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1. Bad Can Blow off Test Trip Blow off System Message All Faults Normal ONLINE 10 12 2003 3 08PM Set up Parameters This option downloads the Set up data to the M4500 This includes print trip and varnish unit response times and blow off parameters SYSTEMS Electronics Group 50 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE Timing Channels This option downloads the Machine Timing channel set points as well as the PLS configuration and scale factor to the M4500 PLS Shift Data This option downloads the Shift Data to the M4500 This includes the Trips per Spindle data the Current Shift and the Last Shift data All This option allows the user to completely download All of the set up parameters timing channel set points and shift data to the M4500 Note Only the values contained within the current data file are used If the validity of the current data file is questionable review the data in an Offline mode prior to download 4 2 4 PRINT REPORT The Set up program allows the user to generate a Report printout of all the set up parameters timing channel set points and shift data This function is accessed from the File menu At the top of each page the report displays the name of the set up file being printed At the bottom of each page is the date and time the document was printed as well as the page nu
2. Add each decorator s set up program to your computer s menu software by creating a selection for each decorator called SET UP DECO LINE 1 for the line 1 decorator SET UP DECO LINE2 for the line 2 decorator etc The DOS commands executed for these selections should be Line 1 decorator is shown For the SET UP DECO LINE1 selection CD HSLDECI1 HSLCCSD1 HSLCCSD1 CD SYSTEMS Electronics Group 14 SECTION 2 INSTALLATION 4 To execute the respective decorator s set up program simply select the corresponding SET UP DECO LINE selection from the menu software s menu 2 8 3 SYSdev PROGRAM DEVELOPMENT SOFTWARE INSTALLATION The SYSdev Program Development software is used to perform on line trouble shooting and program modifications to the HSL CCSD1 If SYSdev was purchased with the HSL CCSD1 package and is not already installed on the your computer install SYSdev onto the hard drive of your computer following the steps in outlined in the SYSdev Program Development manual 2 8 4 APPLICATION PROGRAM INSTALLATION The application program is a SYSdev based program loaded into the M4500 module and performs the HSM CCSD logic The program is written in a combination of Ladder logic and High level If the user desires to make program changes or perform on line monitoring of the program execution the files which constitute the HSLCCSD1 program will have to be loaded onto the hard drive of the PC us
3. CH15 CH16 CH17 ASL CCSD1 User s Manual SYSTEMS Electronics Group 19 SECTION 2 INSTALLATION HSL CCSD1 User s Manual 2 10 2 SET MACHINE ZERO Position the machine with a spindle any spindle it does not have to be spindle 1 directly centered on the no can no print sensors and set the offset per section 3 5 4 Zero Machine set Resolver Offset 2 10 3 VERIFY LOCATION OF NO CAN NO PRINT SENSORS The machine is zeroed based on the location of the no can no print sensors not adjustable in the direction of can flow With the machine zeroed as above both no can no print sensors should see a fully loaded can from about 320 degrees first turn on to about 40 degrees where sensors turn off Verify that the sensors do not see an empty spindle sensor too close to spindle and that both do see a fully loaded can sensor not too far out from spindle The sensors should also be set to see the very edge of the open end of the can such that they will only detect fully loaded cans If the sensors are set too far out towards the dome end they may detect cans that are not fully loaded as being loaded which will result in a ring of inside litho at the top of the can that is next printed on that spindle 2 10 4 SET PIN CHAIN BLOW OFF TIMING Using the Keypad Display set the bad can pin chain blowoff timing CH05 such that the timing signal just turns on when the c
4. The Machine Is Now Set Up And Ready To Run SYSTEMS Electronics Group 24 HSL CCSD1 User s Manual SECTION 2 INSTALLATION 2 11 M4500 P4500 D4591 INSTALLATION The following is provided only as a reference These steps are performed by the factory prior to shipping the HSL CCSD1 These steps need only be performed in the event either the M4500 module P4500 power supply or D4591 display need to be replaced Refer to the M4500 User s Manual for general details on installing the M4500 P4500 and D4591 2 11 1 M4500 MODULE INSTALLATION To install the M4500 module perform the following 1 2 3 4 5 Remove the cover from the M4500 chassis retained with three captive screws on the lower front of the cover and two captive screws on each side of the M4500 chassis Install S4563 SLOTO 0 furthest left slot Set the slot address dip switches SW1 on the 4563 to the following positions S4563 SWI switch OFF SWI switch2 OFF Install S4568 SLOTO 1 slot next to 4563 Set the slot address dip switches SW1 on the 4568 to the following positions S4568 SWI switch ON SWI switch2 OFF Install S4573 SLOTO 2 slot next to S4568 Set the slot address dip switches SW1 on the 4573 to the following positions S4573 SWI switch OFF SWI switch2 ON Install the cover back over the M4500 making sure all the board connectors protrude the slo
5. 020 The following selections set the corresponding parameters 5 1 1 SET PRINT TRIP EXTEND RETRACT RESPONSE TIMES Print Trip Retract Response Time This is the time used as the retract response time of the print trip time from solenoid actuation to first break with blanket in milliseconds The M4500 will activate the retract solenoid this amount of time ahead of the Print unit trip timing CHO00 usually set at 20 milliseconds SYSTEMS Electronics Group 74 HSL CCSD1 User s Manual SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE Print Trip Extend Response Time This is the time used as the extend response time of the print trip time from solenoid actuation to first contact with blanket in milliseconds The M4500 will activate the extend solenoid this amount of time ahead of the print trip timing CHO00 usually set at 20 milliseconds 5 1 2 SET VARNISH TRIP EXTEND RETRACT RESPONSE TIMES Varnish Trip Retract Response Time This is the time used as the retract response time of the varnish trip time from solenoid actuation to first break with varnish wheel in milliseconds The HSL CCSD1 will activate the retract solenoid this amount of time ahead of the Varnish trip timing CH01 usually set at 20 milliseconds Varnish Trip Extend Response Time This is the time used as the extend response time of the varnish trip time from solenoid actuation to first contact with varnish wheel in milliseconds The
6. 6 View the Current Shift Data 7 View the Last Shift Data 8 Activate the select a can QC blow off The definitions of the keypad commands and menus are described in the following sections Note For virtually all the menus the NEXT and PREV keys can be used to advance to the next item of the menu or retard to the previous item on the menu SYSTEMS Electronics Group 29 SECTION 3 USING THE KEYPAD DISPLAY 3 1 DEFAULT SCREEN The default screen displayed when no other commands are active contains the following data MACHINE SPEED CPM xxxx GOOD CANS xxxxxxx BLOW OFFS xxxxxx Where the Machine Speed is the current speed of the decorator the Good Cans field is the total number of good cans printed so far into the current shift and the Blow offs field is the total number of cans blown off the machine scrap so far into the current shift This display effectively replaces a speed meter and two can counters This screen is always returned to when no commands are active 3 2 TRIPS PER SPINDLE KEY The Number of trips per spindle menu is provided to aid in the trouble shooting of a loading problem with a spindle or spindles The total number of trips for each spindle since the last reset or end of shift is displayed The operator can reset these counts at any time to aid in the trouble shooting process The data can be viewed simply by pressing this key The display shows a series
7. From the View menu select Online Data The set up program will attempt to communicate with the processor and place the system into an Online mode of operation 4 Set all channels per section 6 General Timing Signal Locations Setpoints for a particular channel are either entered in the field or adjusted by using the increment decrement controls Note Only one set point is used per channel 5 Ifa channel needs to be Recalled or Cleared enter the desired channel number into the PLS Channel field Click the Recall Channel command button to recall the setpoints Click the Clear Channel command button the completely clear all setpoints for the selected channel Note Ifa channel has been cleared or the On and Off setpoints have the same setting the set point will be displayed as cekk k kk Resetting the PLS Configuration As an aid to the user the current PLS configuration is displayed in the PLS Configuration tab of this window The PLS configuration should only be reset if a new module has been installed To reset the PLS configuration click the Reset PLS Config command button This function only resets the PLS configuration to the default settings SYSTEMS Electronics Group 67 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual 4 5 4 THE SHIFT DATA WINDOW The Shift Data window is used to view the shift d
8. HSL CCSD1 User s Manual SYSTEMS Electronics Group 49 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual Once selected a message box is displayed informing the user of the current program revision and checksum of the program loaded in the processor as well as that of the selected program The user must confirm their selection by clicking the Yes command button After the user confirms their choice program download is initiated and the current program download address is displayed When program download is complete the user is prompted to acknowledge Control is passed back to the main program and the set up program remains in an Online edit mode 4 2 3 DOWNLOAD RESTORE DATA The set up program allows the user to download Set up parameters timing channel set points and shift data to the M4500 from the set up Data File This function is accessed from the File menu and the user is given the choice of the following options amp CCSD unnamed Main Display File Edit View Window Help New Ctrl N Open Ctri O Save Ctrl S Save As Export Shift Data Ctrl lt Upload save Data Download Program Download Data ood Cans Q C Blow off pp Spindle Number Set up Parameters EE Blanket Blow off Timing Channels g i Mandrel Blowoff Print Report Ctrl P Shift Data Exit
9. Set up program can open a set up Data File however the data tables will not be properly aligned The user will be alerted to the problem if a set up data file has been created by either a different set up program or a different revision of the software The set up Data File is similar to that of a word processing file When the program first starts the default settings are loaded and the user is able to make any changes as desired The set up program is unaware of the settings and parameters that exist within the M4500 Therefore to normalize the set up program with the processor the user should define or open an existing file then upload All variables from the processor This allows the user to either create a backup of the data or maintain an existing file The user can even open a data file for another decorator save the file to a 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 th
10. output to the PLC logic This should be on when the drive is enabled running and should be off when the drive is disabled this includes auto stop conditions This is true for jog modes as will Add the Alarm Reset output This signal should be on as long as the system reset push button is depressed SYSTEMS Electronics Group 17 SECTION 2 INSTALLATION HSL CCSD1 User s Manual 2 10 TUNING THE HSL CCSD1 The HSL CCSD1 is shipped from the factory with the PLC program HSLCCSD1 loaded in the PLC section and the channel set point file CCSD2TMG loaded in the PLS section These are the standard programs used to implement the standard HSL CCSD1 decorator algorithms In most cases the following user variables and timing signals may have to be altered to tune the HSL CCSD1 to the actual decorator it is controlling Once the HSL CCSD1 is installed and the control system is powered back up perform the following to set up and tune the HSL CCSD1 The set up is performed using the Display Keypad or a PC running the set up program See the HSL CCSD1 Keypad Quick Reference for exact key depress sequences for entering the following parameters See section 3 of this manual for a description of the Keypad commands and menu displays of the HSL CCSD1 Display Keypad See section 4 or 5 for a description of the menus variables and how to use the set up program SYSTEMS Electronics Group 18 SECT
11. the print is controlled by the no can no print sensors 4 Add the Varnish Auto Mode and Vanish Manual In outputs into the PLC logic When both are off the varnish unit will be retracted When the Manual In is on the varnish will be extended varnish position When the Auto Mode is on the varnish unit is controlled by the no can no print sensors 5 Add the Damaged Can Auto Mode and Damaged Can Manual On outputs into the PLC logic When both are off the damaged can blow off is disabled When the Manual On is on the damaged can blow off is on When the Auto Mode is on the damaged can blow off is controlled by the no can no print sensors and infeed open ASL CCSD1 User s Manual SYSTEMS Electronics Group 16 HSL CCSD1 User s Manual 6 7 8 9 SECTION 2 INSTALLATION Add the Pin Chain Manual Blow off output to the PLC logic This can be used as a manual blow off When on the bad can pin chain linear vacuum conveyor blow off is on When off the pin chain blow off functions normally blowing off detected bad cans restart cans etc Add the Can Feed Open output to the PLC logic This is used to indicate to the HSL CCSD1 when the infeed is open This is used for damaged can blow off enable and for can count blow off counts and trips per spindle counts enable Add the Main Drive On
