SECTION 2 INSTALLATION - Sea
Contents
1. reference or section 5 2 2 DOS set up program reference for details on adjusting CH03 thru and CH05 HSL CUP4 User s Manual SYSTEMS Electronics Group wD se HSL CUP4 User s Manual SECTION 2 INSTALLATION Verify Cup Drop Timing With the machine running with the coil stock verify that no false die jam or cup jam faults are occurring If false die jams or cup jams are occurring verify that the cup drop sensors are detecting the cups when they drop If the sensors are detecting the cups adjust the Cup Drop Window timing as necessary to eliminate the false die jam or cup jam faults The cups must drop inside the Cup Drop Window in order to avoid a die jam and must not be detected outside the Cup Drop Window in order to avoid a cup jam Verify that the die jam detection is working correctly by removing the coil stock from the press and then stroking the press with the coil stock override off The press should stop with a die jam alarm for station 1 displayed die jams for all stations actually occur but 1 is displayed since it is the lowest numbered station to fault Verify TDC Stops If the brake wear compensation is enabled verify that the press does stop at the desired location in both the high and the mid speeds Note When the HSL CUP4 is first installed it will take a few successive stops for the algorithm to program the TDC timing channels to the correct position Also the compensation is ena2. Set this parameter to the value where the brake response is considered too long and service to the brake should be performed typically 270 to 300 degrees HSL CUP4 User s Manual SYSTEMS Electronics Group 19 SECTION 2 INSTALLATION Cupper Running Speeds Set the Cupper running Low Speed and High Speed to the speeds that the cupper will actually run at when the respective speed is selected Note This is not a speed reference but is instead parameters used by the HSL CUP4 to know when to switch between the TDC Low TDC Mid and TDC High timing as well as the Air Strip Low Air Strip Mid and High timing etc See section 3 5 1 Using the Keypad Display section 4 5 2 Windows set up program reference or section 5 1 3 DOS set up program reference for details on setting the set up parameters 2 8 3 SET LUBRICATOR SPEED REFERENCES Set the Lubricator Maximum Speed and Lubricator Idle Speed as desired These parameters are used to control the speed of the lubricator via the 0 10Volt lubricator speed reference output of the HSL CUP4 module Lubricator Maximum Speed The Lubricator Maximum Speed parameter is used to scale the 0 10VDC analog output such that when the cupper is running at the speed entered in Lubricator Maximum Speed the analog output will be at 10 volts Lubricator Idle Minimum Speed This parameter determines the speed the lubricator will run at when the cup
3. SECTION 2 INSTALLATION 5 Add the Coil Stock O Ride output into the PLC program The signal is used to by pass the die jam and cup jam detection when the press is stroked without coil stock Note The HSL CUP4 will produce an COIL STOCK MODE fault if cups are detected dropping while the coil stock override is on This prevents the machine from being run in production with the coil stock override accidentally left on 6 Add the Alarm Reset output This signal should be on as long as the system reset push button is depressed 2 8 HSL CUP4 SET UP The HSL CUP4 is shipped from the factory with the PLC program loaded into the PLC section of the module The PLS channel set point file CUP7TMG loaded in the PLS section In most cases the following user variables and timing channels may have to be altered to tune the HSL CUP4 to the actual cupper it is controlling Once installed and the control system is powered back up perform the following to set up and tune the HSL CUP4 The set up is performed using the Keypad Display or a PC running the set up program See section 3 for a description of the Keypad commands and menu displays of the HSL CUP4 Keypad Display See section 4 for a description of the menus variables and how to use the Windows based set up program See section 5 for a description of the menus variables and how to use the DOS based set up program HSL CUP4 User s Manual SYSTEMS Elec
4. ails to drop within the Cup Drop Window timing CH06 The Cup Jam alarm is generated if any cup is detected when the Cup Drop Window is off cups must be clear by this time See section 3 5 3 Using the Keypad Display section 4 5 3 Windows set up program reference or section 5 2 2 DOS set up program reference for details on setting the location of the cup drop window CH06 HSL CUP4 User s Manual SYSTEMS Electronics Group 21 SECTION 2 INSTALLATION CUP DROP CUP DROPS WINDOW CDW WITHIN CDW lt CHO6 CDW ON EXAMPLE 19 NO DIE JAM NORMAL GOOD OR CUP JAM CUP DROP EXAMPLE 2 9 DIE JAM NO CUP DROP ALARM EXAMPLE 3 CUP JAM CUP JAMED ALARM AT SENSOR 0 180 360 CUP DETECTED OUTSIDE CDW CDW OFF Figure 2 Cup Drop Check Timing Sequence 2 8 6 VERIFY MACHINE OPERATION Once steps 2 8 2 thru 2 8 5 are complete run the machine in normal production at all speeds where practical and verify the following Verify Air Strip Timing With the machine running with the coil stock verify that the cups are dropped with out any problems verify at low medium and high speed If a problem is occurring adjust the respective Air Strip timing CH03 High Speed CH04 Mid Speed CH05 Low Speed until the problem is corrected See section 3 5 3 Using the Keypad Display section 4 5 3 Windows set up program
