No Container - Computrol, Inc.
Contents
1. INSTALLATION I 1438 i gt t 4 ETNA 0 813 m 6 0 Le y d 0 250 r 4 000 s 8 000 4 3 500 gt 1 032 Agen 0475 T p za A 4450 1 775 1 875 0 187 l 0 750 Ff j j j t T t d t ALL DIMENSIONS ARE SYMMETRICAL UNLESS OTHERWISE NOTED Figure 3 2 NEMA 4 Panel Cutout SECTION 3 INSTALLATION 3 4 WIRING TO THE NC NF NC NL Referring to the electrical control schematic in Appendix D wire the NC NF NC NL as follows 3 4 1 Incoming Power Be sure all power is disconnected before wiring the system In general when wiring the NC NF NC NL keep all 24VDC wiring away from high voltage wiring 1 110 240VAC 50 60HZ power to the M4502 NC NF NC NL module 2 24VDC power to the S4568 I O boards and M4502 for use with the input INO 3 4 2 Input Sensors Connect 24VDC power to all input sensors Note that pull up resistors 4 7k 2 may be required to provide a minimum load for sensors using NPN outputs Check the specifications for the sensor model used If no information on minimum load is available install the pull up resistor Filler Container Sensor PRX1 Filler Timing Sensor PRX2 Infeed Sensor PRX3 optional Seamer Discharge Sensor PRX4 optional Lockout Response Feedback Sensor PRX5 Seamer Container Sensor PRX6 option to use as Filler Discharge also Seamer Timing Sensor PRX7 Soy po 3 4 8 Setup Protection Input2. 29 NC NF NC NL SYSTEM IN SETUP MODE 10 INFEED LOW TIME SECONDS 30 NC NF NC NL SYSTEM IN SETUP MODE 11 INFEED RESTART TIME SECONDS 31 NC NF NC NL SYSTEM IN SETUP MODE 12 FILL STATIONS FROM CONT TO EXIT 32 NC NF NC NL SYSTEM IN SETUP MODE 13 SEAM STATIONS FROM CONT TO EXIT 33 NC NF NC NL SYSTEM IN SETUP MODE 14 CONTAINERS MISSING FOR EXIT JAM 34 NC NF NC NL SYSTEM IN SETUP MODE 15 INPUT POLARITY TCAFDITC 35 NC NF NC NL SYSTEM IN SETUP MODE 16 SEAM STATIONS FROM CONT TO LID FEED 36 NC NF NC NL SYSTEM IN SETUP MODE 17 LID FEED CLOSE LEAD TIME MS 37 NC NF NC NL SYSTEM IN SETUP MODE 18 LID FEED OPEN LEAD TIME MS 38 NC NF NC NL SYSTEM IN SETUP MODE 19 LID FEED SOLENOID S ON TIME MS 39 NOT USED 40 FILLER CONTAINER RELATIVE TIMING wo Gow T T E7 APPENDIX E DF1 Communication 41 SEAMER CONTAINER RELATIVE TIMING TEX e AE T T 42 ALARM FILLER SPEED CPM ALARM FILLS LOCKOUTS E8 APPENDIX E DF1 Communication 43 LOCKOUT SWITCH IN FILL PRESS WASH DOWN IF CLEANING THE FILLER 44 LOCKOUT SWITCH IN NO FILL 45 PULLOUT CAM SWITCH IN RETRACT MAY FILL 46 PULLOUT CAM SWITCH IN EXTEND NEVER FILL 47 LID FEED SWITCH IN FEED ALWAYS FEED 48 LID FEED SWITCH IN CLOSE NEVER FEED 49 NOT USED 50 WASH DOWN BYPASS REQUESTED ARE
3. 108 SLI AOV3N N3lSAS woo WOD sel an ON E USNIVINOD ON aanddns s3woisno O qe Tia ON i ug M3NNINOO ON ngn P roa 8 91018 ON3531 IN3AJInD3 u nov NIS SEL Z U ze GaSN Zu SHOSNSS ALINIXONd 3dAL 0 ug NaN N3HM OGA Z ONY INdNl Old HOVA 3000 wk 1018 s s1018 N33M3B Q3MInD3H SI MOIEN WHO NCT V l Ei woo woo Ier LON out oct Svo Diener o A o ola y roa 691 oinov ONIY ei SE yos vi O SNA O 891 821 ewe ON BONN S rios Lal Di SC aa Lemmer ro O YHA 991 92i 01 ve SNOVA 1018 T1018 z Z 10L8 s91 i O val vei ma E lino oo aha Are Vioi8 i 1018 91 INI ea O EO zai zu na on lino og vana ero 01018 9 01018 dd INL e r vi O ZNAD og ozi wod 4 Fees GR 651 ONI eu 1 310N 338 SNIALL ava est au 10 Lxud 90018 9 Les wic o LSI pu SR TE 106 L ALON 335 S39NvHO dniss YINIVINO W3AVIS 981 Tena SUL Los Mid O dl s 0018 S SGI O eu 0018 ONINNOY SOT a3sn JON eur ei yu TS esi u ro018 nara DIE LOS Ol os 1 310N 335 DECH 3sNods3Y 1NOHDOT zal JON SI 08d A AN eu 106 Do O 0018 FOTE wyc Ge DI 5 105 ASES ut 1 310N 335 d0ls 3 YOSNAS OWYHOSIA ost i GE I 084 O ou 105 rid O LNdlNO 20018 Fass oso cay ANS Leo 3 ru Tos 60 AOE T 1 ALON 335 YOO TMSINI ve MOSN3S Q33 NI en al O ing 20 10S a WALSAS 10018 rans Ro Ly O 0 DALY Zonk Zoe zos 1 310N 338 SNIALL WITH sr 901 106 Zxud O 90A vc Q3llddns HANOLSNO 00018 0 Fooss TA Sn a n o 0 sol x
4. Computrol or the end user The M4502 module is programmed using the DOS based SYSdev programming package which allows the module to be programmed in any combination of Ladder or high level subset of C as well as perform on line monitoring troubleshooting and module fault diagnostics SECTION 1 INTRODUCTION 1 2 FUNCTIONAL DESCRIPTIONS 1 2 1 Lockout Actuator Control The NC NF NC NL provides direct control for the No Container No Fill Lockout Actuator Solenoid s The actuator is controlled by the Filler Container Sensor working in conjunction with the Filler Timing Sensor such that when the Container Sensor does detect a container somewhere between fill station timing signals the Lockout Actuator will not be activated However when the Container Sensor does not detect a container between timing signals the Lockout Actuator will be activated at a precise time to hit the lockout pin to prevent an empty station from being filled As soon as the Container Sensor begins detecting containers again the actuator will be retracted to prevent any containers from not being filled The reaction of the Lockout Actuator is speed compensated This means that as the speed of the machine increases time period between fill stations decreases the activation and deactivation point of the actuator will be advanced to compensate for the speed of the machine and the reaction time of the actuator If the sensed reaction time of the Lockout Act
5. Expected With the Lockout Actuator fully retracted the Lockout Response Feedback Sensor should be on Once the Actuator begins to extend the sensor should turn off 4 1 3 2 Placement of Sensor Sensor should be placed on the Lockout Actuator in a way to give the signal expected 4 1 4 Verify Infeed Sensor Optional 4 1 4 1 Signal Expected The Infeed Sensor should turn on only when a container is present at its location resulting in a single pulse per container 4 1 4 2 Placement of Sensor The infeed sensor should be located at the end of the infeed track very near to where the containers are first loaded into the machine 4 1 4 3 If the Pull out Cam is controlled Count the number of stations between the Pull out Cam to the point where containers are transferred to the filler turret The Infeed Sensor should be located at least 3 stations further from the transfer point than the Pull out Cam The Infeed Sensor should not be located more than 45 stations from the Container Sensor 4 1 5 Verify Discharge Sensor Optional 4 1 5 1 Signal Expected The Infeed Sensor should turn on only when a container is present at its location resulting in a single pulse per container 4 1 5 2 Placement of Sensor Verify that the discharge sensor is located on the discharge track where the filled containers are discharged from the machine 4 1 6 Verify Seamer Timing Sensor 4 1 6 1 Signal Expected With the mach
