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1. M4530 Mapped PLC Description Add Add Add Function General M4530 Status Word 1 to PLC W4600 N7 0 R O Bad Seal Pocket 1 Bit 00 B628 0 B4600 0 N7 0 0 Bad Seal Pocket 2 Bit 01 B628 1 B4600 1 N7 0 1 Bad Seal Pocket 3 Bit 02 B628 2 B4600 2 N7 0 2 Bad Seal Pocket 4 Bit 03 B628 3 B4600 3 N7 0 3 Bad Seal Pocket 5 Bit 04 B628 4 B4600 4 N7 0 4 Bad Seal Pocket 6 Bit 05 B628 5 B4600 5 N7 0 5 Bad Seal Pocket 7 Bit 06 B628 6 B4600 6 N7 0 6 Bad Seal Pocket 8 Bit 07 B628 7 B4600 7 N7 0 7 Bad Seal Pocket 9 Bit 08 B629 0 B4601 0 N7 0 8 Bad Seal Pocket 10 Bit 09 B629 1 B4601 1 N7 0 9 Bad Seal Pocket 11 Bit 10 B629 2 B4601 2 N7 0 10 Bad Seal Pocket 12 Bit 11 B629 3 B4601 3 N7 0 11 Spare Bit 12 B629 4 B4601 4 N7 0 12 Spare Bit 13 B629 5 B4601 5 N7 0 13 Spare Bit 14 B629 6 B4601 6 N7 0 14 Spare Bit 15 B629 7 B4601 7 N7 0 15 M4530 Status Word 2 to PLC W4602 NT7 1 R O Excessive Good Can Rejection Bit 00 B121 4 B4602 0 N7 1 0 PMT Calibration in Process Bit 01 F34 B4602 1 N7 1 1 PMT Calibration Error Bit 02 F38 B4602 2 N7 1 2 Timing Signal Fail Bit 03 F18 B4602 3 N7 1 3 Spare Bit 04 B4602 4 N7 1 4 thru thru thru Spare Bit 15 B4603 7 N7 1 15 Machine Speed CPM W580 W4604 N7 2 R O Resolver Position W180 W4606 N7 3 R O Shift Data Current Shift Good Cans Lo W1100 W4608 N7 4 R O Good Cans Hi W1102 W4610 N7 5 R O Total Rejects Lo W1104 W4612 N7 6 R O Total R
2. Print Repott Ctrl P Exit n volts 1101 Calibrate PMT PMT Input Offset Value 0 PMT Average last 36 good cans 0 PMT Input Reject Threshold 75 AER Alarm Resel System Message All Faults Normal ONLINE 10 9 2003 3 23PM M4530 PROG Port This option allows the user to download the set up parameters timing channel set points and shift data to the M4530 If not connected to the M4530 PROG port a message will be displayed alerting the user 4030 CAL Port This option allows the user to download the PMT set up parameters to the S4030 PMT Processor board If not connected to the M4530 PROG port a message will be displayed alerting the user Note Only the values contained within the current data file are used If the validity of the current data file is questionable review the data in an Offline mode prior to download HSL RT6 M45 User s Manual SYSTEMS Electronics Group 43 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 2 5 PRINT REPORT The Set up program allows the user to generate a Report printout of all the set up parameters timing channel set points and shift data This function is accessed from the File menu At the top of each page the report disp lays the name of the set up file being printed At the bottom of each page is the date and time the document was printed as well as the page number To printout a re
3. Leeds e Ls De at 1 2 3 4 2 6 T 8 9 1 4 Position the machine with pocket 1 perfectly aligned with the PMT This is the machine zero position 5 Auto zero the resolver by selecting F10 Set Offset Enter 0 in the offset field and press lt ENTER gt The M4530 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 6 Exit back to the PLS Main Development menu by pressing lt ESC gt Exit back to the HSLRT6 set up main menu by pressing lt ESC gt again HSL RT6 M45 User s Manual SYSTEMS Electronics Group 73 SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE 6 3 2 ADJUSTING THE TIMING CHANNEL SET POINTS To set or alter any of the timing signal CH02 thru CH07 set points perform the following 1 2 3 4 From the HSLRT6 set up program main menu select the 3 Set Machine Timing selection Select 1 Online Channel Setpoint Programming Set points are entered for a particular channel by typing in the set point in the form XXX YY Y lt ENTER gt in the first set point of the given channel 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 Once the desired cha
4. 000 M4530 PMT Input Spit v4 50 7 PHT Input Offset 250 to 250 000 PMT Reject Can Threshold 075 Automatic Offset Mode Enabled VN oW E VES Desired Good Can PMT Value 030 Allowed Good Can Error 5 002 PMT Gain Calibration Mode Enabled Pty Anis 55 UN ERE RS a VES Desired Calibrated Leaker Reject PMT value 120 Allowed Calibrated Leaker Reject Error 005 PMT Gain PMT Voltage 0 1200V This value adjusts the voltage applied to the tube thus adjusting the gain of the tube The value is set in 5 volt increments thus when a number is entered it will be rounded to the nearest 5 volt increment This parameter is set by the user in manual gain mode see section 3 5 or is adjusted automatically when calibration is performed in the auto gain mode see section 3 3 Gain Calibrate PMT Input Average This is the average PMT input value of the last 6 samples taken while a calibration cycle is in process The M4530 compares this value to the Desired Calibrated Leaker Reject PMT Value and adjusts the PMT gain accordingly while a calibrate cycle is in progress see section 3 4 M4530 PMT Input Sensitivity This is a value from 0 to 7 which adjusts how much the output from the PMT input to the M4530 is amplified internally in the M4530 The higher the number the higher the M4530 sensitivity will be In general this is set at the highest amplifica
5. System Message All Faults Normal ONLINE 10 9 2003 3 30PM _ port on the computer to the CAL PORT on the M4530 This window utilizes a TAB control to divide the set up parameters into two categories These sections are as follows PMT Setup Parameters 1 Automatic Offset Mode Enabled When Checked the automatic offset mode is enabled see section 3 1 Automatic Offset Adjustment When Unchecked the manual offset mode is enabled see section 3 2 Manual Offset Adjustment HSL RT6 M45 User s Manual PMT Input Offset 250 to 250 This is the input offset value and adjusts the M4530 input offset proportionally This parameter is set by the user in manual offset mode or is adjusted automatically when in the automatic offset mode Desired Good Can PMT Value Used in the automatic offset mode This value is set by the user to specify the desired good can average The M4530 adjusts the input offset until the average good can input is within the specified error see section 3 1 Automatic Offset Adjustment 62 SYSTEMS Electronics Group 4 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE Allowed Good Can Error This parameter is used in conjunction with the Desired Good Can PMT Value to adjust the PMT input offset in the automatic offset mode The M4530 will adjust the offset until the good can average is within the value entered in Allowed Good Can Error of the Desired Good C
6. IF USED 2 3 S4 Internally the PLC 5 should be set up for RS 232C communication Refer to the dip switch settings guide on the side of the processor HSL RT6 M45 User s Manual SYSTEMS Electronics Group B 1 APPENDIX B DF1 COMMUNICATIONS 4516 DF1 to SLC SLOT 0 Swi sw2 m on fm on SLC500 S4516 DF1 SEN COMMUNICATIONS CO CPU LU RXD O 2 RX RS 232 TxD 1 3 TX Se 2 5 sc ioi kf 3 4 DTR m RXD 4 E Beds 7 RTS RS 422 8 cts TXD 6 U TxD 7 PPM ee ee 0 F s3000 NETWORK COMMUNICATIONS l f GF USED 2 23 S 4 Additionally the S4516 DF1 should be switched for RS 232 communication Dip switch SW1 is the RS 232 RS 422 dip switch should be set to POLE 1 ON POLE 2 OFF Dip switch SW2 is the slot address and is dependent upon the rest of the cards in the M4530 rack For the HSL RT6 control system SW2 should be set to POLE 1 ON POLE 2 OFF HSL RT6 M45 User s Manual SYSTEMS Electronics Group B2 APPENDIX B DF1 COMMUNICATIONS SOFTWARE PLC5 The following sample RSLogix5 code is used to execute the message control function to allow a PLCS processor to communicate with the S4516 DF1 serial communications board E LAD 3 DF1 COMM 3 JN MAIN A DF4 COMM I P HSL RT6 M45 User s Manual SYSTEMS Electroni
7. No to the Enable Automatic Offset Mode Then observe the PMT Input from the View PMT Data and adjust the PMT Offset as necessary until the PMT Input is between 25 and 30 this assumes the reject threshold is set to 35 or above This establishes the proper base value for good cans such that bad leaker cans can be detected 3 Ifthe PMT gain is subsequently manually adjusted see section 3 5 the PMT offset will then again have to be adjusted and so forth until both values are set properly Note The automatic offset mode is strongly recommended for use over the manual offset mode The automatic offset mode automatically compensates for PMT drift due to temperature etc The manual mode would require adjustment periodically as climate changes etc take place HSL RT6 M45 User s Manual SYSTEMS Electronics Group 25 SECTION 3 OFFSET GAIN AND CALIBRATION MODES 3 3 AUTOMATIC GAIN ADJUSTMENT CALIBRATION The automatic PMT gain adjustment mode is enabled by setting the PMT Gain Calibration Mode Enabled to YES using the HSLRT6 set up program In addition the user must set the Desired Calibrated Leaker Reject PMT value for calibrated leak cans as well as the Allowed Calibrated Leaker Reject Error deviation from the specified calibrated leak can value The Desired Calibrated Leaker Reject PMT value is typically set between 50 and 200 The Allowed Calibrated Leaker Reject Err
8. Spare CHOS Spare CHS wen Spare CHO inei 3 PLS Channel o 2 Recall Channel Elear Channel RPM 0 Position 254 Offset 90 Scale 360 s ystem Message All Faults Normal ONLINE 10 9 2003 3 26PM _ 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 HSL RT6 M45 User s Manual 52 SYSTEMS Electronics Group SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE Zeroing the Machine setting the resolver offset To set the machine zero resolver offset perform the following 1 2 3 4 5 6 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4530 and go online with the processor 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 Observe the POS field Verify that as the machine is rotated
9. SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 5 3 THE SERIAL COMMUNICATIONS WINDOW The Serial Communications window is used to view the configuration status of the 4516 serial communications board if installed as well as view the status of the Allen Bradley DF1 communication protocol and set up the Allen Bradley PLC communication parameters From this window the user can view or adjust the following parameters e View the 4516 configuration status e View the S4516 DF1 serial communication status e View the Allen Bradley Link Layer serial communication status e Select the Allen Bradley PLC type PLC5 or SLC500 to communicate to e View Set the Allen Bradley PLC destination node e Select the starting Allen Bradley PLC destination file number r 4516 DF1 Communication Status 4 rDF1 Communication Set up 54518 Configuration Status Sues re Transmit Data Status 0 Unknown Status g Transmit Data Status prev 0 Unknown Status Destinar Nede EE Canen anan a Desination File Number 10 jJ Active Command Read Number of BYTES Received 0 Received Command BIT Status Command AJB Link Layer Status Status 00 Success No Error Current Transaction Received 0 System Message All Faults Normal ONLINE 10 9 2003 3 26PM 7 4516 Configuration Status This displays the current state of the configuration of the S4516 serial comm
10. on the View M4530 Data menu and try again This can be increased to a maximum of 1200 volts Note Running the PMT Gain above 1100 volts will shorten the life of the PMT 5 Ifthe problem still persists perform steps 5 through 10 of section 7 1 HSL RT6 M45 User s Manual SYSTEMS Electronics Group 84 SECTION 8 RECOMMENDED SPARES The following are the recommended spares for the HSL RT6 M45 All parts are available through Systems Engineering Quantity Part Number lea M4530 1ea P4500 1ea 4568 1ea 84516 1ea 4573 lea D4591 lea RSV34 MS1 1ea PS2000N1 1ea 9956B 16 1ea B2F RFI HSL RT6 M45 User s Manual Description PLC PLS PMT Module Power Supply 8 IN 8 OUT 10 30VDC I O BOARD Communications board if used 16 Point 10 30VDC Output Board if used Display Keypad Resolver 2K Volt PMT Power Supply Photo Multiplier Tube PMT Housing with C634 PMT Preamp and C641 PMT Gating Circuit SYSTEMS Electronics Group 85 SECTION 8 RECOMMENDED SPARES This Page Intentionally Left Blank HSL RT6 M45 User s Manual SYSTEMS Electronics Group 86 APPENDIX A MODBUS COMMUNICATIONS MODBUS PORT CONFIGURATION The MODBUS driver uses the following data format and parameters the MODBUS port on the MODICON PLC must be set to match these MODBUS Port PLC address 5 MODBUS Baud 19 2K MODBUS framing mode RTU Number of start bits 1 Number of data bits 8 Number of stop
11. 6 HSLRT6 DOS Based Set up Program Reference 67 6 1 M4530 Set Up Menu CAL Port 68 6 2 View M4530 PMT Data CAL Port 70 6 3 Set Machine Timing PROG Port 72 6 3 1 Zeroing the Machine 73 6 3 2 Adjusting the Timing Channel Set points 74 6 4 Number of Rejects per Pocket Data PROG Port 75 6 5 Current Shift Data PROG Port 76 6 6 Last Shift Data PROG Port 76 6 7 Download Program to M4530 PROG Port 7T 7 Trouble Shooting 79 7 1 Gain Calibrate Error 79 7 2 Offset Error 81 7 3 M4530 Fault 82 7 4 Excessive Good Cans Rejected 83 7 5 Calibrated Leakers Not Rejected 84 8 Recommended Spare Parts 85 HSL RT6 M45 User s Manual SYSTEMS Electronics Group iii HSL RT6 M45 User s Manual MODBUS Communications MODBUS Port Configuration Data Written to the MODICON PLC Data Read from the MODICON PLC Allen Bradley DF1 Communications Hardware Software Using the MSG Instruction Channel 0 Setup Read Write Data Definitions Drawings iv CONTENTS APPENDICES Appendix A A 1 A 1 A 4 Appendix B B 1 B 3 B 5 B 9 B 12 Appendix C SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 1 FEATURES e Allows detection and rejection of leakers at speeds in excess of 2400CPM e Performs the following control functions 1 Detection of leakers pin holes split flanges gross leakers etc Does not reject good cans following a gross leaker or missing can 2 Auto photo multiplier tube PMT cal
12. generated once per 12 cans and used to specify pocket 1 and a Sync pulse generated once per pocket and used for the PMT sample and reject timing The PMT tube is gated on at both the leading and trailing edges of the sync pulse The leading edge gate pulse is used to actually sample the can for leaks and occurs when the tube is aligned with the pocket The trailing edge gate pulse occurs between pockets at the dark portion of the shutter This is used as a base dark measurement for offset calibration Note The tube is only gated on at these leading and trailing edge transitions for less than one millisecond and not just enabled continuously This prevents the tube from saturating when a gross leaker or missing can is present at the pocket allowing the following cans to be fully tested and not just rejected while the tube recovers from saturation Two parameters set in the M4530 module are used to calibrate the tube They are the PMT gain and PMT input offset The PMT gain is a 0 to 6 volt analog output on the M4530 which is feed into the 0 to 2000 volt power supply which supplies power to the tube This parameter is used to set the gain of the tube such that the desired minimum leak will be rejected Adjusting this output between 0 and 6 volts adjusts the voltage applied to the PMT between 0 and 1200 volts where 0 volts would result in no light detected zero gain and 1200 volts would result in the maximum sensitivity maximum
13. Pocket Reject Totals If a particular pocket is rejecting a significantly higher number of cans than the other pockets that pocket most likely has a bad light seal or some other mechanical problem Fix that pocket s seal and try again If all pockets show high reject rates continue to step 2 2 Verify that all pocket seals are in good condition with no visible leaks Verify pocket air pressure Verify that no light leakage is occurring at any of the PMT seals machine shutter to light seal plate PMT to light seal plate or at the PMT housing itself If these all look good proceed to step 3 3 If the M4530 is setup too sensitive PMT Reject Can Threshold too low Desired Calibrated Leaker Reject PMT Value too high or PMT Gain too high excessive good cans will be rejected Perform steps 4 through 7 to lower the sensitivity 4 Select the M4530 Set up menu and set the Desired Calibrated Leaker Reject PMT Value to a lower value between 40 and 200 Note The Desired Calibrated Leaker Reject PMT value must be greater than the PMT Reject Can Threshold 35 to 75 which in turn must be greater than the Desired Good Can PMT Value 20 to 30 Perform the calibration procedure and try again If a calibrate error occurs at this point trouble shoot per section 7 1 5 If excessive cans are still being rejected from the M4530 Set up menu increase the PMT Reject Can Threshold no
14. Rejection 21 2 13 M4530 P4500 D4591 Installation 22 2 13 1 M4530 Module Installation 22 2 13 2 P4500 Power Supply Installation 23 2 13 3 D4591 Keypad Display Installation 24 2 13 4 Download HSLRT6 Program to M4530 24 HSL RT6 M45 User s Manual SYSTEMS Electronics Group HSL RT6 M45 User s Manual 3 Offset Gain and Calibration Modes Automatic Offset Adjustment Manual Offset Adjustment Automatic Gain Adjustment Calibration Calibration Procedure Manual Gain Adjustment Using the Keypad Display Default Screen Rejects per Pocket Key Reset Rejects per Pocket Key Current Shift Key Last Shift Key Manual Reject Key View PMT Data Key Calibrate Gain Key Adjust Gain Key Adjust Threshold Key Set Machine Zero Set Resolver Offset Key 5 HSLRT6 Windows Based Set up Program Reference 5 1 5 2 5 3 5 4 5 5 5 5 General Description The File Menu 5 2 1 The Set Up Data File 5 2 2 Upload save Data 5 2 3 Download Program 5 2 4 Download restore Data 5 2 5 Print Report The Edit Menu 5 3 1 Enable Offline Editing 5 3 2 Setup Comm Port The View Menu 5 4 1 Target Board Interface 5 4 2 View Online Data 5 4 3 View Offline Data The Window Menu 5 5 1 The Main Display Window 5 5 2 The Machine Timing Window 5 5 3 The Serial Communications Window 5 5 4 The Shift Data Window 5 5 5 Thel O States Window The PMT Window CONTENTS SYSTEMS Electronics Group diis CONTENTS
15. Value 030 Allowed Good Can Error 002 PMT Gain Calibration Mode Enabled Y N YES Desired Calibrated Leaker Reject PMT value 120 Allowed Calibrated Leaker Reject Error 005 Where XXX of the Gain Calibrate PMT Input Average can be any number This will change when a calibrate cycle is performed 2 12 2 SET MACHINE ZERO Unlike the original encoder the resolver shaft is not mechanically adjusted to zero the timing but instead is electronically adjusted in the PLS section Position the machine with pocket 1 precisely aligned with the PMT this is the machine zero location Set the resolver offset per section 4 11 HSL RT6 Keypad Display Refer to section 5 Windows based setup program reference or section 6 DOS based setup program reference to set the resolver using the setup program Note The M4530 PLS is automatically programmed with the Sync timing CH00 and Marker timing CH01 No other PLS timing channel programming is required by the user The Sync timing goes on at the centerline of PMT tube to pocket alignment and goes off at the centerline in between pockets HSL RT6 M45 User s Manual SYSTEMS Electronics Group 18 SECTION 2 INSTALLATION 2 12 3 VERIFY THE B2F RFI PMT HOUSING OFFSET The C634 A1H Preamp board inside the B2F RFI housing contains an offset potentiometer used to null any offset of both the PMT and amplifier circuitry If this inherent offset of the PMT and amplifier i