12. Disk SYSTEMS Electronics Group SECTION 2 INSTALLATION HSL CCSD1 User s Manual 2 1 3 HSL CCSD1 OPTIONS The following items can be purchased separately as required or desired All items are compatible with both the back panel mountable package or the NEMA 12 enclosed package lea HSL QCSTA Remote Select A Can PB station lea HSL DSP Remote RPM Position Display lea RSV34 MSI1 Resolver lea RSV RSCBLE XX Resolver Cable 2 2 POWER REQUIRED The HSL CCSD1 is powered from 115VAC 230VAC 50 60HZ and 24VDC The 115VAC 230VAC is used to power the HSL CCSD1 module while the 24VDC is used to power the 24VDC I O sensors trip and blow off solenoids Note 24VDC solenoids must be used for all trip and blow off solenoids These provide a much more consistent and repeatable response time than 115VAC solenoids Assuming 24VDC solenoids were used in the existing system the 24VDC current required by the HSL CCSD1 is no more than the existing systems 24VDC current requirement therefore the existing 24VDC power supply should be adequate SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 3 MOUNTING AND WIRING THE HSL CCSD1 If installing the HSL CCSD1 package mounted in the NEMA 12 enclosure mount the HSL CCSD1 NEMA 12 enclosure in proximity to the existing control cabinet If installing the HSL CCSD1 BP package mount the back panel in the existing control cabinet Referring to the figure below create a cut out
13. HSL CCSD1 will activate the extend solenoid this amount of time ahead of the Varnish trip timing CH01 usually set at 20 milliseconds SYSTEMS Electronics Group 75 SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual 5 2 Set Pin Chain QC Blow off Parameters This selection is used to set the pin chain QC blow off parameters in the HSL CCSD1 When selected the Pin Chain QC Blow off Set up menu is invoked The Pin Chain QC Blow off Set up menu contains the following selections HSLCCSD1 EXE Systems HSM CCSD2 Set up Menu Version 1 9 Pin Chain QC Blow off set up Set Bad Can pin chain blow off response times Set number of cans to blow off pin chain Set number of pins to pin chain blow off port Setup QC select a can blow off Enter Selection ESC to exit Pin Chain Bad Can Blow off FON low off solenoid on response time msec 015 Blow off solenoid off response time msec 020 of bad cans to blow off for misload of cans to blow off from infeed open 00S of cans to blow off from print at restart 000 of cans to blow off from varnish at restart 033 of pins to pin chain blow off port 028 QC_ select a can Blow off Blow off solenoid on response time msec 015 Blow off solenoid off response time msec 020 QC can blow off port shift offset 1 O17 The foll
14. Set up program allows the user to upload blow off parameters timing channel set points and shift data from the M4500 into a set up Data File This function is accessed from the File menu and the user is given the choice of the following options CCSD unnamed Main Display Iof x Fie Edit View Window Help New Ctrl N Open Ctrl O Save Ctri S Save As Export Shift Data Ctrl gt lt Upload save Data Set up Parameters Download Program Timing Channels Download Data gt Shift Data r Q C Blow off Spindle Number e Blanket Blow off EN ai i 7 Mandrel Blowoff Bad Can Blow off Test Trip Blow off Print Report Ctrl P Exit ONLINE 10 12 2003 3 06PM System Message All Faults Normal Set up Parameters This option only uploads the Set up data from the M4500 This includes the print trip and varnish unit response times as well as blow off parameters and solenoid response times Timing Channels This option only uploads the Machine Timing channel set points as well as the PLS configuration and scale factor Shift Data This option only uploads the Shift Data from the M4500 This includes the Trips per Spindle data the Current Shift and the Last Shift data All This option allows the user to completely upload Al of the set up parameters timing
15. an Offline mode This is accessed by the View menu by selecting Offline Data or by simply pressing the F4 function key This allows the user to perform Offline editing All values displayed in Offline edit mode reflect the actual values contained in the currently loaded set up data file Note The program can be toggled between Online and Offline by simply double clicking on the Online or Offline panel displayed in the status bar at the bottom of the window Once invoked the set up program will close the Comm port and cease communication with the M4500 SYSTEMS Electronics Group 57 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual 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 CCSD unnamed Main Display File Edit View Window Help Messages 2 Set up Parameters 3 Machine Timing 4 Shift Data 51 0 States Machine CPHM Good Cans r Q C Blow off 0 te Spindle Number _ m Blanket Blow off Pi 3 r Blow offs 0 Mandrel Blowoff Bad Can Blow off Test Trip Blow off System Message All Faults Normal ONLINE 10 1 2 2003 3 11PM 4 Once a window menu ite
16. and status messages specific to the M4500 as well as the current Online or Offline status of the set up program By simply scrolling the display the user is able to view all active alarm and status messages If no alarm or status messages are active a default message is displayed Machine CPM This display is only active while Online and displays the current speed of the machine in Cans Per Minute Good Cans This display is the Current Shift good can count Blow offs This display is the Current Shift total blow off count SYSTEMS Electronics Group 59 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE Q C Blow off This display is only active while Online and it allows the operator to perform a QC Select A Can blow off HSL CCSD1 User s Manual The operator can perform a Single blow off by entering in the desired spindle number and clicking the Single Blow off command button The operator can perform a Blanket blow off by clicking the Blanket Blow off command button The blanket blow off will initiate a blow off sequence such that a can printed by each blanket is blown off at the QC blow off port starting with a can printed by blanket 1 The operator can perform a Mandrel Blow off by clicking the Mandrel Blow off command button The mandrel blow off will initiate a blow off sequence such that a can printed on each mandrel will b
17. can count blow off count trips per spindle 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 no can no print sensors both drive and offside and all trip and blow off solenoids e Based on high performance M4503 PLC PLS module which allows easy trouble shooting and user customization using SYSdev DOS based programming package e Built in PLS provides all machine timing eliminating need for an additional PLS 1 2 FUNCTIONAL DESCRIPTION The HSL CCSD1 Decorator High Speed Front End is an electronic upgrade for the Crown Cork amp Seal decorator which e Detects miss loaded cans e Performs speed compensated print and varnish trip e Single space pin chain linear vacuum conveyor blow off at speeds in excess of 2000 CPM e Select A Can pin chain blow off for print quality verification of each blanket Alarm detection is provided including o Infeed track jam e Timing signal failure Data collection both for the current shift and previous last shift includes e Total good can count e Blow off counts e Trips misloads per side e Trips misloads per spindle per side SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION The package interfaces directly to e Machine mounted resolver e Nocan no print sensors e Trip and blow off solenoids e Host PLC via discrete DC I O The package is n
18. in the existing control cabinet door and mount the D4591 display 4 475 ag 4 475 0 250 4 a os 4 875 1 875 0 218 DIA HOLE 0 475 1 775 a 4 450 i TYPICAL 7 PLACES D4591 Recommended Panel Door Cut out Note The D4591 must be located within 6 feet of the M4500 module to avoid EMI pick up on the Display ribbon cable Connect the ribbon cable from the M4500 module to the D4591 module HSL CCSD1 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION Referring to the electrical control schematic at the back of this manual wire the HSL CCSD1 to the existing control system as follows Note Keep all 24VDC wiring resolver cable and sensor cable wiring away from high voltage wiring Wire the machine mounted resolver directly to the 8 pin resolver input connector on the M4500 1 Incoming Power 115VAC 230VAC to FU1 neutral to 900 and ground to GND 24VDC to 501 and common to 500 2 Interlocks from existing control system to HSL CCSD1 terminals 110 through 120 3 Interlocks to existing control system from HSL CCSD1 terminals O17 through O25 4 Print Trip Varnish Trip Damaged Can Blow off both drive and offside and Pin Chain Blow off solenoids terminals O10 through O16 5 No Can No Print Sensors both drive and offside terminals 108 109 and Spindle No 1 I D Sensor terminal 109 using three conductor shielded cables The shields of
19. is saved to a Set up Data file sdt whenever changes are made to a parameter or if the data is uploaded from the processor amp CCSD unnamed Main Display File Edit View Window Help Messages Machine CPM Good Cans Q C Blow off ead a Spindle Number EE m Blanket Blow off r Blow offs 1 Mandel Blowoff Bad Can Blow off Test Trip Blow off System Message All Faults Normal R ONLINE 10712 2003 3 05 PM Z HSL CCSD1 User s Manual SYSTEMS Electronics Group 43 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 4 1 GENERAL DESCRIPTION Title Bar At the top of the window is the Title Bar The title bar is used to display the name of the working Set up Data file as well as 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 clickin
20. milliseconds The M4500 will activate the solenoid this amount of time ahead of the QC blow off timing CH06 usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids QC Can Blowoff Port Shift Offset This is the number of spindles difference from detection of the spindle 1 flag to the QC blow off port This is a number between 1 and 24 and is empirically set by selecting spindle 1 for blow off and adjusting this value until the can from spindle 1 is the can that is blown off SYSTEMS Electronics Group 78 SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE 5 3 SET MACHINE TIMING The Set Machine Timing selection is used to invoke the PLS programming command menus When selected the PLS programming main development menu will be invoked using the default CCSD2TMG channel set point file From this menu the user can zero the machine set the resolver offset and adjust the timing channel set points The following sections describe how to perform these functions Section 6 provides a complete description of each timing signal HSLCCSD1 EXE Systems PLS Program Development PLSdev M4500 Version 4 2 Program Name CCSD2TMG Main Development Menu Online Channel Setpoint Programming Offline Channel Setpoint Programming Edit PLS Configuration Download Channels to PLS Upload Channels from PLS Print Channels File Utilities Return to SY
21. 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 SYSTEMS Electronics Group 83 SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual The set up data consists of the print varnish response times pin chain QC blow off parameters and the spindle trip shift offset Timing channel set points are not stored as part of the set up data these are stored in the CCSD2TMG file To upload the set up data perform the following 1 Select 6 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 2 Once data upload is initiated the current address being uploaded will be displayed Note Program execution is not ceased therefore data upload can be performed while the machine is running 3 Once set up data upload is complete press any key to return to the main menu SYSTEMS Electronics Group 84 HSL CCSD1 User s Manual SECTION 6 GENERAL TIMING SIGNAL LOCATIONS The following is a general description of the timing signals and the locations they should be set at CHOO CHO01 CH02 CH03 Print Tri
22. timing ON position usually set at 15 to 20 milliseconds ASL CCSD1 User s Manual SYSTEMS Electronics Group 64 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 10 Q C Can Blow off Solenoid Off Response Time This is the time used as the off response time of the QC blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid OFF this amount of time ahead of the QC blow off timing ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids 4 5 3 THE MACHINE TIMING WINDOW The Machine Timing window is used to invoke the PLS programming command menus From this window the user can view or adjust the following parameters e Adjust Timing Channel setpoints Set the Main Crank resolver offset Clear or Recall a PLS timing channel View the current PLS configuration Reset the PLS configuration to default settings amp CCSD unnamed Machine Timing File Edit View Window Help Timing Channels PLs Configuration Timing Channels r Resolver Offset ON OFF 0 Print Trip Timing CHoO 120 a 160 a Set Offset VYamish Trip Timing chon 275 315 a Can Clock Timing CHO2 180 a 0 a PLS Channel Damaged Can Blow off Low CHO3 120 230 a o so ies off im 30 220 Damaged Can Bl
23. 1 etc 6 Q C Can Blow off Port Shift Offset This is the number of spindles difference from detection of the spindle 1 flag to the QC blow off port This is a number between 1 and 24 and is empirically set by selecting spindle 1 for blow off and adjusting this value until the can from spindle 1 is the can that is blown off 7 Bad Can Blow off Solenoid ON Response Time This is the time used as the on response time of the pin chain blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid ON this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds 8 Bad Can Blow off Solenoid Off Response Time This is the time used as the off response time of the pin chain blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid OFF this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids 9 Q C Can Blow off Solenoid ON Response Time This is the time used as the on response time of the QC blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid ON this amount of time ahead of the QC blow off
