to verify that none of these signals are coming in within 60 degrees of the Sync timing If any of them do the system could potentially miss clock the FIFO causing the wrong can to be intermittently rejected E HSMLT unnamed Set Up SYSTEMS Electronics Group 66 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE 4 5 3 THE SERIAL COMMUNICATIONS WINDOW The Serial Communications window is used to view the configuration status of the S4516 serial communications board 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 PLC5 or SLC500 to communicate to e View Set the Allen Bradley PLC destination node e Select the starting Allen Bradley PLC destination file number HSMLT unnamed 54516DF1 EE 5 xl File Edit View Window Help r 4516 DF1 Communication Status 4 rDF1 Communication Set up 4516 Configuration Status 2 Success SF Transmit Data Status 1 Busy Dest
30. SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE 4 3 3 EDIT SETUP PASSCODE The edit Set up Passcode is an Online function only This allows the user the ability to directly change the value of the Keypad Display Set up Passcode Once selected an input box is displayed allowing the user to view the current Passcode setting and to change the value if necessary Keypad Set up Passcode x Please Enter New Passcode 0 65535 Cancel If the passcode is set to zero passcode entry is disabled The operator can press the Set up key on the Keypad Display and simply press the lt ENTER gt key to gain access to the set up parameters without having to enter a zero If the value of the Set up Passcode is set somewhere between and 65 000 Passcode Entry is enabled This requires the operator to enter in the Correct passcode to gain access to the set up parameters Note Passcode entry is only in effect when the Set up Enable input is off If an invalid value is entered the passcode value will not be reset and a message box notifying the user of the error is displayed HSL LTA LTS User s Manual SYSTEMS Electronics Group 5 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE 4 4 THE VIEW MENU The View menu allows the user to perform the following functions e View the Target Board Interface e View Online Data e View Offline Data amp
31. Save Etre Save As Export Shift Data Ctrl Upload save Data m Leaker Rejects Vision Rejects Download Program Download restore Data 294 165 Print Report Cul P rap total ZScrap leaker ZScrap vision Exit 0 12 0 07 Bad Can Blow off Alarm Reset Reset Alarms System Message All Faults Normal 43 ONLINE 10 14 2003 3 08PM SYSTEMS Electronics Group SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 4 2 1 THE SET UP DATA FILE The set up Data File sdt is a binary access file designed for fast file I O operation When the set up program is first invoked the default set up parameters are loaded into memory If changes are made to any of the set up parameters either online or offline as well as shift data the user will be flagged to Save Changes upon exit of the program Note Any windows based Set up program can open a set up Data File however the data tables will not be properly aligned The user will be alerted to the problem if the set up data file was created by 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 withi
32. Transmit Data Status This represents the state 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 M4503 If this displays Command then a command action was received by the M4503 SYSTEMS Electronics Group 68 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE 7 A B Link Layer Status This displays the status of the receipt 8 9 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 Transactio
33. UP PROGRAM REFERENCE HSL LTA LTS User s Manual 3 4 5 Once program download is initiated program execution will cease the current address being downloaded will be displayed and the RUN LED on the module will flash continuously Once the download is complete the RUN LED on the module will illuminate solid and program execution will resume Press any key to return back to the HSMLT main menu This selection can also be used to verify the program ident revision and checksum without downloading the program Perform steps 1 thru 3 above but instead of initiating the download in step 3 simply press the lt ESC gt key to abort the download once the ident revision and checksum have been displayed 5 7 DOWNLOAD SET UP DATA TO MODULE This selection is used to download the previously uploaded saved set up variables to the module This should only be performed when replacing the module Note The set up data consists of the can presence leaker reject vision reject shift register presets the can neck size and the timing signal set points To download the set up data perform the following 1 2 3 4 Connect the RS 232 cable from the COM port on the computer to the PROG port on the HSMLT module Select 6 Download Set up data to Module A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key Once dat
34. a 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 Once set up data download is complete press any key to return to the HSMLT main menu SYSTEMS Electronics Group 82 SECTION 5 HSMLT DOS BASED SET UP PROGRAM REFERENCE 5 8 UPLOAD SAVE SET UP DATA FROM MODULE This selection is used to save the set up variables from the HSMLT module to the hard drive current directory selected This should be performed anytime any of the set up variables have been changed Note When the set up variables are changed they are changed directly in the module not on the file in the computer By uploading saving the set up variables to disk they can be downloaded to the module in the event the module must be replaced The set up data consists of the can presence leaker reject vision reject shift register presets the can neck size and the timing signal set points 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 HSMLT module 2 Select 7 Upload Save Set up data from Module A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key 3 Once data upload is initiated the current address being uploaded will be displ
35. aker Rejects Pocket 04 Leaker Rejects Pocket 05 Leaker Rejects Pocket 06 Leaker Rejects Pocket 07 Leaker Rejects Pocket 08 Leaker Rejects Pocket 09 Leaker Rejects Pocket 10 Leaker Rejects Pocket 11 Leaker Rejects Pocket 12 Leaker Rejects Pocket 13 Leaker Rejects Pocket 14 Leaker Rejects Pocket 15 Leaker Rejects Pocket 16 Leaker Rejects Cocco ccc cc Cocco ccc 0c Pocket xx Leaker Rejects This is the total number of leaker rejects for each pocket This data is displayed and updated continuously in the respective field for each pocket A disproportionately high count for a particular pocket indicates a light seal problem for that pocket SYSTEMS Electronics Group 78 SECTION 5 HSMLT DOS BASED SET UP PROGRAM REFERENCE 5 4 CURRENT SHIFT DATA This selection 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 data when the end of shift input transfers from a 0 to a 1 This can be at the end of either an 8 or 12 hour shift or alternatively could be done at label changes such that the data collected would be for label runs rather than complete shifts This data cannot be reset either from this menu or by the operator only at the end of shift input transition fe hsmlt EXE _ gl x Systems HSM LT Set up Menu Version 2 1 Current Shift Totals so far Press ESC to return to main menu Total
36. at top speed continuously with cans 3 Verify the FIFO average is correct by verifying that the correct bad can is being blown off In general the FIFO average will be about equal to discharge distance 6 per can where discharge distance is the distance in inches from where the can is first released from the discharge star wheel to the reject photo eye 4 Enable the FIFO error correction as follows a With the machine running at top speed press the SET UP key b Press 5 Calibrate FIFO Error Detection c With the FIFO Error Calibration menu displayed press the 1 key d This enables the FIFO error correction by setting the CHKSPD to 60 of the current speed top speed MIN to 83 of AVG and MAX to 117 of AVG The FIFO error correction is now calibrated and enabled If the FIFO average deviates either lower than MIN or higher than MAX while the machine is running at greater than 60 of top speed the FIFO will automatically be corrected and the respective LoCorr or HiCorr count will be incremented In general the system should always be operated with the FIFO error correction calibrated and enabled SYSTEMS Electronics Group 25 SECTION 2 INSTALLATION HSL LTA LTS User s Manual 2 10 7 VIEW CRITICAL INPUT POSITIONS MENU The View Critical Input Positions menu is used to view the position in degrees that the Reject Receiver Array Fau
37. ausing jamming Typically this is set from 10 to 12msec The valid range for this parameter is 8 to 50msec Diverter Solenoid Pulse Time 01sec This is the amount of time in 01seconds the leaker vision diverter solenoid if used is pulsed for to divert a leaker reject down a separate leakers only reject chute The valid range for this parameter is 0 to 250 2 5seconds HSL LTA LTS User s Manual SYSTEMS Electronics Group 34 SECTION 3 USING THE KEYPAD DISPLAY 3 5 3 SET MACHINE TIMING SET POINTS ETC This menu is activated when the 3 key SET MACHINE TIMING is pressed while the primary set up menu is active The following timing set up parameters may then be adjusted or viewed Sync Timing CH00 The Sync Timing is used to clock in the reject data from the Reject Array Receiver Array Fault Receiver and the vision system reject signal as well as clock the data from the Can Presence sensor The Sync Timing should be as far as possible from the occurrence of the above four signals For the LT 10 this is at 0 degrees for the LT 16 the is at 180 degrees Pocket 1 Timing CH01 The Pocket 1 Timing is used to reset the pocket count to pocket 1 Set the Pocket 1 Timing 90 degrees following the Sync Timing Discharge Timing CH02 The Discharge Timing CH02 should be set about 30 degrees before the location that the can is released from the tester With cans in the machine rotate the tester by hand to the locati
38. ayed 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 HSMLT main menu HSL LTA LTS User s Manual SYSTEMS Electronics Group 83 SECTION 5 HSMLT DOS BASED SET UP PROGRAM REFERENCE This Page Intentionally Left Blank HSL LTA LTS User s Manual SYSTEMS Electronics Group 84 HSL LTA LTS User s Manual SECTION 6 TROUBLE SHOOTING The following is provided as a quick reference to aid in the trouble shooting of the HSL LTA LTS Definitions and causes of the various alarm messages displayed by the HSMLT module is provided as well as a general step by step trouble shooting process 6 1 HSMLT ALARM MESSAGE DEFINITIONS In addition to the default and set up messages described in the previous sections alarm and status messages are displayed on the HSMLT display These messages correspond to the binary code output on B101 5 bitO through B101 7 bit2 The definitions of these messages are as follows Leak Detection Array Fault This message occurs when a fault in a leak detection array head occurs Array Fault Receiver did not detect array head LED when array head passed by Output Code 001 Can Jam or Back up at Discharge This message is displayed if either a jam occurs at the discharge of the tester Reject Photo Eye covered continuously or if the Reject Photo Eye fails In gene
39. be any integer file address The 5 elements written to the M4503 PLC are defined in the last section Read Write Data Definitions HSL LTA LTS User s Manual SYSTEMS Electronics Group A 6 HSL LTA LTS User s Manual APPENDIX A 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 45 elements read from the M4503 PLC are defined in the last section Read Write Data Definitions 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 SYSTEMS Electronics Group A 7 APPENDIX A DF1 COMMUNICATIONS WRITE INSTRUCTION SLC500 The write message MSG command for a SLC500 is setup as follows MSG N12 40 14 Elements N Note The Data Table Address can be any integer file address The 5 elements written to the M4503 PLC are defined in the last section Read Write Data Definitions HSL LTA LTS User s Manual SYSTEMS Electronics Group A 8 HSL LTA LTS User s Manual APPENDIX A DF1 COMMUNICATIONS CHANNEL 0 SETUP PLC5 The Channel 0 Serial Port should be setup as follows Edit Channel Properties Full Duplex Modem gt Note The Communication Mode is setup for System Point to Point SYSTEMS Elect