16. and 200 and try again Note The Desired Calibrated Leaker Reject PMT value must be greater than the PMT Reject Can Threshold 35 to 75 which in turn must be greater than the Desired Good Can PMT Value 20 to 30 Perform the calibration procedure again If the problem persists proceed to steps 3 and 4 below 3 If after calibration the PMT Gain is less than 500 volts and the Gain Calibrate PMT Input Average is greater than the Desired Calibrated Leaker Reject PMT value the PMT detected too much light and was not able to reduce the gain of the PMT adequately to compensate for the amount of light detected Verify that the calibrated leaker has a 0025 calibration hole in it and does not have any other areas of leakage in the can Verify that the seal at the pocket used for calibration is not leaking Verify that no light leakage is occurring at any of the PMT seals machine shutter to light seal plate PMT to light seal plate or at the PMT housing itself Perform the calibrate procedure per section 3 4 and try again Proceed to step 5 if the problem persists HSL RT6 M45 User s Manual SYSTEMS Electronics Group 79 SECTION 7 TROUBLE SHOOTING 4 If after calibration the PMT Gain is at 1101 volts and the Gain Calibrate PMT Input Average is less than the Desired Good Can PMT Value by more than 5 then the PMT did not detect enough light and was not able to increase the gain en
17. bits 1 Parity NONE The MODBUS communications driver uses the S4516 communications board to both read and write data to a MODICON PLC DATA WRITTEN TO THE MODICON PLC The following data is written to the MODICON PLC MODICON Dest 4x Address Data Definition 401700 Speed CPM 401701 Resolver Position Current Shift Data 401702 Number of Good Cans Lo 0 to 9 999 401703 Number of Good Cans Hi 10 000 s 401704 Total Rejects Lo 0 to 9 999 401705 Total Rejects Hi 10 000 s 401706 Rejects Pocket 1 current shift thru thru 401717 Rejects Pocket 12 current shift Diagnostics Counts resettable by the operator 401718 Rejects Pocket 1 diagnostic thru thru 401729 Rejects Pocket 12 diagnostic HSL RT6 M45 User s Manual M4530 Source Address W182 W180 W1100 W1102 W1104 W1106 W1108 thru W1130 W1050 thru W1072 SYSTEMS Electronics Group APPENDIX A MODBUS COMMUNICATIONS MODICON Dest 4x Address Data Definition PMT Set Up Status Variables 401730 401731 401732 401733 401734 401735 HSL RT6 M45 User s Manual PMT Gain in volts 498 to 1200 PMT Offset Magnitude 0 to 250 PMT Offset sign 0 1 Reject Threshold 0 to 255 PMT Good Can Average Value Status to MODICON A 2 M4530 Source Address W1000 B1002 B1003 B1004 B1005 W790 SYSTEMS Electronics Group The bits of the APPENDIX A MODBUS COMMUNICATIONS Status register to the MODICON from the M45
18. by typing in the set point Note CH00 Sync timing and CH01 Marker timing are automatically programmed at power up and should not be modified by the user Only CH02 thru CH07 can be programmed by the user if additional timing signals are required by the user these channels are not used by the HSLRT6 program Only one set point is can be programmed per channel If a channel needs to be Recalled or Cleared enter the desired channel number into the PLS Channel field Click the Recall Channel command button to recall the setpoints Click the Clear Channel command button the completely clear all setpoints for the selected channel Note Ifa channel has been cleared or the On and Off setpoints have the same setting the set point will be displayed as HSL RT6 M45 User s Manual SYSTEMS Electronics Group 54 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE Resetting the PLS Configuration As an aid to the user the current PLS configuration is displayed in the PLS Configuration tab of this window The PLS configuration should only be reset if a new module has been installed To reset the PLS configuration click the Reset PLS Config command button This function only resets the PLS configuration to the default settings EE HSLRTE unnamed Machine Timing Eea Ega oa Ean Bal jos 507 EDS CINCO HSL RT6 M45 User s Manual SYSTEMS Electronics Group 55
19. each of the HSLRT6 directories created in section 2 11 2 copy all the files from the disk to each of these subdirectories 2 12 TUNING THE HSL RT6 M45 The HSL RT6 M45 is shipped from the factory with the PLC program HSLRT6 loaded in the M4530 module PLC section This is the standard program used to implement the standard HSL RT6 M45 light tester algorithms Once the HSL RT6 M45 is installed and the control system is powered back up perform the following to set up and tune the HSL RT6 M45 The set up is performed using a PC running the HSLRT6 set up program or the optional Keypad Display See sections 5 or 6 for a description of the HSLRT6 menus and variables and how to use the HSLRT6 program See section 4 for a description of the Keypad commands and menu displays of the HSL RT6 Keypad Display At the initial installation prior to performing the set up steps below verify that the default user variables see section 2 12 1 are set to the values listed HSL RT6 M45 User s Manual SYSTEMS Electronics Group 17 SECTION 2 INSTALLATION 2 12 1 DEFAULT SET UP VARIABLES As shipped the user variables of the PMT section of the M4530 are set to the following defaults PMT Gain PMT Voltage 0 1200V 1101 Gain Calibrate PMT Input Average XXX M4530 PMT Input Sensitivity maf PMT Input Offset 75 to 75 000 PMT Reject Can Threshold 075 Automatic Offset Mode Enabled Y N YES Desired Good Can PMT
20. gain The M4530 provides both manual and automatic modes of adjustment for the PMT gain see sections 3 3 and 3 5 The PMT input offset parameter is an internal M4530 adjustment which adjusts the offset of the PMT output at the input to the M4530 This adjustment is used to set the proper balance between the PMT value of good cans and the PMT value of bad cans such that the good cans are not rejected while the bad leak cans are this essentially gets the PMT value into the proper range The M4530 provides both manual and automatic modes of adjustment for the offset see sections 3 1 and 3 2 HSL RT6 M45 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION In general optimum performance is achieved when both automatic offset and gain adjustment is selected The automatic offset adjustment allows the M4530 to compensate for PMT drift due to temperature etc continuously while the machine is running The automatic gain or calibration mode provides the simplest method of calibrating the PMT gain allowing the operator to calibrate the PMT using just a calibrated leak can and no other special equipment 1 3 ALARM DETECTION The package detects the following alarms BAD POCKET If any pocket rejects more than a 4 cans per 10 revolutions of the tester this alarm is generated for that pocket This indicates that either the light seal for the respective pocket is bad or that some other mechanical problem relating to that p
21. of the Desired Good Can PMT Value see section 3 1 PMT Gain Calibration Mode Enabled When set to YES the automatic gain calibration mode is enabled see section 3 3 When set to NO the manual gain mode is enabled see section 3 5 Desired Calibrated Leaker Reject PMT Value Used in the auto gain mode This value is set by the user to specify the desired reject average The M4530 adjusts the PMT gain until the average calibrate value is within the specified error see section 3 3 Allowed Calibrated Leaker Reject Error This parameter is used in conjunction with the Desired Calibrated Leaker Reject PMT Value to adjust the PMT gain in the auto gain mode The M4530 will adjust the gain until the calibrate average is within the value entered in Allowed Calibrated Leaker Reject Error of the Desired Calibrated Leaker Reject PMT Value see section 3 3 HSL RT6 M45 User s Manual SYSTEMS Electronics Group 69 SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE 6 2 VIEW M4530 PMT DATA CAL PORT The View M4530 Data Menu is used to view the good can and reject data in real time as well as manually fine tune the PMT gain This menu is invoked by selecting 2 View M4530 PMT Data CAL PORT from the Main Menu Note Prior to selecting this selection make sure the RS 232 cable is connected from the COM1 port on the computer to the CAL PORT on the M4530 le HSLRT6 EXE B x Systems M4530
22. performed stop the tester align a calibrated leak test can at the PMT and select the Calibrate PMT button If the button is pressed the calibration will be performed see section 3 3 Automatic Gain Adjustment Calibration Once the calibration is initiated the message display will show PMT Gain Calibration In Progress The applied PMT gain will display the current gain in volts If the calibration is not successful the message display will show Calibration Error See section 3 4 Calibration Procedure for details on the calibration error Note This function is only available while online with the processor through the PROG port and the tester is stopped HSL RT6 M45 User s Manual SYSTEMS Electronics Group 5 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 5 2 THE MACHINE TIMING WINDOW The Machine Timing window is used to invoke the PLS programming command menus From this window the user can view or adjust the following parameters e Adjust Timing Channel setpoints e Set the resolver offset e Clear or Recall a PLS timing channel e View the current PLS configuration e Reset the PLS configuration to default settings Timing Channels PLS Configuration Timing Channels Resolver Offset ON OFF o Sync Timing cH00 0 15 Set Offset Marker Timing CHOI 345 165 Spare CHO2 7 SpareicHos S 7 4 Spare CH04 a zi a zi
23. starwheel is polished If the machine seems to be rejecting an excessive amount of cans select the 4 View Can Reject Counts selection from the Main Menu of the HSLRT6 set up program or the Rejects Per Pocket selection of the HSL RT6 DSP display and observe the Per Pocket Reject Totals If a particular pocket is rejecting a significantly higher number of cans than the other pockets then that pocket most likely has a bad light seal or some other mechanical problem In general this menu can be used to evaluate the reject performance of the machine HSL RT6 M45 User s Manual SYSTEMS Electronics Group 21 SECTION 2 INSTALLATION 2 13 M4530 P4500 D4591 INSTALLATION The following is provided only as a reference These steps are performed by the factory prior to shipping the HSL RT6 M45 These steps need only be performed in the event either the M4530 module P4500 power supply or D4591 display need to be replaced Refer to the M4530 User s Manual for general details on installing the M4530 P4500 and D4591 2 13 1 M4530 MODULE INSTALLATION To install the M4530 module perform the following 1 Remove the cover from the M4530 chassis retained with three captive screws on the lower front of the cover and two captive screws on each side of the M4530 chassis 2 Install S4568 SLOTO 0 This is the basic input output board reject solenoids etc Set the slot address dip switches SW1 on the S4568 to the following p
24. the INC GAIN or DEC GAIN key is used to adjust the gain up or down respectively by 5 volts each time the corresponding key is depressed Increasing the gain increases the sensitivity of the system decreasing the gain decreases the sensitivity of the system Once the gain has been adjusted as desired press ESC to return to the previous menu Note This selection is only enabled when the SET UP ENABLE key switch is in the ENABLE position HSL RT6 M45 User s Manual SYSTEMS Electronics Group 35 SECTION 4 USING THE KEYPAD DISPLAY 4 10 ADJUST THRESHOLD KEY This selection is used to increase or decrease the Reject Threshold Once activated the INC THRES or DEC THRES key can be used to adjust the threshold up or down respectively by one each time the corresponding key is depressed Increasing the threshold decreases the sensitivity of the system decreasing the threshold increases the sensitivity of the system Once the threshold has been adjusted as desired press ESC to return to the previous menu Note This selection is only enabled when the SET UP ENABLE key switch is in the ENABLE position 4 11 SET MACHINE ZERO SET RESOLVER OFFSET KEY To zero the machine set the resolver offset perform the following 1 Select VIEW PMT DATA and observe the POS field Verify that as the machine is rotated forward that the position increases linearly f
25. the Control Panel Status Bar At the bottom of the window is the Status Bar The status bar is used to display system messages online or offline mode as well as the current time and date as set by the operating system The system messages panel displays general information about operation of the system The Online Offline mode panel displays the status of the current set up program mode of operation The mode of operation can be changed by simply double clicking the online offline mode panel Hot Keys Hot keys are activated by holding down the ALT key and simultaneously pressing the underlined letter of the desired function Almost every function can be activated by either pressing a series of hot keys or using the TAB key to move between fields Online Offline Modes The set up program allows the user to make changes while Online with the processor The Offline mode is used to preset parameters prior to download All functions are available to the user while Online however specific Online functions are disabled in the Offline edit mode Note Offline changes can only be made by enabling Offline Editing accessed under the Edit menu Getting Help The entire contents of the user s manual is contained within the help file Pressing Ctr 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 inform
26. the end of either an 8 or 12 hour shift or alternatively could be done at label changes such that the data collected would be for label runs rather than complete shifts This data cannot be reset either from this menu or by the operator only at the end of shift input transition To exit back to the main menu press lt ESC gt Total Good Cans Processed This is the total number of good cans tested so far into the shift This is essentially a can counter Total Rejected Cans This is the total number of rejected cans for all pockets of the machine Pocket 01 rejects thru Pocket 12 rejects This is the total rejected cans for each pocket A disproportionately high count for a particular pocket indicates a sealing problem for that pocket 6 6 LAST SHIFT DATA PROG PORT 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 Refer to section 6 5 for definitions of the data fields in the Last Shift data menu HSL RT6 M45 User s Manual SYSTEMS Electronics Group 76 SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE 6 7 DOWNLOAD PROGRAM TO M4530 PROG PORT This selection is used to download the HSLRT6 application program to the M4530 module This should only be performed when replacing the M4530 module see s
27. the rear as shown in figure 1 and slide up until seated against the front lip of the PMT housing Tighten the collet set screws against the PMT to hold the PMT in the collet 4 Mount the entire PMT assembly to the machine frame using the existing PMT mounting holes When mounting the assembly make sure the front of the PMT assembly is seated and sealed in the existing shutter gimbal HSL RT6 M45 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 6 INSTALLING THE PMT TUBE INSIDE THE PMT HOUSING These instructions are used to install the tube in the housing both at the initial installation of the HSL RT6 MAS and when it is necessary to replace the tube The 9956B 16 tube is installed inside the B2F RFI housing once the housing is installed on the machine as follows IMPORTANT For your safety power to the PMT housing must be off prior to removing the Preamp Gating Circuit assembly from the B2F RFI housing The Preamp Gating Circuit and PMT are supplied with as much as 2000 volts DC This power must be removed before any part of the B2F RFI housing seal is broken The housing is powered from the PS2000N1 which is powered from the 24VDC power supply Therefore disconnecting the 24VDC power supply will power down the PS2000 power supply 1 Disconnect the 24VDC power supply which powers the PMT section and PS2000N1 high voltage power supply 2 Remove the Preamp Gating circuit assembly from the B2F RFI housing b
28. then remove the high frequency lamp driver box Mount the HSL RT6 M45 in the location the high frequency lamp driver box was mounted as conveniently close to the PMT as possible 2 4 MOUNTING THE RSV34 MS1 RESOLVER The HSL RT6 MAS is designed to interface to a resolver not encoder for machine timing To mount the resolver perform the following 1 Remove the existing encoder 2 Mount the resolver in place of the encoder making sure the resolver shaft does not bind when the machine is rotated Refer to the RSV34 MSI data sheet for details on mounting the resolver 3 Connect the supplied RSV RSCBLE 20 cable to the MS connector on the resolver Route the resolver cable in a separate conduit away from all other high voltage motor leads and control wiring Wire the cable directly to the 8 pin resolver connector on the M4530 see section 2 7 HSL RT6 M45 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 5 MOUNTING THE PMT HOUSING The HSL RT6 M45 PMT replaces the entire existing Reynolds PMT assembly with the exception of the shutter gimbal which is used and is actually mounted in the same location To mount the PMT perform the following 1 Remove the existing Reynolds PMT assembly 2 Mount the supplied 15 002 2 PMT collet to the 15 002 1 mounting plate as shown in figure 1 on the drawing at the back of this manual if not already done 3 Carefully slide the 15 002 assembly over the PMT housing from