24. 1 User s Manual SYSTEMS Electronics Group 81 SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual 5 4 DOWNLOAD PROGRAM TO MODULE This selection is used to download the HSLCCSD1 application program to the M4500 module This should only be performed when replacing the module or when changes to the program have been made To download the program perform the following 1 Select 4 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 HSLCCSD1 file could not be opened is displayed then the HSLCCSD1 application program is not installed in the current directory 2 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 3 Once the download is complete the RUN LED on the module will illuminate solid and program execution in the M4500 will resume Press any key to return back to the main menu Note This selection can also be used to verify the program ident revision and checksum without downloading the program Perform step 1 above but instead of initiatin
25. 4 4 3 View Offline Data The Window Menu 4 5 1 The Main Display Window 4 5 2 The Setup Parameters Window 4 5 3 The Machine Timing Window 4 5 4 The Shift Data Window 45 5 The I O States Window CONTENTS SYSTEMS Electronics Group Aie CONTENTS 5 HSLCCSD1 DOS Based Set up Program Reference _____73 5 1 Set Print Varnish Response Times 74 5 1 1 Set Print Trip extend retract response 74 5 1 2 Set Varnish Trip extend retract response 75 5 2 Set Pin Chain QC Blow off Parameters 76 5 2 1 Set Bad Can pin chain blow off response 76 5 2 2 Set number of cans to blow off pin chain 77 5 2 3 Set number of pins to pin chain blow off port ___ 77 5 2 4 Setup QC select a can blow off 78 5 3 Set Machine Timing 79 5 3 1 Zeroing the Machine 80 5 3 2 Adjusting the Timing Channel Set points 81 5 4 Download Program to Module 82 5 5 Download Set up data to Module 83 5 6 Upload Save Set up data from Module 83 6 General Timing Signal Locations 85 7 Recommended Spare Parts 87 HSL CCSD1 User s Manual SYSTEMS Electronics Group iii CONTENTS LIST OF FIGURES Figure 1 D4591 Recommended Panel Door Cut out 9 APPENDICES Drawings Appendix A HSL CCSD1 User s Manual SYSTEMS Electronics Group iv HSL CCSD1 User s Manual SECTION 1 GENERAL DESCRIPTION This section describes the features of the HSL CCSD1 Crown Cork amp Seal Decorator High Speed Front End This includes the functional description alarms detect
26. ASED SETUP PROGRAM REFERENCE HSL CCSD1 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 M4500 are shown This includes the interrupt inputs INO and IN1 the analog I O and the resolver These values are displayed as read by the M4500 processor E CCSD unnamed 170 Status SYSTEMS Electronics Group lt T HSL CCSD1 User s Manual SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE The DOS based HSLCCSD1 set up program is menu driven allowing the user to easily view data alter set up variables and set the machine timing machine offset timing signal locations etc using a laptop or personal computer The set up variables are used to configure and tune the HSLCCSD1 to match the configuration and performance of the specific decorator see Tuning the HSL CCSD1 section 2 10 The main menu of the HSLCCSD1 set up program incorporates the following menu selections le HSLCCSD1 EXE B x Systems HSM CCSD2 Set up Menu Version 1 0 Main Menu Set Print Varnish Response Times Set Pin Chain QC Blow off Parameters Set Machine Timing Download Program to Module Download Set up data to Module Upload Save Set up data from Module AU Che Enter Selection ESC to exit NOTE Before selecting one of the six selections listed a
27. CT 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 As the passcode is entered the digits are not displayed Instead characters are displayed as each digit 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 displayed Refer to section 3 7 Set Keypad Display Set up passcode for details on setting the passcode HSL CCSD1 User s Manual SYSTEMS Electronics Group 34 HSL CCSD1 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 input such that when the switch is in the enable position the input is on Note 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 be displayed automatically When the last paramete
28. Communications Network Error Codes Current Comm Error Code 00H No Network Comm Error Last Comm Error Code 00H No Network Comm Error HSL CCSD1 User s Manual SYSTEMS Electronics Group 56 HSL CCSD1 User s Manual SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 4 4 2 VIEW ONLINE DATA This function allows the user to place the set up program in an Online mode with the processor This is accessed by the View menu by selecting Online Data or by simply pressing the F3 function key Note The program can be toggled between Offline and Online by simply double clicking on the Online or Offline panel displayed in the status bar at the bottom of the window Once invoked the set up program will attempt to open the Comm port and communicate with the M4500 If the set up program is unsuccessful a warning message will be displayed prompting the user to either Retry 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
29. DISPLAY INSTALLATION To install the D4591 perform the following steps 1 2 With the gasket installed on the mounting studs of the D4591 install the D4591 in the cut out either in the HSL CCSD1 enclosure or the cut out in the user s control cabinet Secure the display to the enclosure using 7ea 8 32 nuts and external lock washers Connect the display ribbon cable to the connector on the lower back of the display the connector on the cable is polarized and should mate with connector on the M4500 only one way 2 11 3 DOWNLOAD APPLICATION PROGRAM AND SET UP DATA TO M4500 Once the M4500 P4500 and D4591 are installed perform the following to download the application program to the M4500 as well as download the previously saved set up data and timing channel set points 1 2 3 4 5 7 Power up the M4500 and the PC used to interface with the HSL CCSD1 and connect an RS 232 cable from the COM port on the computer to the PROG port on the M4500 Initiate the respective setup program CCSD for Windows systems HSLCCSD1 exe for DOS systems Download the application program to the M4500 See section 4 2 3 for Windows systems see section 5 7 for DOS Download the PLS timing set points to the M4500 See section 4 2 3 for Windows systems section 5 3 for DOS Download the previously saved set up data to the M4500 See section 4 2 3 for Windows systems section 5 8 for DOS The M4500 is now ready
30. HSL CCSD1 Crown Cork amp Seal Decorator High Speed Front End User s Manual Systems Engineering Associates Inc 14989 West 69th Avenue Arvada Colorado 80007 U S A Telephone 303 421 0484 Fax 303 421 8108 www sea seg com 03 2004 HSL CCSD1 Crown Cork amp Seal Decorator High Speed Front End User s Manual Copyright 2001 Systems Engineering Associates Inc All Rights Reserved Revised 25 March 2004 WARNING To ensure the equipment described by this User Manual as well as the equipment connected to and used with it operates satisfactorily and safely all applicable local and national codes that apply to installing and operating the equipment must be followed This includes the National Electric Code in the USA and other applicable legislation regulations and codes in practice elsewhere Since codes can vary geographically and can change with time it is the user s responsibility to determine which standards and codes apply and to comply with them FAILURE TO COMPLY WITH APPLICABLE CODES AND STANDARDS CAN RESULT IN DAMAGE TO EQUIPMENT AND OR SERIOUS INJURY TO PERSONNEL Persons supervising and performing installation or maintenance must be suitably qualified and competent in these duties and should carefully study this User Manual and any other manuals referred to by it prior to installation and or operation of the equipment The contents of the User Manual are believed to be correct at the time of print
31. ION 2 INSTALLATION 2 10 1 DEFAULT SET UP VARIABLES As shipped the user variables for the HSL CCSD1 are set the following defaults Print Trip Print Trip retract response time msec 020 Print Trip extend response time msec 020 Varnish Trip Varnish Trip retract response time msec 020 Varnish Trip extend response time msec 020 Bad Can pin chain Blowoff Blowoff solenoid on response time msec 015 Blowoff solenoid off response time msec 020 of bad cans to blowoff for misload 001 of cans to blowoff from infeed open 005 of cans to blowoff from print at restart 000 of cans to blowoff from varnish at restart 033 of pins to pin chain blowoff port 028 QC Can select a can Blowoff Blowoff solenoid on response time msec 015 Blowoff solenoid off response time msec 020 QC can blowoff port shift offset 017 Spindle Trip Offset 022 The CCSD2TMG timing channel file as shipped contains the following default timing set points CHAN ON OFF DESCRIPTION CHOO 120 160 Print Trip timing CH01 275 315 Varnish Trip timing CH02 180 000 Can No Can clock CHO3 120 230 Damaged Can Blow off Low speed CH04 080 220 Damaged Can Blow off High speed CHO5 155 195 Pin Chain Blow off bad can timing CHO6 160 200 Select A Can QC Blow off timing CHO7 000 040 Spare Timing CH10 000 180 PLC Clock Timing CH11 CH12 CH13 CH14
32. OINT Enter the position in degrees where the set point should go on and press lt ENTER gt The display will now prompt OFF SETPOINT Enter the position in degrees where the set point should go off and press lt ENTER gt The channel will now be programmed with a set point that goes on at the on position entered and off at the off position entered 4 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 SYSTEMS Electronics Group 40 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 Select 3 SET MACHINE TIMING and observe the POS field Verify that as the machine is rotated forward either jogged or barred that the position increases linearly from 0 through 359 If not swap the S1 and S3 leads of the resolver at the HSL CCSDI1 resolver connector Then verify that the position then indeed does increase with forward movement Press lt ESC gt to exit back to the primary set up menu 2 Position the machine at machine zero spindle centered on No Can No Print Sensors 3 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 sh
33. POINT xxx channel name RPM yyyy POS zzz OFFSET wwww SCALE 360 Each field is defined as follows Field Definition Chuu Currently selected channel CH00 thru CH17 where uu is the octal channel number SETPOINT xxx Channel on or off set point where xxx is the set point position State of channel set point blank off solid block character on channel name selected channel name CH00 PRINT TRIP CH01 VARNISH UNIT TRIP etc RPM yyyy Current machine speed where yyyy is in CPM POS zzz Current resolver position where zzz is in degrees OFFSET wwww Resolver offset where wwww is the offset in degrees SCALE 360 Resolver SCALE FACTOR 360 degrees per revolution In addition to displaying the timing set point menu the following keys are also enabled ENTER SET POINT CLEAR CHANNEL SELECT CHANNEL and SEARCH CHANNEL ASL CCSD1 User s Manual SYSTEMS Electronics Group 39 SECTION 3 USING THE KEYPAD DISPLAY HSL CCSD1 User s Manual The ENTER SET POINT key is used to enter a new set point both on and off set points in the selected channel The CLEAR CHANNEL key is used to clear all set points from the selected channel The SELECT CHANNEL key is used to select a new channel for programming The SEARCH CHANNEL is used to view both the on and off set points in the select
34. Sdev Shell Enter selection ASL CCSD1 User s Manual SYSTEMS Electronics Group 79 SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE 5 3 1 ZEROING THE MACHINE gt HSLCCSD1 EXE CHANNEL 00 DESCRIPTION Print Trip Timing PROG MODE ONLINE CHANNEL SET POINTS ON OFF ON OFF ON OFF ON OFF Pals 31 41 ON OFF 0120 0160 11 12 el D Aa EN su Poon Fe EA TV SUB eesti VS R E l MOn 1 2 ale BIE 6 le 8 g Hee o wi SCALE FACTOR 36 MESSAGE Position 189 Speed RPH 0000 To set the machine zero resolver offset perform the following 1 Select the 3 Set Machine Timing selection from the HSL CCSD1 set up program main menu 2 Select 1 Online Channel Setpoint Programming from the Main Development menu 3 Select F9 POS RPM and observe the POS field Verify that as the machine is rotated forward either jogging or barred that the position increases linearly from 0 through 359 If not swap the S1 and S3 leads of the resolver at the HSL CCSDI1 resolver connector Then verify that the position then indeed does increase with forward movement Press lt ESC gt to exit the POS RPM update 4 Position the machine at machine zero spindle centered on No Can No Print sensors 5 Auto zero the resolver by selecting F10 Set Offset Enter 0 in the
35. ace e View Online Data e View Offline Data amp CCSD unnamed Main Display Target Board Interface k HSL CCSD1 User s Manual SYSTEMS Electronics Group 55 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 4 4 1 TARGET BOARD INTERFACE This function allows the user to view fault codes S3000 network communication error codes and review the current Ident and Revision of the application program This is accessed by the View menu by selecting Target Board Interface Once invoked the set up program will prompt the user to select a program to compare with the one existing in the processor Whether a program is selected or the user cancels the setup program will attempt to communicate with the M4500 If unsuccessful a warning message will be displayed prompting the user to either Retry or Cancel the operation If the operation is canceled and communication with the processor cannot be established the system will be placed in an Offline mode however the Target Board Interface window will be displayed Target Board Interface l O x Eault Codes Status l Program Ident Revision Set Network Address Set Time amp Date r Internal Fault Code Current Fault Code 00H No Internal Fault has Ocurred Last Fault Code 00H No Internal Fault has Ocurred Reset Faults Corrective Action None p E r