6. Lockout Actuator is longer than the period for two stations the speed compensation function cannot operate properly When this is first detected a display will be triggered to notify the operator If Alarm Reset is pressed this message will not return until the condition goes away and returns LOCKOUT SOLENOID RESPONSE gt 2 STATIONS PRESS RESET TO ACKNOWLEDGE 5 6 2 Lockout Actuator Response Changing If the measured response of the Lockout Actuator is more than 20ms different from the setup value being used a display will be triggered to notify the operator This is intended to notify the operator in changes in lockout actuation time indicating faulty operation of the actuator itself If Alarm Reset is pressed this message will not return until the condition goes away and returns L O RESPONSE MEASURED lt gt SETUP VALUE CHECK SETUP VALUE RESET TO ACKNOWLEDGE 5 7 WASH DOWN BYPASS MODE If the system is in Wash Down Bypass Mode and none of the feedback messages are active the display will indicate the trigger for Wash Down Bypass Mode SYSTEM IN WASH DOWN BYPASS BY KEYPAD PRESS RESET OR WASH DOWN TO CANCEL SYSTEM IN WASH DOWN BYPASS BY REM SWITCH 28 SECTION 5 DISPLAYS 5 8 CLOSE AUTO OPEN SWITCH SELECTION If any Lockout Pullout Lid Feed Switch is not in Auto the display will say so LOCKOUT SWITCH IN FILL PRESS WASH DOWN IF CLEANING THE FILLER LOCKOUT SWITCH IN NO FILL PULLOUT CAM SWITC
7. Timing Sequence 14 SECTION A SETTING UP 4 1 1 Verify Filler Timing Sensor 4 1 1 1 Signal Expected With the machine running the Timing Sensor should pulse once and only once for every fill station 4 1 1 2 Placement of Sensor The Timing Sensor must turn on at the position the Lockout Actuator is to be tripped This sensor can be placed anywhere on the periphery of the machine that will pick up the timing signal 4 1 2 Verify Filler Container Sensor 4 1 2 1 Signal Expected The Container Sensor should turn on only when a container is present at its location resulting in a single pulse per container 4 1 2 2 Placement of Sensor Count the number of stations between the Lockout Actuator to the point where containers are transferred to the filler turret The Container Sensor should be located at least 3 no more than 15 stations further from the transfer point than the Lockout Actuator Press the T C T key to bring up the Relative Timing display Note that pressing Prev or Next will toggle between Filler and Seamer displays FILLER CONTAINER RELATIVE TIMING 3 woe kt T T Using the Relative Timing display verify that the container sensor signal stays between the same two stations for the full speed range of the setup This means that the relative timing number should not cross the 0 100 threshold 15 SECTION A SETTING UP 4 1 3 Verify Lockout Response Feedback Sensor 4 1 3 1 Signal
8. X00 SS 6 re Ba wore z G 602 T 108138 REIS pri olny eoz g WYO 100 Td ox xod ec we wona Hora xs o o zoz x zMS Z4 YO HE 902 x iws 7 LLL D Daer R sls old ECH e x o 01 193NNO2 sve 00118 0 gorm Ka Z Tu mu ON e vz KONG Ge 402 CHEN 9 X LMS 1N0 g N 8 1no 201 Td O x zMS bod BG iss Tue bez ez SH ke T zz zoz 1309 15yS K E WE Z0 101S 09 105 ove 008 ooz ic Sheet 2 Schemat D D Figure D 2 D3 Appendix E DEI Communication Option The NC NF NC NL has the capability of communicating via Allen Bradley DFI Full Duplex protocol The S4516 DF1 board must be added to the rack default slot 02 With this optional card in place the NC NF NC NL can communicate directly with an A B PLC via Channel 0 RS232C A KF2 or equivalent card could also be used to connect the NC NF NC NL directly to an A B Data Highway Plus network Refer to page 2 of the NC NF NC NL schematic for connection details The NC NF NC NL will respond to MSG Block Read and Write commands intended for a SLC500 PLC An example program has been enclosed with this manual and is shown in section E 2 The data is stored in accordance with Figure E 1 El APPENDIX E DF1 Communication Figure E 1 SLC Replicated Memory Addresses inside the NC NF NC NL NT Used For Represents 0 Filler Previous
9. YOU SURE YES NO 51 LOCKOUT SOLENOID RESPONSE gt 2 STATIONS PRESS RESET TO ACKNOWLEDGE 52 L O RESPONSE MEASURED lt gt SETUP VALUE CHECK SETUP VALUE RESET TO ACKNOWLEDGE 53 SYSTEM IN WASH DOWN BYPASS BY KEYPAD PRESS RESET OR WASH DOWN TO CANCEL 54 SYSTEM IN WASH DOWN BYPASS BY REM SWITCH 55 CHANGES IN SETUP ARE NOT ENABLED CHECK MANUAL FOR SETUP PROCEDURE 56 END OF SHIFT REQUESTED ARE YOU SURE YES NO 38 48 57 MESSAGE LOGIC ERROR MESSAGE NOT FOUND NO MESSAGE ENTERED FOR B152 E9 APPENDIX E DF1 Communication E 1 3 Lockout Actuator Response Times Measured N7 15 N7 16 The Lockout Actuator Response Times are measured in 1 0ms increments E10 APPENDIX E DF1 Communication E 1 4 Keypad Entry N7 20 The register N7 20 will act as a virtual keypad The register will be monitored in parallel with the keypad on the front of the NC NF NC NL The physical keypad will be acted upon first if both inputs are active simultaneously The key repeat feature is not supported on the virtual keypad Set N7 20 according to the following table Figure E 2 Virtual Keypad Legend N7 20 KEY ON KEYPAD 1 ALARM RESET 2 INC 3 T C T 4 WASH DOWN 3 ACK ALARM 9 PREV 10 SETUP 11 NEXT 12 END OF SHIFT 17 YES 18 DEC 19 NO 20 L O SOL TIMES E 1 5 Setup Values N7 25 N7 43 These are the same param
10. alarm will automatically reset to allow the filler to run These parameters will only appear if Infeed Sensor is enabled in Parameter 7 Parameter 7 1 or 3 21 SECTION 4 SETTING UP 4 3 11 Number of Filler Stations Container Sensor to Discharge Sensor NC NF NC NL SYSTEM IN SETUP MODE 12 FILL STATIONS FROM CONT TO EXIT Count the number of stations between the Filler Container Sensor and the Seamer Container Sensor This information is used to detect a Discharge Jam alarm 4 3 12 Number of Seamer Stations Container Sensor to Discharge Sensor NC NF NC NL SYSTEM IN SETUP MODE 13 SEAM STATIONS FROM CONT TO EXIT Count the number of stations between the Seamer Container Sensor and the Discharge Sensor This information is used to detect a Discharge Jam alarm 4 3 13 Number of Missing Containers to Constitute a Discharge Jam NC NF NC NL SYSTEM IN SETUP MODE 14 CONTAINERS MISSING FOR EXIT JAM Enter the number of containers lost between the Container Sensor and the Discharge Sensor before a Discharge Jam alarm is latched 4 3 14 Input Polarity NC NF NC NL SYSTEM IN SETUP MODE 15 INPUT POLARITY TCAFDITC The NC NF NC NL software is designed to handle PNP 24VDC 1 or NPN OVDC inputs The input polarity can be changed for all 7 sensors plus the auxiliary contact from the Main Drive The Push button and Selector Switch inputs are assumed PNP The legend is given as a reminder of the sch
11. ims 4n0 g i g l 210N 335 DES SE SIG EA wad 5 HOSSJDOHd O asses Sh l l eor 0 1015 zu VO SON vL DI DI Noo oz os L 4 005 7 oyi ZH 09 08 OWA 0 Z 0ZL GANddNS HAWOLSNO 001 ic Sheet 1 Schemat D D Figure D 1 D2 APPENDIX D Schematic EES 06 020 0 K s E amg oa GEN ann OLIYWAHOS OMINOO wO Dm IN AN ON ona a 130 M IN ON 3N ON p E NOV QNVIS ZOG W 207973 cano an anou ER anie 3wos GE pa u danej 9 ZN 00980700 N3G109 dd a IG DNI 1OH LNdAO aaan at ae auts a S VLINAOLINOO 2 Lit ez 2 az oer saz G r 4 inum sez vez cz ezz Osma 9 ena eez zt zez uz Coss tia Iez ozz ocz B9z Deech tua ezz 292 ezz 97 Kee Lee izz vi o9z t O ozz soz wile z Lila ezz vi voz 8na vaz an waao O QIONTIOS Fo 90 0334 Ql che ra vs L ta a NA m D vi Lnd an oN 38010 O ONTOS RE Ee cho ra Eau o 01118 uz EE wx sos vi 097 9n4 O ozz 00x E esz Log L Frons o o ez Bsz El gt X00 9 LSZ 90 18 9 BD ES 03347 zeen 992 olny az 0334 Qn Manes Ces EE Sez olla s gora Ke e ousj JO O8UU0J 13638 fe 310 38 vet nz d Nid 6 xo HY CH olla vois 0 0 u NO 440 tet SSVdAB NMOQHSVM eue 00x Eet y x z isz coe Cora b e osz oz 6