29. 2 Program Name RI6TMG Main Development Menu 1 Online Channel Setpoint Programming 2 Offline Channel Setpoint Programming 3 Edit PLS Configuration 4 Download Channels to PLS 5 Upload Channels from PLS 6 Print Channels 7 File Utilities 12 Return to SVSdev Shell Enter selection HSL RT6 M45 User s Manual SYSTEMS Electronics Group 232 SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE 6 3 1 ZEROING THE MACHINE To set the machine zero resolver offset perform the following 1 From the HSLRT6 set up program main menu select 3 Set Machine Timing selection 2 Select 1 Online Channel Setpoint Programming 3 Select F9 POS RPM and observe the POS field Verify that as the machine is rotated forward that the position increases linearly from 0 through 359 If not swap the S1 and S3 leads of the resolver at the M4530 resolver connector Then verify that the position then indeed does increase with forward movement Press ESC to exit the POS RPM update HSLRT6 EXE _ 5 x CHANNEL 00 DESCRIPTION Sync Timing PROG MODE ONLINE CHRNNEL SET POINTS ON OFF ON OFF ON OFF ON OFF ON OFF 0000 0015 11 0200 0315 21 31 41 0030 0045 12 0330 0345 22 0060 0075 13 23 0090 0105 0120 0135 0150 0165 0180 0195 0210 0225 0240 0255 0270 0285 SCALE FRCTOR 360 MESSAGE Position 254 Speed RPH 0000
30. 30 are mapped as follows W790 Status to MODICON 4x address 401735 in MODICON B790 0 thru B791 3 B791 4 B791 5 B791 6 B791 7 The Status bits B790 0 thru B791 3 B791 4 B791 5 B791 6 B791 7 Bad Seal Pocket 1 thru Bad Seal Pocket 12 Excess Good Can Rejection Alarm PMT Calibration in Progress PMT Calibration Error Timing Signal Fail Alarm sent to the MODICON PLC are defined as follows Bad Seal Pocket 1 Bad Seal Pocket 12 The respective Bad Seal pocket alarm for pockets 1 thru 12 are activated when the corresponding pocket incurs over 4 rejects within 10 cans tested Excess Good Can Rejection Alarm this bit is set to a 1 if 10 consecutive cans are rejected The bit is cleared when 10 good consecutive cans are detected or when the machine stops This generally indicates that a major compromise in the light seal shutter plate to PMT gimbal or pocket seals has occurred In addition this may also indicate an infeed track jam This bit should be interlocked with the infeed low sensor to stop the machine if the infeed low sensor is covered and the bit is set to a 1 PMT Calibration in Progress this bit is set to a 1 when the PMT Gain calibration is in progress When this bit goes back to a 0 bit6 of this byte should be tested to see if a calibration error occurred or not see below PMT Calibration Error this bit is set to a 1 if a calibration error occu
31. 6 M45 User s Manual SYSTEMS Electronics Group 45 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 4 THE VIEW MENU The View menu allows the user to perform the following functions e View the Target Board Interface e View Online Data e View Offline Data amp HSLRATE unnamed Main Display Target Board Interface HSL RT6 M45 User s Manual SYSTEMS Electronics Group 46 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 4 1 TARGET BOARD INTERFACE This function allows the user to view fault codes S3000 network communication error codes and review the current Ident and Revision of the application program This is accessed by the View menu by selecting Target Board Interface Target Board Interface Program Ident Revision Set Network Address Set Time amp Date r Internal Fault Code Current Fault Code 00H No Internal Fault has Ocurred Last Fault Code 00H No Internal Fault has Ocurred Heset Faults Corrective Action None E r Communications Network Error Codes Current Comm Error Code 00H No Network Comm Error Last Comm Error Code 00H No Network Comm Error Once invoked the set up program will prompt the user to select a program to compare with the one existing in the processor Whether a program is selected or the user cancels the setup program will att
32. ASED SETUP PROGRAM REFERENCE 5 2 1 THE SET UP DATA FILE The set up Data File sdt is a binary access file designed for fast file I O operation When the set up program is first invoked the default set up parameters are loaded into memory If changes are made to any of the set up parameters either online or offline as well as shift data the user will be flagged to Save Changes upon exit of the program Note Any windows based Set up program can open a set up Data File however the data tables will not be properly aligned The user will be alerted to the problem if a set up data file has been created by either a different set up program or a different revision of the software The set up Data File is similar to that of a word processing file When the program first starts the default parameters are loaded and the user is able to make changes as desired The set up program is unaware of the settings and parameters that exist within the M4530 Therefore to normalize the set up program with the processor the user should define or open an existing file then upload All variables from the processor This allows the user to either create a backup of the data or maintain an existing file The user can even open a data file for another tester save the file to a new name make the necessary changes and simply download the new parameters to another processor The following functions can be accessed any time
33. HSL RT6 M45 Reynolds RT 6 Tester Control M4530 Based User s Manual Systems Engineering Associates Inc 14989 West 69th Avenue Arvada Colorado 80007 U S A Telephone 303 421 0484 Fax 303 421 8108 www sea seg com 02 2004 HSL RT6 M45 Reynolds RT 6 Tester Control M4530 Based User s Manual Copyright 1995 Systems Engineering Associates Inc All Rights Reserved Revised 9 February 2004 WARNING To ensure the equipment described by this User Manual as well as the equipment connected to and used with it operates satisfactorily and safely all applicable local and national codes that apply to installing and operating the equipment must be followed This includes the National Electric Code in the USA and other applicable legislation regulations and codes in practice elsewhere Since codes can vary geographically and can change with time it is the user s responsibility to determine which standards and codes apply and to comply with them FAILURE TO COMPLY WITH APPLICABLE CODES AND STANDARDS CAN RESULT IN DAMAGE TO EQUIPMENT AND OR SERIOUS INJURY TO PERSONNEL Persons supervising and performing installation or maintenance must be suitably qualified and competent in these duties and should carefully study this User Manual and any other manuals referred to by it prior to installation and or operation of the equipment The contents of the User Manual are believed to be correct at the time of printing however
34. Light Source Assembly HSL RT6 M45 User s Manual M4530 User s Manual HSL RT6 M45 Program Disk 2 1 2 HSL RT6 M45 OPTIONS PURCHASED SEPARATELY The following items can be purchased separately as required or desired tea 4516 Data Communications Board MODBUS and DF1 protocols lea HSL RT6 DSP Data Set up Display D4591 2 Line X 40 character display with 24 key keypad mounted in a NEMA 12 mini pedestal for direct mounting to the HSL RT6 M45 enclosure tea 4573 16 Point 10 30VDC Output to drive individual pocket reject indicators HSL RT6 M45 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 2 POWER REQUIRED The HSL RT6 M45 is powered from 115VAC 50 60HZ and 24VDC The 115VAC is used to power the M4530 module and the Halogen Light source while the 24VDC is used to power the PMT section 2000 volt power supply and 24VDC I O odd even reject solenoids etc The 24VDC current required by the HSL RT6 MAS is approximately only 1 0 AMP more than the existing system s 24VDC current requirement therefore the existing 24VDC power supply should be adequate Note The 24VDC must be regulated 10 2 3 MOUNTING THE HSL RT6 M45 ENCLOSURE The HSL RT6 M45 enclosure should be mounted in the location that the high frequency lamp driver box was located This is directly below the PMT location on the machine To install the enclosure first remove the wiring associated with the high frequency lamp driver and
35. NICATIONS WRITE INSTRUCTION SLC500 The write message MSG command for a SLC500 is setup as follows MSG N12 40 14 Elements Note The Data Table Address can be any integer file address The 10 elements written to the M4530 PLC are defined in the last section Read Write Data Definitions HSL RT6 M45 User s Manual SYSTEMS Electronics Group B8 APPENDIX B DF1 COMMUNICATIONS CHANNEL 0 SETUP PLC5 The Channel 0 Serial Port should be setup as follows Edit Channel Properties o s Paigo sl s Z EnorDetect ecc sj E Full Duplex Modem Note The Communication Mode is setup for System Point to Point HSL RT6 M45 User s Manual B 9 SYSTEMS Electronics Group APPENDIX B DF1 COMMUNICATIONS The Channel 0 Options are setup as follows Edit Channel Properties The Detect Duplicate Messages should be unchecked HSL RT6 M45 User s Manual SYSTEMS Electronics Group B10 APPENDIX B DF1 COMMUNICATIONS SLC500 The Channel 0 Serial Port should be setup as follows Channel Configuration The Duplicate Packet Detect should be unchecked HSL RT6 M45 User s Manual SYSTEMS Electronics Group B 11 APPENDIX B DF1 COMMUNICATIONS READ WRITE DATA DEFINITIONS Data Read From The M4530 50 Elements Is Defined As Follows
36. OR PROBLEM MAINT Led on M4530 is on SOLUTION Select the M4530 Set up and verify the following 1 2 3 4 5 6 7 If the MAINT Alarm entry in the Set up menu displays either Offset Exceeded 250 or Offset Exceeded 250 then the automatic offset routine attempted to adjust the offset outside the maximum or minus offset limits If the offset exceeds or 250 in an attempt to set the PMT Input Average equal to the Desired Good Can PMT Value the MAINT LED on the M4530 will be illuminated This indicates that the PMT is detecting an excessive amount of light both when the cans are sampled and at the in between pocket measurement or that the offset potentiometer in the PMT B2F RFI housing is set incorrectly Verify that the Desired Good Can PMT Value is within a reasonable range 20 to 35 If this value is outside this range say 0 or 255 the M4530 cannot adjust the offset enough to compensate for this unrealistic value If the value was outside the range set the Desired Good Can PMT Value between 20 and 35 and proceed to step 5 Note The Desired Calibrated Leaker Reject PMT value must be greater than the PMT Reject Can Threshold 35 to 75 which in turn must be greater than the Desired Good Can PMT Value 20 to 30 Verify that the B2F RFI PMT housing offset potentiometer is set correctly see section 2 12 3 Verify that the machin
37. PMT Data menu displays the following set up variables PMT GAIN VOLTS XXXX PMT OFFSET XXX THRESHOLD XXX PMT AVERAGE XXX POS XXX The data is shown in real time and reflects any change in value that may occur for each set up parameter To exit this menu simply press ESC to return to the default menu PMT Gain Volts This value adjusts the voltage applied to the tube adjusting the gain The value is set in 5 volt increments from 498 to 1200 This parameter is adjusted when the PMT Gain calibration is performed see section 4 8 or by adjusting the gain manually using the ADJUST GAIN key see section 4 9 PMT Offset This is the input offset value between 250 and 250 and adjusts the M4530 input offset proportionally This parameter is adjusted automatically in response to variations of the PMT offset see section 3 1 Threshold This value specifies the reject threshold If the PMT Input value is below the threshold the can is considered good and is not rejected If the PMT Input value is above the threshold the can is considered a leaker and is rejected This parameter is typically set between 35 and 75 This parameter is adjusted using the ADJUST THRES key see section 4 10 PMT Average This is the average of all good cans and the in between pocket dark measurements for 36 consecutive cans POS This is the current angular position of the resolver in degrees The resolver makes one revo
38. PORT or the PROG PORT on the M4530 as specified in the selection Note The HSLRT6 program is an on line communications program used to interface with the M4530 module The data displayed in the menus and set in the menus is communicated directly to the M4530 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 HSLRT6 to the respective port CAL or PROG on the M4530 as indicated in the selection The following sections are a complete description of the HSLRT6 selections and menus HSL RT6 M45 User s Manual SYSTEMS Electronics Group 67 SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE 6 1 M4530 SET UP MENU CAL PORT The M4530 Set up Menu is used to set the offset and gain modes of the M4530 as well as the reject threshold This menu is invoked by selecting 1 M4530 Set up CAL PORT from the Main Menu Note Prior to selecting this selection make sure the RS 232 cable is connected from the COM1 port on the computer to the CAL PORT on the M4530 HSLRT6 EXE lol xi Systems M4530 Tester Set up Monitoring Version 1 0 M4530 Set up Menu 1 Set Reject Threshold 2 Set M4530 PMT Input Sensitivity 3 Automatic Offset Mode 4 PMT Gain Calibration Mode 5 Help Screen Enter Selection ESC to exit PHT Gain PMT Voltage 0 1200V 1101 5 Gain Calibrate PMT Input Average
39. SL RT6 M45 User s Manual SYSTEMS Electronics Group 60 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 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 M4530 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 M4530 processor HSLRT6 unnamed 170 Status ini x LL HSL RT6 M45 User s Manual SYSTEMS Electronics Group 61 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 6 THE PMT WINDOW The PMT window is used to view and adjust any of the PMT setup parameters Note Prior to selecting PMT window make sure the RS 232 cable is connected from the COM1 PMT Offset PMT Input amp HSLRTE unnamed PMT Ioj x Fie Edit View Window PMT Help s View PMI Data Enable Automatic Offset Mode M PMT Gain Voltage 0 1200 1101 PMT Input Offset 250 to 250 0 PMT Input Sensitivity 0 7 7 Desired Good Can PMT Value 15 35 3 Allowed Good Can Error 0 20 2 a m Leaker Calibration Enable Automatic Gain Calibration Mode v Calibrated Leaker PMT Value Input Avg 8E Desired Calibrated Leaker PMT Value 35 240 120 E Calibrated Leaker Reject Error 0 20 5 Leaker Reject Threshold 0 255 75
40. SYSdev file can be downloaded with the set up program Care should be taken when selecting a program to download If not connected to the M4530 PROG port a message will be displayed alerting the user Once selected a message box is displayed informing the user of the current program revision and checksum of the program loaded in the processor as well as that of the selected program The user must confirm their selection by clicking the Yes command button After the user confirms their choice program download is initiated and the current program download address is displayed When program download is complete the user is prompted to acknowledge Control is passed back to the main program and the set up program remains in an Online edit mode HSL RT6 M45 User s Manual SYSTEMS Electronics Group 42 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 2 4 DOWNLOAD RESTORE DATA The set up program allows the user to download Set up parameters timing channel set points and shift data to the M4530 and S4030 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 HSLRTE unnamed Main Display File Edit View Window PMT Help New Ctrl N Open Etre Save Ctrl S Save As Export Shift Data Ctrl lt Upload save Data gt Download Program Download Data Good Cans Rejects
41. T UP HSL RT6 The DOS commands executed for this selection should be For the SET UP HSL RT6 selection CD HSLRT6 lt ENTER gt HSLRT6 lt ENTER gt CD xXENTER gt 4 To execute the set up program simply select the SET UP HSL RT6 selection from the menu software s menu HSL RT6 M45 User s Manual SYSTEMS Electronics Group 16 SECTION 2 INSTALLATION 2 11 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 RT6 MAS If SYSdev was purchased with the HSL RT6 M45 package and is not already installed on the your computer install SYSdev onto the hard drive of your computer following the steps of the SYSdev Program Development manual 2 11 4 APPLICATION PROGRAM INSTALLATION The HSLRT6 application program is a SYSdev based program loaded into the M4530 module and performs the HSL RT6 MAS logic The HSLRT6 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 HSLRT6 program will have to be loaded onto the hard drive of the PC which is used to support the HSL RT6 The SYSdev Program Development Software will also have to be loaded on the PC To install this program perform the following 1 Install the disk labeled HSL RT6 M45 PROGRAMS into the drive 2 For
42. Tester Set up Monitoring Version 1 0 View M4530 PMT Data Menu Increase PMT gain by Svolts Decrease PMT gain by Svolts Reset MAINT alarm 4 Help Screen Enter Selection ESC to exit whore PMT Gain 1101 5V PHT Input 000 PHT Offset 000 MAINT Alarm NONE Rejected Can Data Average Reject Value 000 Good Can Data averaged of Rejects of last 36 cans 000 over last 36 cans Last Reject Value 000 PMT Input flverage 000 2nd to Last Reject Value 000 PMT Up Deviation 000 3rd to Last Reject Value 000 PHT Down Deviation 000 4th to Last Reject Value 000 Up Deviation Count 000 5th to Last Reject Value 000 Down Deviation Count 000 6th to Last Reject Value 000 Up Peak Max 000 7th to Last Reject Value 000 Down Peak Min 000 8th to Last Reject Value 000 PMT Gain This value adjusts the voltage applied to the tube thus adjusting the gain of the tube The value is set in 5 volt increments thus when a number is entered it will be rounded to the nearest 5 volt increment This parameter is set by the user in manual gain mode see section 3 5 is adjusted automatically when calibration is preformed in the auto gain mode see section 3 3 or is incremented or decremented by 5 from this menu PMT Offset This is the input offset value and adjusts the M4530 input offset proportionally This parameter is set by
43. Value and try the calibration again If the Desired Calibrated Leaker Reject Value is lowered the PMT Reject Can Threshold should also be lowered it should be between the Desired Good Can PMT Value and the Desired Calibrated Leaker Reject Value 5 Remove the calibrated leak can and restart the machine With the machine running at normal speeds run calibrated leak cans through the machine and verify that all the calibrated leak cans are rejected If any are not rejected repeat steps 1 through 3 using the calibrated leak cans which were not rejected HSL RT6 M45 User s Manual SYSTEMS Electronics Group 28 SECTION 3 OFFSET GAIN AND CALIBRATION MODES 3 5 MANUAL GAIN ADJUSTMENT Manual PMT gain mode is enabled by setting the PMT Gain Calibration Mode Enabled to NO using the HSLRT6 set up program In this case the user enters the absolute value of the PMT Gain after the automatic gain is disabled The PMT Gain is set to a number between 500 and 1200volts This corresponds to the voltage applied to the PMT Note The gain will round off to or 5 volts of the value entered As an alternative the gain can be increased or decreased by 5 from the View PMT Data of the HSLRT6 set up program or using the ADJUST GAIN INC GAIN DEC GAIN key on the HSL RT6 Keypad Display In this case the gain can be adjusted manually regardless of whether the PMT auto gain calibration mode is enabled or di
