SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL
Contents
1. 200 Response Time Compensation msec 220 Color Gain CG 100 per 2000CPM 100 Feedback Enable Stations 1 8 N 6 6 MANUAL OFF AUTO CONTROL The ductor MANUAL OFF AUTO selector switch is used to determine the mode of the ductors The three different modes operate as follows MANUAL Ductors cycle normally while the decorator is running Ductor Auto On input from host PLC ignored Ductors turn off rest on first steel roll when the decorator reaches zero speed While the decorator is stopped each individual ductor can be toggled on and off by pressing the keypad number corresponding to it s station This provides a test method to verify the operation of each ductor OFF Ductors always off resting against first steel roll AUTO Ductors cycle normally while decorator is running and the Ductor Auto On input from the host PLC is on Ductors turn off when decorator reaches zero speed or when Ductor Auto On input from host PLC is off HSL DC5 User s Manual SYSTEMS Electronics Group 94 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 7 OVERVIEW OF KEYS RELATING TO THE COLOR CONTROL lt COLOR CONTROL gt Pressing this key allows the operator to select a new label number adjust the Cycle and On durations independently for each ink stations or program a new label from scratch This key is passcode protected when the Set Up Enable sw2. SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL This section describes the features of the pneumatic ductor color control This includes the functional description the user and operator selectable parameters etc 6 1 FEATURES e Replaces the mechanically cammed ductors on the decorator e Directly controls the cyclic ductor solenoids to a resolution of one tenth of a can at speeds up to 2400CPM e Enables the operator to perform quick label changes by recalling the ductor Cycle and On duration used the last time the particular label was run e Incorporates optional ductor feedback sensor inputs to compensate for the response time of the solenoid and verify that the ductors are cycling e Keypad adjustment of label parameters label number cycle duration and on duration e Stores label parameters for up to 100 labels e User selectable ductor configuration parameters including maximum Cycle duration maximum On duration response time compensation and individual ductor feedback enable e Passcode security access for adjusting label parameters e Manual Off Auto modes of operation e Provides control for up to 8 ink station machines HSL DC5 User s Manual SYSTEMS Electronics Group 89 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 2 FUNCTIONAL DESCRIPTION The pneumatic ductor color control replaces the mechanically cammed ductors with pneumatically controlled ductors The ductors are no
3. code protection is enabled the operator must enter the proper passcode in order to make adjustments to the color control parameters If the Set Passcode input is ON then a new passcode can be entered If a passcode is not entered the value is reset to zero HSL DC5 User s Manual SYSTEMS Electronics Group 9 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 5 SET UP PNEUMATIC DUCTOR PARAMETERS This menu is activated when the 2 key SET PNEUMATIC DUCTOR PARAMETERS is pressed while the primary set up menu is active using the Keypad Display The following four set up parameters may then be adjusted or viewed Note For virtually all the menus the lt NEXT gt and lt PREV gt keys can be used to advance to the next or previous parameter respectively To change the currently displayed parameter enter the new value on the numeric keypad and press lt ENTER gt The value will be entered and the next parameter will automatically be displayed When the last parameter in a section is entered the primary set up menu is again displayed Pressing lt ESC gt at anytime will exit back to the primary set up menu The following parameters are used to define the ductor configuration Maximum Cycle Duration The maximum Cycle duration is set to 1 10 of a can resolution The range of this parameter is from 140 to 650 and defines the upper limit or the longest amount of time between ductor cycles Care should be taken n
4. e On duration for the response time of the solenoids HSL DC5 User s Manual SYSTEMS Electronics Group 90 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 3 DUCTOR FEEDBACK Sensors mounted on the machine sense the actuation of the ductor arm verifies that the ductor is cycling and compensates for the response time of the solenoid As the speed of the machine changes the feedback sensor is used to adjust the amount of time the ductor is in contact with the fountain roll This allows consistent ink transfer throughout the entire speed range of the machine If a ductor is not detected as cycling an output is activated to indicate a fault in the ductors cycling operation Note The feedback sensor must go ON when the ductor is in contact with the fountain roll 6 4 OPERATOR ADJUSTABLE PARAMETERS The following parameters can be adjusted through the Color Control key on the Keypad Display e Label Number 0 99 e Ink Station On Duration e Ink Station Cycle Duration Note The above values are passcode protected to prevent unauthorized personnel from making adjustments Also the On duration and Cycle duration cannot be set with in 14 cans of one another Passcode protection can be enabled or disabled via the passcode itself If the passcode is set to zero or the Set Up Enable input is ON then passcode protection is disabled otherwise passcode protection is enabled If pass