40. change of state or when it misses cans set too far out to detect all the cans or is missed timed sees leading edge of can coincident with Sync timing In some cases this can be caused by the Reject Photo Eye simply double clocking damaged fiber cables or miss adjusted lenses Verify the machine set up be performing the steps in the section 6 2 Output Code 111 SYSTEMS Electronics Group 86 SECTION 6 TROUBLE SHOOTING 6 2 CAN TRACKING ERRORS TROUBLE SHOOTING If the system is intermittently rejecting the wrong can or incurring Excessive FIFO Correction faults perform the following to trouble shoot the system 1 Verify the FIFO Error Correction is calibrated correctly Perform all the steps in section 2 10 6 If after calibrating the FIFO correction the system is still not functioning correctly perform the following steps 2 thru 4 2 Check the RSV34 MSI Resolver mounting and resolver coupler for obvious damage broken or loose coupler or mount 3 Check the Can Presence Sensor for obvious damage bent mounting bracket sensor damaged etc 4 Check Reject Photo Eye and fiber cables for obvious damage damaged L2 lenses on fiber cables crushed or broken fiber cables fiber cable mounting in Q23SP6 photo eye loose or damaged Q23SP6 sensor failed etc 5 If no obvious damage is detected in steps 2 thru 4 above perform the following steps 6 thru 13 6 Position
41. cket for each pocket This data can be viewed locally on the display 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 activated manually on a label run basis depending on the user s preference This data 1s also available to the host PLC via discrete count outputs In addition to the shift data collection a separate buffer is available to collect rejects per pocket counts as a diagnostics aid to the operator for trouble shooting a bad seal on a specific pocket 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 pocket attempt to correct the problem reset the counts and then recheck the counts to determine if the problem still persists SYSTEMS Electronics Group HSL LTA LTS User s Manual SECTION 1 GENERAL DESCRIPTION 1 6 TESTER REQUIREMENTS The reject blow off assembly is mounted in the discharge track work at the immediate exit of the tester Thus certain installation requirements must be met in order to implement the system Aluminum Can Installations HSL LTA For machines testing aluminum cans the can is rejected up and out of the discharge track work into a reject chute This requires a straight section of track work 18 long from where the track work mates to the t
42. contains the following data MACHINE SPEED CPM xxxx GOOD CANS xxxxxxx REJECTS xxxxxx Where the Machine Speed is the current speed of the tester the Good Cans field is the total number of good cans tested so far into the current shift and the Rejects field is the total number of leaker cans rejected from 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 REJECTS PER POCKET KEY The Number of Rejects per Pocket menu is provided to aid in the trouble shooting of a light seal problem with a pocket or pockets The total number of leaker rejects for each pocket 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 pockets from through 10 as shown below DIAGNOSTICS REJECTS PER POCKET 1 Xxxx 2 XXXX 3 XXXX 4 XXXX Where the numbers 1 through 4 are the first 4 pockets and the xxxx would be the actual counts for the respective pockets 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 prompts the user to reset the counts by pressing 0 If the counts are to be reset press the 0 key if not press the ESC
43. corrections the number of High FIFO corrections as well as the calibrated Min Max threshold parameters SYSTEMS Electronics Group 2203 SECTION 2 INSTALLATION The Calibrate FIFO Error Detection menu contains the following fields CPM xxxx CHK SPD xxxx MIN x X Max x x FIFO xx AVG x x LoCorr xxx HiCorr xxx The above fields are defined as follows CPM CHK SPD MIN MAX FIFO AVG LoCorr HSL LTA LTS User s Manual This is the current speed Cans Per Minute of the tester This is calculated automatically when the FIFO error calibration is performed and is set to 60 of the speed of the tester when the calibration is performed This is used to enable the error correction when the speed is greater than this value This is calculated automatically when the FIFO error calibration is performed and is set to 83 of the average number of cans in the FIFO at calibration If the average number of cans in the FIFO drops below this value when running within 6096 of top speed the FIFO is corrected up one can and the LoCorr count is incremented This is calculated automatically when the FIFO error calibration is performed and is set to 11796 of the average number of cans in the FIFO at calibration If the average number of cans in the FIFO goes above this value when running within 6096 of top speed the FIFO is corrected down one can and the HiCorr count is incremented This is the instantane
44. ct Shifts Vision System to Discharge 4 Reject Parameters Can Neck Size in 0 01 inches lt 215 Reject Solenoid Pulse Time msec 10 Diverter Solenoid Pulse Time 01sec 100 Machine Timing Sync Timing CHO0 On Position 000 Pocket 1 Timing CH01 On Position 090 Discharge Timing CH02 On Position 020 PLC Timing CH03 On Position 000 2 10 2 DEFAULT SET UP VARIABLES LT 12 The following are the default parameters for the LT 12 Tester Reject Shift Registers Pocket 1 Offset for Rejects per Pocket Counts 3 Can Presence Shifts Can PRX to Discharge Bod Leaker Reject Shifts Leak Detector to Discharge 4 Vision Reject Shifts Vision System to Discharge 4 Reject Parameters Can Neck Size in 0 01 inches 215 Reject Solenoid Pulse Time msec 10 Diverter Solenoid Pulse Time 01sec 100 Machine Timing Sync Timing CHO0 On Position 220 Pocket 1 Timing CH01 On Position 310 Discharge Timing CH02 On Position 100 PLC Timing CH03 On Position 000 HSL LTA LTS User s Manual SYSTEMS Electronics Group 2 SECTION 2 INSTALLATION 2 10 3 DEFAULT SET UP VARIABLES LT 16 The following are the default parameters for the LT 16 Tester Reject Shift Registers Pocket 1 Offset for Rejects per Pocket Counts 11 Can Presence Shifts Can PRX to Discharge 1 Leaker Reject Shifts Leak Detector to Discharge nS Vision Reject Shifts Vision System to Discharge 5 Rejec
45. ded spares for the HSL LTA LTS These parts are available through Systems Engineering Assoc Inc Quantity Part Number lea HSMLT lea RSV34 MSI lea Q23SP6FPY 1ea PIT43TSSS 2ea L2 lea Bil0U G30 AP4X lea 711C 12 PI 551BA lea 55B 12 PI 551BA 95 Description Reject Control Module SEG Resolver SEG Photo Eye Banner Sheathed Fiber Cable Banner Plastic Fiber Lenses Banner Proximity Sensor Turck Solenoid Mac Solenoid Mac SYSTEMS Electronics Group SECTION 7 RECOMMENDED SPARES This Page Intentionally Left Blank HSL LTA LTS User s Manual SYSTEMS Electronics Group 96 HSL LTA LTS User s Manual APPENDIX A 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 SLOT 0 3 swt sw2 m ON IN ON m PLC5 S4516 DF1 Pru COMMUNICATIONS CO CPU 1 MICE RXD 0 2 T RS 232 TXD 1 3 RX SG 2 7 sc wW iv 3 4 RTS RXD 4 ES E 6 DSR RS 422 18 oco TXD 6 TxD 7 e 0 T s3000 NETWORK COMMUNICATIONS T iF USED 2 S4 oven calle Internally the PLC 5 should be set up for RS 232C communication Refer to the dip switch settings guide o
46. e pocket where cans are released from the machine typically set to the same value as the leaker reject shifts shifts SYSTEMS Electronics Group 33 SECTION 3 USING THE KEYPAD DISPLAY 3 5 2 SET REJECT BLOW OFF PARAMETERS This menu is activated when the 2 key SET REJECT 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 Can Neck Size in 0 01 inches This parameter is used to calculate when to activate the reject blow off as a function of the can speed The can neck size is simply the diameter of the neck at it s most narrow point in 0 01 inches For example if the neck measures 2 15 at it s most narrow point simply enter 215 for the can neck size The valid range of this value is 180 to 350 The Can Neck Size parameter can be used to compensate for the response time of the blow off solenoids To advance the blow off activate solenoids earlier make the Can Neck Size larger To retard the blow off activate the solenoids later make the Can Neck Size smaller Reject Solenoid Pulse Time msec This is the number of milliseconds that the reject solenoids will be pulsed for when a bad can is rejected This is adjusted to get a strong pulse of air to reject the can Too short of time will result in the can not being fully rejected jamming Too long of time will disturb the following can at high speeds also c
47. e 100 Clean Blow off Photo Eye Lenses Dirty This message indicates that the lenses of the Reject Photo Eye fiber optic cable mounted on the Reject Blow off assembly should be cleaned This occurs when an excess film deposit of contaminants has formed over the fiber optic lenses of the Reject Blow off Photo Eye reducing the gain of the eye If the lenses are not cleaned the eye will cease to function correctly causing a Photo Eye Fail alarm once too much contamination occurs This fault can also be caused by a damaged fiber optic cable causing low gain or if the Reject Photo Eye gain potentiometer is set too low Output Code 101 Tester did not Reject Defective Can This message indicates that the Reject Verification sensors in the reject chute did not detect a can rejected when the reject blow off was activated This indicates that a problem with the blow off solenoid air or blow off photo eye may exist Verify the operation of the blow off solenoid by depressing the Test Blow off key on the HSMLT module while the machine is running A single can should be rejected when the key is depressed If not trouble shoot the reject blow off system Output Code 110 Can Presence Sensor Failure This message is generated when the Reject Photo Eye detects a significantly greater number of cans coming out of the machine than the Can Presence Sensor sees coming in Generally this occurs when the Can Presence Sensor fails no
48. e HSMLT selections and menus 5 1 MAIN MENU The main menu of the HSMLT set up program incorporates the following menu selections Systems HSM LT Set up Menu Version 2 1 Main Menu Reject Set up Parameters Number of Rejects per Pocket data Current Shift data Last Shift data Download Program to Module Download Set up data to Module Upload Save Set up data from Module Enter Selection ESC to exit SACRE OM NOTE Before selecting one of the seven selections listed above connect an RS 232 cable from the COM port on the computer to the PROG PORT on the HSM LT module SYSTEMS Electronics Group 235 SECTION 5 HSMLT DOS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 5 2 REJECT SETUP PARAMETERS This selection is used to set all the set up variables in the HSL LTA LTS When selected the Reject Set up menu is invoked fe hsmlt EXE Systems HSM LT Set up Menu Version 2 1 Reject Set up Menu Set Reject Shift Registers Set Can Neck Size Set Blow off Solenoid Parameters Set Machine Timing Enter Selection ESC to exit FON Reject Shift Registers Pocket 1 Offset for Rejects per Pocket Counts 11 Can Presence Shifts Can PRX to Discharge 01 Leaker Reject Shifts Leak Detector to Discharge 05 Vision Reject Shifts Vision System to Discharge 05 Reject Parameters Can Neck Size in 0 01 inches 215 Reject Solenoid Pulse T
49. e PWR and RUN LEDs on the HSMLT module are on and the FLT LED is off SYSTEMS Electronics Group 26 HSL LTA LTS User s Manual 6 7 8 9 SECTION 2 INSTALLATION Connect an RS 232 cable from the computer COM port to the PROG port on the HSMLT From the computer s menu program select the respective tester s SET UP TESTER selection The HSMLT set up program will be invoked with the corresponding HSMLT application program for that tester Download the HSMLT application program to the module by selecting 5 Download Program to Module from the HSL LT main menu Press the lt ENTER gt key to start the download Press any key to return back to the HSL LT main menu Download the previously saved set up data to the module by selecting 6 Download Set up data to Module from the HSL LT main menu Press the lt ENTER gt key to start the download Once the download is complete press any key to return to the HSL LT main menu See section 5 7 for complete details 10 The HSMLT is now ready to run loaded with the HSMLT program and set up data that was previously saved for the respective tester Press lt ESC gt to return back to the computer s menu software program SYSTEMS Electronics Group lt 37 SECTION 2 INSTALLATION This Page Intentionally Left Blank HSL LTA LTS User s Manual SYSTEMS Electronics Group 28 SECTION 3 USING THE KEYPAD DISPLAY The keypad of the HSMLT contain