44. ad PMT set up parameters and data from the S4030 PMT processor board If not connected to the S4030 CAL port a message will be displayed alerting the user HSL RT6 M45 User s Manual SYSTEMS Electronics Group 4 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 2 3 DOWNLOAD PROGRAM The Set up program allows the user to Download the HSLRT6 SYSdev program to the M4530 amp HSLRTE unnamed Main Display Fie Edit View Window PMT Help New CtrleN Open Ctl O0 Save Ctl S Save As Export Shift Data Ctrl gt lt Upload save Data Good Cans Rejects Download Data gt 9 0 Print Report Ctrl P Exit N TOT 4l Calibrate PMT PMT Average last 36 good cans 0 PMT Input Reject Threshold 75 E PMT Input Offset Value 0 Alarm Reset System Message All Faults Normal ONLINE 107972003 3 23PM 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 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 M4530 PLC
45. al number of rejected cans 3 Total number of rejected cans for each pocket This data can either be viewed locally on the display by the operator viewed through the HSLRT6 set up program or can be sent to the host PLC via RS 232 communications MODBUS or Allen Bradley DF1 protocols using the optional 4516 communications board This information is updated current shift transferred to Last shift based on the change of state of a discrete input This input can be activated on an 8 or 12 hour shift basis or alternatively could be activated manually on a label run basis depending on the user s preference In addition to the shift data collection a separate buffer is available to collect rejected cans per pocket counts as a diagnostics aid to the operator for trouble shooting a bad seal problem for a specific pocket Unlike the shift data these counts can be reset manually by the operator at will This allows the operator to note an abnormally high count on a specific pocket attempt to correct the problem reset the counts and then check the counts at a latter time to determine if the problem is corrected This data is viewed on the HSL RT6 DSP display 1 5 HALOGEN LIGHT SOURCE The HSL RT6 M45 package is provided with a halogen light source which replaces the existing fluorescent lamps and high frequency lamp driver This provides light in the spectrum the PMT is optimized for but provides a number of additional benefits as well i
46. alogen light source assembly as follows 1 Remove the cover from the existing fluorescent lamp hood 2 Remove the existing fluorescent lamps ballast lamp brackets and wiring essentially gut the existing lamp hood 3 The existing curved plexi glass cover mounted on the hood between the star wheel and hood is retained This prevents grease from being slung onto the halogen lamp glass covers Clean the inside of the curved plexi glass cover before mounting the halogen lamp assembly 4 Mount the halogen light source assembly on top of the hood in the same fashion that the hood cover was mounted the halogen lamp assembly replaces the hood cover 5 Wire 115VAC power to the halogen lamps and fans of the assembly as shown in the schematic at the end of this manual 6 This is also a good time to make sure the plexi glass light windows at the pocket seals are clean and free of contaminates 7 The hub of the starwheel is used as a reflector to illuminate the underside of the can to be tested Verify that the hub is clean and well polished Due to the high radiated heat levels of halogen lamps the lamps are turned off after a time delay when the machine stops This prevents the halogens from baking the can that stops at the light test pocket Once the machine starts again the lamps are turned on immediately This is controlled by CRI in the HSL RT6 M45 enclosure In addition a buck transformer is used to reduce the volta
47. alue HSL RT6 M45 User s Manual SYSTEMS Electronics Group 20 SECTION 2 INSTALLATION 2 12 5 VERIFY CALIBRATED LEAKER REJECTION Run the machine at normal production speeds and verify that calibrated leakers when run through the machine are rejected Using the HSLRT6 set up program observe both the Good Can Data and the Rejected Can Data The PMT Input Average should be within plus or minus 2 of the Desired Good Can PMT Value set in the M4530 Set up Menu normally set to 30 The Up Peak Max and Down Peak Min should be within plus or minus 5 of the PMT Input Average As leaker cans are rejected they will appear in the Last Reject Value through 8th to Last Reject Value stack When the calibrated leakers are run through the machine the reject values of these cans will also appear in this stack If any of the calibrated leakers are not rejected when run through the machine lower the PMT Reject Can Threshold and try again This value can be lowered to within 5 above the Desired Good Can PMT Value If some of the calibrated leakers still are not rejected increase the PMT Gain this can be increased to a maximum of 1200 volts and try again Note Running the gain of the PMT above 1100 volts will shorten the life of the PMT If some of the calibrated leakers are still not rejected verify that the quality of light is adequate both halogen lamps are on and hub of
48. an PMT Value PMT Gain Calibration Mode Enabled When Checked the Automatic Gain Calibration mode is enabled see section 3 3 Automatic Gain Adjustment When Unchecked the Manual Gain mode is enabled see section 3 5 Manual Gain Adjustment Gain Calibrate PMT Input Average This is the average PMT input value of the last 6 samples taken while a calibration cycle is in process The M4530 compares this value to the Desired Calibrated Leaker Reject PMT Value and adjusts the PMT gain accordingly while a calibrate cycle is in progress see section 3 4 Calibration Procedure Desired Calibrated Leaker Reject PMT Value Used in the auto gain mode This value is set by the user to specify the desired reject average The M4530 adjusts the PMT gain until the average calibrate value is within the specified error Allowed Calibrated Leaker Reject Error This parameter is used in conjunction with the Desired Calibrated Leaker Reject PMT Value to adjust the PMT gain in the auto gain mode The M4530 will adjust the gain until the calibrate average is within the value entered in Allowed Calibrated Leaker Reject Error of the Desired Calibrated Leaker Reject PMT Value see section 3 3 Automatic Gain Adjustment PMT Reject Can Threshold This value specifies the reject threshold If the PMT Input value is below this threshold the can is considered good and is not rejected If the PMT Input value is above this th
49. anual SYSTEMS Electronics Group Sai SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE This Page Intentionally Left Blank HSL RT6 M45 User s Manual SYSTEMS Electronics Group 78 SECTION 7 TROUBLE SHOOTING This section provides information for fault situations Calibrate error offset error MAINT and an M4530 fault as well as set up or tuning problems excessive cans rejected calibrated leakers not rejected With the exception of the M4530 fault all trouble shooting is performed with HSLRT6 7 1 GAIN CALIBRATE ERROR PROBLEM CAL LED on M4530 off after calibration is performed and CALIBRATION ERROR message displayed on HSL RT6 DSP SOLUTION Select the M4530 Set up and verify the following 1 Verify that the PMT Calibration Mode Enabled is set to YES If the PMT calibration mode is disabled the M4530 cannot adjust the gain and sensitivity when the calibration procedure is performed and this will result in the calibrate error Enable the PMT Calibration Mode per section 5 Windows setup program reference or section 6 DOS setup program reference and perform the calibration procedure again 2 Verify that the Desired Calibrated Leaker Reject PMT value is at a reasonable value 40 to 200 If this value is outside this range say 0 or 255 the M4530 cannot adjust the gain to achieve calibration Set the Desired Calibrate Leaker Reject PMT value between 40
50. are a stack that contain the values of the last 8 rejects HSL RT6 M45 User s Manual SYSTEMS Electronics Group 65 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE This Page Intentionally Left Blank HSL RT6 M45 User s Manual SYSTEMS Electronics Group 66 SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE The HSLRT6 set up program is a DOS based menu driven program which allows the user to easily view the HSL RT6 MAS data or alter the HSL RT6 M45 set up variables using an IBM PC or compatible In addition to setting the set up variables HSLRT6 can be used to set the machine timing machine offset timing signal locations etc The set up variables are used to configure and tune the HSL RT6 M45 to match the configuration and performance of the specific light tester see section 2 12 Tuning the HSL RT6 M45 The main menu of the HSLRT6 set up program incorporates the following menu selections le HSLRT6 EXE loj x Systems M4530 Tester Set up Monitoring Version 1 0 Main Menu M4530 Set up CAL PORT View M4530 PMT Data CAL PORT Set Machine Timing PROG PORT Number of Rejects per Pocket Data PROG PORT Current Shift Data MR a Last Shift Data PROG PORT Download Program to M4530 PROG PORT IACI Conor Enter Selection ESC to exit NOTE Before selecting one of the seven selections listed above connect an RS 232 cable from the COM port on the computer to either the CAL
51. arm Reset System Message All Faults Normal ONLINE 10 9 2003 3 22PM _ The following is a list of the functions of the Main Display window Messages The Messages display is continuously updated It displays alarm and status messages specific to the M4530 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 tester in Cans Per Minute Good Cans This display is the Current Shift good can count Rejects This display is the Current Shift total reject count PMT Applied Gain Volts This is the voltage applied to the tube The value is set in 5 volt increments between 498 and 1200 This parameter is adjusted when the PMT Gain calibration is performed It can also be adjusted manually using the up down increment control Adjusting this value adjusts the gain of the tube HSL RT6 M45 User s Manual SYSTEMS Electronics Group 50 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE Adjusting the PMT Gain This selection is used to manually increase or decrease the PMT Gain Once online with the M4530 through the PROG port this control is active The up down increment control can be used to adjust the
52. ation as desired Selecting About HSLRT6 from the Help menu will display a dialog box listing information about the current revision of the setup program and how to obtain technical support HSL RT6 M45 User s Manual SYSTEMS Electronics Group 38 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 2 THE FILE MENU The File menu allows the user to perform the following functions e Create a New set up Data File e Open an existing Data File Save any changes made to the current Data File to disk Upload save Data from the Processor Download a SYSdev sdv program to the processor Download restore Data from the current set up Data File to the processor Print a Report of the current set up parameters e Exit the set up program amp HSLRATE unnamed Main Display O x File Edit View Window PMT Help Open Ctrl O Save Ctl S Save As Export Shift Data Ctrl lt Upload save Data gt Good Cans Rejects Download Program Download Data gt Print Report Ctrl P Exit Calibrate PMT n volts 1101 __ Calibrate PMT PMT Input Offset Value 0 PMT Average last 36 good cans 0 PMT Input Reject Threshold 75 a EET Alarm Rese System Message All Faults Normal ONLINE 10 9 2003 3 22PM HSL RT6 M45 User s Manual SYSTEMS Electronics Group 39 SECTION 5 HSLRT6 WINDOWS B
53. c Offset Mode Enabled to YES using the HSLRT6 set up program In addition the user must set the value of the Desired Good Can PMT value as well as the Allowed Good Can Error deviation from the specified good can value The Desired Good Can PMT value is typically set at 25 to 35 The Allowed Good Can Error deviation is typically set to 2 or 3 When the automatic offset feature is enabled the M4530 averages the value of all good cans detected as well as the in between pocket dark measurement over 36 consecutive pockets and automatically adjusts the PMT input offset until this average equals the Desired Good Can PMT value within the specified error Allowed Good Can Error This adjustment occurs continuously and compensates for any drift in the PMT due to temperature variations 3 2 MANUAL OFFSET ADJUSTMENT Manual PMT input offset mode is enabled by setting the Automatic Offset Mode Enabled to NO using the HSLRT6 set up program In this case the user enters the absolute value of the offset after the automatic offset is disabled The offset is set to a number between 250 and 250 Perform the following to manually set the offset 1 Using the HSLRT6 set up program view the M4530 PMT data and monitor the Average PMT Input This is the average of all good cans and the in between pocket dark measurement through 36 consecutive pockets 2 Using the HSLRT6 set up program select
54. cs Group B 3 APPENDIX B DF1 COMMUNICATIONS SLC500 The following sample RSLogix500 code is used to execute the message control function to allow a SLC500 processor to communicate with the S4516 DF1 serial communications board Target Device Local Remote Control Block N12 0 Control Block Length 14 Setup Screen Type Peer To Peer Read Write Write DN Target Device 500CPU Local Remote Local ERD Control Block N12 40 Control Block Length 4 Setup Screen 0002 0003 0004 END 3 N MAIN DF1 COMM HSL RT6 M45 User s Manual SYSTEMS Electronics Group B4 APPENDIX B DF1 COMMUNICATIONS USING THE MSG INSTRUCTION READ INSTRUCTION PLC5 The read message MSG command for a PLCS is setup as follows MSG MG20 0 1 Elements General This PLC 5 Control Bits j Communication Command PLC 3 Word Range Read Ignore if timed out TO 0 Data Table Address NT0 0 To be retried NA 0 Size in Elements 5 Awaiting Execution EW fo Port Number Continuous Run C0 0 Error ERI 0 Target Device Message done DN bo Data Table Address _ N7 0 Message Transmitting ST fo Local Station Address oct dec Message Enabled EN 0 Local Remote Loca m Error Error Code Hex 0 m Error Description No errors Note The Communication Command is PLC3 W
55. directly above the PROG port on the M4530 PWR On when S5VDC power is supplied from the P4500 power supply to the M4530 RUN On steady when the M4530 PLC section is running a valid user s program Off when an internal fault is detected or when a valid user s program has not been loaded The RUN LED will flash during program download as well FLT On when an internally detected fault has occurred in the M4530 PLC section See section 7 3 for details HSL RT6 M45 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION This Page Intentionally Left Blank HSL RT6 M45 User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION The standard HSL RT6 M45 package is provided ina NEMA 12 enclosure for mounting on the machine directly 2 1 WHAT S INCLUDED Verify that the following items are included when unpacking the HSL RT6 M45 2 1 1 HSL RT6 M45 STANDARD PACKAGE 1ea 1ea 1ea 1ea 1ea 1ea 1ea 1ea 1ea 1ea 1ea HSL RT6 M45 NEMA 12 enclosure including the following tea M4530 PLC PLS PMT module 1ea P4500 Power Supply 1ea PS2000N1 High Voltage 2000 volts Power Supply 9956B 16 Photo Multiplier Tube B2F RFI PMT Housing with ATH PMT Preamp and GB1BH PMT Gating Circuit PMT Mounting bracket set 15 002 1 and 15 002 2 PMT Cable Set 2ea BNC Cables 4ft 1ea Lemo Cable 4ft RSV34 MS1 Resolver RSV RSCBLE 20 Resolver Cable Halogen
56. e View PMT Data menu of the HSL RT6 Keypad Display and verify the following a Ifthe PMT Gain is less than 500 volts and the Gain Calibrate PMT Input Average is greater than the Desired Calibrated Leaker Reject PMT Value by more than 5 the PMT detected too much light and was not able to reduce the gain of the PMT adequately to compensate for the amount of light detected Verify that the calibrated leaker has a 0025 or less calibration hole in it and does not have any other areas of leakage in the can Verify that the seal at the pocket used for calibration is not leaking Verify that no light leakage is occurring at any of the PMT seals machine shutter to light seal plate PMT to light seal plate or at the PMT housing itself HSL RT6 M45 User s Manual SYSTEMS Electronics Group Ug SECTION 3 OFFSET GAIN AND CALIBRATION MODES b Ifthe PMT Gain is at 1101 volts and the Gain Calibrate PMT Input Average is less than the Desired Good Can PMT Value by more than 5 then the PMT did not detect enough light and was not able to increase the gain enough to calibrate the M4530 Verify that the calibrated leaker has a 0025 calibration hole in it and verify that the light source is generating an adequate supply of light lamps are on when calibration is performed If so set the Desired Calibrated Leaker Reject PMT Value to a lower value it can be set as low as 10 above the Desired Good Can PMT
57. e PLC section of the M4530 incurs an internal fault Perform the following to read the M4530 fault code 1 Connect computer to PROG port of M4530 2 Initiate SYSdev and select the HSLRT6 program or program which is normally downloaded to M4530 3 From the Main Development Menu select 6 Target Board Interface 4 From the Target Board Interface menu select 4 Target Board Fault Codes Status 5 Ifthe fault code displayed was 45H User program system fault sfunc09 call the PMT Interface section incurred the fault All other fault codes pertain to the PLC section of the M4530 6 Perform the corrective action described in the SYSdev fault menu and reset the fault code as prompted to by SYSdev If the M4530 faults again try cycling power to the M4530 If the M4530 faults again and will not run replace the M4530 downloading the HSLRT6 program or other program if used and perform the setup per section 2 13 HSL RT6 M45 User s Manual SYSTEMS Electronics Group 82 SECTION 7 TROUBLE SHOOTING 7 4 EXCESSIVE GOOD CANS REJECTED PROBLEM Excessive good cans rejected from machine SOLUTION Excessive good cans are rejected from the machine either when a particular pocket or pockets has a bad light seal or when the M4530 is setup too sensitive Perform the following to trouble shoot 1 Select the 4 Number of Rejects per Pocket Data selection from the HSLRT6 main menu and observe the Per