36. actuation to first contact with varnish wheel in milliseconds The HSL CCSD1 will activate the extend solenoid this amount of time ahead of the Varnish unit trip timing CH01 usually set at 20 milliseconds Note All response times entered must be in the range of 5 to 65 milliseconds Number of Shifts to Varnish Unit This is the number of spindles from the Can Sensor to the varnish unit minus 2 In general this is set such that the varnish unit retracts out on the can ahead of the misloaded spindle This is set to 5 SYSTEMS Electronics Group 62 HSL CCSD1 User s Manual SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE Blow off Parameters This section is used to set the Pin Chain QC Blow off parameters in the M4500 This section contains the following selections amp CCSD unnamed Set Up Iof x Fie Edit View Window Help Print Trip Varnish Trip r Blow off Set up Number of Pins to Pin Chain Blow off Port 28 Number of Cans to Blow off for Each Mis load i Number of Cans to Blow off at Infeed Open is Number of Cans to Blow off from Print at Restart fo S Number of Cans to Blow off from Varnish at Restart a3 Q C Can Blow off Port Shift Offset 17 Solenoid Response Times Test Blow off ae ne Bad Can Blow off Bad Can Blow off Solenoid 15 l 20 O C Can Blow off zi Q C Blow off Solenoid 15 24 2 System Message All Faults N
37. ain Blow off Timing 20 2 10 5 Set of Cans to Pin Chain Blow off Port 21 2 10 6 Set Print Trip Retract Extend Response Times 22 2 10 7 Set Varnish Trip Retract Extend Response Times 23 2 10 8 Set of Cans to Blow off at Restart 23 2 10 9 Set QC Blow off Shift Offset 23 2 10 10 Set Spindle Trip Offset 24 2 11 M4500 P4500 D4591 Installation 25 2 11 1 M4500 Module Installation 25 2 11 2 P4500 Power Supply Installation 26 2 11 3 D4591 Keypad Display Installation 27 2 11 4 Download HSLCCSD1 Program and Set up Data to M4500 27 ASL CCSD1 User s Manual SYSTEMS Electronics Group HSL CCSD1 User s Manual 3 Using the Keypad Display 3 1 3 2 3 3 3 4 3 5 3 6 3 7 Default Screen Trips per Spindle Key Current Shift Key Last Shift Key Set up Key 3 5 1 Set Print Varnish Response Times 3 5 2 Set Pin Chain QC Blow off Parameters 3 5 3 Set Machine Timing Set Points etc 3 5 4 Zero Machine Set Resolver Offset QC Blow off Key Set Keypad Display Set Up Passcode 4 CCSD Windows Based Set up Program Reference 4 1 4 2 4 3 4 4 4 5 General Description The File Menu 4 2 1 The Set Up Data File 4 2 2 Upload save Data 4 2 3 Download Program 4 2 3 Download restore Data 4 2 4 Print Report The Edit Menu 4 3 1 Enable Offline Editing 4 3 2 Setup Comm Port 4 3 3 Edit Setup Passcode The View Menu 4 4 1 Target Board Interface 4 4 2 View Online Data
38. an existing Data File Save any changes made to the current Data File to disk Upload save Data from the Processor Download a SYSdev sdv program to the processor e Download restore Data from the current set up Data File to the processor e Print a Report of the current set up parameters e Exit the set up program amp CCSD unnamed Main Display File Edit View Window Help Open Ctrl O Save Ctri S Save As Export Shift Data Ctrl gt lt Upload save Data gt r Q C Blow off Download Program Download Data gt Print Report Ctrl P Spindle Number x Blanket Blow off EE ies T Exit i Mandel Blowoff r Bad Can Blow off Test Trip Blow off System Message All Faults Normal HSL CCSD1 User s Manual SYSTEMS Electronics Group 45 ONLINE 10 12 2003 3 06PM SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE HSL CCSD1 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
39. as any print on it from the leading edge of the label image the Print Trip retract out response time is too short and is not retracting soon enough Increase the Print Trip retract out response time by 5 milliseconds and try again Continue increasing this time until the 2nd can misloaded can is fully silver and the can ahead of it the Ist can is fully printed If the 1st can is not fully printed the Print Trip retract out response time is too long and is retracting too soon Decrease the Print Trip retract out response time by 5 milliseconds and try again Continue decreasing this time until the 1st can is fully printed and the 2nd can misload is fully silver no print on it If the 3rd can can following the misload is not fully printed the Print Trip extend in response time is too short and is not extending soon enough Increase the Print Trip extend in response time by 5 milliseconds and try again Continue increasing this time until the 3rd can is fully printed and the 2nd can misload is fully silver If the 2nd misload can has any print on it from the trailing edge of the label image the Print Trip extend in response time is too long and is extending too soon Decrease the Print Trip extend in response time by 5 milliseconds and try again Continue decreasing this time until the 2nd can misload is fully zero and the 3rd can is fully printed SYSTEMS Electronics Gr
40. ata collected by the M4500 This window is selected from the Window menu CCSD unnamed Shift Data E E lolx File Edit View Window Help Trips Per Spindle Current Shit Last Shift Spindle Trip Drive Side Trips Off Side Tips Spindle 1 Trip Offset 22 1 0 13 0 1 0 13 0 Tripped Spindle 10 2 38 T ep 8 if 0 ie ee 4 aa CR Reset Trips 4 0 16 sal 4 Soin ef e ee Git sete eters fom ele Gen Aap eal Foden WS e Simon wien efron wis Sameon 22 f_o 1 a7 08 40 0 A co soot eo 0 0 0 0 System Message All Faults Normal al ONLINE 10 1 2 2003 3 13 PM 7 This window utilizes a TAB control to divide the set up parameters into three categories similar to that of the Keypad Display These sections are as follows Trips per Spindle The Number of trips per spindle display is provided to aid in the trouble shooting of a loading problem with a spindle or spindles The total number of trips for each spindle since the last reset or end of shift is displayed The operator can reset these counts at anytime to aid in the trouble shooting process The following data is displayed in the Trips per Spindle section 1 Spindle 1 Trip Offset The Spindle Trip Offset can be entered from this section This is used to compensate for the location of the can no can sensor and the spindle 1 I D sensor location Use
41. bove connect an RS 232 cable from the COM port on the computer to the PROG PORT on the HSM CCSD2 Note The HSLCCSD1 program is an on line communications program used to interface with the M4500 module The data displayed in the menus and set in the menus is communicated directly to the M4500 Therefore prior to selecting any of the above selections make sure an RS 232 cable is connected from the COM port on the computer running HSLCCSD1 to the PROG port on the M4500 The following sections are a complete description of the HSLCCSD1 selections and menus SYSTEMS Electronics Group 73 SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual 5 1 SET PRINT VARNISH RESPONSE TIMES This selection is used to set the print and varnish trip response times in the M4500 When selected the Print Varnish Trip Set up menu is invoked The Print Varnish Trip Set up menu contains the following selections fe HSLCCSD1 EXE Systems HSM CCSD2 Set up Menu Version 1 9 Print arnish Trip set up 1 Set Print Trip extend retract response times 2 Set Varnish Trip extend retract response times Enter Selection ESC to exit Print Trip Print Trip retract response time msec 020 Print Trip extend response time msec 020 Varnish Trip Varnish Trip retract response time msec 020 Varnish Trip extend response time msec
42. channel set points and shift data from the M4500 SYSTEMS Electronics Group 48 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 3 DOWNLOAD PROGRAM The Set up program allows the user to Download any SY Sdev program file to the M4500 A CCSD unnamed Main Display File Edit View Window Help New Ctri N Open Ctrl O Save Ctrl S Save As Export Shift Data Ctrl lt Upload save Data gt Q C Blow off Spindle Number x Blanket Blow off 1 a fl i E Mandrel Blowoff Bad Can Blow off Test Trip Blow off Download Data Print Report Ctrl P Exit System Message All Faults Normal ONLINE 10 1 2 2003 3 07PM 4 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 M4500 PLC SYSdev file can be downloaded through the set up program Care should be taken when selecting a program to download
43. dle per side counts as a diagnostics aid for trouble shooting a loading problem on a specific mandrel Unlike the shift data these counts can be reset manually at will SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION This Page Intentionally Left Blank HSL CCSD1 User s Manual SYSTEMS Electronics Group HSL CCSD1 User s Manual SECTION 2 INSTALLATION The standard HSL CCSD1 package is provided for back panel mounting inside the existing user s control cabinet In addition the HSL CCSDI1 can be purchased in a self contained NEMA 12 enclosure for mounting adjacent to the existing control cabinet by specifying part number HSL CCSD1 ENCL 2 1 WHAT S INCLUDED Depending on which package is purchased verify that the following items are included when unpacking the HSL CCSD1 2 1 1 HSL CCSD1 for back panel mounting lea HSL CCSD1 back panel for mounting in the existing user s control cabinet including the following lea M4500 PLC PLS module lea P4500 Power Supply lea D4591 Display with ribbon cable for mounting in the existing control cabinet door lea HSL CCSD1 User s Manual lea M4500 User s Manual lea HSL CCSD1 Program Disk 2 1 2 HSL CCSD1 ENCL with NEMA 12 enclosure lea HSL CCSD1 NEMA 12 enclosure including the following lea M4500 PLC PLS module lea P4500 Power Supply lea D4591 Display Keypad lea HSL CCSD1 User s Manual lea M4500 User s Manual lea HSL CCSD1 Program
44. e File menu or press Ctrl O This displays a dialog box allowing the user to select an existing data file to open The name of the file will be displayed in the title bar If any changes were made to the existing file the user will be prompted to save any changes before terminating the program SYSTEMS Electronics Group 46 HSL CCSD1 User s Manual SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE Save To Save data file to disk select Save from the File menu or press Ctrl S If this is a New file a dialog box allowing the user to select a folder and enter a name for the file will be displayed The user will be notified if the file already exists and the extension sdt will automatically be added to the 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 SYSTEMS Electronics Group 47 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual 4 2 2 UPLOAD SAVE DATA The
45. e can printed on spindle number one to the QC can blowoff port shift offset Note This variable must be a number between 1 and 24 Once set up verify that a can from spindle 1 is blown off when 1 is dialed in on the thumbwheel and the select a can pushbutton is pressed SYSTEMS Electronics Group 93 2 SECTION 2 INSTALLATION HSL CCSD1 User s Manual 2 10 10 SET SPINDLE TRIP SHIFT OFFSET Using the Keypad Display set the Spindle trip shift offset as follows 1 2 3 4 5 6 Initially set the Spindle trip offset to zero Wrap a piece of tape around the drive side spindle 1 such that cans will not load on this spindle Run the machine very slowly with the can gate open and verify that indeed cans do not load on spindle 1 and the print is tripped for that spindle Observe the Trips Per Spindle data and determine which spindle is being incremented The spindle number that should be incrementing is the drive side spindle 1 If it is not subtract 1 from the spindle number that is being incremented and enter this value as the spindle trip offset Note This variable must be a number between 0 and 23 Verify that the spindle 1 count is incremented every time the print trips for spindle 1 If it still increments another spindle number other than the drive side 1 continue adjusting the spindle trip offset until it does Stop the machine and remove the tape from spindle 1
46. e consecutively blown off at the QC blow off port starting with mandrel 1 Bad Can Blow off This display is only active while Online and it allows the operator to test the action of the control system by electronically inducing a mis loaded or Bad Can into the system By clicking on the Test Trip Blow off command button a Bad Can will be electronically induced into the system to test the response of the control system due to a Mis Loaded can SYSTEMS Electronics Group 60 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 2 THE SETUP PARAMETERS WINDOW The Set up Parameters window is used to view and adjust any of the set up parameters This window is selected from the Window menu amp CCSD unnamed Set Up O x File Edit View Window Help Blow off Parameters Print Trip Retract out Response Time msec 20 Extend in Response Time msec 20 m arnish Unit Retract out Response Time msec 2 Extend in Response Time msec i 2 Number of Shifts to Varnish Unit E Test Blow off Bad Can Blow off m Se System Message All Faults Normal i ONLINE 10 1 2 2003 3 12 PM Z This window utilizes a TAB control to divide the set up parameters into two categories similar to that of the Keypad Display Print Trip Varnish Trip This section is used to set the print trip Retract Exte
47. e not to be reset press the ESC key The default screen will then be displayed Note The ESC key can also be used at any time to abort the trips per spindle data display and return to the default screen SYSTEMS Electronics Group 3 SECTION 3 USING THE KEYPAD DISPLAY HSL CCSD1 User s Manual 3 3 CURRENT SHIFT KEY The Current Shift key is used to view the current shift data This is the totals so far into the shift The data is transferred to the Last shift data when the end of shift input transfers from a 0 to a 1 This can be at the end of either an 8 or 12 hour shift or alternatively could be done at label changes such the data collected would be for label runs rather than complete shifts This data cannot be reset by the operator only at the end of shift input transition Note The Current shift Good Cans and Blow offs 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 printed so far into the shift This is essentially a can counter Blow offs This is the total number of cans blown off the machine This includes all types of blow offs e Cans blown off due toa mis loaded e Infeed open blow offs e Restart blow offs e Manual blow offs e Select A Can QC blow offs Bad Cans This is the total number of cans blown off due to misloads When a can misloads on one side of