12. time of the actuator so that corrective action can be taken Maximum Lockout Response Time 3 LOCKOUT MAX RESPONSE TIME MS The measured response times for extend and retract will be checked against this limit to personnel know that there are mechanical response problems in the Lockout Actuator 4 3 3 Number of Stations Container Sensor to Lockout Actuator NC NF NC NL SYSTEM IN SETUP MODE Count the number of stations between the Lockout Actuator to the point where containers are transferred to the filler turret Now count the number of stations between the those two numbers If the Lockout Actuator is consistently hitting a complete station before or after the intended station change this parameter 19 SECTION 4 SETTING UP 4 3 4 Automatic End Of Shift Timer NC NF NC NL SYSTEM IN SETUP MODE 5 AUTO SHIFT TIMER H M S counts are maintained for the current shift the previous shift and the lifetime of the system In order to protect the integrity of the shift counters the shift times must be can also be rolled over using the keypad If the shift counts are updated by either of these means the Auto Shift Timer will reset Consecutive Lockouts to Extend Pull out Cam 6 LOCKOUTS TO EXTEND PULL OUT CAM The Pull out Cam resets the lockout pins for the next revolution of the filler If a to reduce wear and tear on the Lockout Actuator and the Cam itself The Cam will be retracted upon the first container
13. will be closed at a precise time to prevent a lid from feeding an empty station As soon as the Container Sensor begins detecting containers again the lid feed will be opened to assure all containers receive a lid SECTION 1 INTRODUCTION The reaction of the Lid Feed Downstacker Actuator is speed compensated This means that as the speed of the machine increases time period between seam stations decreases the activation and deactivation point of the actuator will be advanced to compensate for the speed of the machine and the reaction time of the actuator Optionally the system can include a Close Auto Feed three position switch allowing the operator to manually override the NC NL controls Statistics are kept for containers with no lid and lids with no container caused by the switch in manual override 1 2 4 Wash Down Bypass Mode The NC NF NC NL system provides for a Wash Down Bypass condition This can be activated through the module keypad or by an optional remote switch When the system is in Wash Down Bypass the Lockout Actuator and Pull out Cam are locked in the to fill position Lid Feed is off production and lockout counts are frozen and most alarms are disabled Because the Lockout Actuator is locked in position and fill counts are frozen the NC NF NC NL system is not expecting to detect any containers throughout the system If the Container Sensor detects a container while the system is in Wash Down Bypass mod
14. 15 16 amp 17 These should be used to stop the machine and indicate the problem when any one of the following alarms occurs The outputs will follow the following pattern Figure 2 1 Alarm Output Table fo 0 0 None PLC Module Fault 1 0 0 1 Filler or Seamer Timing Sensor Failure l 2 0 J 1 0 LockoutExtendTooSlow__ L3 0 IL Labon Retract Too Slow l 4 1 0 0 ContanerinWash Down 5 1 0 1 infeed am _________ 6 1 LL infeed tow L7 1 po to 1 Filler or Seamer Discharge Jam SECTION 2 INTERLOCKS 2 2 INCOMING INTERLOCKS The following interlocks can be provided by the existing control system to the NC NF NC NL 2 2 1 Filler Seamer Running This signal tells the NC NF NC NL system when to look for the Timing Sensor signals 3 INSTALLATION This section gives instructions for installing the NC NF NC NL system for the first time 3 1 PACKING LIST Verify that the following items are included when unpacking the NC NF NC NL lea NC NF NC NL M4502 Module with required I O lea NC NF NC NL Control System Manual lea M4500 User s Manual 3 2 POWER REQUIREMENTS NC NF NC NL M4502 Module Voltage 115 230 VAC Current 0 5 0 3 A NC NF NC NL I O Sensors Output Solenoids etc Voltage 24 VDC Current Device dependent Note that 24VDC solenoids must be used for the output solenoids This is because DC solenoids provide a more consistent repeatable response t
15. Enable Setup Changes switch A switch inside the panel is recommended to prevent unauthorized access 3 4 4 Close Auto Open Selector Switches optional These switches allow a manual override of the NC NF NC NL allowing the Lockout Actuator Pull out Cam and Lid Feed to be forced open to fill or closed no fill 10 SECTION 3 INSTALLATION 3 4 5 Outputs Note that 24VDC coils must be used for all outputs Wire CRI Relay into Slot 0 Output 2 Note polarity of coil Wire Fill Lockout Solenoid s Wire Pull out Cam Solenoid s optional Wire Lid Feed Solenoid S hop ou pora 4 6 Interlocks Between Existing System and NC NF NC NL System Ready dry contact interlock to inputs on existing PLC Alarm Binary Code outputs to inputs on existing PLC Auxiliary contact from main drive to NC NF NC NL Optional E Stop or machine control system MCR contact LA HA Wire CRI Relay into NC NF NC NL FLT Output Note polarity of coil 11 SECTION 3 INSTALLATION 3 5 POWER UP SEQUENCE Once the connectors are wired and replaced in their respective sockets apply 115 230VAC power to the M4502 The Power Up sequence occurs as follows 1 At initial power up the module is reset for approximately half a second During this time the fault interlock will be off and the FLT RUN and PWR LED s will all be on All outputs will be off Once the reset cycle is complete the module will begin to
16. H IN RETRACT MAY FILL PULLOUT CAM SWITCH IN EXTEND NEVER FILL LID FEED SWITCH IN FEED ALWAYS FEED LID FEED SWITCH IN CLOSE NEVER FEED 5 9 MESSAGE LOGIC ERROR If the program after a revision contains an error in the message logic where a message is called for but not found a display is provided for troubleshooting the problem MESSAGE LOGIC ERROR MESSAGE NOT FOUND NO MESSAGE ENTERED FOR B152 29 Appendix A Keypad Quick Reference ALARM RESET L O SOL TIMES T C T END OF SHIFT WASH DOWN YES NO SETUP NEXT PREV INC DEC ACK ALARM Resets all displays and acknowledged alarms Triggers the Lockout Actuator Response Display Loop Activates the Relative Timing display Transfers the Current Shift Production data to Previous Shift and resets the Current Shift Must be confirmed Puts the NC NF NC NL in Wash Down Bypass Mode Must be confirmed Confirms End of Shift or Wash Down requests Declines End of Shift or Wash Down requests Activates the Setup Mode display loop Moves display to next message in current display loop Moves display to previous message in current display loop Increases the value of the Setup Parameter 1f changes are enabled Decreases the value of the Setup Parameter if changes are enabled Acknowledges the currently shown
17. IOW aaa dee 24 5 1 3 Lockout Retract Too Slow did 24 5 1 4 Container Detected In Wash Down Bypass sss 25 Deh dnfeed EE 25 SLO AT AI A iE 25 SSL Discharge ENEE 25 32 LOCKOUT RESPONSE LOOP eski A RA WA 26 3 3 PRODUCTION COUNT LOOP 45 ortis tne eie Due ra otn bica 26 5 4 RELATIVE TIMING DISPLAY EE 27 3 5 OPERATOR KEYPAD REQUESTS dirt tbe kod Ig hp aia pub 27 Ad PGE OP SKU za wokal motu pe ete donis ee edo dua ptu tede tu pund 27 2 9 2 Wash Down Bypass Mode seit dv W ryby GA 27 5 6 LOCKOUT ACTUATOR POSSIBLE PROBLEMS FEEDBACK 28 5 6 1 Lockout Actuator Response Too Long for Speed Compensation 28 5 6 2 Lockout Actuator Response Changing eese eene 28 5 7 WASH DOWN BYPASS MODE eene ooo aaa OTOR RARA TORT AT Rr 28 5 8 CLOSE AUTO OPEN SWITCH SELBOTION essen 29 59 MESSAGE LOGIC ERROR gees edel 20 APPENDIX A Saa KEYPAD QUICK REFERENCE APPENDIX DSi M4502 APPEARANCE DRAWINGS APPENDIX C Su oszcz CONTACTING COMPUTROL INC A1 B1 C1 TABLE OF CONTENTS APPENDIX D ii eg SCHEMATICS APPENDIX E EEN DF1 COMMUNICATION OPTION KEE E3 E 2 INTERPRETING N7 DATA eene EERROR BOOKMARK NOT DEFINED E 2 1 Production Counts N7 0 N7 11 N7 50 N7 61 eee E4 E 2 2 Message Number NZ 121 E4 E 2 3 Lockout Actuator Response Times Measured N7 15 N7 16 E10 ELA Keypad Entry Eet EEN ENEE ee eu Eege Ell E 2 5 Setup Va