58. e is timed properly per section 2 12 2 and that no light leakage is occurring at any of the PMT seals machine shutter to light seal plate PMT to light seal plate or at the PMT housing itself Reset the MAINT Alarm by selecting 3 Reset MAINT alarm Run the machine with cans at normal line speeds and verify that the offset is automatically adjusted until the PMT Input Average is equal to the Desired Good Can PMT Value plus or minus 2 If the offset is again adjusted either up to the 250 max limit or down to the 250 max limit perform step 6 below Verify all cables between the M4530 and the PMT and try again If the problem persists verify that and 12VDC is present at the 12 VDC 12VDC and AGND pins on the M4530 and try again HSL RT6 M45 User s Manual SYSTEMS Electronics Group 81 SECTION 7 TROUBLE SHOOTING 8 Ifthe problem persists verify that 24VDC is being supplied to the PS2000N1 power supply and try again 9 Ifthe problem persists replace the 9956B 16 PMT tube and try again 10 If the problem persists replace the PMT housing A1H Preamp GB1BH Gating circuit and try again 11 If the problem persists replace the M4530 module Set the module up per section 2 13 and try again 7 3 M4530 FAULT PROBLEM FLT LED on M4530 module on M4530 none functional SOLUTION The FLT LED on the M4530 is illuminated when either the PMT Interface section of the M4530 or th
59. ection 2 13 or when the program has been changed To download the program perform the following Note Program download cannot be performed while the tester is running All outputs on the M4530 are turned off and no program execution is performed Leak can detection would not take place such that if a bad can entered the machine it would not be rejected The tester should therefore be stopped while the download takes place approximately 15 to 45 seconds depending on the computer used 1 2 3 4 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4530 Select 7 Download Program to M4530 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 HSLRT6 REV file could not be opened is displayed then the HSLRT6 application program is not installed in the current directory To install the program perform the steps in section 2 11 4 to install the program Once program download is initiated M4530 program execution will cease the current address being downloaded will be displayed and the RUN LED on the M4530 will flash continuously Once the download is complete the RUN LED on the M4530 will illuminate solid and program execution in the M4530 will resume Press any key to return back to the HSLRT6 main menu HSL RT6 M45 User s M
60. ejects Hi W1106 W4614 N7 7 R O Pocket 1 Rejects W1108 W4616 N7 8 R O thru thru thru thru R O Pocket 12 Rejects W1130 W4638 N7 19 R O HSL RT6 M45 User s Manual B12 SYSTEMS Electronics Group APPENDIX B DF1 COMMUNICATIONS M4530 Mapped PLC Description Add Add Add Function Diagnostic Counts resettable Rejects Pocket 1 W1050 W4640 N7 20 R O thru thru thru thru R O Rejects Pocket 12 W1072 W4662 N7 31 R O PMT Settings PMT Gain in volts W1000 W4664 N7 32 R O PMT Offset Magnitude 0 to 250 B1002 W4666 N7 33 R O PMT Offset sign O 1 B1003 W4668 N7 34 R O Reject Threshold 0 to 255 B1004 W4670 N7 35 R O PMT Good Can Average Value B1005 W4672 N7 36 R O Spare Registers Spare W4674 N7 37 R O Spare W4676 N7 38 R O Spare W4678 N7 39 R O Spare W4680 N7 40 R O Spare W4682 N7 41 R O Spare W4684 N7 42 R O Spare W4686 N7 43 R O Spare W4688 N7 44 R O Spare W4690 N7 45 R O Spare W4692 N7 46 R O Spare W4694 N7 47 R O Spare W4696 N7 48 R O Spare W4698 N7 49 R O HSL RT6 M45 User s Manual B 13 SYSTEMS Electronics Group APPENDIX B DF1 COMMUNICATIONS Data Written To The M4530 10 Elements Is Defined As Follows M4530 Mapped PLC Description Add Add Add Functio
61. empt to communicate with the M4530 If unsuccessful a warning message will be displayed prompting the user to either Retry or Cancel the operation If the operation is canceled and communication with the processor cannot be established the system will be placed in an Offline mode however the Target Board Interface window will be displayed HSL RT6 M45 User s Manual SYSTEMS Electronics Group 47 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 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 M4530 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 p
62. er Pocket Cur Last Shift Current Shift Total Good Cans 0 0 1 2 3 4 5 6 7 8 9 End of Shift 10 Transfer Data 11 Total Rejected Cans 0 0 0 0 0 0 0 0 0 0 0 0 System Message All Faults Normal ONLINE 10 9 2003 3 27PM 4 Note The Transfer Data command button is only active while Online The Current shift data menu displays the following information 1 Total Good Cans Processed 2 Total Rejected Cans for all pockets Number of Rejected Cans for each pocket Pocket 1 thru Pocket 12 This data is the totals so far into the shift This data is transferred to the Last shift data when the end of shift input transfers from a 0 to a 1 This can be at the end of either an 8 or 12 hour shift or alternatively could be done at label changes such that the data collected would be for label runs rather than complete shifts HSL RT6 M45 User s Manual SYSTEMS Electronics Group 59 SECTION 5 HSLRT6 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 amp HSLRTE unnamed Shift Data prin Ine cdd ris E ig Esq jor yam BEL jee 8 H
63. er the ability to make any necessary changes to the set up parameters while not online with the processor If offline editing is not enabled the user is only able to view the set up parameters and shift data When the program is first invoked the default setting is offline editing disabled The user will need to select Enable Offline Editing from the edit menu or press function key F2 to enable disable this feature 5 3 2 SETUP COMM PORT This function allows the user to specify the serial communications port and rate to talk to the M4530 The programming port of the M4530 is set to 9600 baud r Comm Port r Port Speed Com 9600 C Com2 C 19200 C Com3 C Com 4 Cancel Once selected a dialog box requesting the user to select a Comm Port and Baud Rate will be displayed The default setting is COM1 at 9600 baud The option to select the 19200 baud rate is to allow the user to communicate with the processor via the 4516 serial communications board In most cases the user will only need to specify the communications port and leave the baud rate at 9600 If communication problems occur make sure there is a secure connection from the PC to the PLC Then check the Comm port In most cases the user will only need to select a new Comm port If communication problems persist there may be another program causing a conflict with the port Check the port configuration from the Windows Settings folder HSL RT
64. erage Reject Value ea Average PMT Input moss Number of Rejects last 36 cans Eazy PMT Deviation Up avg oss Last Reject Value Eva PMT Deviation Down avg juo 2nd to Last Reject Value Ewa Deviation Count Up cans 0 3id to Last Reject Value 0 Deviation Count Down f cans mosey 4th to Last Reject Value 3977 Up Peak Max PMT input pone 5th to Last Reject Value RYE Down Peak Min PMT input Jio Bth to Last Reject Value po 7th to Last Reject Value Teo um 8th to Last Reject Value Eu System Message All Faults Normal ONLINE 10 9 2003 3 30PM _ PMT Gain This value adjusts the voltage applied to the tube thus adjusting the gain of the tube The value is set in 5 volt increments thus when a number is entered it will be rounded to the nearest 5 volt increment This parameter is set by the user in manual gain mode or adjusted automatically when a calibration is preformed in the auto gain mode or is incremented or decremented by 5 from this menu PMT Offset This is the input offset value and adjusts the M4530 input offset proportionally This parameter is set by the user in manual offset mode or is adjusted automatically when in the automatic offset mode PMT Input This is the value 0 to 255 of the last PMT sample and is proportional to the amount of light detected by the PMT where 0 equals no light detected and 255 equals maximum light detected PMT Input Average This is the average of all
65. ers 1 through 4 are the first 4 pockets and the xxxx would be the actual counts for the respective pockets Screens for pockets 5 thru 8 9 thru 12 are shown in this fashion each for a time delay of 10 seconds In addition the user can advance to the next screen or retard to the previous screen by pressing the NEXT or PREV key respectively The ESC key can also be used at any time to abort the rejects per pocket data display and return to the default screen 4 3 RESET REJECTS PER POCKET KEY This key is used to reset the rejected cans per pocket counts that are displayed in the Rejected Cans per Pocket menu When this key is pressed the display will prompt PRESS ENTER TO RESET THE REJECTS PER POCKET COUNTS OR ESC TO EXIT Press the Enter key to reset the rejects per pocket counts Press the ESC to exit without resetting the counts The rejects per pocket counts collected for the current shift will not be reset when this key is hit HSL RT6 M45 User s Manual SYSTEMS Electronics Group 332 SECTION 4 USING THE KEYPAD DISPLAY 4 4 CURRENT SHIFT KEY The Current shift data menu displays the following information Good Cans xxxxxx Rejects xxxxx Rejected Cans per Pocket 1 12 xxxx This data is the totals so far into the shift This data is transferred to the Last shift data when the end of shift input transfers from a 0 to a 1 This can be at the end o
66. et 48 c0 Pocket 49 2 8 Pocket 10 0 Pocket 11 25 8 Pocket 12 0 Note Prior to selecting this selection make sure the RS 232 cable is connected from the COM port on the computer to the PROG port on the M4530 When selected from the main menu the total rejects per pocket is displayed and updated continuously in fields that read Pocket xx To exit back to the main menu press lt ESC gt Note A disproportionately high count for a particular pocket indicates a sealing problem for that pocket To reset the pocket reject counts simply press 1 The counts will be reset in the M4530 To exit back to the main menu press lt ESC gt HSL RT6 M45 User s Manual SYSTEMS Electronics Group 235 SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE 6 5 CURRENT SHIFT DATA PROG PORT The Current shift data menu displays the following information HSLRT6 EXE ioj x Systems M 530 Tester Set up Monitoring Version 1 0 Current Shift Totals so far Press ESC to return to main menu Total Good Cans Processed Total Rejected Cans for all pockets 0 Number of He jected tans for each packen Pocket Pocket Pocket Pocket Pocket Pocket Pocket Pocket Pocket Pocket Pocket Pocket This data is the totals so far into the current shift This data is transferred to the Last shift data when the end of shift input transfers from a 0 to a 1 This can be at
67. f 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 Rejects is displayed as part of the default Good Cans This is the total number of good cans tested so far into the shift This is essentially a can counter Rejects This is the total number of rejected cans for all pockets of the machine Rejected Cans per Pocket 1 12 This is the total rejected cans for each pocket A disproportionately high count for a particular pocket indicates a bad pocket seal for that pocket 4 5 LAST SHIFT KEY The Last Shift data is identical to the current shift data except it is for the previous 8 or 12 hour shift or previous label run however the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period 4 6 MANUAL REJECT KEY The MANUAL REJECT key is used to manually reject cans from the tester either to test the reject solenoids or to reject cans for QC purposes The tester will reject cans from either the odd or even solenoids as long as the MANUAL REJECT key is depressed HSL RT6 M45 User s Manual SYSTEMS Electronics Group 33 SECTION 4 USING THE KEYPAD DISPLAY 4 7 VIEW PMT DATA KEY The View
68. f the D4591 install the D4591 in the cut out in the HSL RT6 M45 display enclosure Secure the display to the enclosure using 7ea 8 32 nuts and external lock washers 2 Connect the display ribbon cable to the connector on the lower back of the display the connector on the cable is polarized and should mate with connector on the M4530 only one way 2 13 4 DOWNLOAD HSLRT6 PROGRAM TO M4530 Once the M4530 P4500 D4591 are installed perform the following to download the HSLRT6 application program to the M4530 1 Power up the M4530 and the PC used to interface with the HSL RT6 M45 2 Connect an RS 232 cable from the computer COM port to the PROG port on the M4530 3 Execute the HSLRT6 set up program 4 Download the HSLRT6 application program to the M4530 refer to section 5 2 3 Windows setup program reference or section 6 7 DOS setup program reference 5 Set the resolver zero as outlined in section 2 12 2 6 Verify the PMT offset calibrate the PMT Gain and verify the calibrated leaker rejection as outlined in sections 2 12 3 thru 2 12 5 7 The M4530 is now ready to run HSL RT6 M45 User s Manual SYSTEMS Electronics Group 24 SECTION 3 OFFSET GAIN AND CALIBRATION MODES The following sections describe the different offset and gain modes as well as the calibration procedure in detail 3 1 AUTOMATIC OFFSET ADJUSTMENT Automatic PMT input offset mode is enabled by setting the Automati
69. forward that the position increases linearly from 0 through 359 If not swap the S1 and S3 leads of the resolver at the M4530 resolver connector Then verify that the position then indeed does increase with forward movement Position the machine with pocket 1 perfectly aligned with the PMT This is the machine zero position Auto zero the resolver by entering 0 in the offset field and then Click the Set Offset button The M4530 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 Note The offset can only be changed while online with the processor with the machine stopped HSL RT6 M45 User s Manual SYSTEMS Electronics Group 53 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE Adjusting the Timing Channel Setpoints To set any of the timing signal setpoints perform the following Note Any changes made to the timing channel setpoints will be saved as part of the setup data file 1 2 3 4 5 Connect an RS 232 SYSdev cable from the COM port on the computer to the PROG port on the M4530 From the Window menu select Machine Timing From the View menu select Online Data The set up program will attempt to communicate with the processor and place the system into an Online mode of operation Set points are entered for a particular channel simply
70. 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 an existing data file select Open from the File menu or press Ctrl O This displays a dialog box allowing the user to select an existing data file The name of the file will then be displayed in the title bar If any changes are made to the parameters including shift data the user will be prompted to save any changes before terminating the program Save To Save the data to disk select Save from the File menu or press Ctrl S This displays a dialog box allowing the user to select a folder and enter a name for the file The user will be notified if the file exists The extension sdt will automatically be added to the file name If this is a New file the user will be prompted to enter a file name Save As To save the data file to a new name select Save As from the File menu This displays a dialog box allowing the user to select a folder and enter in a new name for the file The user will be notified if the file exists and the extension sdt will automatically be added to the file name E
71. fthe offset is greater then 20 disconnect the 24VDC power that powers the PS2000N1 high voltage power supply and remove the top of the B2F RFI housing side that contains connectors and adjust the potentiometer on the AIH Preamp board first board below connectors Turning the pot clockwise will decrease the offset turning it counter clockwise will increase the offset One turn of the potentiometer changes the offset by about 40 to 50 4 Re install the top of the B2F RFI housing power up the 24VDC power supply that powers the PMT section of the M4530 and the PS2000N1 power supply and perform step 1 again Repeat steps 1 thru 3 until the offset is less than 20 while the machine is running with good cans The closer the offset is to zero the better HSL RT6 M45 User s Manual SYSTEMS Electronics Group 19 SECTION 2 INSTALLATION 2 12 4 CALIBRATE THE PMT GAIN Stop the machine install a calibrated leaker in the machine at the PMT and perform the gain calibration per section 3 4 If no calibration error occurred proceed to section 2 12 5 If a calibration error did occur CAL LED on front of M4530 off at completion of the calibration procedure observe the value of the PMT gain either on the M4530 Set up menu of the HSLRT6 set up program or the View PMT Data menu of the HSL RT6 Keypad Display and verify the following 1 Ifthe PMT Gain is less than 500 volts and the Gain Calibrate PMT I
72. gain by 5 volts each time the corresponding key is depressed Increasing the gain will increase the sensitivity of the system decreasing the gain will decrease the sensitivity of the system PMT Offset This is the input offset value between 250 and 250 and adjusts the M4530 input offset proportionally This parameter is adjusted automatically in response to variations of the PMT offset see section 3 1 Automatic Offset Adjustment Threshold This value specifies the reject threshold If the PMT Input value is below this threshold the can is considered good and is not rejected If the PMT Input value is above this threshold the can is considered a leaker and is rejected Typically this parameter is set between 35 and 75 This parameter is adjusted using the up down increment control Adjusting the Threshold This selection is used to increase or decrease the Reject Threshold Once online with the M4530 through the PORG port this control is active The up down control can be used to adjust the threshold by one each time the corresponding key is depressed Increasing the threshold will decrease the sensitivity of the system decreasing the threshold will increase the sensitivity of the system PMT Average This is the average of all good cans and the in between pocket dark measurements for 36 consecutive cans Calibrate PMT This selection is used to execute the PMT Gain calibration procedure If the calibration is to be