48. e the back cover of the display and set the dip switches as outlined on the electrical control schematic at the back of this manual Mount the display and wire per the schematic at the back of this manual A selector switch can also be mounted and wired as shown to select either CPM or position 2 6 MOUNTING THE RSV34 MS1 RESOLVER IF REQUIRED The HSL CCSD1 is designed to interface to a resolver not encoder for machine timing If the machine is not already equipped with a resolver then the existing encoder will have to be removed and an RSV34 MS1 resolver will have to be mounted in it s place If this is the case refer to the RSV34 MS1 data sheet for details on mounting the resolver ASL CCSD1 User s Manual SYSTEMS Electronics Group ll SECTION 2 INSTALLATION HSL CCSD1 User s Manual Note The resolver must make one revolution for each spindle 24 revolutions per spindle wheel revolution Use the RSV RSCBLE cable to connect the resolver to the HSL CCSD1 Route the resolver cable in a separate conduit away from all other high voltage and control wiring Wire the cable directly to the 8 pin resolver connector on the HSL CCSD1 see section 2 3 Wiring the HSL CCSD1 2 7 MOUNTING THE SPINDLE 1 I D SENSOR NOT PROVIDED If the machine is not already provided with a spindle 1 I D sensor then one will have to be mounted This sensor is used to determine which spindle is the 1 spindle for both the QC select a ca
49. ed etc 1 1 FEATURES e Performs high speed control functions of Crown Cork amp Seal Decorator to speeds in excess of 2000 CPM This includes detection of mis loaded cans damaged can blow off speed compensated print and varnish trip and single space pin chain linear vacuum conveyor blow off e High speed front end upgrade package which interfaces with existing control system e Accurate damaged can blow off prior to the print station eliminates cut blankets e Speed compensated print trip and varnish trip control eliminates inside deco and varnish problems at all speeds zero to 2000CPM e Accurate speed compensated single space pin chain linear vacuum conveyor blow off reduces scrap and eliminates silver and partially printed cans down the line e Single select a can QC pin chain blow off allows operator to blow off a can from a selected spindle or blanket to verify print quality of each blanket with machine running at full production speeds e Alarm detection infeed track jam and timing signal fail detection e Data Acquisition 1 Total number of good cans printed 2 Total number of blow offs 3 Total trips per side drive and offside 4 Trips per spindle per side for both current shift and last shift SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSL CCSD1 User s Manual e Built in 2 Line X 40 character sealed display with 24 key membrane keypad allows local viewing of collected data
50. ed channel Searching Channel To view the set points in a channel simply press the SEARCH CHANNEL key The next off to on or on to off position is shown in the SETPOINT field If the transition was off to on the state character will be a solid block If the transition was on to off the state character will be blank Entering or Adjusting Set point To set or adjust a timing channel perform the following 1 Select the channel to be adjusted by pressing the SELECT CHANNEL key entering the channel number 00 to 17 and pressing lt ENTER gt In addition the NEXT and PREV keys can be used to advance to the next channel or retard to the previous channel 2 Press CLEAR CHANNEL to clear the existing set point out Note Entering a new set point does not automatically clear the old set point out If the two set points are not in the same place the channel will simply have two set points in it if the old one is not cleared out first Therefore always clear the channel before entering a new set point A set point may however be extended by programming another set point onto an existing set point using either the existing on or off set point as the starting position for the new set point This will result in one larger set point 3 Press ENTER SET POINT to enter the new set point The display will then prompt ON SETP
51. ed to support the system The SYSdev Program Development Software will also have to be loaded on the PC To install this program perform the following 1 Install the PROGRAMS disk into the drive 2 For each of the HSLDEC directories created in section 2 8 2 copy all the files from the disk to each of these subdirectories HSL CCSD1 User s Manual SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION 2 9 MODIFY EXISTING PLC PROGRAM Modify the existing control system PLC program to interface with the HSL CCSD1 by incorporating the following into the existing PLC ladder logic 1 The HSL CCSD1 now controls e The damaged can blow off e Print trip e Varnish trip e Pin chain blow off If the existing host PLC was previously controlling these functions 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 connecting the respective solenoids to the HSL CCSD1 will effectively defeat the logic 2 Add the Infeed Track Jam and Timing Signal Failure alarms as inputs to the host PLC These should stop the machine anytime either of these alarms are on 3 Add the Print Trip Auto Mode and Print Trip Manual In outputs into the PLC logic When both are off the mandrel will be retracted When the Manual In is on the mandrel will be extended print position When the Auto Mode is on
52. essed simply press lt ENTER gt to proceed to the set up menu If the passcode protection will be used set the passcode to a number from 1 to 64999 Then when the Set up key is pressed the actual valid passcode number will have to be entered 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 42 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE The Windows based set up program is menu driven allowing the user to easily view data alter set up variables or set machine timing machine offset timing signal locations etc using a PC running the Windows 95 98 ME 2000 XP NT operating system The set up variables are used to configure and tune the M4500 to match the configuration and performance of the specific decorator see Tuning the HSL CCSD1 section 2 10 Note The set up program is an on line communications program used to interface with the M4500 module The data displayed and set in the windows is communicated directly to the module while in the Online edit mode Therefore prior to going online with the processor make sure an RS 232 cable is connected from the COM port on the computer to the PROG port on the M4500 The variables displayed while in the Online edit mode are read directly from the processor Data
53. f Cans To Blowoff From Print At Restart This is the number of cans which will be blown off from the print station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc Of Cans To Blowoff From Varnish At Restart This is the number of cans which will be blown off from the varnish station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc 5 2 3 SET NUMBER OF PINS TO PIN CHAIN BLOW OFF PORT Of Pins To Pin Chain Blowoff Port This is the number of pins from the spindle wheel to linear vacuum conveyor transfer location to the first can blown off at the Pin Chain blow off port minus two This can be a number from 0 to 999 SYSTEMS Electronics Group Sai SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual 5 2 4 SETUP QC SELECT A CAN BLOW OFF QC Can Blowoff Solenoid On Response Time This is the time used as the on response time of the QC blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the QC blow off timing CH06 usually set at 15 to 20 milliseconds QC Can Blowoff Solenoid Off Response Time This is the time used as the off response time of the QC blow off port time from off solenoid actuation to air stopping at port in
54. f Port This is the number of pins from the spindle wheel to disk transfer location to the first can blown off at the Pin Chain blow off port minus two This can be a number from 0 to 999 Pin Chain bad can Solenoid on Response Time msec This is the time used as the on response time of the pin chain blow off port time from on solenoid actuation to first air out port in milliseconds The HSL CCSD1 will activate the solenoid this amount of time ahead of the Pin Chain blow off timing CH05 usually set at 15 to 20 milliseconds Valid range 5 to 50 msec HSL CCSD1 User s Manual SYSTEMS Electronics Group 37 SECTION 3 USING THE KEYPAD DISPLAY Pin Chain bad can Solenoid off Response Time msec This is the time used as the off response time of the pin chain blow off port time from off solenoid actuation to air stopping at port in milliseconds The HSL CCSD1 will activate the solenoid this amount of time ahead of the Pin Chain blow off timing CH05 usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Valid range 5 to 50 msec QC Blow off Solenoid on Response Time msec This is the time used as the on response time of the QC blow off port time from on solenoid actuation to first air out port in milliseconds The HSL CCSD1 will activate the solenoid this amount of time ahead of the QC blow off
55. f by pulling the fuses for both the drive and offside damaged can blow off solenoids Note For the next set up steps misloads can be induced by pressing the blank key on the Keypad Display This simulates a misloaded can by blanking out the no can no print sensor input for one can space in the logic This allows a fully loaded non damaged can to be blown off at the pin chain blow off without being printed This is done so that the print and varnish trip can be verified by inspecting the can ahead misloaded silver can and the can behind Proceed To Step 2 10 6 HSL CCSD1 User s Manual SYSTEMS Electronics Group 21 SECTION 2 INSTALLATION HSL CCSD1 User s Manual 2 10 6 SET PRINT TRIP RETRACT EXTEND RESPONSE TIMES Using the Keypad Display verify the print trip by running the machine at high speed inducing mis loads by pressing the blank key on the keypad and observing the cans blown off of the pin chain With the damaged can blow off disabled the mis loaded can will now be blown off at the pin chain blowoff and should be completely silver The can ahead of the mis load can the print retracted after should be blown off at the pin chain blow off port and should be fully printed The can behind the mis load the can the print extended before should be blown off at the pin chain blow off port and should be fully printed If the 2nd can blown off which should be the misload and fully silver h
56. g the download simply press the lt ESC gt key to abort the download once the ident revision and checksum have been displayed SYSTEMS Electronics Group 82 HSL CCSD1 User s Manual SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE 5 5 DOWNLOAD SET UP DATA TO MODULE This selection is used to download the previously uploaded saved set up variables to the HSL CCSD1 module This should only be performed when replacing the module Note The set up data consists of the print varnish response times pin chain QC blow off parameters and the spindle trip shift offset Timing channel set points are not stored as part of the set up data these are stored in the CCSD2TMG file To download the set up data perform the following 1 Select 5 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 2 Once data download is initiated the current address being downloaded will be displayed Note Program execution is not ceased therefore data download can be performed while the machine is running 3 Once set up data download is complete press any key to return to the main menu 5 6 UPLOAD SAVE SET UP DATA FROM MODULE This selection is used to save the set up variables from the HSL CCSD1 module to the hard drive current directory selected This should be performed anytime any
57. g the online offline mode panel Hot Keys Hot keys are activated by holding down the ALT key and simultaneously pressing the underlined letter of the desired function Almost every function can be activated by either pressing a series of hot keys or using the TAB key to move between fields Online Offline Modes The set up program allows the user to make changes while Online with the processor The Offline mode is used to preset parameters prior to download All functions are available to the user while Online however specific Online functions are disabled in the Offline edit mode Note Offline changes can only be made by enabling Offline Editing accessed under the Edit menu Getting Help The entire contents of the user s manual is contained within the help file Pressing Ctrl H will display the help file window Pressing the F1 key will display the contents file Hot spots allow jumps to other topics to display additional information as desired Selecting About CCSD 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 ASL CCSD1 User s Manual SYSTEMS Electronics Group 44 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 THE FILE MENU The File menu allows the user to perform the following functions Create a New set up Data File Open
58. ge detects the following alarms Infeed Track Jam The infeed track jam alarm occurs when 6 consecutive empty mandrels are detected on either side by the no can no print sensors after the can gate is opened Timing Signal Fail The timing signal fail occurs when any of the timing signals generated in the PLS section fail to change state periodically while the machine is running The above alarms are available to the host PLC via discrete outputs These should be used to stop the machine and indicate the problem when any one of the alarms occurs 1 6 DATA COLLECTION The following data is collected for both the current shift and previous last shift 1 Total number of good cans printed 2 Total number of cans blown off 3 Total number of bad cans cans blown off because of misloads 4 Total number of restart blow offs 5 Total number of manual blow offs 6 Total number of select a can QC blow offs 7 Total trips per side drive and offside 8 Total trips per spindle per side for each spindle This data can be viewed on the Keypad Display The information is updated current shift transferred to Last shift based on the change of state of a discrete input This can be activated on an 8 or 12 hour shift basis or alternatively could be activated manually on a label run basis depending on the user s preference In addition to the shift data collection a separate buffer is available to collect trips per spin