5. e keys open and closed at the required areas on the can The following sections describe the recommended procedure for setting up a label and the recommended procedure for a label change over using a label which has previously been programmed into the color control HSL DC5 User s Manual SYSTEMS Electronics Group 96 HSL DC5 User s Manual SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 9 SELECTING THE LABEL NUMBER To select a label perform the following 1 Press the lt COLOR CONTROL gt key to enter the adjustment mode 2 Ifthe prompt ENTER PASSCODE is displayed enter the corresponding 1 to 5 digit passcode on the numeric keypad and press lt ENTER gt If the prompt ENTER PASSCODE INCORRECT PASSCODE is displayed enter the correct passcode and press lt ENTER gt 3 The LABEL field is displayed Enter a new label 0 99 on the numeric keypad and press lt ENTER gt or press the lt NEXT gt key to use the existing label Note The decorator must be stopped in order to change the label number 4 Ifno further changes are to be made to the ink stations settings press lt ESC gt to exit 6 10 LIGHT DARK COLOR ADJUSTMENT The On duration and Cycle duration for each ink station can be set individually for each label number The On duration can be viewed as a Course adjustment and the Cycle duration can be viewed as a Fine adjustment Observe how changin
6. g either the On duration or Cycle duration changes the relative Color Density Note If an ink station is not used simply set its On duration to zero to disable the cycling operation Use the Color Density display as an indication of the amount of ink being transferred by the ductor Different settings of the On and Cycle durations will achieve the same Color Density SYSTEMS Electronics Group 97 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL Note To reduce Light and Dark variations in print between cycle times adjust both the On duration and Cycle duration down to achieve the same Color Density For a new label or existing label that needs color adjustment perform the following 1 Press the lt COLOR CONTROL gt key to enter the adjustment mode if not already in adjustment mode 2 To select the desired ink station for adjustment press the lt NEXT gt or lt PREV gt keys until the desired ink station is displayed 3 To lighten the color start by decreasing the On duration or increasing the Cycle duration Watch the Color Density to see how your adjustments change this value Remember think of the On duration as a Course adjustment and the Cycle duration as a Fine adjustment 4 To darken the color start by increasing the On duration or decreasing Cycle duration Watch the Color Dens
7. itch is not disabled When the Color Control key is depressed the label selection screen is displayed The operator may enter in a new label number or press either the lt NEXT gt or lt ENTER gt keys to advance to the next station lt NEXT gt Pressing this key moves to the next adjustment field Holding this key depressed for one second will move to the next field continuously If selection has reached bottom of the order this key will have no effect lt PREV gt Previous Pressing this key moves to the previous adjustment field Holding this key depressed for one second will move to the previous field continuously If selection is returned to the top of the order this key will have no effect lt INC gt Increment Pressing this key once increments the currently selected value by one Holding this key depressed for one second will increment the currently selected value continuously This key is only active in the Color Control mode lt DEC gt Decrement Pressing this key once decrements the currently selected value by one Holding this key depressed for one second will decrement the currently selected value continuously This key is only active in the Color Control mode HSL DC5 User s Manual SYSTEMS Electronics Group 95 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 8 RECOMMENDED PROCEDURE FOR USING THE COLOR CONTROL With a mechanically cammed ductor the keys on the fountain are used t
8. ity to see how your adjustments change this value Once again think of the On duration as a Course adjustment and the Cycle duration as a Fine adjustment 5 Check the color quality and continue to increase or decrease the Color Density until the desired color quality is achieved 6 Perform steps 2 through 4 above for all ink stations used as necessary 7 Once the label quality is satisfactory press the lt ESC gt key to exit the adjustment mode and save the changes for the selected label HSL DC5 User s Manual SYSTEMS Electronics Group 98 HSL DCS5 User s Manual SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 11 CHANGEOVER USING AN EXISTING LABEL When a label is run again perform following to set up the label at change over 1 Select the respective label number on the Keypad Display 2 Set the keys open predefined number of turns a number which is used for all ink stations on all labels on the areas of the can that will have ink and closed on areas that will not have ink 3 Run the machine and verify that ink is being distributed on the can correctly The ink will be metered at the same rate as previously set the last time the label was run Only minor adjustments to the keys may be necessary to assure that ink is not distributed to areas where no color is applied resulting in slinging due to ink build up SYSTEMS Electronics Group 99