73. ge on the lamps to about 8096 of nominal line voltage This reduces the radiated heat from the lamps without significantly reducing the lumens produced HSL RT6 M45 User s Manual SYSTEMS Electronics Group 12 SECTION 2 INSTALLATION 2 9 HALOGEN BULB REPLACEMENT Perform the following to replace either of the Halogen bulbs 1 Disconnect power to the light source assembly and let the lamps and lamp housing glass covers cool 2 Remove the lamp housing glass cover by removing the two wing nuts which secure the glass cover retainer with one hand and holding the glass cover with the other hand while the wing nuts are removed Remove the glass cover from the assembly 3 With a clean rag remove the Halogen bulb from the fixture One contact of the fixture is spring loaded the bulb is removed by compressing the spring loaded contact and then removing the bulb 4 Replace bulb with GE part number Q350T3 CL HIR bulbs only These are 350W Halogen IR lamps which produce approximately 5096 more lumens per watt than ordinary Halogen lamps 5 Install new bulb again using a clean rag to hold the bulb while it is being installed Do not handle the quartz envelope directly as fingermarks or any type of grease may cause devitrification of the quartz resulting in reduced performance and possible breakage or shattering 6 Once the bulb is re installed mount the glass cover back over the lamp housing securing the cover with the retainer and
74. good cans and the in between pocket dark measurements for 36 consecutive cans PMT Up Deviation This is the average up deviation from the good can PMT Input Average for 36 consecutive cans The lower the number the less deviation between all good cans the higher the number the more deviation HSL RT6 M45 User s Manual SYSTEMS Electronics Group 64 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 6 PMT Down Deviation This is the average down deviation from the good can PMT Input Average for 36 consecutive cans The lower the number the less deviation between all good cans the higher the number the more deviation 7 Up Deviation Count This is the number of good cans that deviated up from the good can PMT Input Average in the last 36 consecutive pockets 8 Down Deviation Count This is the number of good cans that deviated down from the good can PMT Input Average in the last 36 consecutive pockets 9 Up Peak Max This is the highest PMT input value detected as a good can in the last 36 consecutive pockets 10 Down Peak Min This is the lowest PMT input value detected as a good can in the last 36 consecutive pockets 11 Average Reject Value This is the average value of the PMT input for the last 8 rejects 12 of Rejects of Last 36 cans This is the number of leakers rejects detected in the last 36 consecutive pockets 13 Last Reject Value through 8th to Last Reject Value These 8 variables
75. ibrate feature which continuously calibrates the PMT offset with machine running in normal operation 3 Static PMT gain calibration feature allows operator to calibrate the gain of the PMT at the push of a button using a calibrated leak can with the machine not running 4 Controls Odd and Even reject solenoids to reject cans at speeds greater than 2400CPM using the existing solenoids 5 Detects the following alarm conditions Bad Pocket excessive rejects from pocket excessive good can rejection light seals of machine compromised timing signal failure and PMT calibrate error 6 Data collection built in including total number of cans rejected count number of cans rejected per pocket and total number of good cans processed For both current shift and last shift e Halogen light source replaces both the existing fluorescent lamps and high frequency lamp driver for both increased test lumens and reliability e Optional Data Set up display 2 line X 40 character display with 24 key membrane keypad allows local viewing of collected data can count total rejects rejects per pocket by the operator and set up of all user variables key switch enabled by authorized personnel e Set up and monitoring performed using HSLRT6 an easy to use menu driven software package which runs on any IBM PC or compatible e Provided with resolver for machine mounting replaces existing encoder and built in programmable limit switch PLS wi
76. in the following sections Note For virtually all the menus the NEXT and PREV keys can be used to advance to the next item of the menu or return to the previous item on the menu HSL RT6 M45 User s Manual SYSTEMS Electronics Group 31 SECTION 4 USING THE KEYPAD DISPLAY 4 1 DEFAULT SCREEN The default screen displayed when no other commands are active contains the following data MACHINE SPEED CPM xxxx GOOD CANS xxxxxxx REJECT S xxxxxx Where the Machine Speed is the current speed of the tester the Good Cans field is the total number of good cans tested so far into the current shift and the Rejects field is the total number of rejected cans for all pockets 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 4 2 REJECTS PER POCKET KEY The number of rejected cans per pocket menu is provided to aid in the trouble shooting of a bad seal with a particular pocket The total number of rejected cans for each pocket since the last reset or end of shift is displayed The operator can reset these counts at any time to aid in the trouble shooting process see section 4 3 The data can be viewed simply be pressing this key The display shows a series of screens each with four pockets from 1 through 12 as shown below REJECTED CANS PER POCKET 1 XXxx 2 XXXX 3 XXXX 4 XXXX Where the numb
77. ix B for a description of the data read from and written to an Allen Bradley PLC 5 5 4 THE SHIFT DATA WINDOW The Shift Data window is used to view the shift data collected by the M4530 This window is selected from the Window menu HSLRT6 unnamed Shift Data O x File Edi View Window PMT Help ket Current Shift Last Shift Rejects Per Pocket Reset Rejects 2 System Message All Faults Normal ONLINE 10 9 2003 327PM 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 Rejects Per Pocket The number of rejects per pocket menu is provided to aid in the trouble shooting of a bad seal with a particular pocket The total number of rejects for each pocket since the last reset or end of shift is displayed The user can reset these counts at any time to aid in the trouble shooting process HSL RT6 M45 User s Manual SYSTEMS Electronics Group 58 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE Current Shift Data This section is used to view the Current Shift data This data is the totals so far into the shift This data is transferred to the Last shift at the end of either an 8 or 12 hour This data can be reset by the user from this section amp HSLRATE unnamed Shift Data File Edi View Window PMT Help Rejects P
78. lowest PMT input value detected as a good can in the last 36 consecutive pockets Average Reject Value This is the average value of the PMT input for the last 8 rejects of Rejects of Last 36 cans This is the number of leakers rejects detected in the last 36 consecutive pockets Last Reject Value through 8th to Last Reject Value These 8 variables are a stack that contain the values of the last 8 rejects HSL RT6 M45 User s Manual SYSTEMS Electronics Group zs SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE 6 3 SET MACHINE TIMING PROG PORT The Set Machine Timing selection is used to invoke the PLS programming command menus these are the same menus used in SYSdev to program the PLS section of the M4530 When selected the PLS programming main development menu will be invoked using the default RT6TMG channel set point file From this menu the user can zero the machine set the resolver offset and adjust the timing signal set points of CH02 thru CH07 additional user channels if used Note CH00 Sync timing and CH01 Marker timing are automatically programmed at power up and should not be modified by the user The following sections describe how to perform these functions Also prior to selecting the Machine Timing selection make sure the RS 232 cable is connected from the COM port on the computer to the PROG PORT on the M4530 les HSLAT6 EXE _ 5 x Systems PLS Program Development PLSdev M4500 Version 4
79. lution for one revolution of the shutter wheel one revolution per 12 pockets Thus there are 30 degrees between pockets This parameter is used to zero the machine set the resolver zero see section 4 11 HSL RT6 M45 User s Manual SYSTEMS Electronics Group 34 SECTION 4 USING THE KEYPAD DISPLAY 4 8 CALIBRATE GAIN KEY This selection is used to execute the PMT Gain calibration procedure When selected the display will prompt PLACE CALIBRATED LEAKER AT THE PMT AND PRESS ENTER OR ESC TO EXIT To calibrate the PMT gain e Stop the tester e Align a calibrated leak test can at the PMT and press the ENTER key If the calibration is not to be performed press the ESC key to return to the previous menu If the ENTER key is pressed the calibration will be performed per section 3 3 Once the calibration is initiated the current gain in volts is displayed If the calibration is successful the display will display CALIBRATION COMPLETE PRESS ESC If the calibration is not successful the display will show either CALIBRATION ERROR NO LIGHT DETECTED or CALIBRATION ERROR EXCESS LIGHT DETECTED See section 3 4 for details on the calibration error Note This selection is only enabled when the SET UP ENABLE key switch is in the ENABLE position 4 9 ADJUST GAIN KEY This selection is used to manually increase or decrease the PMT Gain Once activated
80. mber of BYTES Received This displays the current number of bytes received from either a Command or Reply message packet Received Command BIT Status This displays the state of the command received If this displays a Reply then the command was sent from the M4530 If this displays Command then a command action was received by the M4530 A B Link Layer Status This displays the status of the receipt of the message packet sent to the Allen Bradley PLC If the delivery is not successful an error code along with a description is displayed Refer the to the Allen Bradley Communication Protocol and Command Set reference manual for more information on Link Layer error codes AIB Link Layer Current Transaction Received This is the Transaction number received from the Allen Bradley PLC PLC Type This is used to specify the Type of PLC the M4530 will communicate to The user can choose from PLCS or SLC500 Note This parameter should be set prior to communicating with an A B processor Destination Node This is used to set the node number of the A B PLC to send and receive data from This also displays the node number of the A B PLC that send a Command message packet HSL RT6 M45 User s Manual SYSTEMS Electronics Group 57 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE Destination File Number This is the file number the M4530 will read and write data from See Append
81. n General PLC Status Word 1 from PLC W792 W4700 N7 50 W O End of Shift 1 Transfer Data Bit 00 B792 0 B4700 0 N7 50 0 Reset Rejects Per Pocket Bit 01 B792 1 B4700 1 N7 50 1 PMT Gain Calibrate Initiate Bit 02 B792 2 B4700 2 N7 50 2 PMT Gain Increase by 5 volts Bit 03 B792 3 B4700 3 N7 50 3 PMT Gain Decrease Bit 04 B792 4 B4700 4 N7 50 4 Reject Threshold Increase Bit 05 B792 5 B4700 5 N7 50 5 Reject Threshold Decrease Bit 06 B792 6 B4700 6 N7 50 6 Alarm Reset Bit 07 B792 7 B4700 7 N7 50 7 Set Resolver Zero Bit 08 B793 0 B4701 0 N7 50 8 Spare Bit 09 B793 1 B4701 1 N7 50 9 Spare Bit 10 B793 2 B4701 2 N7 50 10 Spare Bit 11 B793 3 B4701 3 N7 50 11 Spare Bit 12 B793 4 B4701 4 N7 50 12 Spare Bit 13 B793 5 B4701 5 N7 50 13 Spare Bit 14 B793 6 B4701 6 N7 50 14 Spare Bit 15 B793 7 B4701 7 N7 50 15 PLC Status Word 2 from PLC W4702 N7 51 W O Spare Bit 00 B4702 0 N7 51 0 Thru thru thru Spare Bit 15 B4703 7 N7 51 15 Spare W4704 N7 52 W O Spare W4706 N7 53 W O Spare W4708 N7 54 W O Spare W4710 N7 55 W O Spare W4712 N7 56 W O Spare W4714 N7 57 W O Spare W4716 N7 58 W O Spare W4718 N7 59 W O HSL RT6 M45 User s Manual SYSTEMS Electronics Group Bl4
82. ncluding 1 Increased test lumens which allows for a greater degree of system sensitivity 2 Elimination of the high frequency lamp driver and the failures associated with the driver The halogen lamps are powered directly from 120V AC 50 60HZ for the ultimate in lamp source simplification and reliability 3 Reduction of light emitted in the UV spectrum as compared to the use of black light fluorescent for increased personnel safety The halogen light source is mounted on the existing lamp hood once the existing fluorescent lamps ballast and hood cover are removed HSL RT6 M45 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 6 LED STATUS INDICATIONS The following 4 status LEDs are located directly above the CAL port on the M4530 PWR On when 24VDC power is applied to the PMT section of the M4530 this 24VDC also supplies power to the 2000 volt power supply of the PMT CAL On after the calibrate procedure has been performed and the M4530 was able to calibrate the PMT gain successfully Off if the PMT gain was not successfully calibrated Flashing while the calibrate procedure is in process See section 3 3 for details on the calibrate procedure MAINT On when an offset error has occurred See section 7 2 for details REJ On when a leaker can is detected by the PMT Off when a good can is detected by the PMT The following 3 status LEDs are located
83. nnels are programmed press lt ESC gt to exit back to the PLS Main Development Menu Press lt ESC gt again to exit back to the HSLRT6 set up main menu The new channels will be saved both in the M4530 and in the RT6TMG file on the hard drive Note CH00 Sync timing and CH01 Marker timing are automatically programmed at power up and should not be modified by the user Only CH02 thru CH07 can be programmed by the user if additional timing signals are required by the user these channels are not used by the HSLRT6 program HSL RT6 M45 User s Manual SYSTEMS Electronics Group 74 SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE 6 4 NUMBER OF REJECTS PER POCKET DATA PROG PORT The number of rejects per pocket menu is provided to aid in the trouble shooting of a bad seal with a particular pocket The total number of rejects for each pocket since the last reset or end of shift is displayed The operator can reset these counts at any time to aid in the trouble shooting process This menu is invoked by selecting 4 Number of Rejects per Pocket Data from the Main Menu HSLRT6 EXE lol x Systems M4530 Tester Set up Monitoring Version 1 0 Rejects per Pocket Menu 1 Reset Rejects per Pocket counts Enter Selection ESC to exit Number of Rejects for each pocket Pocket 41 0 Pocket 42 2 2 222 0 Pocket H3 8 Pocket 44 o Pocket 5 0 Pocket 6 0 Pocket Nj Pock
84. 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 1995 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description 1 Features 1 Functional Description 2 Alarm Detection 3 Data Collection 4 Halogen Light Source 4 LED Status Indications 5 ee ee ee ee ee OuRWN 2 Installation 7 2 1 What s Included 7 2 1 1 HSL RT6 M45 Standard Package 7 2 1 2 HSL RT6 M45 Options 7 2 2 Power Required 8 2 3 Mounting the HSL RT6 M45 Enclosure 8 2 4 Mounting the RSV34 MS1 Resolver 8 2 5 Mounting the PMT Housing 9 2 6 Installing the PMT Tube inside the PMT Housing 10 2 7 Wiring the HSL RT6 M45 11 2 8 Mounting the Halogen Light Source 12 2 9 Halogen Bulb Replacement 13 2 10 Mounting the Keypad Display Optional 14 2 11 HSL RT6 M45 Software Installation 15 2 11 1 Windows Based Set up Program Installation 15 2 11 2 DOS Based Set up Program Installation 16 2 11 3 SYSdev Program Development Software Installation 17 2 11 4 Application Program Installation 17 2 12 Tuning the HSL RT6 M45 17 2 12 1 Default Set up Variables 18 2 12 2 Set Machine Zero 18 2 12 3 Verify the B2F RFI PMT Housing Offset 19 2 12 4 Calibrate the PMT Gain 20 2 12 5 Verify Calibrated Leaker
85. nput Average is greater than the Desired Calibrated Leaker Reject PMT Value by more than 5 the PMT detected too much light and was not able to reduce the gain of the PMT adequately to compensate for the amount of light detected Verify that the calibrated leaker has a 0025 or less calibration hole in it and does not have any other areas of light leakage in the can Verify that the seal at the pocket used for calibration is not leaking Verify that no light leakage is occurring at any of the PMT seals machine shutter to light seal plate PMT to light seal plate or at the PMT housing itself 2 Ifthe PMT Gain is at 1101 volts and the Gain Calibrate PMT Input Average is less than the Desired Good Can PMT Value by more than 5 then the PMT did not detect enough light and was not able to increase the gain enough to calibrate the M4530 Verify that the calibrated leaker has a 0025 calibration hole in it and also verify that the light source is generating an adequate supply of light lamps are on when calibration is performed If so set the Desired Calibrated Leaker Reject PMT Value to a lower value it can be set as low as 10 above the Desired Good Can PMT Value and try the calibration again If the Desired Calibrated Leaker Reject Value is lowered the PMT Reject Can Threshold should also be lowered it should be between the Desired Good Can PMT Value and the Desired Calibrated Leaker Reject V
86. o interface with the M4530 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 M4530 The variables displayed while in the Online edit mode are read directly from the processor Data is saved to a Set up Data file sdt whenever changes are made to a parameter or if the data is uploaded from the processor File Edit View Window PMT Help Messages i Machine CPM Good Cans 1 r Rejects 0 0 PMT Data Calibrate PMT PMT Applied Gain vols 7707 4 CaibtePMT PMT Input Offset Value 0 PMT Average last 36 good cans PMT Input Reject Threshold 75 d Alarm Reset Alarm Rese System Message All Faults Normal ONLINE 10 9 2003 322PM 7 HSL RT6 M45 User s Manual SYSTEMS Electronics Group 37 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 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
87. ocket is occurring EXCESSIVE GOOD CAN REJECTION If ten consecutive cans are rejected this alarm is generated Once ten consecutive good cans are detected the alarm is cleared This generally indicates that a major light leakage has occurred either between the PMT shoe gimbal and the shutter wheel or in the pocket seals This output can be used by the existing control system to stop the machine preventing the rejection of excessive good cans TIMING SIGNAL FAILURE DETECTION 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 PMT CALIBRATE ERROR If the M4530 is unable to calibrate the gain of the tube when a static calibration is performed this alarm is set This occurs either when the PMT does not detect enough light and the gain is maximized or when the PMT detects too much light and the gain is minimized In addition this alarm occurs if the automatic offset adjustment routine adjusts the offset to the maximum or minimum offset but still cannot compensate for the offset of the PMT The above alarms can be mapped to discrete outputs on the M4530 to interface with the existing system if desired HSL RT6 M45 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 4 DATA COLLECTION The following data is collected for both the current shift and the previous last shift 1 Total number of good cans tested 2 Tot