59. hain linear vacuum conveyor blowoff port is centered between cans on the chain or conveyor The signal should be 40 degrees wide Note Follow steps 2 10 5 through 2 10 7 to systematically set up the pin chain blow off print trip and varnish trip These steps need to be followed sequentially as they depend on each other and the order they are executed SYSTEMS Electronics Group 20 SECTION 2 INSTALLATION 2 10 5 SET OF CANS TO PIN CHAIN BLOW OFF PORT Using the Keypad Display 1 Set the Of Pins To Pin Chain Blowoff Port Count the number of cans from where cans are transferred from the spindle wheel to the linear vacuum conveyor to the bad can pin chain blowoff port Subtract 2 and enter this number this is still just an approximation 2 Set the Of Bad Cans To Blowoff For Misload equal to three Run the machine at low speed with cans and induce misloads Verify that for a miss load three bad cans are blown off mis loaded silver can blown off at damaged can blowoff port printed cans ahead and behind mis loaded can blown off at pin chain port If not adjust Of Pins To Pin Chain Blowoff Port accordingly until they are Note Silver cans may get through the line until this variable is set up properly Once this is set you should be blowing off the can ahead of the misload missing can the misloaded can which is missing and the can behind the misload 3 Disable the damaged can blow of
60. he total number of misloads on the drive side This is only incremented once for every misload on a drive side spindle 8 OffSide Trips This is the total number of misloads on the offside This is only incremented once for every misload on a offside spindle 9 Drive Side Misloads per Spindle 1 24 This is the total trips mis loads for each spindle on the drive side A disproportionately high count for a particular spindle indicates a loading problem for that spindle 10 Offside Misloads per Spindle 1 24 This is the total trips mis loads for each spindle on the offside A disproportionately high count for a particular spindle indicates a loading problem for that spindle Note When a misload occurs it is only counted on the spindle of the spindle of the side that it on HSL CCSD1 User s Manual SYSTEMS Electronics Group 70 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE Last Shift Data The Last Shift data is identical to the current shift data except it is for the previous 8 or 12 hour shift or previous label run however the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period CCSD unnamed Shift Data Oo x Bay ma Ew ZS Era A EN a E mE ER Ea E wa pear ma oon fence fate ras E m E p 444999444444 HSL CCSD1 User s Manual SYSTEMS Electronics Group 71 SECTION 4 CCSD WINDOWS B
61. ing however 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 Speed Compensated Trip Control Bad Can and Select A Can Pin Chain Blow off Alarm Detection Data Collection a d oo MA OnORWN gt ankhwWhNDd 2 Installation 7 2 1 What s Included 7 2 1 1 HSL CCSD1 for back panel mounting 7 2 1 2 HSL CCSD1 ENCL with NEMA 12 enclosure __ 7 2 1 3 HSL CCSD1 Options 8 2 2 Power Required 8 2 3 Mounting and Wiring the HSL CCSD1 9 2 4 Mounting the HSL QCSTA optional 11 2 5 Mounting the HSL DSP Remote Display optional 11 2 6 Mounting the RSV34 MS1 Resolver if required 11 2 7 Mounting the Spindle 1 I D Sensor 12 2 8 HSL CCSD1 Software Installation 13 2 8 1 Windows Based Setup Program Installation ___ 13 2 8 2 DOS Based Setup Program Installation 14 2 8 3 SYSdev Program Development Software Installation 15 2 8 4 Application Program Installation 15 2 9 Modify Existing PLC Program 16 2 10 Tuning the HSL CCSD1 18 2 10 1 Default Set Up Variables 19 2 10 2 Set Machine Zero 20 2 10 3 Verify Location of No Can No Print Sensors ___ 20 2 10 4 Set Pin Ch
62. is identical to the current shift data except it is for the previous 8 or 12 hour shift or previous label run however the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period Refer to section 3 3 Current Shift Key for definitions of the data fields in the Last Shift data menu HSL CCSD1 User s Manual SYSTEMS Electronics Group 33 SECTION 3 USING THE KEYPAD DISPLAY 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 PRINT VARNISH RESPONSE TIMES 2 SET PIN CHAIN QC BLOW OFF PARAMETERS 3 SET MACHINE TIMING SET POINTS ETC 4 ZERO MACHINE SET RESOLVER OFFSET 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 press the corresponding numeric key 1 thru 4 The following sections describe these sub menus and the definitions of the setup variables Note The primary set up menu is passcode protected When the set up key is first depressed an ENTER PASSCODE prompt is displayed The correct 5 digit passcode must be entered to gain access to the setup menus If the passcode entered is correct the primary set up menu is displayed and any of the parameters accessed by this menu may be changed If the passcode entered is incorrect the message INCORRE
63. m causing a conflict with the port Check the port configuration from the Settings folder SYSTEMS Electronics Group 53 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual 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 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 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 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 selector switch is in the Disable position If an invalid value is entered the passcode value will not be reset and a message box notifying the user of the error is displayed SYSTEMS Electronics Group 54 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 4 4 THE VIEW MENU The View menu allows the user to perform the following functions e View the Target Board Interf
64. m is selected a check mark is placed next to the selected item and the selected window is displayed with the name changed in the title bar of the main window Note Read only variables are displayed in blue with a gray background Any variables that can be altered by the user are displayed in black with a white background In most cases a parameter that can be changed by the user will have associated with it increment and decrement controls The user can either click on the desired parameter to adjust and enter in a new value or use the increment or decrement controls to change the value by 1 unit SYSTEMS Electronics Group 58 HSL CCSD1 User s Manual SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 1 THE MAIN DISPLAY WINDOW The Main Display window is used to display the general state of the control system This window is selected from the Window amp CCSD unnamed Main Display Iof x File Edit View Window Help Messages Machine CPM Good Cans Q C Blow off l 0 e Spindle Number _ m Blanket Blow off m 4 r Blow offs 0 Mandrel Blowoff Bad Can Blow off Test Trip Blow off System Message All Faults Normal i ONLINE l 10 12 2003 3 05 PM Us The following is a list of the functions of the Main Display window Messages The Messages display is continuously updated It displays alarm
65. mber To printout a report of the settings contained in the set up Data File perform the following 1 From the File menu select Print Report or press Ctrl P This displays the Print Setup dialog box allowing the user to select a printer as well as the paper size and orientation Once the user selects OK the report is generated and sent to the specified printer device This function makes use of the windows print manager which allows the user to continue with their work while the document is being printed ASL CCSD1 User s Manual SYSTEMS Electronics Group 51 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual 4 3 THE EDIT MENU The Edit menu allows the user to perform the following functions CCSD unnamed Main Display File Edit View Window Help oh Comm Port Ctrl M Set up Passcode Machine CPM Good Cans Q C Blow off em aa Spindle Number Blanket Blow off ri ae r Blow offs E i f Mandrel Blowoff Bad Can Blow off Test Trip Blow off System Message All Faults Normal ONLINE 10 12 2003 3 09PM 4 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 parame
66. mmunicate with the processor and place the system into an Online mode of operation 4 Observe the Position field at the bottom of the window Verify that as the machine is rotated forward that the position increases linearly from 0 through 359 degrees If not swap the S1 and S3 leads at the resolver connector on the M4500 Then verify that the position does indeed increase with forward movement 5 Position the machine at machine zero see section 3 5 4 Zero Machine Set Resolver Offset 6 Auto zero the resolver by entering 0 in the Resolver Offset field and clicking the Set Offset command button A message box will appear prompting the user to confirm their choice Select Yes to set the resolver offset SYSTEMS Electronics Group 66 HSL CCSD1 User s Manual SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 7 The M4500 will calculate the actual offset value required to make this the 0 position The new offset value will be displayed in the Offset field and the position will then read zero Adjusting the Timing Channel Setpoints To set any of the timing signal setpoints perform the following Note Any changes made to the timing channel setpoints will be saved as part of the setup data file 1 Connect an RS 232 SYSdev cable from the COM port on the computer to the PROG port on the M4510 2 From the Window menu select Machine Timing 3
67. n Damaged Can Blowoff Lo Timing This signal is used to activate the damaged can blowoff solenoid at low speeds below 1300CPM The damaged can blowoff on solenoid will actually be on for the duration of CH03 when a mis loaded can is detected This signal should be set on 10 degrees after air starts to leave the damaged can port and set off 180 degrees before air stops leaving the port SYSTEMS Electronics Group 85 SECTION 6 GENERAL TIMING SIGNAL LOCATIONS CH04 Damaged Can Blowoff Hi Timing This signal is used to activate the damaged can blowoff solenoid at high speeds above 1300CPM The damaged can blowoff on solenoid will actually be on for the duration of CH04 when a mis loaded can is detected This signal should be set on 40 degrees before CH03 turns on and set off 10 degrees before CH03 turns off Note The No Can No Print sensors must normally first see a good can at least 30 degrees prior to the off to on transition of CH04 if not retard both CH03 and CH04 as necessary CH04 is the timing channel that actually clocks in the good can bad can data from the No Can No Print sensors CHO05 Pin Chain Bad Can Blow off Timing This should turn on when the chain blow off port is centered between cans on the linear vacuum conveyor This signal should be 40 degrees wide CHO6 QC Select A Can Blow off Timing This should turn on
68. n blow off and the trips per spindle count This must see a target once every revolution of the spindle wheel once every 24 spindles Any non discriminating 10 30VDC proximity sensor can be used and it can be mounted anywhere around the periphery of the spindle wheel The target it looks at should be either a large steel bolt head or 1 by 1 square steel target mounted on the spindle wheel in the vicinity of spindle 1 SYSTEMS Electronics Group 12 SECTION 2 INSTALLATION 2 8 HSL CCSD1 SOFTWARE INSTALLATION Follow the steps below to install either the Windows or DOS based setup programs and PLC application program on a PC used to support the HSL CCSD1 control system 2 8 1 WINDOWS BASED SETUP PROGRAM INSTALLATION The CCSD setup program is compatible with Windows 95 98 ME 2000 XP operating systems and is used to 1 Setup tune the user adjustable variables 2 Adjust the timing channel set points 3 Download the application program to the M4500 module 4 Download restore or upload save the user setup variables from the M4500 5 View Shift and Trips per Spindle data To install the set up software perform the following steps 1 Insert the HSM CCSD CD into the drive 2 From the Windows desktop Click Start and then select run 3 From the Run dialog box Click the Browse button 4 Select the drive with HSM CCSD CD Select the setup exe file and Click O
69. nd response times and the varnish unit Retract Extend response times in the M4500 This section contains the following selections 1 Print Trip Retract out Response Time msec This is the time used as the retract response time of the print trip time from solenoid actuation to first break with blanket in milliseconds The HSL CCSD1 will activate the retract solenoid this amount of time ahead of the Print trip timing CH00 usually set at 20 milliseconds HSL CCSD1 User s Manual SYSTEMS Electronics Group 61 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual 2 3 4 5 Print Trip Extend in Response Time msec This is the time used as the extend response time of the print trip time from solenoid actuation to first contact with blanket in milliseconds The HSL CCSD1 will activate the extend solenoid this amount of time ahead of the Print trip timing CH00 usually set at 20 milliseconds Varnish Trip Retract out Response Time msec This is the time used as the retract response time of the varnish trip time from solenoid actuation to first break with varnish wheel in milliseconds The HSL CCSD1 will activate the extend solenoid this amount of time ahead of the Varnish unit trip timing CH01 usually set at 20 milliseconds Varnish Trip Extend in Response Time msec This is the time used as the extend response time of the varnish trip time from solenoid