9. o control the areas the ink is applied as well as the color quality light or dark The keys are adjusted proportionally to where the color was located as well as how much area the color covered and how dark the color was With the pneumatic ductor the color quality is now controlled by the frequency and duty cycle of the ductor as set through the Keypad Display The fountain keys are simply used to define the locations top bottom middle etc the color is located on the can The keys should not be adjusted proportional as before but should be either closed at areas where there will be no color on the can or opened a predefined number of turns on areas where the color is located on the can This allows label changes to occur quicker by simply setting the keys open or closed at the locations required on the can and selecting the label number for the respective label on the Keypad Display thus setting the color quality to the same level as previously set for that label The M4508 is capable of saving the settings for up to 100 labels in the internal memory As different labels are run on the machine different labels can be programmed and added to the internal database When a label which has already been programmed is run again simply recall the label number and the ductors will oscillate at the same frequency and duty cycle they did the last time the label was run The only additional set up required at label change is to set th
10. ot to set this parameter too low as this would restrict the operators range of adjustment The Cycle duration is set individually for each ink station and is the rate at which ink is transferred from the fountain roll Maximum On Duration The maximum On duration is set to 1 10 of a can resolution The range of this parameter is from 0 to 200 and defines the upper limit or the longest amount of time the ductor roll can be in contact with the fountain roll The On duration is set individually for each ink station and is the amount of time the ductor roll is in contact with the fountain roll HSL DC5 User s Manual SYSTEMS Electronics Group 92 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL Response Time Compensation The response time compensation parameters is used to adjust the On duration based on the difference between the ON and off response time of the ductor solenoid As and example if the ON response time were 40 msec and the off response time was 15 msec then this parameter would need to be set to 25 msec The ON response time is defined as the time ductor is activated to the time it comes in contact with the fountain roll The off response time is the time the ductor is deactivated to the time it lifts off of the fountain roll If the optional feedback sensors are to be used this parameter should be set to zero Color Gain This parameter allows the color den
11. sity to be increased proportionately up or down as a function of machine speed The valid range of this parameter is 50 to 150 per 2000 CPM When set to 100 no increase or decrease as a function of speed will occur When set to 50 the color density will drop 50 from 0 to 2000CPM When set to 150 the color density will increase by 50 from 0 to 2000CPM This parameter is used to compensate for ink atomization misting as a function of speed higher speed proportionately higher ink misting Feedback Enable stations 1 8 This parameter enables the individual feedback faults and should only be used when the optional feedback sensors are used Once enabled the M4508 will verify that the ductor is cycling properly If a ductor is not detected as cycling properly the Ductor Feedback Fault is energized indicating a problem with the ductor cycling control If a Ductor Feedback Fault does occur the ductors should be manually activated to verify proper cycling operation as well as the sensor for proper feedback operation The feedback sensor should be set such that it is only ON when the ductor is in contact with the fountain roll HSL DC5 User s Manual SYSTEMS Electronics Group 93 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 5 1 DEFAULT DUCTOR CONFIGURATION SETTINGS As shipped the ductor configuration settings are as follows Maximum Cycle Duration 0 1 cans 500 Maximum ON Duration 0 1 cans
12. w activated by air cylinders controlled by solenoids driven by the M4508 This allows the cycle duration number of cans between one complete ductor cycle and the duty cycle the time the ductor is in contact with the fountain roll or On duration to be adjusted independently for each ink station This allows the ink flow rate of each station to be adjusted based on the amount of ink required for each particular color on the label The maximum Cycle duration maximum On duration and Response Time compensation are set using the Keypad Display These values are used with all labels The color control allows up to 100 labels to be saved This allows the operator to perform quick label changes by recalling the settings used the last time the particular label was run Thus when a label change is made the corresponding label number is selected and settings for each ink station used for that label previously are used again When the machine first starts up the ductors are staged ON in one can increments At the beginning of each cycle the ductor solenoid is activated and the ductor roll comes in contact with the fountain roll Once the On duration is complete the solenoid is deactivated and the ink is transferred to the first steel roll At the completion of the cycle there is a 5 can dwell period before the next cycle starts During this dwell period ductor cycling operation is checked and adjustments made to th
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