18. OF PREV NEXT OF LO ves D I No soL TIMES Figure B 2 Front View of NC NF NC NL Controller Appendix C Contacting Computrol Inc We at Computrol are committed to providing excellent technical support for our control systems We are also interested in any comments or suggestions you may have toward improving these systems If you need troubleshooting help or just have a suggestion for an improvement please feel free to contact us Computrol Inc 15485 W 44 Ave Unit A Golden CO 80403 Phone 303 989 441 7 Toll Free 800 989 441 7 Fax 303 989 4471 E mail sales computroll net Cl Appendix D Schematics The schematic for this system is included for quick reference D1 APPENDIX D Schematic ER gia i 06 020 Den mamo CH el B OLIYWAHOS OMINOO TWOIHLO313 LAS IN AN ON as 140 M IN ON 3N ON p E a SNOT QNvIS ZOGYN EE al A a EN de cane BN avon LEE ER asen sal GER E NSN 09580105 N3d105 E ONI IlOulfidINO nenas 2 LA oos T et 9 EN 601 Saco Wf Hoig 4
19. Shift Production Count Low Word 1 Filler Previous Shift Production Count High Word 2 Filler Previous Shift Lockout Count Low Word 3 Filler Previous Shift Lockout Count High Word 4 Filler Current Shift Production Count Low Word 5 Filler Current Shift Production Count High Word 6 Filler Current Shift Lockout Count Low Word 7 Filler Current Shift Lockout Count High Word 8 Filler System Life Production Count Low Word 9 Filler System Life Production Count High Word 10 Filler System Life Lockout Count Low Word 11 Filler System Life Lockout Count High Word 12 Message Number 13 14 Not Used 15 Lockout Actuator Extend Time Measured 16 Lockout Actuator Retract Time Measured 17 19 Not Used 20 Keypad Entry 21 24 Not Used 23 Lockout Actuator Extend Lead Time 26 Lockout Actuator Retract Lead Time 27 Maximum Lockout Solenoid Response Time 28 Number of Stations from Container Sensor to Lockout Actuator 29 Auto Shift Timer 30 Number of Lockouts to Extend Pull out Cam 31 Enable Optional Sensors 32 Number of Stations between Infeed and Container Sensors 33 Number of Missing Containers for Infeed Jam 34 Infeed Low Shutdown Timer 35 Infeed OK Restart Timer 36 Filler Number of Stations from Container Sensor to Discharge Sensor 37 Seamer Number of Stations from Container Sensor to Discharge Sensor 38 Number of Missing Containers for Discharge Jam 39 Input Polarity Summary 40 Number of stations from Seamer Container to Lid Feed Act
20. TTING UP THE SYSTEM PARAMETERS err 18 4 2 1 Navigating the Setup EE 18 4 2 2 Changing Setup Parameter 18 Table of Contents TABLE OF CONTENTS 4 3 PARAMETER DEFINITION Genie isnt aan A 18 4 3 1 Lockout Actuator Lead Times Extend and Retract esses 19 4 3 2 Maximum Lockout Response Time eee 19 4 3 59 Number of Stations Container Sensor to Lockout Actuator 19 454 Automatic End Of Shift Ter 20 4 3 5 Consecutive Lockouts to Extend Pull out Com 20 4 3 6 Enable Optional Sensors Infeed and or Discharge 20 4 3 7 Number of Stations Infeed Sensor to Container Sensor ssssssss2221 21 4 3 8 Number of Missing Containers to Constitute an Infeed Jam 21 4 3 9 Infeed Low ARA A at ae hie th ass Taek 21 4 3 10 A etx d e EE E pies 21 4 3 11 Number of Filler Stations Container Sensor to Discharge Sensor 22 4 3 12 Number of Seamer Stations Container Sensor to Discharge Sensor 22 4 3 13 Number of Missing Containers to Constitute a Discharge Jam 22 MOM 2 InpulPolarity used ere ele motas eio Tom eee 22 4 3 15 Number of Stations Seamer Container Sensor to Lid Feed Actuator 23 4 3 16 Lid Feed Actuator Lead Times Open and Close 23 4 3 17 Lid Feed Solenoid s Pulse Duration sss sese 23 5 DISPLAYS x oo ai 24 5 f ALARM MESSAGES 1 id aia 24 odd le ATTEN 24 ede Locko t Extend Lou D
21. Time 4 3 17 Lid Feed Solenoid s Pulse Duration NC NF NC NL SYSTEM IN SETUP MODE 19 LID FEED SOLENOID S ON TIME MS This is the duration of the pulse sent to the solenoid s that actuate the lid feed downstacker Pulsing the output s allows for the possibility of overdriving the coil s 23 5 DISPLAYS 5 1 ALARM MESSAGES The NC NF NC NL package detects the following alarms Timing Sensor Failure Lockout Extend Too Slow Lockout Retract Too Slow Container Detected in Wash Down Bypass Infeed Jam Infeed Low and Discharge Jam If any alarm is detected the system enable is turned off and the drive to the machine should be disengaged With no alarms detected the system enable will be on and the drive to the machine should be enabled The highest priority active alarm will be written to the display 5 1 1 Timing Sensor Failure FILLER TIMING SIGNAL FAILURE CHECK SENSOR PRX2 AND RESET SEAMER TIMING SIGNAL FAILURE CHECK SENSOR PRX7 AND RESET The timing sensor is used to determine the period between stations and the speed of the machine The time period between stations is tracked If after 3 0 seconds of the drive running interlock on the current period between stations is 1 5 times greater than the previous time period this alarm is latched If this alarm is detected make sure that the Timing Sensor senses every station If the drive running interlock is not used the check for this alarm will not be performe
22. alarm Al Appendix B M4502 Appearance Drawings Lo OFAN OON qe QNM dQ K Z eee Op 0000000000000000 ne EECH ge O NO s iD IS ee e e el D OOOOOOOOOOOOOOOO 53 FOTNMYTNORDOTAMYONORO d e O w 100r oe Oe NM UD e e e e e e ee Ef 06000000000000000 no a cz o 2z se FO JO OO 000 INO IN1 FLT AINO COM AIN1 COM AOUT CON SYSTEMS a ELECTRONICS GROUP INC COM 50 60HZ TFO AOUTO AC POWER 100 240 VAC z o Figure B 1 Top View of NC NF NC NL Controller ALARM ror WASH ACK RESET INC T DOWN ALARM pry SETUP yey E d
23. anufacturer reserves the right to change the specification of the product or its performance or the contents of the User Manual without notice 1 INTRODUCTION AAA in id A 1 ET FEATURES sc ss oba EE 1 12 FUNCTIONAL DESCRIPTIONS 5 tee bein i a aa 3 1 2 1 Lockout EE 3 1 2 2 Pull Out Cam E 3 1 2 5 Lid Feed Downstacker Actuator Control 3 E GE 4 2 INTERLOCKS WITH EXISTING CONTROL SYSTEM 2000s220000000000000 5 zl OUTGOINGINIEREOGCKHS A RAKOWA 5 SE EE 5 2A D AATA EE A Sede pnt RAT 5 22 INCOMING INTERLOCK T 6 2 2 1 EE 6 Se INSTALLATION E 7 3d PACKING ACES NEE 7 342 POWER REQUIREMENTS surtido E epus E 3 33 INSTALLING THE NC NF NC NL MODUL 8 3 4 WIRING TO THE NC NF NC NL a a A A A 10 Sud Incoming POWER O O A o AK 10 SE 10 E gt Setup POLEO TNp t ae ele gek Ee A 10 3 4 4 Close Auto Open Selector Switches optional 10 DU MESURE 11 3 4 6 Interlocks Between Existing System and NC NF NC NL eene 11 357 POWERICUP SEOUBNGE i eee vitet ian Ip RAT TR HR gece 12 3 6 MODIFY EXISTING PLC PROGRAM 12 ds SETTING UP T 13 41 SETTING UP THE SENSORS A O A 14 4 1 1 Verify Filler Timing Senor 15 4 1 2 Verify Filler Container Sensor EE 15 4 1 3 Verify Lockout Response Feedback Sensor 16 4 1 41 Verfylnfeed Sehsor Optlonal secca ii AE l 4 1 5 Verify Discharge Sensor Optional 16 4 1 6 Verify EE 16 4 1 7 Verify Seamer Container Sensor n ono nono nono nono nono nro nn nro nnnonos 17 4 2 SE