70. of screens each with four spindles from 1 through 24 for the Drive Side as shown below DRIVESIDE MISLOADS PER SPINDLE 1 XXXX 2 XXXX 3 XXXX 4 XXXX Where the numbers 1 through 4 are the first 4 spindles of the drive side and the xxxx would be the actual counts for the respective spindles Screens for spindles 5 thru 8 9 thru 12 etc are shown in this fashion each for a time delay of 10 seconds In addition the user can advance to the next screen or retard to the previous screen by pressing the NEXT or PREV key respectively HSL CCSD1 User s Manual SYSTEMS Electronics Group 30 HSL CCSD1 User s Manual SECTION 3 USING THE KEYPAD DISPLAY Once all 24 spindles for the Drive Side are displayed a series of screens each with four spindles from 1 through 24 for the Offside as shown below OFFSIDE MISLOADS PER SPINDLE 1 XXXX 2 XXXX 3 XXXX 4 XXXX As with the Drive Side all 24 spindles of the offside are shown this way Note When a spindle misloads it is only counted on the spindle of the side that it misloaded e g if a can misloads on the drive side spindle 3 the count for the Drive Side Spindle 3 will be incremented while the count for the Offside Spindle 3 is not incremented The final screen of this menu prompts the user to reset the counts by pressing 0 This provides the opportunity to reset the counts for trouble shooting If the counts ar
71. offset field and press lt ENTER gt HSL CCSD1 User s Manual SYSTEMS Electronics Group 80 SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE 6 The M4500 will calculate the actual offset value required to make this the 000 position and will display this number in the offset field The position will now read 0 7 Exit back to the PLS Main Development menu by pressing lt ESC gt 5 3 2 ADJUSTING THE TIMING CHANNEL SET POINTS To set or alter any of the timing signal set points perform the following 1 Select the 3 Set Machine Timing selection from the HSL CCSD set up program main menu 2 Select 1 Online Channel Setpoint Programming from the Main Development menu 3 Set all channels per section 6 Set points are entered for a particular channel simply by typing in the set point in the form XXX YYY lt ENTER gt in the first set point of the given channel Note For the decorator only one set point is used per channel and this should be entered in the number set point The XXX is the location the set point will turn on while YYY is the location where the set point will turn off Use the PgUp PgDn F1 Next Chan or F2 Prev Chan keys to select the desired channel for programming 4 Once all channels are programmed press lt ESC gt to exit back to the PLS Main Development Menu Note The new channels will be saved both in the module and in the CCSD2TMG file HSL CCSD
72. onds Varnish Trip Extend in Response Time msec This is the time used as the extend response time of the varnish trip time from solenoid actuation to first contact with varnish wheel in milliseconds The HSL CCSD1 will activate the extend solenoid this amount of time ahead of the Varnish unit trip timing CH01 usually set at 20 milliseconds Note All response times entered must be in the range of 5 to 65 milliseconds HSL CCSD1 User s Manual SYSTEMS Electronics Group 36 SECTION 3 USING THE KEYPAD DISPLAY 3 5 2 SET PIN CHAIN QC BLOW OFF PARAMETERS This menu is activated when the 2 key SET PIN CHAIN QC BLOW OFF PARAMETERS is pressed while the primary set up menu is active The following blow off set up parameters may then be adjusted or viewed Cans to Blow off at Infeed Open This is the number of cans that will be blown off when the infeed is first opened Valid range 0 to 99 Cans to Blow off from Print at Restart This is the number of cans that will be blown off from the print station when the machine is restarted Valid range 0 to 99 Cans to Blow off from Varnish at Restart This is the number of cans that will be blown off from the varnish station when the machine is restarted Valid range 0 to 99 Cans to Blow off for each Misload This is the number of cans blown off at the pin chain port when one mis loaded can is detected typically set at 1 can Pins to Pin Chain Blow of
73. ormal ONLINE 10 12 2003 312PM_ Note The Bad Can Blow off command button will electronically induce a mis loaded can into the system as well as the Q C Can Blow off will blow off a can printed on spindle 1 at the QC blow off port 1 Number of Pins to Pin Chain Blow off Port This is the number of pins from the spindle wheel to disk transfer location to the first can blown off at the Pin Chain blow off port minus two This can be a number from 0 to 999 2 Number of Cans to Blow off for Each Mis load This is the number of cans blown off at the pin chain port when one mis loaded can is detected typically set at 1 can 3 Number of Cans to Blow off at Infeed Open This is the number of cans which will be blown off when the infeed is first opened To blow off no cans at infeed open set equal to 0 to blow off one can set equal to 1 etc SYSTEMS Electronics Group 63 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 4 Number of Cans to Blow off from Print at Restart This is the number of cans which will be blown off from the print station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc 5 Number of Cans to Blow off from Varnish at Restart This is the number of cans which will be blown off from the varnish station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to
74. ot a dedicated black box but is instead implemented using the high performance SYSTEMS M4503 PLC PLS module This allows easy customization by either SEA or the end user The M4503 module is programmed using the DOS based SYSdev programming package This allows the module to be programmed in any combination of Ladder or High level subset of C as well as perform on line monitoring and trouble shooting The 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 SPEED COMPENSATED TRIP CONTROL Speed compensated trip control at speeds in excess of 2000 CPM is incorporated to compensate for the response time of the trip solenoid cylinder The print or varnish is always extended or retracted such that a miss loaded mandrel is not printed or varnished regardless of machine speed This is achieved by implementing a speed compensation algorithm that leads the trip point by the response time of the print solenoid cylinder The control is capable of leading the trip point by up to one station 60msec at 2000 CPM HSL CCSD1 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 4 BAD CAN AND SELECT A CAN PIN CHAIN BLOW OFF Both the bad can pin chain blow off and select a can pin chain linear vacuum conveyor blow off incorporate speed compensation to compensate for
75. oup wD se HSL CCSD1 User s Manual SECTION 2 INSTALLATION 2 10 7 SET VARNISH TRIP RETRACT EXTEND RESPONSE TIME Set the varnish extend and retract response times in the same fashion as was done for the print In general the mis loaded can should have no varnish on it and the cans ahead and behind should be fully varnished Once The Print And Varnish Are Set Up 1 Set the Of Bad Cans To Blowoff For Misload to 1 2 Reduce the Of Pins To Pin Chain Blowoff Port by 1 such that only the misloaded silver can is blown off 3 Enable the damaged can blow off by installing the fuses for both drive and offside damaged can blow off solenoids 2 10 8 SET OF CANS TO BLOW OFF AT RESTART Using the Keypad Display set the following as desired e Of Cans To Blowoff From Infeed Open e Of Cans To Blowoff From Print At Restart e Of Cans To Blowoff From Varnish At Restart 2 10 9 SET QC BLOW OFF SHIFT OFFSET Using the Keypad Display set the QC can blowoff port shift offset as follows 1 Dial in spindle 1 on the select a can thumbwheel switch 2 With the machine running slowly mark cans printed on spindle 1 so they can be identified while they are on the chain 3 Press the select a can pushbutton and observe the can that was blown off with the location of a can printed on spindle 1 4 Add the number of cans difference between the can blown off and th
76. ow off High CH04 a Recall Channel Clear Channel Bad Can Blow off Timing chos 155 I 195 Im Q C Blow off Timing CHOS 160 200 4 Test Blow off Spare Timing CHO 0 Hf 40 4 Danie PLC Clock Timing CH10 0 lt 4 180 QC Can Blow off RPM 0 Position 139 Offset 0 Scale 360 System Message All Faults Normal ONLINE 10 12 2003 3 13PM Ui HSL CCSD1 User s Manual SYSTEMS Electronics Group 65 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE HSL CCSD1 User s Manual In addition the following parameters are displayed at the bottom of this window RPM This is the current speed in Revolutions per Minute of the main crank resolver Position This is the current Position in degrees of the main crank resolver Offset This is the current resolver offset set in degrees Scale This is the scale factor of the resolver or the number of divisions in one revolution Note The General Timing Signal Locations section provides a complete description of each timing channel signal Zeroing the Machine setting the resolver offset To set machine zero perform the following 1 Connect an RS 232 SYSdev cable from the COM port on the computer to the PROG port on the M4500 2 From the Window menu select Machine Timing 3 From the View menu select Online Data The set up program will attempt to co
77. owing selections set the corresponding parameters 5 2 1 SET BAD CAN PIN CHAIN BLOW OFF RESPONSE TIMES Bad Can Blowoff Solenoid On Response Time This is the time used as the on response time of the pin chain blow off port time from on solenoid actuation to first air out port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the Pin Chain blow off timing CH05 usually set at 15 to 20 milliseconds SYSTEMS Electronics Group 76 HSL CCSD1 User s Manual SECTION 5 HSLCCSD1 DOS BASED SETUP PROGRAM REFERENCE Bad Can Blowoff Solenoid Off Response Time This is the time used as the off response time of the pin chain blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4500 will activate the solenoid this amount of time ahead of the Pin Chain blow off timing CH05 usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids 5 2 2 SET NUMBER OF CANS TO BLOW OFF PIN CHAIN Of Bad Cans To Blowoff For Misload This is the number of cans blown off at the pin chain port when a mis loaded can is detected typically set at 1 can Of Cans To Blowoff From Infeed Open This is the number of cans which will be blown off when the infeed is first opened To blow off no cans at infeed open set equal to 0 to blow off one can set equal to 1 etc O
78. owing the POS at zero 4 The HSL CCSD1 will calculate the actual offset value required to make this the 000 position and will display this number in the offset field 5 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 6 QC BLOW OFF KEY This key is used to blow off a can from a selected spindle at the Pin Chain QC Blow off port To blow off a can press the QC BLOW OFF key The display will then prompt Enter Spindle to Blow Can off Enter the desired spindle number 1 24 and press enter A can from that spindle will be blown off at the Pin Chain QC blow off port ASL CCSD1 User s Manual SYSTEMS Electronics Group 4 SECTION 3 USING THE KEYPAD DISPLAY HSL CCSD1 User s Manual 3 7 SET KEYPAD DISPLAY SET UP PASSCODE The Set Passcode input to the HSL CCSD1 is used to set or view the passcode of the set up menu Normally this input should be off To the passcode jumper this input to 24VDC and press the Set Up key The ENTER PASSCODE prompt along with the current 5 digit passcode will be displayed This allows the passcode to be viewed if necessary To change the passcode enter any number between 0 and 64999 and press lt ENTER gt Note If passcode protection will not be used set the passcode to 0 Then when the passcode is prompted for after the Set up key is pr
79. p This signal should just turn on when a blanket is in between spindles previous can has been completely printed next spindle has not yet made contact with the pre spin of the blanket it is to be printed on The leading edge of this timing signal is used to both extend and retract the print so the width of the timing signal is not critical This signal should be 40 degrees wide Varnish Trip This signal should just turn on when the varnish wheel is in between spindles previous can has been completely varnished and is no longer in contact with the varnish wheel next spindle has not yet made contact with the pre spin of the varnish wheel The leading edge of this timing signal is used to both extend and retract the varnish so the width of the timing signal is not critical This signal should be 40 degrees wide Can No Can Clock This signal is used to clock the bad can shift register which activates the print varnish and pin chain blow off for mis loaded cans It is also used as a general purpose clock for all shift registers counters etc The can no can clock is generally set on at 180 degrees and off at 000 degrees The off to on transition of CH02 cannot however coincide with either the CHOO Print trip CHO1 Varnish trip CH04 Damaged H1 or CH05 Pin Chain Blow off timing signals These timing signals must be set at least 20 degrees ahead or behind the CH02 off to on transitio
80. pen and then Ok 5 Follow the instructions that appear on the screen to complete the installation process The CCSD setup program can be executed from the Systems folder located under Programs from the Start menu HSL CCSD1 User s Manual SYSTEMS Electronics Group 13 SECTION 2 INSTALLATION HSL CCSD1 User s Manual 2 8 2 DOS BASED SETUP PROGRAM INSTALLATION The HSL CCSDI1 set up software is used to 1 2 3 4 5 Setup tune the user adjustable variables Adjust the timing channel set points Download the application program to the M4500 module Download restore or upload save the user setup variables from the M4500 to disk View Shift and Trips per Spindle data To install the DOS based set up software perform the following steps 1 2 3 Create a directory off the root for each decorator These will be used to store the HSLCCSD1 EXE setup program and set up data for each decorator Create these directories by typing the following at the DOS prompt MD HSLDECI lt ENTER gt line 1 Decorator MD HSLDEC2 lt ENTER gt line 2 Decorator MD HSLDEC3 lt ENTER gt line 3 Decorator etc Install the PROGRAMS disk into the drive For each HSLDEC directory you created switch to that directory and install the HSLCCSD 1 set up programs by typing the following at the DOS prompt Line 1 decorator is shown CD HSLDECI lt ENTER gt A INSTALL lt ENTER gt