5. ake wear compensation is used enable it by setting the Brake Wear Compensation Enable to Y and set the Desired TDC Stop Position Mid and High The Desired TDC Stop positions is the location of the ram when it comes to rest after a TDC stop Both the Mid and High desired stopping positions are generally set to 000 degrees Enabling the brake wear compensation allows the HSL CUP4 to automatically adjust the TDC timing channels CH00 High and CH01 Mid as necessary such that the press will stop at the desired stopping position regardless of the actual brake response If the brake wear compensation is not used disable it by setting the Brake Wear Compensation Enable to N Disabling the brake wear compensation requires the TDC High timing CH00 and the TDC Mid timing CH01 signals to be set manually such that the press stops at TDC Note If the brake response then changes the press will not stop at the desired position if the brake wear compensation is disabled Maximum Allowed Stopping Response This parameter defines the maximum allowed brake response before a Brake Response Too Long alarm is generated If the actual brake response number of degrees from when the brake is activated to the position where the press ends up at rest when a TDC stop is performed is longer than this number the alarm is generated If the actual brake response is less the alarm is not generated
6. bled after the press has been running at a fixed speed in continuous The TDC timing channels will not be modified when single strokes are made or if press is started in continuous and then immediately stopped again Wait about 5 seconds after the press is started before performing the TDC stop to verify the stop position If the brake wear compensation is disabled manually adjust both the TDC High timing CH00 and the TDC Mid timing CH01 such that the press stops at back dead center at both respective speeds Note The TDC Low timing must be set manually since it does not incorporate the compensation algorithm See section 3 5 3 Using the Keypad Display section 4 5 3 Windows set up program reference or section 5 2 2 DOS set up program reference for details on adjusting CH00 and CHO1 The Machine Is Now Set Up And Ready To Run SYSTEMS Electronics Group 93 2
7. per is stopped de clutched Note When the cupper is running the lubricator speed reference is proportional as set by the Lubricator Maximum Speed scaling to the speed of the cupper This parameter is used to provide the speed reference when the cupper speed is zero for lubricator jog etc See section 3 5 2 Using the Keypad Display section 4 5 2 Windows set up program reference or section 5 1 4 DOS set up program reference for details on setting the set up parameters HSL CUP4 User s Manual SYSTEMS Electronics Group 20 SECTION 2 INSTALLATION 2 8 4 SET MACHINE ZERO Inch the cupper up to top dead center TDC and set the HSL CUP4 resolver offset See section 3 5 4 Using the Keypad Display section 4 5 3 Windows set up program reference or section 5 2 1 DOS set up program reference for details on setting machine zero 2 8 5 VERIFY LOCATION OF CUP DROP WINDOW CHO06 By inching the machine verify that the Cup Drop Window timing CH06 of the HSL CUP4 first turns on at the point where the cups are first freed from the punches see figure 2 This is the earliest point the sensors might see the cups drop The Cup Drop Window should then be set to stay on all the way up to about 20 degrees before this location this is almost one complete stroke This allows the greatest amount of time for the cups to drop The Die Jam alarm is generated if a cup from any station f
8. tronics Group 17 SECTION 2 INSTALLATION 2 8 1 DEFAULT SET UP VARIABLES As shipped the user variables for the HSL CUP4 are set to the following defaults Brake Wear Compensation Enabled N Desired TDC Stop Position Mid Speed 000 Desired TDC Stop Position High Speed 000 Maximum Allowed Stopping Response degrees 300 Cupper Running Speeds Low Speed SPM 100 High Speed SPM 250 Lubricator Speed Reference Maximum Speed 250 Idle Speed Cupper stopped 075 The CUP7TMG timing channel file as shipped contains the following default timing set points CHAN ON OFF DESCRIPTION CHOO 120 140 TDC High timing CH01 160 180 TDC Mid timing CH02 200 220 TDC Low timing CHO3 120 200 Air Strip High timing CH04 140 220 Air Strip Mid timing CHO5 150 230 Air Strip Low timing CHO6 140 120 Cup Drop Window timing CHO07 000 020 PLC Timing CH10 _ CH11 CH12 so CH13 se CH14 CH15 _ CH16 ___ CH17 so ASL CUP4 User s Manual SYSTEMS Electronics Group 18 SECTION 2 INSTALLATION 2 8 2 SET CUPPER SET UP PARAMETERS The Cupper set up parameters include e Enabling or Disabling The Brake Wear Compensation e Setting the Desired Mid and High Speed Stopping Points if the brake wear compensation is enabled e Setting the Maximum Allowed Stopping Response e Setting the Cupper Running Low and High Speeds Brake Wear Compensation If the br
Download Pdf Manuals
Related Search