50. e Number B2072 W3914 N7 7 R O Machine Speed CPM W182 16 W3916 N7 8 R O Current Shift Data Good Cans Lo W1100 W3918 N7 9 R O Good Cans Hi W1102 W3920 N7 10 R O Leaker Reject Count Lo W1104 W3922 N7 11 R O Leaker Reject Count Hi W1106 W3924 N7 12 R O Vision Reject Count Lo W1108 W3926 N7 13 R O Vision Reject Count Hi W1110 W3928 N7 14 R O Spare Lo W1112 W3930 N7 15 R O Spare Hi W1114 W3932 N7 16 R O Rejects Per Pocket 1 W1166 W3934 N7 17 R O Thru Thru Thru Thru Rejects Per Pocket 16 W1146 W3964 N7 32 R O HSL LTA LTS User s Manual A 12 SYSTEMS Electronics Group APPENDIX A DF1 COMMUNICATIONS M4503 Mapped PLC Description Add Add Add Function FIFO Error Detection Can Check Speed W1002 16 W3966 N7 33 R O Current Number of Cans in FIFO B82 W3968 N7 34 R O Number of Cans in FIFO max B1012 W3970 N7 35 R O Number of Cans in FIFO min B1013 W3972 N7 36 R O Number of Cans in FIFO avg B650 W3974 N7 37 R O FIFO Low Correction Count B657 W3976 N7 38 R O FIFO Hi Correction Count B656 W3978 N7 39 R O Spare Registers Spare W3980 N7 40 R O Spare W3982 N7 41 R O Spare W3984 N7 42 R O Spare W3986 N7 43 R O Spare W3988 N7 44 R O Spare W3990 N7 45 R O Spare W3992 N7 46 R O Spare W3994 N7 47 R O Spare W3996 N7 48 R O Spare W3998 N7 49 R O HSL
51. e funneling plate is 8 In general an opening of less than 8 will not allow the can to cleanly reject at high speeds SYSTEMS Electronics Group 9 SECTION 6 TROUBLE SHOOTING HSL LTA LTS User s Manual 7 Verify the distance from the centerline of the Reject Photo Eye 8 9 fiber lenses to the centerline of the reject manifold is 5 This distance is assumed by the system and is used as part of the speed calculation to lead when to activate the blow off Changing this distance will change where the air hits the can Verify and if necessary adjust the Reject Solenoid Pulse time see section 3 5 2 2 Set Reject Blow off Parameters Verify and if necessary adjust the Can Neck Size see section 3 5 2 2 Set Reject Blow off Parameters The Can Neck Size parameter can be used to compensate for the response time of the blow off solenoids To advance the blow off activate solenoids earlier make the Can Neck Size larger To retard the blow off activate the solenoids later make the Can Neck Size smaller SYSTEMS Electronics Group 92 SECTION 6 TROUBLE SHOOTING Steel Can Installations 1 Verify that both reject solenoids are firing Verify a pulse of air from the both the nozzle and manifold when the Test Blow off key is depressed 2 Verify air pressure to reject system is 90psi or greater 3 Verify that the length of the air line from the reject solenoid t
52. e placed in an Offline mode however the Target Board Interface window will be displayed HSL LTA LTS User s Manual SYSTEMS Electronics Group 53 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 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 from the View menu by selecting Online Data or by simply pressing the F3 function key Note The program can be toggled between Offline and Online by simply double clicking on the Online or Offline panel displayed in the status bar at the bottom of the window Once invoked the set up program will attempt to open the Comm port and communicate with the M4503 If the set up program is unsuccessful a warning message will be displayed prompting the user to either Retry or Cancel the operation If the operation is canceled and communication with the processor cannot be established the system will be placed in an Offline edit mode Note Anytime while the set up program is Online with the processor and communication is interrupted a warning message will be displayed prompting the user to either Retry or Cancel the operation 4 4 3 VIEW OFFLINE DATA This function allows the user to place the set up program in an Offline mode This is accessed by the View menu
53. elopment with SYSdev HSL LTA LTS User s Manual SYSTEMS Electronics Group 18 SECTION 2 INSTALLATION 2 9 MODIFY EXISTING PLC PROGRAM Modify the existing control system PLC program to interface with the HSL LTA LTS by incorporating the following into the existing PLC ladder logic 1 The HSL LTA LTS now controls the leak detection and rejection If the existing host PLC was previously controlling these functions it no longer will be with the addition of the HSL LTA LTS This logic can optionally be removed from the existing host PLC if desired In most cases this logic can be left in the program as the odd even reject solenoids will no longer be used 2 Add the FLT interlock relay as an input to the host PLC This should stop the machine anytime the FLT relay is off When the FLT interlock is de activated the corresponding fault message that caused the alarm will be displayed on the HSL LTA LTS display In most applications it will be sufficient to indicate REJECT FAULT SEE HSL LT when a fault occurs The operator can then go look at the HSL LTA LTS display to see what the actual fault was 3 The encoded alarm outputs O15 thru O17 from the HSL LTA LTS can be optionally added to the existing host PLC logic This allows the actual fault message to be displayed on the primary existing system display as well as the HSL LTA LTS display The alarms are encoded as follows O17 O16 O15 Alarm Definitio
54. ester discharge An opening in the top of this 18 length of track work is made for a reject clearance and to mount a discharge funnel plate For air tunnels the upper lips of the air tunnel must be cut off welded to the plenum and ground flush For gravity track work the upper half round rails are cut off In either case either a new reject chute is manufactured or the existing reject chute is modified to interface with the new reject blow off system Steel Can Installations HSL LTS For machines testing steel cans the can is rejected down off a magnetic conveyor located at the discharge of the tester If the tester does not already have a magnetic conveyor at the immediate tester exit such as a gravity track instead one will have to be added Note The magnetic conveyor must start immediately from the discharge of the tester The reject blow off assembly is mounted on this magnetic conveyor and blows the can down either into a reject chute or bucket The magnetic conveyor is supplied by the customer and is not provided as part of the HSL LTS package For both the aluminum and steel can installations labor and material to modify the discharge track work conveyor and manufacture or modify the reject chute is not provided as part of the HSL LTA LTS packages This is supplied by the customer SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION This Page Intentionally Left Blank HSL LTA LTS User s Manual SYSTE
55. for that pocket 3 4 LAST SHIFT KEY The Last Shift data is identical to the current shift data except it 1s the totals 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 HSL LTA LTS User s Manual SYSTEMS Electronics Group 31 SECTION 3 USING THE KEYPAD DISPLAY HSL LTA LTS User s Manual 3 5 SET UP KEY This selection is used to invoke the primary set up menu This consists of the following four selections 1 SET REJECT SHIFT REGISTERS 2 SET REJECT BLOW OFF PARAMETERS 3 SET MACHINE TIMING SET POINTS ETC 4 ZERO MACHINE SET RESOLVER OFFSET 5 CALIBRATE FIFO ERROR DETECTION 6 VIEW CRITICAL INPUT POSITIONS When selected each of the above selections brings up a sub menu with the corresponding set up parameters To select the respective set up sub menu simply press the corresponding numeric key 1 thru 6 The NEXT and PREV keys can be used to advance to the next or the previous variable respectively To change a value simply enter the new value on the numeric keypad and press lt ENTER gt The value will be entered and the next variable will automatically be displayed When the last variable 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 The primary se
56. hanical 1 Ifnecessary manufacture new reject chute to be compatible with pneumatic reject system refer to appropriate aluminum or steel detail at the back of this manual Electrical 1 Mount the HSL LTA LTS 14 X 12 X 8 enclosure This can be mounted wherever is convenient for the plant on the light tester on the existing control cabinet or somewhere else close to the tester that is convenient for operator access 2 Run conduit between the HSL LTA LTS enclosure existing control cabinet and light tester Refer the interconnect diagram at the back of this manual 3 Pull wire between the enclosure existing control cabinet and light tester as outlined in the interconnect diagram at the back of this manual 4 Terminate the wires in the HSL LTA LTS enclosure 5 Configure the BRK LTB SOL Reject Assembly for the particular discharge configuration of the light tester if not already done so 6 Make a copy of the existing control system program and modify it to interface with the HSL LTA LTS see section 2 9 HSL LTA LTS User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 4 INSTALLATION DOWN DAY The following must be performed with the machine stopped and power off Thus this is usually performed on a scheduled maintenance day The following consists of both mechanical and electrical tasks performed by plant personnel or contractors Mechanical 1 Aluminum can installations a Mod
57. he 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 HSL LTA LTS User s Manual SYSTEMS Electronics Group 40 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE Getting Help The entire contents of the user s manual is contained within the help file Pressing Ctrl H will display the help file window amp HSMLT unnamed Main Display Help Topics Ctrl H k Pressing the F1 key will display the contents file Help Topics HSMLT Help ALCDA Light Tester Pneumatic Reject Control System e HSM LT General Description Installation Using the Keypad Display Set up Program Reference Q amp Trouble shooting Recommended Spare Parts Allen Bradley DF1 Full Duplex Communication Protocol Control Drawings SYSTEMS Electronics Group 4 SECTION 4 HS
58. he following 1 From the File menu select Print Report or press Ctrl P This displays the Print Setup dialog box allowing the user to select a printer as well as the paper size and orientation Once the user selects OK the report is generated and sent to the specified printer device This function makes use of the windows print manager which allows the user to continue with their work while the document is being printed 4 3 THE EDIT MENU The Edit menu allows the user to perform the following functions e Enable Disable Offline Editing e Set up the Comm Port e Set Up Passcode S HSMLT unnamed Main Display File Edit View Window Help 15 x Comm Port Ctrl M Set up Passcode Machine CPM _ Good Cans m Leaker Rejects Vision Rejects 249 790 294 165 r Scrap total Scrap leaker Z Scrap vision 0 18 0 12 0 07 Bad Can Blow off Alarm Reset Reset Alarms System Message All Faults Normal ONLINE 10 14 2003 3 10PM 4 SYSTEMS Electronics Group 49 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 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
59. ify discharge track work to provide an 18 opening in the upper portion of the discharge track work to allow rejection of bad cans see Aluminum Discharge Detail at the back of this manual For air tunnels the upper lips of the air tunnel will have to be cut off and the plenum welded and ground to the steel air tunnel For gravity discharge track works the upper half rounds will have to be cut off b Mount funneling plate provided in last 10 of 18 cut out of discharge track work see Aluminum Discharge Detail at the back of this manual 2 Mount and pipe the Reject Assembly refer to appropriate aluminum or steel detail drawing In general the air lines from the reject solenoids to the manifold or nozzle must be less than 4 On aluminum installations the face of the manifold should not be closer than 1 4 from the can see figure 2 of the aluminum detail drawing 3 Remove middle and lower discharge guide rails and mount Reject Fiber optic sensors to rails as shown in Discharge Detail at the back of this manual Ground off the welded spacers from the rails where the sensors will mount and drill a clearance hole in each rail for the 2 mounting hole of the sensor bracket Bolt one sensor to each bracket as shown and re mount the rails The sensors should be spaced to see the neck of the can 4 Remove or move out of the way the existing reject fingers in the discharge star wheel If these are not removed they must be