24. ctuator 5 Automatic End of Shift Timer 6 Number of consecutive Lockouts to extend Pull out Cam 7 Enable Optional Sensors Infeed and or Discharge 8 Number of stations Infeed sensor to Container sensor 9 Number of missing containers to constitute an Infeed Jam 10 Infeed Low Timer 0 1 second time base 11 Infeed Restart Timer 0 1 second time base 12 Number of stations Container sensor to Discharge sensor Filler 13 Number of stations Container sensor to Discharge sensor Seamer 14 Number of missing containers to constitute a Discharge Jam 15 Input Polarity 16 Number of stations Container Sensor to Downstacker Actuator 17 Downstacker Actuator Close Lead Time 18 Downstacker Actuator Open Lead Time 19 Downstacker Actuator Solenoid Pulse Duration Parameter only accessed if related sensor is enabled The discharge sensing for the filler and Seamer are enabled together The Container sensor for the Seamer is also used as a discharge sensor for the Filler 7 Alarm Detection Filler Timing Sensor Failure Seamer Timing Sensor Failure Lockout Extend Too Slow Lockout Retract Too Slow Container Detected in Wash Down Bypass Mode Infeed Jam Infeed Low Filler Discharge Jam Seamer Discharge Jam O a parcs 8 The NC NF NC NL package can be set up as a dedicated black box or as a fully programmable PLC implementing the high performance SYSTEMS M4502 PLC that allows easy customization by
25. d 5 1 2 Lockout Extend Too Slow LOCKOUT EXTEND RESPONSE TOO SLOW CHECK PRX5 AND MAX TIME SETTING PRESS RESET This alarm is generated whenever the measured Extend Response time of the Lockout Actuator is greater than the setup parameter Maximum Allowable Lockout Response 5 1 3 Lockout Retract Too Slow LOCKOUT RETRACT RESPONSE TOO SLOW CHECK PRX5 AND MAX TIME SETTING PRESS RESET This alarm is generated whenever the measured Retract Response time of the Lockout Actuator is greater than the setup parameter Maximum Allowable Lockout Response 24 SECTION 5 DISPLAYS 5 1 4 Container Detected In Wash Down Bypass WASH DOWN BYPASS FAILURE CONTAINER WAS SEEN AT PRX1 IN WASH DOWN PRESS RESET When the NC NF NC NL system is in Wash Down Bypass Mode production and lockout counts are bypassed To maintain the integrity of these statistics no containers should pass through the system while it is in this mode 5 1 5 Infeed Jam INFEED JAM CONTAINER SEEN AT INFD BUT NOT AT CONT CHECK INFEED SCREW amp RESET The Infeed Sensor and the Container Sensor are placed in the infeed track to verify that containers are being fed into the machine If containers are detected at the Infeed Sensor and are not detected by the Container Sensor several stations later the container is considered missing After a user defined number of missing containers setup parameter an Infeed Jam is detected If the Infeed Sensor is not enabled th
26. d timeout The Prev and Next keys will toggle between Filler and Seamer FILLER CONTAINER RELATIVE TIMING 3 woe 4 T T SEAMER CONTAINER RELATIVE TIMING mea HE T T The percentage represents the ratio of the time between the Timing Sensor and the Container Sensor over the period between Timing Sensor pulses Minimum value is 0 if both signals are detected at the same time Maximum value is 99 if the Container Sensor is detected immediately before the next Timing Sensor pulse 5 5 OPERATOR KEYPAD REQUESTS 5 5 1 End of Shift The operator can manually transfer and reset the current shift data using the End of Shift key on the keypad When the End of Shift key is pressed a confirmation is requested END OF SHIFT REQUESTED ARE YOU SURE YES NO Pressing the Yes key will transfer and reset the data Pressing the No key will cancel the request 5 5 2 Wash Down Bypass Mode The operator can manually enter Wash Down Bypass mode using the Wash Down key on the keypad When the Wash Down key is pressed a confirmation is requested WASH DOWN BYPASS REQUESTED ARE YOU SURE YES NO Pressing the Yes key will put the system in Wash Down Bypass mode Pressing the No key will cancel the request 21 SECTION 5 DISPLAYS 5 6 LOCKOUT ACTUATOR POSSIBLE PROBLEMS FEEDBACK 5 6 1 Lockout Actuator Response Too Long for Speed Compensation If the measured response of the
27. detected Enter the number of consecutive missing 4 3 6 NC NF NC NL SYSTEM IN SETUP MODE 7 SENSOR ENABLE 1 IN 2 EXIT 3 BOTH Sensors In order to avoid nuisance alarms if these sensors are not installed the installed sensors must be enabled for the related logic to be processed To enable the logic related Discharge Sensor only set this parameter to 2 To enable both sensors set this parameter to 3 If either of the sensors is disabled the related parameters will be 20 SECTION 4 SETTING UP 4 3 7 Number of Stations Infeed Sensor to Container Sensor NC NF NC NL SYSTEM IN SETUP MODE 8 STATIONS FROM INFD TO CONT HH Enter the number of stations between the Infeed and Container Sensors This information 1s used for detecting Infeed Jams 4 3 8 Number of Missing Containers to Constitute an Infeed Jam NC NF NC NL SYSTEM IN SETUP MODE 9 CONTAINERS MISSING FOR INFEED JAM Enter the number of containers lost between the Infeed Sensor and the Container Sensor before an Infeed Jam alarm is latched 4 3 9 Infeed Low Timer NC NF NC NL SYSTEM IN SETUP MODE 10 INFEED LOW TIME SECONDS If no containers are detected at the Infeed Sensor for this long the Infeed Low alarm will be latched to shut the filler down 4 3 10 Infeed Restart Timer NC NF NC NL SYSTEM IN SETUP MODE 11 INFEED RESTART TIME SECONDS Containers will be detected at the Infeed Sensor for this long before the Infeed Low
28. e an alarm is latched and the system enable interlock will be turned off 2 INTERLOCKS WITH EXISTING CONTROL SYSTEM The NC NF NC NL system will need to exchange information with the existing filler controls These pieces of information are broken down into two categories outgoing from NC NF NC NL to Filler Seamer and incoming from Filler Seamer to NC NF NC NL 2 1 OUTGOING INTERLOCKS The following are signals from the NC NF NC NL to the existing control system 2 1 1 System Ready Interlock This dry contact interlock indicates to the existing control system that the NC NF NC NL system is ready for production The contact will close when the NC NF NC NL system is ready It is recommended that if the System Ready interlock is off the Filler Seamer should not run The System Ready Interlock combines the following 2 1 1 1 Module Fault Protection The NC NF NC NL module contains a comprehensive fault detection routine that verifies the proper operation of the module at all times The sources of these faults range from a hardware failure of the module to an error in the loaded program If a module fault is detected all outputs are disabled 2 1 1 2 System Enable The system enable provides a summary of all alarms detected by the NC NF NC NL software When the System Enable signal is off the Alarm Interlock should be referenced for the cause 2 1 2 Alarm Interlock The alarms are available to the host PLC via discrete 24VDC outputs