88. ontrol schematic at the back of this manual for details Wire 24VDC power from the user supplied 24VDC power supply to FU3 and wire 500 as shown Wire 115V AC 50 60HZ power to fuses FU and FU2 as shown Connect the BNC cable marked GATE to the GATE connector on the B2F RFI housing and then to the GATE connector on the side of the HSL RT6 M45 enclosure This signal gates the PMT on applies the high voltage to the PMT when the sample is taken Connect the BNC cable marked SIG to the SIG connector on the B2F RFI housing and then to the SIGNAL connector on the side of the HSL RT6 M45 enclosure This is the output of the preamp from the PMT Connect the MHV connector on the end of the PS2000NI cable to the HV connector on the B2F RFI housing Connect the Lemo cable to the corresponding connectors on the B2F RFI housing and the side of the HSL RT6 M45 enclosure This supplies 12VDC to the Preamp Gating circuits of the B2F RFI housing Keep the coax cables mounted in steps 5 through 8 above away from all other wiring These signals are low level signals and should not be mixed with any other wiring HSL RT6 M45 User s Manual SYSTEMS Electronics Group 1 SECTION 2 INSTALLATION 2 8 MOUNTING THE HALOGEN LIGHT SOURCE The HSL RT6 M45 package is provided with a halogen light source which replaces the existing fluorescent lamps and high frequency lamp driver Mount the h
89. or deviation is typically set to 5 When the automatic gain feature is enabled calibration is performed by stopping the machine and placing a calibrated leak can a can with a 0025 calibrated leak hole in the machine lined up exactly with the PMT The calibration is initiated either from the CALIBRATE push button inside the M4530 housing box or from the CAL PMT GAIN key on the HSL RT6 Keypad Display The M4530 will now generate a series of sync pulses and take a series of samples from the PMT During this sampling process the M4530 will adjust the gain of the PMT until the samples read from the PMT are equal to the number entered in the Desired Calibrated Leaker Reject PMT value within the Allowed Calibrated Leaker Reject Error The CAL LED on the front of the M4530 will flash while the calibration is in progress Once the calibrate process is complete the CAL LED on the front of the M4530 will either illuminate continuously indicating the calibration was successful or will extinguish indicating a calibration error occurred Note When locating the calibrated leak can in front of the PMT the can should be oriented with the 0025 hole in the least light intensive area Generally this is with the hole facing the direction of movement of the can along the wheel Thus when the M4530 is calibrated it will be calibrated for the worst case lighting situation HSL RT6 M45 User s Manual SYSTEMS Electronics Gr
90. ord Range Read The Data Table Address can be any integer file address The 50 elements total read from the M4530 PLC are defined in the last section Read Write Data Definitions The Local Station Address is only necessary to define if communications with the S4516 DF1 is executed over a Data Highway network via a DataLink Module HSL RT6 M45 User s Manual SYSTEMS Electronics Group B 5 APPENDIX B DF1 COMMUNICATIONS WRITE INSTRUCTION PLC5 The write message MSG command for a PLCS is setup as follows MSG MG22 0 1 Elements PLC 3 Word Range Write 10 50 Note The Communication Command is PLC3 Word Range Write The Data Table Address can be any integer file address The 10 elements written to the M4530 PLC are defined in the last section Read Write Data Definitions HSL RT6 M45 User s Manual SYSTEMS Electronics Group B6 APPENDIX B DF1 COMMUNICATIONS READ INSTRUCTION SLC500 The read message MSG command for a SLC500 is setup as follows MSG N12 0 14 Elements Note The Data Table Address can be any integer file address The 50 elements total read from the M4530 PLC are defined in the last section Read Write Data Definitions The Local Station Address is only necessary to define if communications with the S4516 DF1 is executed over a Data Highway network via a DataLink Module HSL RT6 M45 User s Manual SYSTEMS Electronics Group B 7 APPENDIX B DF1 COMMU
91. ositions slotO S4568 SWI switchl OFF SWI switch2 OFF Install the 4568 in Slot0 0 furthest left slot of the M4530 chassis 3 Install S4516 SLOTO 1 OPTIONAL This is the optional communications MODBUS or Allen Bradley DF1 serial communications board Set the slot address dip switches SW2 on the S4516 to the following positions slot1 S4516 SW2 switchl ON SW2 switch2 OFF Set the RS 232 RS 422 select dip switches SW1 on the S4516 to the following positions RS 232 selected S4516 SWI switchl ON SWI switch2 OFF Install the 4516 in Slot0 1 slot next to S4568 of the M4530 chassis HSL RT6 M45 User s Manual SYSTEMS Electronics Group 22 SECTION 2 INSTALLATION 4 Install S4573 SLOTO 2 OPTIONAL This is the optional pocket reject indicators output board Set the slot address dip switches SW1 on the S4573 to the following positions slot2 4573 SWI switchl OFF SWI switch2 ON Install the 4573 in Slot0 2 slot next to 4516 of the M4530 chassis 5 Install the cover back over the M4530 making sure all the board connectors protrude through the slots in the cover Tighten the three captive screws on the lower front of the cover and the two captive screws on each side of the M4530 chassis 6 Connect the display ribbon cable to the connector on the back of the M4530 the connector on the cable is polarized and should mate wi
92. ot Used thru B793 7 Not Used HSL RT6 M45 User s Manual SYSTEMS Electronics Group A4 APPENDIX A MODBUS COMMUNICATIONS The Status Control bits sent from the MODICON PLC are defined as follows B792 0 B792 1 B792 2 B792 3 B792 4 B792 5 B792 6 B792 7 B793 1 End of Shift Setting this bit to a 1 transfers the current shift data in the M4530 to the last shift data and clears the current shift data to start data collection for the next shift The current shift data in the MODICON should be saved to the last shift data stack prior to setting this bit Reset Rejects per pocket Setting this bit to a 1 clears the rejects per pocket diagnostics data in M4530 words W1050 W1072 MODICON words 401718 401729 This is usually done by the operator through out the shift to verify that one pocket is not rejecting at a higher rate than the other pockets PMT Gain Calibrate Initiate Setting this initiates the gain calibration procedure just the same as the CALIBRATE button inside the panel does The machine should be stopped with the calibrated leaker in front of the PMT prior to performing this PMT Gain Increase Setting this bit to a 1 increases the gain of the PMT by 5 volts This is used to manually increase the gain PMT Gain Decrease Setting this bit to a 1 decreases the gain of the PMT by 5 volts This is used to manually decrease the gain Reject Threshold Increa
93. ough to calibrate the M4530 Verify that the calibrated leaker has a 0025 calibration hole in it and also verify that the light source is generating an adequate supply of light lamps on during calibration If so set the Desired Calibrated Leaker Reject PMT Value to a lower value it can be set as low as 10 above the Desired Good Can PMT Value and try the calibration again If the Desired Calibrated Leaker Reject Value is lowered the PMT Reject Can Threshold should also be lowered it should be between the Desired Good Can PMT Value and the Desired Calibrated Leaker Reject Value Perform the calibrate procedure per section 3 4 and try again 5 Ifthe solutions in 3 and 4 above do not correct the problem verify all cables between the M4530 and the PMT and try again 6 Ifthe problem persists verify that and 12VDC is present at the 12 VDC 12VDC and AGND pins of the PMT of the M4530 and try again 7 Ifthe problem persists verify that 24VDC is being supplied to the PS2000N1 power supply and try again 8 Ifthe problem persists replace the 9956B 16 PMT tube and try again 9 Ifthe problem persists replace the PMT housing AlH Preamp GB1BH Gating circuit and try again 10 If the problem persists replace the M4530 module Set the module up per section 2 13 and try again HSL RT6 M45 User s Manual SYSTEMS Electronics Group 80 SECTION 7 TROUBLE SHOOTING 7 2 OFFSET ERR
94. oup 26 SECTION 3 OFFSET GAIN AND CALIBRATION MODES 3 4 CALIBRATION PROCEDURE Perform the following to calibrate the gain of the PMT 1 Stop the machine and place a calibrated leak can a can with a 0025 hole in the machine With the can oriented with the 0025 hole facing the direction of movement of the can along the wheel line the leak can up exactly with the PMT Note Orienting the can with 0025 facing the direction of movement along the wheel places the hole at the least light intensive area of the PMT sampling station This is done so that when the PMT is calibrated it is calibrated for the worst case lighting situation 2 With the calibrated leak can positioned in front of the PMT initiate the calibration either by pressing the CALIBRATE push button inside the M4530 housing box or with the Set Up Enable switch in the Enable position by pressing the CAL PMT GAIN key on the HSL RT6 Keypad Display 3 The CAL LED on the M4530 will flash while the PMT gain calibration is taking place The CAL LED will illuminate solid if the calibration is successful If the calibration is not successful the CAL LED will extinguish after the calibration was attempted 4 Ifa calibration error did occur CAL LED on front of M4530 off at completion of the calibration procedure observe the value of the PMT gain either on the M4530 Set up menu of the HSLRT6 set up program or th
95. p exe file and Click Open and then Ok 5 This will initiate the installation process Follow the instructions that appear on the screen to complete the installation process The HSLRT6 setup program can be executed from the Systems folder located in Programs from the Start menu HSL RT6 M45 User s Manual SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION 2 11 2 DOS BASED SET UP PROGRAM INSTALLATION The HSLRT6 DOS based set up software is used to 1 Setup tune the user adjustable variables 2 Adjust the timing channel set points 3 Download the application program to the M4530 module 4 Download restore or upload save the user setup variables from the M4530 to disk 5 View Shift and Rejects Per Pocket data To install the DOS based set up software perform the following steps 1 Create a directory off the root directory of the PC for the HSL RT6 M45 called HSLRT6 This will be used to store the HSLRT6 EXE setup program and HSLRT6 application program Create this directory by typing the following at the DOS prompt MD HSLRT6 lt ENTER gt 2 Install the disk labeled HSL RT6 M45 PROGRAMS into the A drive Switch to the HSLRT6 directory and install the HSLRT6 set up program by typing the following at the DOS prompt CD HSLRT6 lt ENTER gt A INSTALL lt ENTER gt 3 Add the HSLRT6 set up program to your computer s menu software by creating a selection called SE
96. port 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 5 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 function makes use of the windows generated and sent to the specified printer device This print manager which allows the user to continue with their work while the document is being printed 5 3 THE EDIT MENU The Edit menu allows the user to per Enable Disable Offline Editing Set up the Comm Port form the following functions amp HSLRATE unnamed Main Display File Edit View Window PMT Help k Comm Port Machine CPM EN PMT Data PMT Applied Gain volts PMT Input Offset Value PMT Average last 36 good cans PMT Input Reject Threshold Good Cans Rejects lh ae j Calibrate PMT ET 5m 4 CebeePwr 0 i 75 E Alarm Reset System Message All Faults Normal ONLINE 10 9 2003 3 23PM _ HSL RT6 M45 User s Manual SYSTEMS Electronics Group 44 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 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 us
97. reshold the can is considered a leaker and is rejected Typically this parameter is set between 35 and 75 10 PMT Gain PMT Voltage 0 1200V Adjusting this value adjusts the voltage applied to the tube thus adjusting the gain of the tube The value is set in 5 volt increments thus when a number is entered it will be rounded to the nearest 5 volt increment This parameter is set by the user in manual gain mode see section 3 5 Manual Gain Adjustment or is adjusted automatically when calibration is performed in the auto gain mode see section 3 3 Automatic Gain Adjustment 11 M4530 PMT Input Sensitivity This is a value from 0 to 7 which adjusts how much the output from the PMT input to the M4530 is amplified internally in the M4530 The higher the number the higher the M4530 sensitivity will be In general this is set at the highest amplification and is only lowered if the PMT is too sensitive HSL RT6 M45 User s Manual SYSTEMS Electronics Group 63 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 1 5 View PMT Data The View PMT Data selection is used to view the good can and reject data in real time as well as manually fine tune the PMT gain HSLRTS unnamed Fie Edt View Window PMT Help PMT Setup Parameters View PMT Data PMT Gain Voltage 0 1200V 1101 4d PMT Input Offset 250to 250 0 r Good Can Data Rejected Can Data PMT Input 0255 Av
98. rmal range is 35 to 75 Note If this is increased too high calibrated leakers will not be rejected Run calibrated leakers through the machine and verify they are still rejected 6 If excessive cans are still being rejected select the View M4530 PMT Data menu and manually lower the PMT Gain Again verify that the calibrated leakers are rejected at the lower gain settings HSL RT6 M45 User s Manual SYSTEMS Electronics Group 83 SECTION 7 TROUBLE SHOOTING 7 Ifthe problem persists perform steps 5 through 10 of section 7 1 7 5 CALIBRATED LEAKERS NOT REJECTED PROBLEM Some or all of the calibrated leakers are not rejected when run through the machine SOLUTION In this case either the sensitivity of the M4530 or PMT tube is too low Other causes could be an inadequate light source burned out tubes or dirty shutter or starwheel Perform the following 1 Verify that the light source is adequate and that there are no burned out bulbs 2 Verify that the machine is clean The windows in the shutter must be free of dust and oil and the plexi glass starwheel should be clean Verify that the PMT tube end window is also clean 3 Ifthe machine is clean and the light source adequate select the M4530 Set up menu and lower the PMT Reject Can Threshold and try again This value can be lowered to within 5 above the Desired Good Can PMT Value 4 Ifthe problem persists increase the PMT Gain
99. rom 0 through 359 If not swap the S1 and S3 leads of the resolver at the M4530 resolver connector Then verify that the position then indeed does increase with forward movement 2 Position the machine with pocket 1 perfectly aligned with the PMT This is the machine zero position 3 Auto zero the resolver by pressing the SET MACH ZERO key The display will prompt TO ZERO RESOLVER ALIGN POCKET 1 WITH PMT AND PRESS ENTER OR ESC EXIT Press the ENTER key to set the resolver offset The M4530 will calculate the actual offset value required to make this the 000 position The View PMT Data menu will be displayed now showing the POS at zero 4 Press the ESC key to return to the default screen Note This selection is only enabled when the SET UP ENABLE key switch is in the ENABLE position HSL RT6 M45 User s Manual SYSTEMS Electronics Group 36 SECTION 5 HSLRT6 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 M4530 to match the configuration and performance of the specific tester see Tuning the HSL RT6 MAS section 2 12 Note The set up program is an on line communications program used t
100. rompting the user to either Retry or Cancel the operation 5 4 3 VIEW OFFLINE DATA This function allows the user to place the set up program in an Offline mode This is accessed by the View menu by selecting Offline Data or by simply pressing the F4 function key This allows the user to perform Offline editing All values displayed in Offline edit mode reflect the actual values contained in the currently loaded set up data file Note The program can be toggled between Online and Offline by simply double clicking on the Online or Offline panel displayed in the status bar at the bottom of the window Once invoked the set up program will close the Comm port and cease communication with the M4530 HSL RT6 M45 User s Manual SYSTEMS Electronics Group 48 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 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 HSLRTE unnamed Main Display File Edit View Window PMT Help Messages MAES 2 Machine Timing 3 Serial Communications 4 Shift Data 51 0 States Machine CPM Good Cans Rejects 0 0 PMT Data Calibrate PMT PMT Applied Gain vols 10T H zoe PMT Input Offset Value 0 PMT A
101. rred when the PMT Gain calibration is performed If this bit is a 0 after the calibration is complete bit5 above back off then the calibration was successful If it is 1 a calibration error occurred Timing Signal Fail Alarm this bit is set to a 1 if either CH00 or CHO1 fails to change state once the tester is running drive on for a time delay HSL RT6 M45 User s Manual SYSTEMS Electronics Group A 3 APPENDIX A MODBUS COMMUNICATIONS DATA READ FROM THE MODICON PLC The following data is read from the MODICON PLC MODICON Dest M4530 Source 4x Address Data Definition Address 401760 Status Control from MODICON W792 The bits of the Status Control register from the MODICON to M4530 are mapped as follows Note For all the following control bits the corresponding action performed by the bit is activated at the leading edge off to on transition of the bit Once a bit is set on it must be set back to off some time latter as if activated by a momentary PB contact W792 Status Control from MODICON 4x address 401760 in MODICON B792 0 End of Shift B792 1 Reset Rejects per pocket diagnostics W1050 W1072 B792 2 PMT Gain Calibrate Initiate B792 3 PMT Gain Increase by 5 volts B792 4 PMT Gain Decrease by 5 volts B792 5 Reject Threshold Increase by one B792 6 Reject Threshold Decrease by one B792 7 Alarm Reset B793 0 Set Resolver Zero Auto Zero B793 1 N