60. ime msec 10 Diverter Solenoid Pulse Time 01sec 050 Machine Timing Sync Timing CH00 On Position degrees 180 Pocket 1 Timing CH01 On Position degrees 270 Discharge Timing CH02 On Position degrees 275 PLC Timing CH03 On Position Qs T TN 000 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 module The following selections set the corresponding parameters 1 SET REJECT SHIFT REGISTERS 1 2 3 Pocket 1 Offset 0 Number of Pockets This number is used to compensate for the number of pockets between the Reject Receiver and discharge location on the tester This number is approximately Total Number of Pockets Leaker Reject Shift plus or minus one pocket Can Presence Shifts 0 44 This is the number of pockets from the Can Presence Sensor to the tester discharge pocket where cans are released from the machine Leaker Reject Shifts 0 44 This is the number of pockets from the Reject Array Receiver pocket to the tester discharge pocket where cans are released from the machine SYSTEMS Electronics Group 76 iol x HSL LTA LTS User s Manual SECTION 5 HSMLT DOS BASED SET UP PROGRAM REFERENCE 4 Vision Reject Shifts 0 44 This is the number of pockets from the vision inspection system reject pocket to
61. ination Node 1 Transmit Data Status prev 34 Unknown Status FERE esination File Number Current Transaction 1 L s Active Command Write Number of BYTES Received 0 Received Command BIT Status Command AJB Link Layer Status Status 00 Success No Error Current Transaction Received 0 System Message All Faults Normal ONLINE 10 14 2003 3 13 PM a HSL LTA LTS User s Manual SYSTEMS Electronics Group 67 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE 1 4516 Configuration Status This displays the current state HSL LTA LTS User s Manual 2 3 4 5 6 of the configuration of the S4516 serial communications board System function sfunc19 S4516 configuration is used to set the 4516 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 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
62. indow menu amp HSMLT unnamed Set Up Ioj x Fie Edit View Window Help Reject Shift Registers Blow off Parameters Machine Timing Calibrate FIFO Critical Input Postions Reject Shift Register Set up Can Presence Shifts can PRX to discharge EH Leaker Reject Shifts leak detector to discharge 5 4 Vision Reject Shifts vision system to discharge 5 4 Pocket 1 Shift Offset 11 Rejected Pocket T Array Fault Offset 5o 4 Faulted Array Head pj System Message All Faults Normal ONLINE 10 14 2003 312PM _ This window utilizes a TAB control to divide the set up parameters into three categories similar to that of the Keypad Display HSL LTA LTS User s Manual SYSTEMS Electronics Group 57 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE Reject Shift Registers 1 Can Presence Shifts 0 44 This is the number of pockets from the Can Presence Sensor to the tester discharge pocket where cans are released from the machine 2 Leaker Reject Shifts 0 44 This is the number of pockets from the Reject Array Receiver pocket to the tester discharge pocket where cans are released from the machine 3 Vision Reject Shifts 0 44 This is the number of pockets from the vision inspection system reject pocket to the tester discharge pocket where cans are released from the machine 4 Pocket 1 Offset 0 Number of Pockets This number is used to compensate
63. is is the total number of good cans tested so far into the shift This is essentially a can counter Total Leaker Rejects This is the total number of leaker cans rejected by the machine so far into the shift Total Vision Inspection Rejects This is the total number of cans rejected by the vision inspection system if used Scrap total This is the total percentage of cans tested that were blown off either due to a vision or leaker reject Scrap leaker This is the total percentage of cans tested that were blown off due to a leaker reject signal Scrap vision This is the total percentage of cans tested that were blown off due to a vision reject signal Note Ifa can is both a vision reject and a leaker reject it will only be counted as a leaker reject and not as both Rejects Per Pocket This is the total leaker rejects for each pocket A disproportionately high count for a particular pocket indicates a light seal problem for that pocket SYSTEMS Electronics Group oya HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE Last Shift The Last Shift data is identical to the current shift data except it is the totals 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 the previous section for definitions of the data fields in the La
64. k labeled HSL LTA LTS PROGRAMS into the A drive For each HSMLT directory you created in the previous step switch to that directory and install the HSMLT set up programs by typing the following at the DOS prompt Line 1 tester is shown CD HSLT1 lt ENTER gt A INSTALL lt ENTER gt Add each tester s HSMLT set up program to your computer s menu software by creating a selection for each tester called SET UP TESTER LINE1 for the line 1 tester SET UP TESTER LINE2 for the line 2 tester etc The DOS commands executed for these selections should be For the SET UP TESTER LINEI selection CD HSLT1 HSMLT CD For the SET UP TESTER LINE2 selection CD HSLT2 HSMLT CD etc SYSTEMS Electronics Group 16 HSL LTA LTS User s Manual SECTION 2 INSTALLATION 4 To execute the respective tester s set up program simply select the corresponding SET UP TESTER LINE selection from the menu software s menu 2 7 SYSdev PROGRAM DEVELOPMENT SOFTWARE INSTALLATION The SYSdev Program Development software is an optional software package to perform on line trouble shooting and program modifications If SYSdev was purchased with the HSL LTA LTS package and is not already installed on the your computer install SYSdev onto the hard drive of your computer following the steps in section 1 5 of the SYSdev Program Development manual SYSTEMS Electronics Group 17 SECTION 2 INSTALLATION 2 8 HSMLT APPLICATION
65. low of cans Note The machine must run for at least 10 seconds at top speed to correctly calibrate the FIFO error detection 4 Verify that the correct Bad Can is being blown off This verifies that the FIFO is correct when the calibration is performed 5 Click the Calibrate FIFO button again This enables the error detection The Can Check Speed is now set as well as the FIFO Min and Max settings Note FIFO error detection calibration can be performed whenever the machine is running with a continuous flow of cans Calibrating the FIFO error detection also resets the fault counts Machine Speed cpm This is the current speed of the tester in CPM Can Check Speed This is calculated automatically when the FIFO error calibration is performed and is set to approximately 80 of the top speed of the machine Whenever the speed of the tester is at or above the can check speed FIFO error detection is enabled Number of Cans in FIFO This is the instantaneous number of cans in the FIFO Number of Cans in FIFO Max This is calculated automatically when the FIFO error calibration is performed This number is set to approximately 110 of the average number of cans in the FIFO when the tester is running at top speed Number of Cans in FIFO Min This is calculated automatically when the FIFO error calibration is performed This number is set to approximately 90 of the average number of cans in the FIFO when the teste
66. lt Receiver Can Presence Sensor and Vision Reject signals are coming in at while the machine is running Primarily this is to verify that none of these signals are coming in within 60 degrees of the Sync timing If any of them do the system could potentially miss clock the FIFO causing the wrong can to be intermittently rejected The 6 View Critical Input Positions menu is accessed from the main set up menu when the SET UP key has been depressed 2 11 HSMLT MODULE REPLACEMENT The following is provided only as a reference These steps need only be performed in the event the HSMLT module needs to be replaced once installed To replace the module perform the following 1 Turn both 115VAC and 24VDC power to the HSL LTA LTS system off and remove the field wiring connectors from the HSMLT module 2 Remove the 8 32 nuts and lock washers 7ea which retain the module in the door and remove the module 3 Remove the supplied field wiring connectors from the new HSMLT module and install the new HSMLT module in the door cut out from the front and re install the 8 32 nuts and lock washers 7ea 4 Install the existing pre wired field wiring connectors on all the I O boards of the module 115VAC power connector I O slots0 1 and 2 resolver connector and INO IN1 connector Make sure the field wiring connectors are fully mated in the module 5 Apply 115VAC and 24VDC power to the HSL LTA LTS and verify that th
67. lver System Message All Faults Normal ONLINE 10 14 2003 312PM 7 1 2 3 4 Sync Timing CH00 The Sync Timing is used to clock in the reject data from the Reject Array Receiver Array Fault Receiver and the vision system reject signal as well as clock the data from the Can Presence sensor The Sync Timing should be as far as possible from the occurrence of the Can Presence sensor Reject Receiver Array Fault Receiver and the Vision Reject input signal Pocket 1 Timing CH01 The Pocket 1 Timing is used to reset the pocket count to pocket 1 Set the Pocket 1 Timing 90 degrees following the Sync Timing Discharge Timing CH02 The Discharge Timing CH02 should be set about 30 degrees before the location that the can is released from the tester With cans in the machine rotate the tester by hand to the location where the can is just released Set the Discharge Timing CH02 to the position 30 degrees before this can release position PLC Timing CH03 The PLC Timing is provided as an extra timing signal which can be used by the existing host control system Set this timing as desired SYSTEMS Electronics Group 61 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 5 6 7 Machine Position This displays the position of the resolver pocket to pocket 360 degrees per pocket Absolute Position This displays the absolute position of the re
68. mber entered into the Leaker Reject Shifts Note For the LT 10 this is 4 for the LT 16 this is 5 13 Set the Vision Reject Shifts to the same number as the Leaker Reject Shifts 14 Set the Can Neck Size to the diameter of the neck at the necks smallest place 15 With the machine stopped disable the FIFO Error Correction see section 2 10 6 The ChkSpd should be set at 4800CPM min at 0 0 and max at 9 9 For the remainder of the set up the machine needs to be run in normal production including the top speed the machine will run at WARNING Until the set up is complete bad cans and calibrated test cans may go down the line With the machine running with cans perform the following 16 Press the Test Blow off key and verify one can is cleanly rejected without disturbing the can ahead or behind the rejected can Adjust the Reject Solenoid Pulse Time if necessary to get a strong pulse of air to reject the can Too short of time will result in the can not being fully rejected jamming Too long of time will disturb the following can at high speeds also causing jamming 17 Verify a calibrated leak can is correctly rejected If not adjust the Leaker Reject Shifts parameter until it is HSL LTA LTS User s Manual SYSTEMS Electronics Group 13 SECTION 2 INSTALLATION HSL LTA LTS User s Manual 18 With the tester running at top speed and rejecting