29. ematic C Filler Container Sensor T Filler Timing Sensor I Infeed Sensor D Discharge Sensor F Feedback Response Sensor A Auxiliary Contact from Main Drive C Seamer Container Sensor T Seamer Timing Sensor A 1 in the Polarity Summary designates PNP while a 0 designates NPN 7 These parameters will only appear if Discharge Sensors are enabled in Parameter 7 Parameter 7 2 or 3 22 SECTION 4 SETTING UP 4 3 15 Number of Stations Seamer Container Sensor to Lid Feed Actuator NC NF NC NL SYSTEM IN SETUP MODE 16 SEAM STATIONS CONT TO LID FEED Count the number of stations between the Lid Feed Actuator to the point where containers are transferred to the Seamer turret Now count the number of stations between the Container Sensor and the transfer point This parameter should be set to the difference of those two numbers If the Lid Feed is consistently hitting a complete station before or after the intended station change this parameter 4 3 16 Lid Feed Actuator Lead Times Open and Close NC NF NC NL SYSTEM IN SETUP MODE 17 LID FEED CLOSE LEAD TIME MS NC NF NC NL SYSTEM IN SETUP MODE 18 LID FEED OPEN LEAD TIME MS The default readouts are 45ms each way If the Lid Feed does close early enough to stop the feed for the intended station increase the Close Lead Time Likewise if the Lid Feed does not open early enough to feed the next loaded station increase the Open Lead
30. eters detailed in section 4 3 The values can be changed directly over DF1 communications The new values will be checked versus the predetermined minimum and maximum values used to control the setup through the module keypad If the new values are valid the values will be written directly into the setup parameters that determine the function of the unit E 1 6 Manual Override Error Counts N7 45 N7 48 N7 95 N7 98 The NC NF NC NL tracks the errors of the NC NF NC NL process caused by the Close Auto Open switches being in Close or Open These counts follow the same conventions as the production counts in N7 0 N7 11 N7 45 and N7 46 count the number of times a station is filled when no container is present due to the switch being in Open N7 47 and N7 48 count the number of containers which are not filled due to the switch being in Close These registers are not tracked by shift Similar Seamer counts are held in N7 95 N7 98 Ell APPENDIX E DF1 Communication E 2 Sample SLC 5 0x Programming for Interfacing with the NC NF NC NL We have enclosed a floppy disk with this manual which contains an example file which you can import into the existing filler control program A B SLC 5 03 OS302 processor or higher Please note that the example program does not enable more than MSG command at a time The DFI driver included inside the NC NF NC NL program can only handle one command at a time If more than one MSG block is enabled at the same time
31. execute the NC NF NC NL application program The fault interlock will turn on sink true low and the FLT LED will turn off If the red FLT LED stays on after the power up is complete read the fault code in the M4502 module see section 6 2 of the M4500 User s Manual for information on viewing fault codes with SYSdev 3 6 MODIFY EXISTING PLC PROGRAM Modify the existing control system PLC program to interface with the NC NE NC NL by incorporating the following into the existing PLC logic 1 Add the System Ready output from the NC NF NC NL as an input into the existing control system to immediately disable the main drive upon loss of signal This can also be used as a Summary Alarm input Add the necessary logic to process the Alarm Binary Code outputs from the NC NF NC NL Optionally add the software necessary to use DF1 to communicate to the NC NF NC NL Refer to Appendix E 12 4 SETTING UP Setting up the NC NF NC NL system involves two steps setting up the sensors and setting up the system parameters DISCHARGE an LOCKOUT LOCKOUT ACTUATOR RESPONSE Figure 4 1 NC NF Filler Layout 13 SECTION 4 SETTING UP 4 1 SETTING UP THE SENSORS 1 TIMING SENSOR 0 CONTAINER 1 SENSOR 0 INFEED 1 SENSOR 0 DISCHARGE 1 SENSOR 0 ALL CONTAINER SENSORS MUST READ ONCE PER TIMING SENSOR SIGNAL Figure 2 Input Sensor
32. f OMPUTROL No Container No Fill No Container No Lid Control System Manual Revised June 6 2002 WARNING To ensure that the equipment described by this 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 Electrical 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 the User Manual and any other manuals referred to by it prior to installation and or operation of the equipment The manufacturer accepts no liability for any consequences resulting from inappropriate negligent or incorrect installation operation or adjustment of the equipment The contents of the User Manual are believed to be correct at the time of printing However no responsibility is assumed for inaccuracies In the interests of a commitment to a policy of continuous development and improvement the m
33. han AC solenoids The input power should be interlocked with the existing control system such that when the main disconnect of the existing control system is turned off all power to the NC NF NC NL is also turned off SECTION 3 INSTALLATION 3 3 INSTALLING THE NC NF NC NL MODULE The NC NF NC NL is designed to mount from the front in the user s cabinet door Use the cutout in Figure 3 1 for NEMA 12 Use the cutout in Figure 3 2 for NEMA 4 wash down area 1 Remove all terminal connectors so that the module can easily slide into the recommended cutout 2 Referring to the appropriate figure see above put a cutout in the door of the enclosure 3 With the gasket installed on the M4502 mounting studs slide the module into the cutout from the front Attach the M4502 to the door with the supplied hardware Once the module is installed a lugged earth ground wire should be installed on one of the mounting screws to insure that the module is grounded 4 In the case of NEMA 4 mounting place the bezel over the front of the display Be careful that the gasket forms a good seal with the front of the display Attach with the supplied hardware 4 Replace all terminal connectors on the module to begin terminating wires 4 475 4 475 m 0 250 8 000 3 500 4 938 Y 1 875 ch 0 475 p 775 UN ago Jr 00 218 Figure 3 1 NEMA 12 Panel Cutout SECTION 3
34. ine running the Timing Sensor should pulse once and only once for every Seamer station 4 1 6 2 Placement of Sensor The Timing Sensor must turn on at the position the Lid Feed Actuator is to be tripped This sensor can be placed anywhere on the periphery of the machine that will pick up the timing signal 16 SECTION A SETTING UP 4 1 7 Verify Seamer Container Sensor 4 1 7 1 Signal Expected The Container Sensor should turn on only when a container is present at its location resulting in a single pulse per container 4 1 7 2 Placement of Sensor Count the number of stations between the Lid Feed Actuator to the point where containers are transferred to the Seamer turret The Container Sensor should be located at least 3 no more than 15 stations further from the transfer point than the Lid Feed Actuator Press the T C T key to bring up the Relative Timing display Note that pressing Prev or Next will toggle between Filler and Seamer displays SEAMER CONTAINER RELATIVE TIMING mea Dt T T Using the Relative Timing display verify that the container sensor signal stays between the same two stations for the full speed range of the setup This means that the relative timing number should not cross the 0 100 threshold 17 SECTION 4 SETTING UP 4 2 SETTING UP THE SYSTEM PARAMETERS 4 2 1 Navigating the Setup Menu The Setup parameters for the NC NF NC NL may be viewed at all times by pressing