81. r 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 SYSTEMS Electronics Group 35 SECTION 3 USING THE KEYPAD DISPLAY 3 5 1 SET PRINT VARNISH RESPONSE TIMES This menu is activated when the 1 key SET PRINT VARNISH RESPONSE TIMES is pressed while the primary set up menu is active The following four set up parameters may then be adjusted or viewed Print Trip Retract out Response Time msec This is the time used as the retract response time of the print trip time from solenoid actuation to first break with blanket in milliseconds The HSL CCSD1 will activate the retract solenoid this amount of time ahead of the Print trip timing CH00 usually set at 20 milliseconds Print Trip Extend in Response Time msec This is the time used as the extend response time of the print trip time from solenoid actuation to first contact with blanket in milliseconds The HSL CCSD1 will activate the extend solenoid this amount of time ahead of the Print trip timing CH00 usually set at 20 milliseconds Varnish Trip Retract out Response Time msec This is the time used as the retract response time of the varnish trip time from solenoid actuation to first break with varnish wheel in milliseconds The HSL CCSD1 will activate the extend solenoid this amount of time ahead of the Varnish unit trip timing CH01 usually set at 20 millisec
82. s Se e e T 3 ME i hes ae a Transfer Data i g a m p 23 Ee L219 24 0 EN 0 ri System Message All Faults Normal ONLINE 10 1 2 2003 3 13PM 4 Note The Transfer Data command button is only active while Online 1 Total Good Cans This is the total number of good cans printed so far into the shift This is essentially a can counter 2 Total Blow offs This is the total number of cans blown off the machine This includes all types of blow offs the can s blown off for each mis load infeed open blow offs restart blow offs manual blow offs select a can QC blow offs etc SYSTEMS Electronics Group 69 SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 3 Total Bad Cans or Mis loads This is the total number of mis loaded cans trips These would be the actual number of damaged cans that did not load properly on the machine This gives an indication of conveying can handling problems 4 Manual Blow offs This is the total number of cans blown off by the operator using the Manual Blow off PB or selector switch 5 QC Blow offs This is the total number of cans blown off by the operator with the Select A Can QC station or QC Blow off key on the M4500 keypad for quality verification 6 Restart Blow offs This is the total number of cans blown off when the infeed opened and from the print station and varnish station at machine restart 7 DrvSide Trips This is t
83. ters 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 SYSTEMS Electronics Group 25 HSL CCSD1 User s Manual SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 4 3 2 SETUP COMM PORT This function allows the user to specify the serial communications port and rate to talk to the M4500 The programming port of the M4500 is set to 9600 baud sComm Port Settings xj r Comm Port m Port Speed Comi 9600 C Com2 C 19200 C Com3 C Com 4 Cancel Once selected a dialog box requesting the user to select a Comm Port and Baud Rate will be displayed The default setting is COM1 at 9600 baud The option to select the 19200 baud rate is to allow the user to communicate with the processor via the 4516 serial communications board In most cases the user will only need to specify the communications port and leave the baud rate at 9600 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 anew Comm port If communication problems persist there may be another progra
84. the Tripped Spindle display to adjust the offset value Follow the procedure outlined in section 2 10 10 Set Spindle Trip Offset SYSTEMS Electronics Group 68 HSL CCSD1 User s Manual SECTION 4 CCSD WINDOWS BASED SETUP PROGRAM REFERENCE 2 Spindle xx Trips This is the total number of trips for each spindle This data is displayed and updated continuously in the respective field for each spindle A disproportionately high count for a particular spindle indicates a loading problem for that spindle Current Shift Data This section is used to view the Current Shift data This data is the totals so far into the shift This data is transferred to the Last shift at the end of either an 8 or 12 hour shift or alternatively could be done at label changes such that the data collected would be for label runs rather than complete shifts This data can be reset by the user from this section CCSD unnamed Shift Data File Edit View Window Help 15 x Trips Per Spindle Current Shit Last Shift r Current Shift Drive Side Trips Off Side Trips TotalGoodCans 0 HETH E 0 1 ne EN na Total Blow offs 2 0 14 0 2 ries 14 za Bad Can Blow off 0 3 0 15 0 H E jam Manual Blow offs 4 0 16 0 4 Pais 16 za Q C Blow off 0 Simoa e n sf e Restart Blow offs 6 0 18 0 6 Bing 18 ie Drive Side Trips 0 E De 5 ee aa a a OffSide Trips 0 eee if oc apo i a ee H ee
85. the machine both cans are blown off Thus this count is incremented twice for every misload Restart Blow offs This is the total number of cans blown off at restart from e Infeed open e The print station e The varnish station Manual Blow offs This is the total number of cans blown off by the operator using the Manual Blow off PB or selector switch QC Blow offs This is the total number of cans blown off by the the Select A Can QC station or QC Blow off key on the Keypad Display for quality verification SYSTEMS Electronics Group 339 SECTION 3 USING THE KEYPAD DISPLAY DrvSide Trips This is the total number of misloads on the drive side This is only incremented once for every misload on a drive side spindle OffSide Trips This is the total number of misloads on the offside This is only incremented once for every misload on an offside spindle Driveside Misloads per Spindle 1 24 This is the total trips mis loads for each spindle on the drive side A disproportionately high count for a particular spindle indicates a loading problem for that spindle Offside Misloads per Spindle 1 24 This is the total trips mis loads for each spindle on the offside A disproportionately high count for a particular spindle indicates a loading problem for that spindle Note When a misload occurs it is only counted on the spindle of the side that it occurs on 3 4 LAST SHIFT KEY The Last Shift data
86. the response time of the blow off solenoids regardless of machine speed This allows accurate rejection of a single can one from each side simultaneously from the pin chain at speeds in excess of 2000 CPM The select a can feature allows the user to dial in a mandrel number either at a remote PB station or from the keypad of the HSL CCSD1 and blow off one can printed on that mandrel Mandrels 1 through 24 can be individually blown off this way to verify the print quality of each mandrel Two other select a can blow off modes are also available 8 and 24 can blow off The 8 can mode blows off 8 consecutive cans printed on blankets through 8 The 24 can mode blows off 24 consecutive cans printed on all 24 mandrels starting with mandrel 1 The following variables can be set by the user for the bad can blow off e Number of cans from machine to blow off port up to 999 e Number of cans to blow off for each misload usually set to one for single can blow off e The on and off solenoid response time used by the speed compensation algorithm The following variables can be set by the user for the select a can blow off e 1 to 24 shift offset this is used to match the actual mandrel number to the selected mandrel number e The on and off solenoid response times HSL CCSD1 User s Manual SYSTEMS Electronics Group HSL CCSD1 User s Manual SECTION 1 GENERAL DESCRIPTION 1 5 ALARM DETECTION The packa
87. the sensor cables should be tied to earth ground at a terminal inside the existing control cabinet and left floating at the sensors 6 Set Up Enable key switch if desired to allow entry to set up variables through Keypad Display 7 Resolver cable from resolver or existing PLS to 8 pin resolver input connector on the M4500 using a three pair two conductor shielded cable The shield of the resolver cable should be tied to the SHLD terminal of the M4500 resolver input connector Make sure the resolver cable shield is left floating at the resolver HSL CCSD1 User s Manual SYSTEMS Electronics Group 10 SECTION 2 INSTALLATION 2 4 MOUNTING THE HSL QCSTA OPTIONAL The HSL QCSTA is used to blow off a can from a selected spindle or blanket from the pin chain for quality verification If the optional HSL QCSTA remote select a can PB station was purchased mount it in the vicinity of the pin chain QC blow off port in a convenient location for the operator Wire the HSL QCSTA to the HSL CCSD1 module referring to the electrical control schematic at the back of this manual 2 5 MOUNTING THE HSL DSP REMOTE DISPLAY OPTIONAL The HSL DSP is a remote 4 digit BCD display which displays either the current CPM or resolver position as selected by the operator If the optional HSL DSP remote RPM Position display was purchased make a cut out in the operator s control console for the display where desired Prior to mounting remov
88. timing CH06 usually set at 15 to 20 milliseconds Valid range 5 to 50 msec QC Blow off Solenoid off Response Time msec This is the time used as the off response time of the QC blow off port time from off solenoid actuation to air stopping at port in milliseconds The HSL CCSD1 will activate the solenoid this amount of time ahead of the QC blow off timing CH06 usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Valid range 5 to 50 msec QC Blow off Shift Offset This is the number of spindles difference from detection of the spindle 1 flag to the QC blow off port This is a number between and 24 and is empirically set by selecting spindle 1 for blow off and adjusting this value until the can from spindle 1 is the can that is blown off Spindle Trip Shift Offset This is the number of spindle difference from the detection of the spindle 1 flag to the No Can No Print sensors This is a number between 0 and 23 and is empirically set such that a mis loaded can on spindle 1 increments the spindle 1 count in the Trips per spindle menu see section 2 10 10 Set Spindle Trip Offset HSL CCSD1 User s Manual SYSTEMS Electronics Group 38 SECTION 3 USING THE KEYPAD DISPLAY 3 5 3 SET MACHINE TIMING SET POINTS ETC This selection brings up the timing set point menu which displays the following fields CHuu SET
89. to run loaded with the application program timing set points and set up data Double check the machine zero position and re zero the resolver if necessary SYSTEMS Electronics Group IT SECTION 2 INSTALLATION This Page Intentionally Left Blank HSL CCSD1 User s Manual SYSTEMS Electronics Group 28 HSL CCSD1 User s Manual SECTION 3 USING THE KEYPAD DISPLAY The Keypad Display of the HSL CCSD1 contains 24 keys consisting of data display commands set up commands and a numeric keypad The display of the HSL CCSD1 is 2 line by 40 character back lit LCD display which displays the selected data and set up menus The keypad display can be used to view data activate the select a can QC blow off and to adjust the timing and all set up parameters passcode or key switch protected SYSTEMS a ELECTRONICS GROUP INC IACHINE SPEED CPM 0000 S 0 BLOW OFFS 0 GOOD CA NX Bi TRIPS z ENTER 4 S eer te T a 1 2 3 enter SPINDLE POINT CURRENT a20 SELECT 4 5 6 Esg SHIFT pa prey CHAN C f 5 E LAST NEXT seaRCH 7 Q c O SHIFT CHAN A J The Keypad Display allows the following to be viewed or adjusted 1 Set Print Varnish Response Times 2 Set Pin Chain QC Blow off Parameters 3 Set Machine Timing 4 Set Machine Zero 5 View the Number of Trips per Spindle
90. ts in the cover Tighten the three captive screws on the lower front of the cover and the two captive screws on each side of the M4500 chassis SYSTEMS Electronics Group 25 SECTION 2 INSTALLATION 6 Connect the display ribbon cable to the connector on the back of the M4500 the connector on the cable is polarized and should mate with the M4500 only one way 7 Mount the M4500 chassis to the HSL CCSD1 back panel using four 8 32 screws 8 With power to the P4500 off install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4500 the connector on the cable is polarized and should mate with the connector on the M4500 only one way 9 Install the respective field wiring arms on all the I O boards of the M4500 I O slots0 thru 2 resolver connector and INO IN1 connector Make sure all field wiring connectors are fully mated in the M4500 2 11 2 P4500 POWER SUPPLY INSTALLATION To install the P4500 perform the following steps 1 Mount the P4500 to the HSL CCSD1 in the mounting holes next to the M4500 left side using two 8 32 screws 2 With power to the P4500 off install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4500 the connector on the cable is polarized and should mate with the connector on the M4500 only one way HSL CCSD1 User s Manual SYSTEMS Electronics Group 26 HSL CCSD1 User s Manual SECTION 2 INSTALLATION 2 11 3 D4591 KEYPAD
91. when the select a can chain blow off port is centered between cans on the linear vacuum conveyor This signal should be 40 degrees wide CHO07 Spare Timing This signal is not used internally by the HSL CCSD1 but must have a set point in it to satisfy the timing signal failure detection Set on at 000 and off at 040 CH10 PLC Clock Timing This signal is provided to the PLC via a discrete DC output This is used for whatever purpose required by the host PLC to clock once per spindle data In general this should be set on for 180 degrees and off for 180 degrees Otherwise set as desired This signal is not used by the HSL CCSD1 package internally in any way HSL CCSD1 User s Manual SYSTEMS Electronics Group 86 HSL CCSD1 User s Manual SECTION 7 RECOMMENDED SPARE PARTS The following are recommended spares for the HSL CCSD1 These parts are available through Systems Engineering Assoc Inc Quantity lea lea lea lea lea lea Part Number M4500 P4500 54563 54568 54573 D4591 87 Description PLC PLS Processor Chassis 4 Slot Power Supply 16 Point 10 30VDC Input Board 8 input 8 output 10 30VDC I O Board 16 point 10 30VDC Output Board Display Keypad SYSTEMS Electronics Group

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