69. n 0 0 0 No Alarm 0 0 1 Leak Detection Array Fault 0 1 0 Can Jam Back up at Discharge 0 1 1 Timing Signal Failure 1 0 0 Excessive Lo Hi FIFO Corrections 1 0 1 Blow off Photo Eye Lenses Dirty 1 1 0 Bad Can did not Reject 1 1 1 Can Presence PRX Fail HSL LTA LTS User s Manual SYSTEMS Electronics Group 19 SECTION 2 INSTALLATION 4 Add the Good Can Count Pulse Leaker Reject Count Pulse and Vision Reject Count Pulse outputs from the HSL LTA LTS to the existing host PLC if desired The HSL LTA LTS accumulates all shift counts but this allows the host PLC to accumulate the counts as well 5 Add the Machine Run output to the PLC logic This should be 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 will 6 Add the Alarm Reset output This signal should be on as long as the system reset push button is depressed HSL LTA LTS User s Manual SYSTEMS Electronics Group 20 SECTION 2 INSTALLATION 2 10 SET UP REFERENCE The following sections are provided as a reference to set up operations performed in section 2 5 2 10 1 DEFAULT SET UP VARIABLES LT 10 The following are the default parameters for the LT 10 Tester Reject Shift Registers Pocket 1 Offset for Rejects per Pocket Counts 6 Can Presence Shifts Can PRX to Discharge 1 Leaker Reject Shifts Leak Detector to Discharge 4 Vision Reje
70. n Received This is the Transaction number received from the Allen Bradley PLC PLC Type This is used to specify the Type of PLC the M4503 will communicate to The user can choose from PLC5 or SLC500 Note This parameter should be set prior to communicating with an A B processor 10 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 11 Destination File Number This is the file number the M4503 will read and write data from See Appendix B for a description of the data read from and written to an Allen Bradley PLC SYSTEMS Electronics Group 69 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 4 5 4 THE SHIFT DATA WINDOW The Shift Data window is used to view the shift data collected by the M4503 This window is selected from the Window menu HSMLT unnamed Shift Data ER EE o x File Edit Vie Mindow Help Rejects Per Pocket Curent Shift Last Shift Leaker Reject Rejects Per Pocket Rejected Pocket sec i E 9 2 Reset Rejects 2 ae 10 0 sep pe cum 2x9 pesa ese ESO 15 msn saa s wel un s o0 ss o Se eod IE tre REO System Message All Faults Normal ONLINE 10 14 2003 313PM _ This window
71. n the M4503 Therefore to normalize the set up program with the processor the user should define or open an existing file then upload All variables from the processor This allows the user to either create a backup of the data or maintain an existing file The user can even open a data file for another tester save the file to a new name make the necessary changes and simply download the new parameters to another processor The following functions can be accessed any time from any set up or display windows New To create a New data file select New from the File menu or press Ctrl N This creates a completely new file loaded with the default variables and the word unnamed is displayed in the title bar If any changes were made to the existing file the user is prompted to save changes to the existing file Open To Open and existing data file select Open from the File menu or press Ctrl O This displays a dialog box allowing the user to select an existing data file to open The name ofthe 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 SYSTEMS Electronics Group 44 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE Save To Save data file to disk select Save from the File menu or press Ctrl S Thi
72. n the side of the processor SYSTEMS Electronics Group A 1 APPENDIX A DF1 COMMUNICATIONS 4516 DF1 to SLC SLOT 0 3 swi SW2 m ON I ON SLC500 S4516 DF1 d COMMUNICATIONS CO CPU 1 E RXD O 2 RX m TXD 1 8 1x SG 2 5 sc kal M 3 4 DTR RXD 4 A DSR C 7 RTS RS 422 8 cts TXD4 6 TXD 7 anum eme iih eem und 0 Tr sz000 NETWORK COMMUNICATIONS 1 F USED 2 3 S4 Ta aL 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 M4503 rack For the HSL LTA LTS control system SW2 should be set to POLE 1 ON POLE 2 ON HSL LTA LTS User s Manual SYSTEMS Electronics Group A 2 APPENDIX A 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 RS LAD 3 DF1 COMM MSG Read Write Message Contro MG20 0 Setup Screen 0002 0003 0004 aor comm 7 0000000 TH HSL LTA LTS User s Manual SYSTEMS Electronics Group A 3 APPENDIX A DF1 COMMUNICATIONS SLC500 The f
73. ncrementing on the Rejects per Pocket screen A can from pocket 1 should be rejected every revolution of the main wheel Continue to increment this parameter until the rejects for pocket number 1 is continuously incrementing Remove the tape from the array head 22 Verify the Array Fault Offset parameter Place a piece of electrical tape over the Array Fault Pickup located between reject LED and array reset pickup on array head number 1 Jog the machine through several revolutions A Leak Detection Array Fault alarm will be generated with the corresponding array head number indicated on the Keypad Display Reset the alarm adjust the offset and jog the machine again Continue to adjusting this parameter until array head number 1 is displayed Remove the tape from the array head SYSTEMS Electronics Group 4 SECTION 2 INSTALLATION 23 The set up is now complete If problems are in countered in any of the previous set up steps refer to the trouble shooting section 6 2 Once all the parameters are set as required save them to disk using the HSMLT set up program see section 5 8 Upload Save Set up Data 2 6 HSMLT SET UP SOFTWARE INSTALLATION Follow the steps below to install the HSMLT Set up software package and the HSMLT application programs onto the IBM PC or compatible used to support the HSL LTA LTS package The HSMLT set up software is used to download the program to the HSMLT module tune se
74. ng Discharge Timing CH02 The Discharge Timing CH02 should be set about 30 degrees before the location that the can is released from the tester With cans in the machine rotate the tester by hand to the location where the can is just released Set the Discharge Timing CHO02 to the position 30 degrees before this can release position PLC Timing CH03 The PLC Timing is provided as an extra timing signal which can be used by the existing host control system Set this timing as desired 2 10 6 FIFO ERROR CORRECTION CALIBRATION The FIFO Error Correction is used to determine when a reject FIFO error has occurred and automatically correct the FIFO such that the correct bad cans are always rejected An error is generally due to the Can Presence Sensor missing a can side wall damage on the can or when the Reject Photo Eye misses a can or double clocks neck damage The error correction logic verifies the reject FIFO is correct by comparing the average number of cans in the FIFO to a calibrated average number of cans that should be in the FIFO The FIFO is corrected if the average falls below a min threshold or above a max threshold The 5 Calibrate FIFO Error Detection menu accessed from the keypad display on the HSL LTA LTS is used to calibrate the error correction as well as observe the instantaneous number of cans in the FIFO the average number of cans in the FIFO the number of Low FIFO
75. ng 30 degrees ahead of the point the can is just released from the discharge wheel For the LT 16 this is 240 degrees for the LT 10 this is 20 degrees WARNING Do not set the Discharge timing any closer to the Sync timing than 20 degrees 11 Set the Can Presence Shifts Feed one can into the machine Move the machine forward until the can is centered over the Can Presence Sensor Move the machine forward to the Sync timing position count this as 0 Move the machine forward one pocket to the Sync position count this as 1 Continue doing this until the can is released Whatever your count is at when the can is released is the number entered into the Can Presence Shifts Note If the Can Presence Sensor is installed where it is supposed to be as shown in the Discharge Detail the Can Presence Shifts will always be set to 1 SYSTEMS Electronics Group 12 SECTION 2 INSTALLATION 12 Set the Leaker Reject Shifts Feed one bad can with a big hole in it into the machine Move the machine forward until the pocket this can is in just turns on the Reject Receiver input INO of the HSMLT module Move the machine forward to the Sync timing position count this as 0 Move the machine forward one pocket to the Sync position count this as 1 Continue doing this until the can is released Whatever your count is at when the can is released is the nu
76. o the reject manifold is less than 4 Air line longer than this will increase the response time solenoid activation to air out manifold and reduce the pressure at the exit of the manifold 4 Verify vortex nozzle of upper reject solenoid points down at an angle into the can This maximizes the reject force 5 Verify the distance from the centerline of the Reject Photo Eye fiber lenses to the centerline of the reject manifold and nozzle is 5 This distance is assumed by the system and is used as part of the speed calculation to lead when to activate the blow off Changing this distance will change where the air hits the can 6 Verify and if necessary adjust the Reject Solenoid Pulse time see section 3 5 2 2 Set Reject Blow off Parameters 7 Verify and if necessary adjust the Can Neck Size see section 3 5 2 2 Set Reject Blow off Parameters The Can Neck Size parameter can be used to compensate for the response time of the blow off solenoids To advance the blow off activate solenoids earlier make the Can Neck Size larger To retard the blow off activate the solenoids later make the Can Neck Size smaller HSL LTA LTS User s Manual SYSTEMS Electronics Group 93 SECTION 6 TROUBLE SHOOTING This Page Intentionally Left Blank HSL LTA LTS User s Manual SYSTEMS Electronics Group 94 HSL LTA LTS User s Manual SECTION 7 RECOMMENDED SPARES The following are recommen
77. ollowing 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 Control Block Control Block Length 14 Type Peer To Peer Read Write Write DN Target Device 500CPU Local Remote Local Control Block N12 40 Control Block Length 14 Setup Screen 0002 0003 0004 END P NDF4 comm HSL LTA LTS User s Manual SYSTEMS Electronics Group A4 APPENDIX A DF1 COMMUNICATIONS USING THE MSG INSTRUCTION READ INSTRUCTION PLC5 The read message MSG command for a PLCS is setup as follows MSG Rung 3 0 MG20 0 PLC 3 Word Range Read INIO10 M5 o Note The Communication Command is PLC3 Word Range Read The Data Table Address can be any integer file address The 45 elements read from the M4503 PLC are defined in the last section Read Write Data Definitions 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 HSL LTA LTS User s Manual SYSTEMS Electronics Group A 5 APPENDIX A DF1 COMMUNICATIONS 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 NIOO 5 o Note The Communication Command is PLC3 Word Range Write The Data Table Address can
78. on where the can is just released Set the Discharge Timing CHO02 to the position 30 degrees before this can release position PLC Timing CH03 The PLC Timing is provided as an extra timing signal which can be used by the existing host control system Set this timing as desired In addition to showing what the currently selected timing channel is set to the display will also show the current angular position of the resolver Note 360 degrees is used for each pocket HSL LTA LTS User s Manual SYSTEMS Electronics Group 35 SECTION 3 USING THE KEYPAD DISPLAY 3 5 4 ZERO MACHINE SET RESOLVER OFFSET This selection is used to auto zero the resolver To set the machine zero resolver offset perform the following 1 Position the machine at machine zero From the infeed side rotate the machine by hand until the reject reset photo detector on the array head number 1 is exactly aligned with the reset lamp This is the machine zero location for the tester 2 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 3 Exit back to the primary set up menu by pressing lt ESC gt Exit back to the default screen by pressing lt ESC gt again 3 5 5 CALIBRATE FIFO ERROR DETECTION The FIFO Error Correction is used to determine when a reject FIFO error has occurred and automatically correct
79. our 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 c hsmit EXE _ gl x Systems HSM LT Set up Menu Version 2 1 Last Shift Total for shift Press ESC to return to main menu Total Good Cans Tested Total Leaker Rejects Total Vision Inspection Rejects Pocket 01 Leaker Rejects Pocket 09 Leaker Rejects Pocket 02 Leaker Rejects Pocket 10 Leaker Rejects Pocket 03 Leaker Rejects Pocket 11 Leaker Rejects Pocket 04 Leaker Rejects Pocket 12 Leaker Rejects Pocket 05 Leaker Rejects Pocket 13 Leaker Rejects Pocket 06 Leaker Rejects Pocket 14 Leaker Rejects Pocket 07 Leaker Rejects Pocket 15 Leaker Rejects Pocket 08 Leaker Rejects Pocket 16 Leaker Rejects eoooooo eooooooo HSL LTA LTS User s Manual SYSTEMS Electronics Group 80 HSL LTA LTS User s Manual SECTION 5 HSMLT DOS BASED SET UP PROGRAM REFERENCE 5 6 DOWNLOAD PROGRAM TO MODULE This selection is used to download the HSMLT application program to the HSMLT module This should only be performed when either replacing the module or when the program has been changed To download the program perform the following eS hsmlt_ EXE ioj x Systems M4500 Program Dump Version 1 0 Copyright C Systems Electronics Group 1998 all rights reserved Program to be loaded to module on disk Program Ident Program