35. is alarm is bypassed 5 1 6 Infeed Low NO CONTAINERS DETECTED AT INFD CHECK INFD amp CONTAINER FLOW PRESS RESET The Infeed Sensor is used to verify that there are containers to be loaded into the machine from the infeed track If no containers are detected at the Infeed Sensor for a predefined period of time setup parameter the infeed low alarm will become true The alarm will reset after containers have been continuously detected at the Infeed Sensor for a setup parameter period of time This alarm is overridden in Wash Down Bypass Mode If the Infeed Sensor is not enabled this alarm is bypassed 5 1 7 Discharge Jam FILLER EXIT JAM CONTAINER SEEN AT CONT BUT NOT AT EXIT CHECK EXIT AREA amp RESET SEAMER EXIT JAM CONTAINER SEEN AT CONT BUT NOT AT EXIT CHECK EXIT AREA amp RESET As containers are being fed into the machine the container sensor determines the state of the fill station container or no container The state of the fill station is tracked to the discharge of the machine If filled containers are expected and the Discharge Sensor does not detect them those containers are considered missing After a user defined number of missing containers setup parameter a Discharge Jam is detected If the Discharge Sensor is not enabled this alarm is bypassed 25 SECTION 5 DISPLAYS 5 2 LOCKOUT RESPONSE LOOP As long as no alarms are active the operator can view the Extend and Retract times measured by pressi
36. lues N7 25 NIE EE Ell E 2 6 Manual Override Error Counts N7 45 N7 48 N7 95 N7 96 Ell E 3 SAMPLE SLC 5 0x PROGRAMMING FOR INTERFACING WITH THE NC NF NC NLE12 E 4 CHANNEL O SETUP OE ONZE El6 D1 El Table of Figures Figure 2 1 Alarm Output Table aoc sa GO Ga Ada odci 5 Figure 3 1 NEMA 12 Panel Cutout 2 co dae 8 Figure 3 2 NEMA 4 Panel GCu tout cia Seet ba 9 Figure 4 1 NC NF Filler Layout e Ue eco i D HUE en de 13 Figure 4 2 Input Sensor Timing Sequence cana dae A tte 14 Pigure 4 3 Setup Parameters oodd A eege 18 Figure B 1 Top View of NC NF NC NL Controller AA Bl Figure B 2 Front View of NC NF NC NL Controller AAA Bl Figure D T Schematie Sheet liinda etc eee testes D2 Figure D 2 Schematic Sheet 2 noche cases geen im teret edic et n c PIT d tp RSN D3 Figure E 1 SLC Replicated Memory Addresses inside the NC NF NC NL E2 iv 1 INTRODUCTION This section describes the features of the NC NF NC NL NC NL package including the functional description alarms detected and the interlocks between control package and existing control system 1 1 FEATURES The NC NF NC NL NC NL is designed to work in conjunction with the existing controls for a food beverage filling station connected directly to a Seamer The system performs the following functions 1 Speed compensated actuator control at speeds in excess of 2000 CPM up to two station advance for both filler lockou
37. mmunication 10 SYSTEM NO CONTAINER FILLS LIFE CONTAINERS NOT FILLED 11 PREVIOUS SHIFT FILLS LOCKOUTS 12 FILLER SPEED CPM FILLS LOCKOUTS 13 SYSTEM LIFE FILLS HB LOCKOUTS 14 SYSTEM NO CONTAINER LIDS LIFE CONTAINERS NO LID 15 PREVIOUS SHIFT LIDS No LIDS 16 FILLER SPEED CPM LIDS NO LIDS 17 SYSTEM LIFE LIDS NO LIDS 18 LOCKOUT MECHANISM RESPONSE AS MEASURED LOCKOUT EXTEND RESPONSE MS 19 LOCKOUT MECHANISM RESPONSE AS MEASURED LOCKOUT RETRACT RESPONSE MS 20 NC NF NC NL SYSTEM IN SETUP MODE 1 LOCKOUT EXTEND LEAD TIME MS 21 NC NF NC NL SYSTEM IN SETUP MODE 2 LOCKOUT RETRACT LEAD TIME MS 22 NC NF NC NL SYSTEM IN SETUP MODE 3 LOCKOUT MAX RESPONSE TIME MS 23 NC NF NC NL SYSTEM IN SETUP MODE 4 FILL STATIONS FROM CONT TO LOCKOUT 24 NC NF NC NL SYSTEM IN SETUP MODE 5 AUTO SHIFT TIMER H M dis E6 APPENDIX E DF1 Communication 25 6 LOCKOUTS TO EXTEND PULLOUT CAM iH 26 NC NF NC NL SYSTEM IN SETUP MODE 7 SENSOR ENABLE 1 IN 2 EXIT 3 BOTH 27 NC NF NC NL SYSTEM IN SETUP MODE 8 STATIONS FROM INFD TO CONT 28 NC NF NC NL SYSTEM IN SETUP MODE 9 CONTAINERS MISSING FOR INFEED JAM
38. ng the L O SOL TIMES key PREV and NEXT will toggle between the two displays The display will reset after 30 seconds of no keys being pressed LOCKOUT MECHANISM RESPONSE AS MEASURED LOCKOUT EXTEND RESPONSE MS LOCKOUT MECHANISM RESPONSE AS MEASURED LOCKOUT RETRACT RESPONSE MS 5 3 PRODUCTION COUNT LOOP If system is in Wash Down Mode or sitting on the Default Current Shift Display the operator can view all 8 of the Production Count Displays by pressing PREV or NEXT These same keys will page through these displays The display will reset after 30 seconds of no keys being pressed SYSTEM NO CONTAINER FILLS LIFE CONTAINERS NOT FILLED PREVIOUS SHIFT FILLS LOCKOUTS FILLER SPEED CPM FILLS t LOCKOUTS A SYSTEM LIFE FILLS LOCKOUTS SYSTEM NO CONTAINER LIDS LIFE CONTAINERS NO LID PREVIOUS SHIFT LIDS NO LIDS FILLER SPEED CPM LIDS NO LIDS HB SYSTEM LIFE LIDS NO LIDS 26 SECTION 5 DISPLAYS 5 4 RELATIVE TIMING DISPLAYS If none of the other feedback displays are active the operator can view the relative timing of the Container and Timing Sensors by pressing the T C T key This display will stay active until T C T or Alarm Reset is pressed no 30 secon
39. ockout Solenoid Response Time Max 4 _ Stations from Container Prx to Lockout 5 Auto Shift Timer 3 3 353 6 Lockouts to Extend Pull out Com 7 Enable Optional Sensors 8 _ Stations from Infeed to Container 9 _ Missing Containers for Infeed Jam 10 Infeed Low Shutdown 11 Infeed OK to Restart 12 Fill Stations from Container to Discharge 13_ Seam Stations Container to Discharge 14 Missing Containers for Discharge Jan I5 Input Polarity 3 35333 16 Seam Stations from Container to Lid Feed _ 17_ Lid Feed Solenoid Lead Time Close 18_ Lid Feed Solenoid Lead Time Open 19 Lid Feed Solenoid Pulse duration 9 18 SECTION 4 SETTING UP 4 3 1 Lockout Actuator Lead Times Extend and Retract NC NF NC NL SYSTEM IN SETUP MODE 1 LOCKOUT EXTEND LEAD TIME MS NC NF NC NL SYSTEM IN SETUP MODE 2 LOCKOUT RETRACT LEAD TIME MS point To access the Lockout Response Feedback displays press the L O SOL TIMES key PREV or NEXT will toggle between Extend and Retract Note that the accurate Use the Close Auto Open Switch The default readouts are 45ms each way If the Lockout Actuator does not extend early enough to hit the lockout pin increase the next loaded station increase the Retract Lead Time Note if the measured time for either extend or retract is more than 20 milliseconds message is intended to alert the operator to changes in the response
40. one of them will fail due to a timeout The enclosed program will retry any MSG command that fails until it is completed successfully This approach will ensure that all commands that are issued will be executed properly Please note that the MSG instructions which write data to the NC NF NC NL system must be enabled with logic that is not included in the enclosed sample The respective enable bits should be latched when a Write is desired The sample code unlatches them when the MSG is completed successfully The MSG Read instruction is always enabled 0000 lt MSG 0001 Read Write Message Type Peer To Peer Read Write Target Device Local Remote Control Block Control Block Length Setup Screen 0002 MSG 0003 Read Write Message Type Peer To Peer Read Write Write Target Device Local Kemote Control Block Control Block Length Setup Screen E12 0004 0005 0006 0007 0008 APPENDIX E DF1 Communication MSG Read Write Message Type Peer To Peer Read Write Write Target Device S500CPU Local Remote Local Control Block N10 30 Control Block Length 14 Setup Screen E13 APPENDIX E DF1 Communication 0010 The Setup Page for N10 0 El4 APPENDIX E DF1 Communication The Setup Screen for N10 15 The Setup Screen for N10 30 El5 APPENDIX E DF1 Communication E 3 Channel 0 Setup Channel 0 of the SLC that will communicate with the NC NF NC NL should use the following set