102. s too great this potentiometer may have to be adjusted to null the offset to zero This is done by running cans through the machine and verifying the value the PMT offset automatically obtains The PMT housing offset only needs to be set at the initial installation or any time the B2F RFI PMT housing is replaced All other offset variations due to temperature etc are automatically compensated for with the automatic offset adjustment feature of the M4530 This adjustment simply makes sure the offset potentiometer of the PMT housing is not set outside the normal range of operation Verify the offset as follows 1 Run the machine with cans at normal line speeds and verify that the offset is automatically adjusted until the PMT Input Average is equal to the Desired Good Can PMT Value within plus or minus 2 Up Peak Max and Down Peak Min should also be within plus or minus 5 of the PMT Input Average 2 Ifthe offset exceeds or 250 in an attempt to set the PMT Input Average equal to the Desired Good Can PMT Value the MAINT LED on the M4530 will be illuminated This indicates that the PMT is detecting an excessive amount of light both when the cans are sampled and at the in between pocket measurement Verify that the machine is timed properly per section 2 12 2 and that no light leakage is occurring at any of the PMT seals machine shutter to light seal plate PMT to light seal plate or at the PMT housing itself 3 I
103. sabled Manually setting the PMT gain requires the user to run calibrated leakers through the machine to verify the PMT gain is set high enough to reject the calibrated cans To set the gain perform the following 1 Using the HSLRT6 set up program view the M4530 PMT data and monitor the Average Reject Value and the last 8 rejects Last Reject Value through 8th to Last Reject Value The Average Reject Value is the average of the last 8 rejects 2 Run some calibrated leak cans through the machine The M4530 should reject all the cans If the M4530 does not reject the cans increase the PMT Gain re adjust the offset as well if the manual offset mode is used see section 3 2 and run the calibrated leakers through the machine again Repeat this step until the M4530 always rejects the calibrated leakers 3 Now observe the Average Reject Value and the last 8 rejects while running the calibrated leakers through the machine The calibrated leakers should result in a reject value of approximately 100 to 200 If the value is just barely above the reject threshold increase PMT Gain until the calibrated leakers result in reject values in the range of 100 to 200 If the calibrated reject value is always higher than 230 decrease PMT Gain until the calibrated leakers typically have a reject value around 100 to 200 4 In general the PMT Gain is set low enough where the calibrated leakers are easily detec
104. se Setting this bit to a 1 increases the Reject Threshold by one thus decreasing the system sensitivity Reject Threshold Decrease Setting this bit to a 1 decreases the Reject Threshold by one thus increasing the system sensitivity Alarm Reset Setting this bit to a 1 resets the bad pocket alarms for pockets 1 12 and the timing signal fail alarm Set Resolver Zero Auto Zero Setting this bit sets the PLS offset such that the current position is 0 To set the resolver zero stop the machine align pocket 1 precisely wit the PMT and then set this bit to a 1 The Sync and Pocket 1 Marker timing are automatically set in the PLS section no other action is required by the user to time the machine HSL RT6 M45 User s Manual SYSTEMS Electronics Group A 5 APPENDIX B DF1 COMMUNICATIONS HARDWARE DF1 communication takes place via the Channel 0 port of the Allen Bradley PLC The RS 232 cable should be constructed and connected as shown below 4516 DF1 to PLC5 SLOT 0 Swi SW2 m ON m ON m PLC5 S4516 DF1 PUN COMMUNICATIONS CO CPU 1 M R 1 RXD O 2 TX RS 232 TXD 1 3 RX SG 2 7 SG vu iv 3 4 RTS RXD 4 S Gls ayes 6 DSR RS 422 8 DCD TXD4 6 airs TXD 7 ae CORRER ee la 0 S3000 NETWORK COMMUNICATIONS 1
105. ted but not so high that the M4530 becomes to sensitive and rejects good cans excessively In addition the higher the gain on the PMT the shorter the life of the tube As the tube ages the sensitivity of the tube reduces requiring the gain to be increased HSL RT6 M45 User s Manual SYSTEMS Electronics Group 29 SECTION 3 OFFSET GAIN AND CALIBRATION MODES This Page Intentionally Left Blank HSL RT6 M45 User s Manual SYSTEMS Electronics Group 30 SECTION 4 USING THE KEYPAD DISPLAY The HSL RT6 Keypad Display contains 24 keys consisting of data display commands and set up commands The display is a 2 line by 40 character back lit LCD display which displays the selected data and set up menus The Keypad Display can be used to view data as well as to adjust the PMT Gain and Threshold key switch protected bs d as f reser m n A f apuus A 2 REJECTS VAN M M 2 KET POCKET REJ CKE GAIN RI 2 E 4 REV ATA NC NC i JL L GAIN LTHRESE JESUS The display keypad allows the following to be viewed or adjusted 1 2 3 4 5 6 7 8 Calibrate the PMT gain Increase Decrease the PMT Gain Increase Decrease the Reject Threshold View the PMT Set up Data Set Machine Zero View the Number of Rejected Cans per Pocket View the Current Shift Data View the Last Shift Data The definitions of the keypad commands and menus are described
106. th auto zero feature to simplify machine timing e Based on high performance M4530 PLC PLS PMT module which allows easy trouble shooting and user customization using SYSdev DOS based programming package HSL RT6 M45 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 2 FUNCTIONAL DESCRIPTION The HSL RT6 M45 light tester package interfaces directly with the machine mounted photo multiplier tube referred to hereafter as the PMT machine mounted resolver and the odd and even reject solenoids The HSL RT6 MAS detects defective cans leakers via the PMT and rejects these cans by activating the respective odd or even reject solenoid at speeds up to 2400CPM The photo multiplier tube PMT outputs a low level high frequency analog value which is proportional to the amount of light entering the tube This output is input directly to the M4530 module and conditioned as necessary by the module to deduce the actual amount of light the tube detected The tube is extremely sensitive and easily capable of detecting a hole of 002 or less diameter in a can The gain of the tube is adjustable by adjusting the voltage applied to the tube 0 1200 volts The light tester package contains a 0 to 2000 volt variable power supply which supplies this voltage for the tube Two timing signals provided by the PLS and machine mounted resolver are used to generate the PMT sample timing and reject timing These signals are a Marker pulse
107. th the connector on the M4530 in only one way 7 Mount the M4530 chassis to the HSL RT6 M45 backpanel 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 M4530 the connector on the cable is polarized and should mate with the connector on the M4530 only one way 9 Install the respective field wiring arms on all the I O boards of the M4530 I O slots 0 and 2 RS 232 connector on USER PORT resolver connector and PMT section connector Make sure all the field wiring connectors are fully mated in the M4530 10 Install the GATE and SIG coax cables to the respective BNC connectors of the M4530 PMT section upper BNC connector is GATE lower BNC connector is SIGNAL 2 13 2 P4500 POWER SUPPLY INSTALLATION To install the P4500 perform the following steps 1 Mount the P4500 to the HSL RT6 M45 in the mounting holes next to the M4530 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 M4530 the connector on the cable is polarized and should mate with the connector on the M4530 only one way HSL RT6 M45 User s Manual SYSTEMS Electronics Group 2203 SECTION 2 INSTALLATION 2 13 3 D4591 KEYPAD DISPLAY INSTALLATION To install the D4591 Keypad Display perform the following steps 1 With the gasket installed on the mounting studs o
108. the HSL RT6 M45 enclosure 5 Remove the four screws retaining the M4530 module to the back panel and install the 26 pin ribbon cable to the display connector on the back of the M4530 module the cable connector is polarized and will only mate with the M4530 connector one way Install the M4530 back on the back panel 6 The HSL RT6 DSP installation is now complete Refer to section 4 for complete details on using the HSL RT6 Keypad Display HSL RT6 M45 User s Manual SYSTEMS Electronics Group 4 SECTION 2 INSTALLATION 2 11 HSL RT6 M45 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 RT6 M45control system 2 11 1 WINDOWS BASED SET UP PROGRAM INSTALLATION The HSLRT6 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 M4530 module 4 Download restore or upload save the user setup variables from the M4530 5 View Rejects Per Pocket and Shift data To install the set up software perform the following steps 1 Insert the HSLRT6 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 HSLRT6 CD Select the setu
109. the user in manual offset mode see section 3 2 or is adjusted automatically when in the auto offset mode see section 3 1 PMT Input This is the value 0 to 255 of the last PMT sample and is proportional to the amount of light detected by the PMT where 0 equals no light detected and 255 equals maximum light detected PMT Input Average This is the average of all good cans and the in between pocket dark measurements for 36 consecutive cans HSL RT6 M45 User s Manual SYSTEMS Electronics Group 70 SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE PMT Up Deviation This is the average up deviation from the good can PMT Input Average for 36 consecutive cans The lower the number the less deviation between all good cans the higher the number the more deviation PMT Down Deviation This is the average down deviation from the good can PMT Input Average for 36 consecutive cans The lower the number the less deviation between all good cans the higher the number the more deviation Up Deviation Count This is the number of good cans that deviated up from the good can PMT Input Average in the last 36 consecutive pockets Down Deviation Count This is the number of good cans that deviated down from the good can PMT Input Average in the last 36 consecutive pockets Up Peak Max This is the highest PMT input value detected as a good can in the last 36 consecutive pockets Down Peak Min This is the
110. tion and is only lowered if the PMT is too sensitive HSL RT6 M45 User s Manual SYSTEMS Electronics Group 68 SECTION 6 HSLRT6 DOS BASED SETUP PROGRAM REFERENCE PMT Input Offset 250 to 250 This is the input offset value and adjusts the M4530 input offset proportionally This parameter is set by the user in manual offset mode see section 3 2 or is adjusted automatically when in the auto offset mode see section 3 1 PMT Reject Can Threshold This value specifies the reject threshold If the PMT Input value is below this threshold the can is considered good and is not rejected If the PMT Input value is above this threshold the can is considered a leaker and is rejected Typically this parameter is set between 35 and 75 Automatic Offset Mode Enabled When set to YES the automatic offset mode is enabled see section 3 1 When set to NO the manual offset mode is enabled see section 3 2 Desired Good Can PMT Value Used in the auto offset mode This value is set by the user to specify the desired good can average The M4530 adjusts the input offset until the average good can input is within the specified error see section 3 1 Allowed Good Can Error This parameter is used in conjunction with the Desired Good Can PMT Value to adjust the PMT input offset in the auto offset mode The M4530 will adjust the offset until the good can average is within the value entered in Allowed Good Can Error
111. unications board System function sfunc19 S4516 configuration is used to set the 84516 configuration network node address network baud rate and USER port baud rate This must be executed prior to executing ether system functions 10 11 or 13 System function 19 is generally executed in the Initialization file of the user program HSL RT6 M45 User s Manual SYSTEMS Electronics Group 56 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE The following values are returned from a system function 19 call 1 Busy 2 Done S4516 Successfully configured 3 Invalid Parameter either network node address network baud rate or USER port baud rate is invalid 4 Timeout no response form S4516 32 Hardware ACK error from 4516 34 Invalid S4516 Slot Address W8156 must be loaded with the slot address of the 4516 prior to executing system function 19 Il Transmit Data Status This represents the state of the data packet transmission This will typically display either Busy or Done If there are problems delivering the message packet the response code along with a description will be displayed Note The Transmit Data Status prev is used to view the last or previous status Current Transaction This is the Transaction number delivered to the Allen Bradley PLC Active Command This displays either Read or Write This is used to view the command type of the current transaction Nu
112. verage last 36 good cans 0 PMT Input Reject Threshold 75 Em Beer Alarm Resel System Message All Faults Normal ONLINE 10 9 2003 3 25PM Once a window menu item is selected a check mark is placed next to the selected item and the selected window is displayed with the name changed in the title bar of the main window Note Read only variables are displayed in blue with a gray background Any variables that can be altered by the user are displayed in black with a white background In most cases a parameter that can be changed by the user will have associated with it increment and decrement controls The user can either click on the desired parameter to adjust and enter in a new value or use the increment or decrement controls to change the value by 1 unit HSL RT6 M45 User s Manual SYSTEMS Electronics Group 49 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 5 1 THE MAIN DISPLAY WINDOW The Main Display window is used to display the general state of the control system This window is selected from the Window menu EHS File E LRTS unnamed Viev findow PMT Help Messages Machine CPM Good Cans Rejects S s PMT Data Calibrate PMT PMT Applied Gain volts 7101 ee PMT Input Offset Value D PMT Average last 36 good cans 0 PMT Input Reject Threshold 75 a Al
113. wing nuts Do not operate the light source assembly without the glass covers installed The glass covers perform a number of functions including preventing debris from being expelled inside the hood if the halogen lamp shatters filtering the UV component of the light spectrum emitted from the lamp and reflecting much of the heat generated from the halogen lamp out the top of the light source assembly instead of down into the machine HSL RT6 M45 User s Manual SYSTEMS Electronics Group 13 SECTION 2 INSTALLATION 2 10 MOUNTING THE KEYPAD DISPLAY OPTIONAL The D4591 HSL RT6 Keypad Display is mounted in a mini pedestal which is mounted to the top of the HSL RT6 M45 enclosure in the user s preferred location To mount the display perform the following 1 Determine the desired location on top of the HSL RT6 M45 enclosure to mount the HSL RT6 DSP and punch a 2 hole at what will be the center of the pedestal Drill 4ea 9 32 holes around the 2 hole to match the pedestal mounting base 2 Mount the HSL RT6 DSP pedestal to the top of the HSL RT6 M45 enclosure using the supplied gasket bolts and nuts 3 Mount the Display enclosure to the top of the pedestal using the supplied gasket bolts and nuts 4 Install the supplied 26 pin ribbon cable to the connector on the back bottom of the D4591 display the cable connector is polarized and will only mate with the D4591 connector one way Route the cable down the pedestal into
114. xport Shift Data This function allows the user to export the shift data to a Tab Delimited text file This allows the user to easily use the shift data to produce production reports HSL RT6 M45 User s Manual SYSTEMS Electronics Group 40 SECTION 5 HSLRT6 WINDOWS BASED SETUP PROGRAM REFERENCE 5 2 2 UPLOAD SAVE DATA The Set up program allows the user to upload set up parameters timing channel set points and shift data from the M4530 into a set up Data File This function is accessed from the File menu and the user is given the choice of the following options amp HSLATE unnamed Main Display File Edit View Window PMT Help New Ctrl N Open Ctl O0 Save Ctl S Save As Export Shift Data Ctrl lt Upload save Data Download Program Download Data gt Ej E Calibrate PMT n volts 1101 F Calibrate PMT Input Offset Value 0 PMT Average last 36 good cans 0 PMT Input Reject Threshold 75 nput Reject Threshol F Alarm Reset Print Repott Ctrl P Exit ONLINE 10 9 2003 3 23PM 7 System Message All Faults Normal M4530 PROG Port This option allows the user to upload set up parameters timing channel set points and shift data from the M4530 If not connected to the M4530 PROG port a message will be displayed alerting the user 4030 CAL Port This option allows the user to uplo
115. y unscrewing the connector plate from the housing and then removing the Preamp Gating assembly The Preamp Gating assembly is attached to the connector plate and is removed from the housing with the plate 3 Carefully install the 9956B 16 tube in the Preamp assembly connector The tube is keyed by a missing pin in the tube and should fit in the Preamp connector only one way 4 Carefully install the Tube Preamp Gating assembly back in the housing making sure the tube seats in the nose of the housing correctly and then screw the connector plate into the housing HSL RT6 M45 User s Manual SYSTEMS Electronics Group 10 SECTION 2 INSTALLATION 2 7 WIRING THE HSL RT6 M45 Perform the following to wire the HSL RT6 M45 1 2 3 4 5 6 7 8 9 Wire the odd even reject solenoids and machine interlocks main drive on sync timing output leaker reject output etc to the existing control system referring to the electrical control schematic at the back of this manual keeping all 24VDC wiring away from high voltage motor leads wiring Wire the machine mounted resolver directly to the 8 pin resolver input connector on the M4530 module using the supplied RSV RSCBLE three pair two conductor shielded cable The shield of the resolver cable should be tied to SHLD terminal of the M4530 resolver input connector Make sure the resolver cable shield is left floating at the resolver Refer to the electrical c

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