80. ous number of cans in the FIFO This is the average number of cans in the FIFO when the machine is running above 800CPM when the machine is running below 800 this is set to 0 0 Low Correction This is the number of times the AVG dropped below MIN when running above 60 of top speed A low correction is caused by either the Can Presence sensor missing a can or the Reject Photo Eye double clocking a can LoCorr can be reset by pressing the 0 key while the Calibrate FIFO Error Detection menu is displayed SYSTEMS Electronics Group 24 HSL LTA LTS User s Manual SECTION 2 INSTALLATION HiCorr High Correction This is the number of times the AVG went above MAX when running above 60 of top speed A high correction is caused by either the Can Presence sensor double clocking a can unlikely or the Reject Photo Eye missing a can HiCorr can be reset by pressing the 0 key while the Calibrate FIFO Error Detection menu is displayed To calibrate the FIFO error correction perform the following 1 First disable the FIFO error detection as follows a With the machine stopped press the SET UP key b Press 5 Calibrate FIFO Error Detection c With the FIFO Error Calibration menu displayed press the 1 key d This disables the FIFO error correction by setting the CHKSPD to 4800CPM MIN to 0 0 and MAX to 9 9 2 Run the machine
81. ower up the system and verify all the I O for correct operation SYSTEMS Electronics Group 10 HSL LTA LTS User s Manual SECTION 2 INSTALLATION 2 5 SET UP Once power is re applied to the system and the I O is verified perform the following to set the parameters of the HSL LTA LTS Refer to section 3 Using the HSMLT Keypad Display for details of display menus and key sequences used to set the parameters 1 2 3 4 5 6 To start with set all the parameters to the default parameters listed for the particular tester see section 2 10 Verify the direction of rotation of the resolver By hand move the tester forward and verify the position counts up If not swap S1 and S3 at the HSMLT resolver connector Zero the resolver see section 2 10 4 Verify 360 degrees per pocket Position the machine at 0 degrees A pocket should be aligned with the reset lamp centered in the reset photo diode of the pocket By hand move the machine forward one pocket such that the next pocket is centered on the reset lamp the position should count up thru 359 and again be at 0 degrees Do this for all the pockets Note The position may deviate 20 degrees from pocket to pocket This is normal and is not a problem If it does deviate significantly more than 20 degrees something is wrong with the resolver or resolver wiring refer to section 6 2 step 7 to trouble shoot Determine the position the
82. 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 M4503 The programming port of the M4503 is set to 9600 baud ia Comm Port Settings Comm Port r Port Speed l i Com 1 S600 C Com2 C 19200 Cancel Once selected a dialog box requesting the user to select a Comm Port and Baud Rate will be displayed The default setting is COM1 at 9600 baud The option to select the 19200 baud rate is to allow the user to communicate with the processor via the 4516 serial communications board In most cases the user will only need to specify the communications port and leave the baud rate at 9600 If communication problems occur make sure there is a secure connection from the PC to the PLC Then check the Comm port In most cases the user will only need to select a new Comm port If communication problems persist there may be another program causing a conflict with the port Check the port configuration from the Settings folder SYSTEMS Electronics Group 50
83. positioned such that the Can Presence Sensor which is mounted in step 8 below will not see the reject fingers HSL LTA LTS User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION HSL LTA LTS User s Manual 5 6 7 8 9 Mount new or modify existing reject chute for pneumatic reject Mount RSV34 MSI Resolver with provided bracket to discharge star wheel shaft Mount Can Presence Sensor to discharge rails where shown in Discharge Detail drawing at the back of this manual Adjust the Can Presence Sensor to within 125 of the can when a can is centered over the sensor Mount and pipe the infeed track gate air cylinder and solenoid in the infeed track of the tester Install Leaker Vision Diverter Nozzle in reject chute 1f used optional 10 Install Reject Verification photo eyes in reject chute 1f used optional Electrical Refer to the electrical control schematic and interconnect diagram at the back of this manual for the following 1 2 3 4 5 6 7 Terminate the wires from the HSL LTA LTS in the existing control cabinet Terminate the wires in the BRK LTB SOL Reject Assembly J box Terminate the Can Presence Sensor in the Reject Assembly J box Terminate the Infeed Track Gate solenoid wires Terminate the Leaker Vision Diverter solenoid wires 1f used optional Terminate the Reject Verification Photo Eyes if used optional P
84. r is running at top speed SYSTEMS Electronics Group 64 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE Number of Cans in FIFO Avg This is the average number of cans in the FIFO when the machine is running above 800 cpm FIFO Low Corrections Count This is the number of FIFO faults that have occurred when the average number of cans in the FIFO has dropped below the FIFO Min A FIFO low fault would be caused by double clocking a can at the Reject Photo Eye This count is retained indefinitely but can be reset by clicking the Calibrate FIFO button FIFO High Corrections Count This is the number of FIFO faults that have occurred when the average number of cans in the FIFO has exceeded the MIFO Max A FIFO high fault would be caused by missing a can at the Reject Photo Eye This count is retained indefinitely but can be reset by clicking the Calibrate FIFO button Missed Can Presence Count This is the number of FIFO faults that have occurred due to missing a can at the Can Presence sensor This count is retained indefinitely but can be reset by clicking the Calibrate FIFO button SYSTEMS Electronics Group 65 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual Critical Input Positions The View Critical Input Positions menu is used to view the position in degrees that the Reject Receiver Array Fault
85. ral if cans are running into the machine but the Reject Photo Eye does not see individual cans coming out this alarm occurs Output Code 010 Timing Resolver Fail The timing resolver fail occurs when any of the four timing signals generated in the PLS section fail to change state periodically while the machine is running Motion must be detected on all four timing signals six seconds after the Machine Run input B110 0 turns on in order to avoid this fault Output Code 011 Excessive FIFO High Corrections This fault occurs when more than five FIFO high corrections see section 2 10 6 occur within 5 minutes of accrued run time Normally no more than a few corrections per hour should occur A High correction occurs when either the Can Presence Sensor double clocks a can unlikely or the Reject Photo Eye misses a can Verify the machine set up be performing the steps in section 6 2 Output Code 100 SYSTEMS Electronics Group 85 SECTION 6 TROUBLE SHOOTING HSL LTA LTS User s Manual Excessive FIFO Low Corrections This fault occurs when more than five FIFO low corrections see section 2 10 6 occur within 5 minutes of accrued run time Normally no more than a few corrections per hour should occur A Low correction occurs when either the Can Presence Sensor misses a can or the Reject Photo Eye double clocks a can Verify the machine set up be performing the steps in section 6 2 Output Cod
86. rom the processor Messages r Machine CPM Good Cans rLeaker Rejects r Mision Rejects 0 243 730 294 165 r Scrap total r Scrap leaker ZScrap vision 0 18 0 12 i 0 07 r Bad Can Blow off r Alarm Reset l Test Blow off Solenoid Reset Alarms System Message All Faults Normal ONLINE 10 14 2003 3 07PM _ HSL LTA LTS User s Manual SYSTEMS Electronics Group 39 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE 4 1 GENERAL DESCRIPTION Title Bar At the top of the window is the Title Bar The title bar is used to display the name of the working Set up Data file as well as the name of the active Window The title bar is dark if the window is active and grayed if another window is active The color depends on the settings of the Display Properties of the Control Panel Status Bar At the bottom of the window is the Status Bar The status bar is used to display system messages online or offline mode as well as the current time and date as set by the operating system The system messages panel displays general information about operation of the system The Online Offline mode panel displays the status of the current set up program mode of operation The mode of operation can be changed by simply double clicking the online offline mode panel Hot Keys Hot keys are activated by holding down t
87. ronics Group A 9 APPENDIX A DF1 COMMUNICATIONS The Channel 0 Options are setup as follows Edit Channel Properties Attention inar SUSE sera The Detect Duplicate Messages should be unchecked HSL LTA LTS User s Manual SYSTEMS Electronics Group E A 10 APPENDIX A DF1 COMMUNICATIONS SLC500 The Channel 0 Serial Port should be setup as follows Channel Configuration The Duplicate Packet Detect should be unchecked HSL LTA LTS User s Manual SYSTEMS Electronics Group A 1 APPENDIX A DF1 COMMUNICATIONS READ WRITE DATA DEFINITIONS Data Read From The M4503 45 Elements Is Defined As Follows M4503 Mapped PLC Description Add Add Add Function General M4503 Status Word 1 to PLC W3910 N7 5 R O Watch Dog Comm Status Bit 00 F119 B3910 0 N7 5 0 Spare Bit 01 B3910 1 N7 5 1 Spare Bit 02 B3910 2 N7 5 2 thru thru thru Spare Bit 14 B3911 6 N7 5 14 Spare Bit 15 B3911 7 N7 5 15 M4503 Status Word 2 to PLC W3912 N7 6 R O Encoded Alarm Bit 0 Bit 00 B121 4 B3912 0 N7 6 0 Encoded Alarm Bit 0 Bit O1 B121 5 B3912 1 N7 6 1 Encoded Alarm Bit 0 Bit 02 B121 6 B3912 2 N7 6 2 Spare Bit 03 B3912 3 N7 6 3 Spare Bit 04 B3912 4 N7 6 4 thru Thru Thru Spare Bit 14 B3913 6 N7 6 14 Spare Bit 15 B3913 7 N7 6 15 Active Alarm Messag
88. s timing set points and shift data to the M4503 from the set up Data File This function is accessed from the File menu amp HSMHLT unnamed Main Display File Edit View Window Help New Ctrl N Open Ctrl O Save Ctrl S Save As Export Shift Data Ctrl Upload save Data m Leaker Rejects Vision Rejects Download Program Download restore Data 234 165 Print Report ZScrap leaker ZScrap vision Exit 0 12 0 07 Alarm Reset Reset Alarms System Message All Faults Normal ONLINE 10 14 2003 3 10PM 7 Note Only the values contained within the current data file are used If the validity of the current data file is questionable review the data in an Offline mode prior to download 4 2 5 PRINT REPORT The Set up program allows the user to generate a Report printout of all the set up parameters timing 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 SYSTEMS Electronics Group 48 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE To printout a report of the settings contained in the set up Data File perform t
89. s 24 keys consisting of data display commands set up commands and a numeric keypad The display of the HSMLT is a 2 line by 40 character back lit LCD display which displays the selected data and set up menus The keypad display can be used by the operator to view data or can be used by authorized personnel passcode or key switch protected to adjust the timing and all set up parameters 7 SYSTEMS A ELECTRONICS GROUP INC MACHINE SPEED CPM 0000 GOOD CANS O REJECTS O KA 1 2 5 cula 4 5 6 m ne 7 8 9 0 The display keypad allows the following to be viewed or adjusted 1 2 3 4 5 6 7 8 9 Set Reject Shift Registers Set Reject Blow off Parameters Set Machine Timing Set Machine Zero Calibrate FIFO Error Detection View Critical Input Positions View the Number of Rejects per Pocket View the Current Shift Data View the Last Shift Data 10 Test the Reject Blow off Solenoid Note For virtually all the menus the NEXT and PREV keys can be used to advance to the next item of the menu or retard to the previous item on the menu HSL LTA LTS User s Manual SYSTEMS Electronics Group 29 SECTION 3 USING THE KEYPAD DISPLAY HSL LTA LTS User s Manual 3 1 DEFAULT SCREEN The default screen displayed when no other commands are active