41. s The Low Word counts up to 32 000 When the Low Word reaches 32 000 it is reset and the High Word is incremented When the total count reaches 1 000 000 000 1 billion both words are reset To determine the total count represented multiply the High Word by 32 000 and add the Low Word For example the Previous Shift Fill Count N7 1 32000 N7 0 Note that resetting the counts directly will not affect the numbers shown on the attached display These registers are kept separate from the internal counts It is possible to reset the Current Shift and Previous Shift data as normal using the virtual keypad N7 20 E 1 2 Message Number N7 12 The message that corresponds to the value of N7 12 can be found in the following list FILLER TIMING SIGNAL FAILURE CHECK SENSOR PRX2 AND RESET INFEED JAM CONTAINER SEEN AT INFD BUT NOT AT CONT CHECK INFEED SCREW amp RESET 3 FILLER EXIT JAM CONTAINER SEEN AT CONT BUT NOT AT EXIT CHECK EXIT AREA H lt RESET 4 WASH DOWN BYPASS FAILURE CONTAINER WAS SEEN AT PRX1 IN WASH DOWN PRESS RESET 5 PRX5 AND MAX TIME SETTING PRESS RESET 6 PRX5 AND MAX TIME SETTING PRESS RESET 7 PRX3 amp CONTAINER FLOW PRESS RESET 8 FILLER TIMING SIGNAL FAILURE CHECK SENSOR PRX2 AND RESET 9 SEAMER EXIT JAM CONTAINER SEEN AT CONT BUT NOT AT EXIT CHECK EXIT AREA RESET E4 APPENDIX E DF1 Communication E5 APPENDIX E DF1 Co
42. t NC NF and Seamer downstacker NC NL Lockout Response Calibration Automatic determination of lockout response for use as extend and retract lead times System Ready Interlock dry contact interlock to indicate to the existing control system that NC NF NC NL system is ready for production 1 Module Fault protection The NC NF NC NL module contains a comprehensive fault detection routine that verifies the proper operation of the module at all times 2 Machine Run Enable Interlock The summation of no active alarms Data Acquisition Total number of containers filled and total number of lockouts for the current shift the previous shift and the lifetime of the system Also the system tracks the number of times a station was filled without a container and the number of containers not filled due to the manual override switch Similar but separate counts are kept for the Seamer as well Built in 2 Line X 40 character sealed display with 24 key membrane keypad Comprehensive status messages to aid in troubleshooting Local viewing of collected data Set up parameters viewed by operator changed by authorized personnel Alarm reset Local Wash Down Bypass mode End of shift data transfer Qv E SECTION 1 INTRODUCTION 6 User Adjustable Parameters protected 1 Lockout Actuator Extend Lead Time 2 Lockout Actuator Retract Lead Time 3 Maximum allowed Lockout response time 4 Number of stations Container Sensor to Lockout A
43. the SETUP key When Setup Mode is accessed the display for the last parameter viewed will be recalled The PREV and NEXT keys move to the Previous and Next parameters respectively 4 2 2 Changing Setup Parameters In order to change the parameter values the Enable Setup Changes input at INO must be on If changes are attempted and INO is off the following will be displayed CHANGES IN SETUP ARE NOT ENABLED CHECK MANUAL FOR SETUP PROCEDURE If Changes are enabled the values can be changed using the INC and DEC keys 4 3 PARAMETER DEFINITIONS Figure 4 3 Setup Parameters Parameter Lockout Solenoid Lead Time Extend Lockout Solenoid Lead Time Retract Lockout Solenoid Response Time Max Stations from Container Prx to Lockout Auto Shift Timer Lockouts to Extend Pull out Cam 99 stations Enable Optional Sensors oOo 0 3 NA Stations from Infeed to Container Missing Containers for Infeed Jam 2 1 9 containers Infeed Low Shutdown 600 0 Infeed OK to Restart Fill Stations from Container to Discharge Seam Stations Container to Discharge Missing Containers for Discharge Jam Input Polarity 255 Seam Stations from Container to Lid Fee Lid Feed Solenoid Lead Time Close S S Lid Feed Solenoid Lead Time Open Lid Feed Solenoid Pulse duration 150 l 0 PK Parameter O o O 1 _ Lockout Solenoid Lead Time Extend 2 _ Lockout Solenoid Lead Time Retrac 3 _ L
44. uator 41 Lid Feed Close Lead Time 42 Lid Feed Open Lead Time 43 Lid Feed Solenoid s Pulse Duration 44 Not Used 45 No Container Fill Count Low Word 46 No Container Fill Count High Word E2 APPENDIX E DF1 Communication 47 Container Not Filled Count Low Word 48 Container Not Filled Count High Word 49 Not Used 50 Seamer Previous Shift Production Count Low Word 51 Seamer Previous Shift Production Count High Word 32 Seamer Previous Shift No Lid Count Low Word 33 Seamer Previous Shift No Lid Count High Word 54 Seamer Current Shift Production Count Low Word 55 Seamer Current Shift Production Count High Word 56 Seamer Current Shift No Lid Count Low Word 57 Seamer Current Shift No Lid Count High Word 58 Seamer System Life Production Count Low Word 59 Seamer System Life Production Count High Word 60 Seamer System Life No Lid Count Low Word 6l Seamer System Life No Lid Count High Word 62 94 Not Used 95 Seamer No Container Lid Count Low Word 96 Seamer No Container Lid Count High Word 97 Container No Lid Count Low Word 98 Container No Lid Count High Word 99 Not Used E3 APPENDIX E DF1 Communication E 1 Interpreting N7 Data E 1 1 Production Counts N7 0 N7 11 N7 50 N7 61 Production Counts Fills and Lockouts are kept for three categories Current Shift Previous Shift and System Life Each count uses two elements word
45. uator exceeds the user defined response time maximum an alarm will be generated Optionally the system can include a No Fill Auto Fill three position switch allowing the operator to manually override the NC NF controls Statistics are kept for Containers not filled and no container fills caused by the switch in manual override 1 2 2 Pull Out Cam Control The NC NF NC NL provides control for the Pull out Cam Actuator Solenoid s When the Pull out Cam is retracted it resets the lockout pins for the next revolution As long as a normal flow of containers is detected the Pull out Cam will stay retracted If there is a predetermined setup parameter number of consecutive lockouts the Pull out Cam will be extended to reduce wear and tear on both the Pull out Cam and the Lockout Actuator Optionally the system can include a Extend Auto Retract three position switch allowing the operator to manually override the NC NF controls 1 2 3 Lid Feed Downstacker Actuator Control The NC NF NC NL provides direct control for the No Container No Lid Downstacker Actuator Solenoid s The actuator is controlled by the Seamer Container Sensor working in conjunction with the Seamer Timing Sensor such that when the Container Sensor does detect a container somewhere between Seamer timing signals the Lid Feed will be opened However when the Container Sensor does not detect a container between timing signals the Lid Feed
46. up parameters Driver DF1 Full Duplex Baud 19200 Parity NONE Stop Bits 1 Control Line No Handshaking Error Detection BCC Embedded Responses Enabled Duplicate Packet Detect Yes ACK Timeout 50 NAK Retries 3 ENQ Retries 3 El6
Download Pdf Manuals
Related Search