90. s displays a dialog box allowing the user to select a folder and enter a name for the file The user will be notified if the file already exists and the extension sdt will automatically be added to the file name If this is a New file the user will be prompted to enter a file name Save As To save the data file to a new name select Save As from the File menu This displays a dialog box allowing the user to select a folder and enter in a new name for the file The user will be notified if the file 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 4 2 2 UPLOAD SAVE DATA The Set up program allows the user to upload set up parameters timing set points and shift data from the M4503 into a set up Data File This function is accessed from the File menu amp HSMHLT unnamed Main Display File Edit View Window Help anl xi New Ctrl N Open Ctrl 0 Save Ctrl S Save As Export Shift Data Ctrl id Cans Leaker Rejects Vision Rejects Download Program Download restore Data EEE Bet 168 Print Report CtP frap total Scrap leaker ZScrap vision Exit 0 12 0 07 Alarm Reset
91. sages specific to the M4503 as well as the current Online or Offline status of the set up program By simply scrolling the display the user is able to view all active alarm and status messages If no alarm or status messages are active a default message is displayed Machine CPM This display is only active while Online and displays the current speed of the machine in Cans Per Minute Good Cans This is the total number of good cans tested so far into the shift This is essentially a can counter Leaker Rejects This is the total number of leaker cans rejected by the machine so far into the shift SYSTEMS Electronics Group 56 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE Vision Rejects This is the total number of cans rejected by the vision inspection system if used Scrap total This is the total percentage of cans tested that were blown off either due to a vision or leaker reject Scrap leaker This is the total percentage of cans tested that were blown off due to a leaker reject signal Scrap vision This is the total percentage of cans tested that were blown off due to a vision reject signal Note Ifa can is both a vision reject and a leaker reject it will only be counted as a leaker reject and not as both 4 5 2 THE SET UP 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 W
92. solver in counts for one full revolution of the discharge star wheel Zero Resolver Position the machine at machine zero This is the location where the pocket 1 reject reset photo detector is perfectly aligned with the reset lamp see Machine Zero2 10 3 Auto zero the resolver by clicking the ZERO MACHINE button The position of the machine will now be displayed at zero Note The Zero Resolver button is only active in the online mode while the machine is at zero speed no motion detected SYSTEMS Electronics Group 62 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE Calibrate FIFO This is used to calibrate the can tracking error detection logic as well as observe the Can Check Speed the instantaneous number of cans in the FIFO average number of cans in the FIFO the min and max error limits and the number of Low corrections High corrections and missed can presence counts HSMLT unnamed Set Up E ET loj x File Edit View Mindow Help Reject Shift Registers Blow off Parameters Machine Timing Calibrate FIFO Critical Input Postions FIFO Error Detection r Machine Speed CPM Can Check Speed 300 D Number of Cans in FIFO 0 Number of Cans in FIFO Max 6 2 Calibrate FIFO Number of Cans in FIFO Min 43 Number of Cans in FIFO Avg o0 FIFO Low Corrections Count ER FIFO High Corrections Count 0s Missed Can
93. st Shift data menu amp HSMHLT unnamed Shift Data atta 11118314 SYSTEMS Electronics Group 7 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE HSL LTA LTS User s Manual 4 5 5 THE I O STATES WINDOW The I O States window is provided to display states of the inputs and outputs The control boards the states of the timing channels as well as states of the M4503 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 M4503 processor E HSMHLT unnamed 170 Status SYSTEMS Electronics Group 74 HSL LTA LTS User s Manual SECTION 5 HSMLT DOS BASED SET UP PROGRAM REFERENCE The HSMLT DOS based set up program is menu driven allowing the user to easily view the data or alter the set up variables using an IBM PC or compatible The set up variables are used to configure and tune the HSL LTA LTS to match the configuration and performance of the specific tester Note The HSMLT program is an on line communications program used to interface with the HSMLT module The data displayed in the menus and set in the menus is communicated directly to the module Therefore prior to selecting any of the above selections make sure an RS 232 cable is connected from the COM port on the computer running HSMLT to the PROG port on the module The following sections are a complete description of th
94. t Key 31 3 5 Setup Key 32 3 5 1 Set Reject Shift Registers 33 3 5 2 Set Reject Blow off Parameters 34 3 5 3 Set Machine Timing Set Points etc 35 3 5 4 Zero Machine Set Resolver Offset 36 3 5 5 Calibrate FIFO Error Detection 36 3 5 6 View Critical Input Positions 37 3 5 7 Set Keypad Display Set Up Key Passcode ___ 37 3 6 Test Blow off Key 38 HSL LTA LTS User s Manual SYSTEMS Electronics Group CONTENTS 4 HSMLT Windows Based Set up Program Reference 1 39 4 1 General Description 40 4 2 The File Menu 43 4 2 1 The Set Up Data File 44 4 2 2 Upload save Data 45 4 2 3 Download Program 46 4 2 4 Download restore Data 48 4 2 5 Print Report 48 4 3 The Edit Menu 49 4 3 1 Enable Offline Editing 50 4 3 2 Setup Comm Port 50 4 3 8 Edit Set Up Passcode 51 4 4 The View Menu 52 4 4 1 Target Board Interface 53 4 4 2 View Online Data 54 4 4 3 View Offline Data 54 4 5 The Window Menu 55 4 5 1 The Main Display Window 56 4 5 2 The Setup Parameters Window 57 4 5 3 The Serial Communications Window 67 4 5 4 The Shift Data Window 70 4 5 5 Thel O States Window 74 5 HSMLT DOS Based Set Up Program Reference 3 75 5 1 Main Menu 75 5 2 Reject Setup Parameters 76 1 Set Reject Shift Registers 76 2 Set Can Neck Size 77 3 Set Blow off Solenoid Parameters 77 4 Set Machine Timing 77 5 3 Number of Rejects per Pocket Data 78 5 4 Current Shift Data 79 5 Last Shift Data 80 5 6 Download Program to Module 81 5 7 Do
95. t Parameters Can Neck Size in 0 01 inches 215 Reject Solenoid Pulse Time msec 10 Diverter Solenoid Pulse Time 01sec 100 Machine Timing Sync Timing CHOO On Position 180 Pocket 1 Timing CH01 On Position 270 Discharge Timing CH02 On Position 240 PLC Timing CH03 On Position 000 2 10 4 MACHINE ZERO The machine is located at machine zero by performing the following 1 From the infeed side rotate the machine by hand until the reject reset photo detector on the array head number 1 is exactly aligned with the reset lamp This is the machine zero location for the tester 2 With the machine located at zero set the resolver offset through the set up menu of the Keypad Display 4 Zero Machine Set Resolver Offset selection HSL LTA LTS User s Manual SYSTEMS Electronics Group 22 HSL LTA LTS User s Manual SECTION 2 INSTALLATION 2 10 5 MACHINE TIMING SIGNALS Sync Timing CH00 The Sync Timing is used to clock in the reject data from the Reject Array Receiver Array Fault Receiver and the vision system reject signal as well as clock the data from the Can Presence sensor The Sync Timing should be as far as possible from the occurrence of the above four signals For the LT 10 this is at 0 degrees for the LT 16 the is at 180 degrees Pocket 1 Timing CH01 The Pocket 1 Timing is used to reset the pocket count to pocket 1 Set the Pocket 1 Timing 90 degrees following the Sync Timi
96. t a Leaker Reject into a separate reject chute The valid range for this parameter is 0 to 250 2 5seconds Can Time msec This is the amount of time in milliseconds that the reject photo eye sees a can Blow off Solenoid ON Time msec The blow off solenoid ON time is the amount of time in milliseconds that the blow off solenoid will be activated to blow off a can Blow off Solenoid Delay Time msec Based on the can neck size and the can time the control system calculates a Delay Time based on the speed of the can Note Adjusting the can neck size will affect the blow off solenoid delay time Bad Can Blow off Test Blow off Solenoid This button is used to test the reject blow off solenoid both while the machine is running with cans or while the machine stopped After making adjustments to the can neck size use this function to test the reject blow off solenoid SYSTEMS Electronics Group 60 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE Machine Timing Reject Shift Registers Blow off Parameters Machine Timing Calibrate FIFO Critical Input Postions m Machine Timing 1 Machine Position Sync Timing CHOO ON Position deg 180 E 240 Pocket 1 Timing CHO1 ON Position deg 270 4 Discharge Timing CH02 ON Position deg 275 zi Absdlate POSU PLC Timing CHO3 ON Position deg 0 4 1863 Zero Reso
97. t can detected by the reject photo eye will be rejected The solenoid is activated with the same delay and pulse times used when a leaker reject can is blown off With the machine stopped de pressing the Test Blow off key will activate the reject blow off immediately for the pulse time This can be used to verify that the solenoid does indeed activate SYSTEMS Electronics Group 38 SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE The Windows based set up program is menu driven allowing the user to easily view data alter set up variables or set machine timing machine offset timing signal locations etc using a PC running the Windows 95 98 ME 2000 XP NT operating system The set up variables are used to configure and tune the M4503 to match the configuration and performance of the specific tester see Set up Reference section 2 10 Note The set up program is an on line communications program used to interface with the M4503 module The data displayed and set in the windows is communicated directly to the module while in the Online edit mode Therefore prior to going online with the processor make sure an RS 232 cable is connected from the COM port on the computer to the PROG port on the M4503 The variables displayed while in the Online edit mode are read directly from the processor Data is saved to a Set up Data file sdt whenever changes are made to a parameter or if the data is uploaded f
98. t up the user adjustable variables of the HSL LTA LTS download and upload save the user set up variables to disk and view rejects per pocket and shift data 2 6 1 WINDOWS INSTALLATION The Windows based HSMLT set up program is compatible with Windows 95 98 NT ME 2000 and XP If the operating system of your computer is either an earlier version of Windows or DOS based follow the steps described in section 2 6 2 DOS installation To install the Windows based set up program run setup exe located in the HSMLT subdirectory of the program disk Follow the onscreen instructions to complete the process If any problems are incurred during the installation process try restarting your computer and running setup exe again Make sure all programs have been exited prior to installation HSL LTA LTS User s Manual SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION 2 6 2 DOS INSTALLATION To install the DOS Based set up program perform the following 1 2 3 HSL LTA LTS User s Manual Create a directory off the root directory for each tester For line 1 tester use HSMLT1 for line 2 tester use HSMLT2 for the line 3 tester use HSMLT3 etc These will be used to store the HSMLT EXE setup programs and set up data for each tester Create these directories by typing the following at the DOS prompt MD HSLT1 lt ENTER gt MD HSLT2 lt ENTER gt MD HSLT3 lt ENTER gt etc Install the dis
99. t up menu is passcode protected When the set up key is first depressed an ENTER PASSCODE prompt is displayed At this point the 5 digit passcode must be entered followed by pressing the lt ENTER gt key The primary set up menu is then displayed and any of the parameters accessed by this menu may be changed If the passcode entered is incorrect the message INCORRECT PASSCODE will be displayed At this time the passcode may be entered again or the lt ESC gt key can be pressed to return back to the main menu When the passcode is entered the digits entered are not displayed Instead characters are displayed as each digit is entered This prevents unauthorized personnel from observing the passcode as it is entered In addition the ENTER PASSCODE prompt is only displayed for a maximum of 60 seconds The correct passcode must be entered within this 60 second period otherwise the set up mode is aborted and the main menu is re displayed SYSTEMS Electronics Group 332 HSL LTA LTS User s Manual SECTION 3 USING THE KEYPAD DISPLAY For user s that would prefer to use a keyed switch to prevent unauthorized access instead of a passcode the Set Up Enable input can be used When this input is on the passcode prompt is bypassed and access to the primary set up menu is provided immediately If the Set Up Enable input is off then the normal passcode prompt is displayed A keyed switch can then be wired to the Set Up Enable
100. the correct leaker test can enable the FIFO Error Correction by pressing the 1 key while in the Calibrate FIFO Error Detection menu The ChkSpd will be set to about 60 of the top speed Generally for the LT 16 min will be set at 1 8 2 2 max will be set to 2 7 3 1 19 If the tester is equipped with a vision system verify the position the vision reject signal is coming in Run a visually defective can through the machine From the View Critical Inputs Position menu observe the position the vision reject signal comes on at in the Vision Reject field This position must not be within 60 degrees of the Sync timing Verify that a vision test can is correctly rejected Note Depending on where the vision system sends it s reject signal out the Vision Reject Shifts may have to be adjusted anywhere from 4 to 16 in order to get the correct defective vision can Keep adjusting the Vision Reject Shift until the correct can is rejected 20 If the system is equipped with the optional leaker vision diverter adjust the Diverted Solenoid Pulse time until a rejected leak can is diverted out the leakers only reject chute correctly 21 Verify the Pocket 1 Offset parameter Place a piece of electrical tape over the Array Reset Pickup center of the array head on array head number 1 Run cans through the machine Verify that Pocket 1 is the pocket i
101. the tester discharge pocket where cans are released from the machine 2 SET CAN NECK SIZE 1 Can Neck Size in 0 01 inches This parameter is used to calculate when to activate the reject blow off as a function of the can speed The can neck size is simply the diameter of the neck at it s most narrow point in 0 01 inches For example if the neck measures 2 15 at it s most narrow point simply enter 215 for the can neck size The valid range of this value is 180 to 300 3 SET BLOW OFF SOLENOID PARAMETERS 1 2 Reject Solenoid Pulse Time msec This is the number of milliseconds that the reject solenoids will be pulsed for when a bad can is rejected This is adjusted to get a strong pulse of air to reject the can Too short of time will result in the can not being fully rejected jamming Too long of time will disturb the following can at high speeds also causing jamming Typically this is set from 10 to 12msec The valid range for this parameter is 8 to 50msec Diverter Solenoid Pulse Time 01sec This is the amount of time in 01seconds the leaker vision diverter solenoid if used is pulsed for to divert a leaker reject down a separate leakers only reject chute The valid range for this parameter is 0 to 250 2 5seconds 4 SET MACHINE TIMING 1 2 Sync Timing CH00 The Sync Timing is used to clock in the reject data from the Reject Array Receiver Array Fault Receiver and the vision system reject signal
102. this speed the can must flow past the sensor and reject port at a constant rate If a can goes past the sensor and then is knocked back by the previous can the reject port will not fire at the right time and a clean reject will not occur Also in severe cases instability in the discharge can flow can cause FIFO error corrections because the Reject Photo Eye may be double clocked when cans bounce back into the machine 12 For steel can installations For steel food cans that do not have a neck make sure the distance between cans on the magnetic conveyor at the tester top speed is 3 8 or more The Reject Photo Eye has to see the individual cans beam must be able to pass between individual cans 13 If after performing the previous steps 1 thru 12 the system is still not functioning correctly perform all the steps in the set up section 2 5 14 If after performing step 13 the system is still not functioning correctly replace the HSMLT M4503 module and try again See section 2 11 for details on replacing the module SYSTEMS Electronics Group 00 HSL LTA LTS User s Manual SECTION 6 TROUBLE SHOOTING 6 3 CAN REJECT PROBLEMS TROUBLE SHOOTING If the system is having problems cleanly rejecting cans from the discharge conveying into the reject chute perform the following Note The reject can be verified at full production speeds using the Test Blow Off key on the keypad of the HSMLT M4503 mod
103. tion If the wiring is OK replace the RSV34 MSI resolver c Check the voltage between S2 and S4 on the HSMLT M4503 module resolver connector just as was done for S1 and S3 above It should read just as S1 and S3 should read d Ifsteps a thru c above check out OK check the resolver coupler Make sure the key in the resolver shaft is installed and the coupler is tight e If a thru d did check out OK but the pocket to pocket 0 location is still not right replace the RSV34 MSI resolver HSL LTA LTS User s Manual SYSTEMS Electronics Group 88 HSL LTA LTS User s Manual 8 9 SECTION 6 TROUBLE SHOOTING Verify the Can Presence Sensor The Can Presence Sensor is used to clock the cans into the FIFO so the set up of the sensor is critical Verify the following a Verify the Can sensor sees a can when positioned in front of it b Verify the Can sensor is set at about 125 from the body of can positioned in front of the sensor Adjust if necessary c Determine the position the Can Presence Sensor turns on With a can in a pocket rotate the machine forward until the Can Presence Sensor just turns on This position cannot be within 60 degrees of the Sync timing Adjust the sensor if necessary to achieve this Verify the Reject Photo Eye The fiber optic lenses of the Reject Photo Eye must be mounted such that the neck of the can breaks the beam Knowing the neck size the time
104. ule Depressing this once will cause one can to be rejected just as a normal reject would occur Also this key can be pressed with the machine stopped to verify the reject solenoids The solenoids will be pulsed for the same time when the key is hit just as if the machine was running Aluminum Can Installations 1 Verify that both reject solenoids are firing Disconnect the air lines from both solenoids and verify a pulse of air from each solenoid when the Test Blow off key is depressed 2 Verify air pressure to reject system is 90psi or greater 3 Verify that the length of the air lines from the reject solenoids to the reject manifold is less than 4 Air lines longer than this will increase the response time solenoid activation to air out manifold and reduce the pressure at the exit of the manifold 4 Verify the distance between the face of the reject manifold and can is 1 4 If the manifold is placed closer to the can than this less reject force occurs because air induction to the stream of air at the exit of the manifold is reduced 5 Verify the manifold is pointed perpendicular or slightly into the flow of cans Pointing the manifold slightly into the flow of cans increases the angle that a can will be rejected Pointing the manifold slightly with the flow of cans will decrease the angle that a can is rejected 6 Verify the distance opening in discharge track work from the centerline of the manifold to the lip of th
105. 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 Rejects Per Pocket The number of leaker rejects per pocket menu is provided to aid in the trouble shooting of a light seal problem with a pocket or pockets The total number of rejects for each pocket since the last reset or end of shift is displayed 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 of the M4503 1 Rejected Pocket This is the number of the last pocket that generated a vision reject This 1s only available in the online mode SYSTEMS Electronics Group 70 HSL LTA LTS User s Manual SECTION 4 HSMLT WINDOWS BASED SET UP PROGRAM REFERENCE 2 Rejects Per Pocket This is the total number of leaker rejects for each pocket This data is displayed and updated continuously in the respective field for each pocket A disproportionately high count for a particular pocket indicates a light seal problem for that pocket 3 Reset Rejects This provides the operator the opportunity to reset the counts for troubleshooting purposes Resetting these counts does not affect the total number of rejects per for the shift This function is only available in the online mode Current Shift This selection is used to view the Current Shift data This data is the totals so far into the shift
106. wnload Set up Data to Module 82 5 8 Upload save Set up Data from Module 83 HSL LTA LTS User s Manual SYSTEMS Electronics Group diis HSL LTA LTS User s Manual 6 Trouble shooting 6 1 HSMLT Alarm Message Definitions 6 2 Can Tracking Errors Trouble shooting 6 3 Can Reject Problems Trouble shooting 7 Recommended Spares Keypad Display Legend Allen Bradley DF1 Communications Hardware Software Using the MSG Instruction Channel 0 Setup Read Write Data Definitions Drawings CONTENTS 85 85 91 95 LIST OF FIGURES 29 APPENDICES Appendix A A 1 A 3 A 5 A 9 A 12 Appendix B SYSTEMS Electronics Group iii HSL LTA LTS User s Manual SECTION 1 GENERAL DESCRIPTION This section describes the features of the HSL LTA and HSL LTS hereafter referred to as the HSL LTA LTS Alcoa Borden s Light Tester electronic reject control packages This includes the functional description alarms detected etc This manual applies to both aluminum can HSL LTA and steel can HSL LTS packages The difference between the packages is the method of pneumatic rejection Otherwise the packages function the same 1 1 FEATURES e Replaces existing odd even mechanical reject mechanism with a reject blow off solenoid assembly mounted in the discharge of the light tester to reject defective cans Proprietary logic tracks cans from the leak detection array receiver to the reject blow off location in the discharge
107. y set or view the passcode of the set up menu Normally this input should be off When the passcode is to be set jumper this input to 24VDC 501 and press the Set Up key The ENTER PASSCODE prompt will be displayed and the current 5 digit passcode will be displayed with the prompt This allows the passcode to be viewed if necessary If the passcode is to be changed enter any number between 0 and 64999 and press lt ENTER gt Note If passcode protection is not to be used set the passcode to un Then when the passcode is prompted for after the Set up key is pressed simply press lt ENTER gt to proceed to the set up menu If the passcode protection is to be used set the passcode to a number between 1 and 64999 Then when the Set up key is pressed the actual valid passcode number will have to be entered in order to gain access to the set up menu Once the passcode is set turn the Set Passcode input back off and now the set up menu will be passcode protected with the number you have entered as the passcode SYSTEMS Electronics Group 37 SECTION 3 USING THE KEYPAD DISPLAY HSL LTA LTS User s Manual 3 6 TEST BLOW OFF KEY This key is used to test the reject blow off solenoid both while the machine is running with cans and with the machine stopped Testing the blow off with the machine running with cans verifies that the blow off delay and pulse times are calculated correctly When de pressed the nex

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