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1. 11 Add the Canfeed Enable Speed into the PLC logic The canfeed enable speed comes ON whenever the speed of the machine is within the canfeed enable window Use this signal to control the canfeed enable whenever this signal is ON 12 Add the Ductors Feedback Fault into the PLC logic If a ductor is not detected as cycling properly the Ductor Feedback Fault is energized indicating a problem with the ductor cycling control If the ductor feedback sensors are used enable the particular stations that have feedback If the ductor feedback is not used disable all stations that do not have feedback If a Ductor Feedback Fault does occur the ductors should be manually activated to verify proper cycling operation as well as the sensor for proper feedback operation The feedback sensor should be set such that it is only ON when the ductor is in contact with the fountain roll 13 Add the Ductors Auto On into the PLC logic This input should be ON whenever cans are feeding into the decorator HSL DC5 User s Manual SYSTEMS Electronics Group 16 HSL DC5 User s Manual SECTION 2 INSTALLATION 2 9 TUNING THE HSL DC5 The HSL DC5 is shipped from the factory with the application program loaded in the PLC In most cases the default variables and timing signals will have to be altered to tune the HSL DC5 to the actual decorator it is controlling Once the system is installed and powered bac
2. Maximum Cycle Duration 0 1 cans 500 Maximum ON Duration 0 1 cans 200 Response Time Compensation msec 25 Color Gain CG 100 per 2000CPM 100 Feedback Enable Stations 1 8 N 6 6 MANUAL OFF AUTO CONTROL The ductor MANUAL OFF AUTO selector switch is used to determine the mode of the ductors The three different modes operate as follows MANUAL Ductors cycle normally while the decorator is running Ductor Auto On input from host PLC ignored Ductors turn off rest on first steel roll when the decorator reaches zero speed While the decorator is stopped each individual ductor can be toggled on and off by pressing the keypad number corresponding to it s station This provides a test method to verify the operation of each ductor OFF Ductors always off resting against first steel roll AUTO Ductors cycle normally while decorator is running and the Ductor Auto On input from the host PLC is on Ductors turn off when decorator reaches zero speed or when Ductor Auto On input from host PLC is off HSL DC5 User s Manual SYSTEMS Electronics Group 94 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 7 OVERVIEW OF KEYS RELATING TO THE COLOR CONTROL COLOR CONTROL Pressing this key allows the operator to select a new label number adjust the Cycle and On durations independently for each ink stations or program a new label from scratch This
3. Set the Canfeed Enable Low Speed and Canfeed enable High Speed in conjunction with one another to define a window within which the can gate can be opened or closed This allows the flow of cans to be controlled whenever the machine speed is inside this window When the machine goes to a stand by condition the speed of the machine will need to be decreased inside this window for the can gate solenoid to be deactivated The M4508 will activate deactivate the can gate solenoid on the Can Gate Timing ON signal 2 9 7 SET NUMBER OF PINS TO PIN CHAIN BLOWOFF PORT Set the of pins to pin chain blowoff port by counting the number of pins from the spindle wheel to disc transfer location to the bad can pin chain blowoff port The number entered is the number counted minus 2 this is just an approximation Set the of bad cans to blow off for each misload equal to one Run the machine at low speed with cans and verify that for each misload the one bad can is blown off If the bad can is not blown off then adjust the of pins to pin chain blow off port accordingly until the misloaded can is blown off Note On this system only one can is normally blown off for each misload on a particular mandrel However the end user may select to blow off up to five cans to get rid of the excess ink on a particular blanket The chain take up must be after the bad can pin chain blow off If the take up is before the port the relative
4. Ga 20 A o Ass 2 30 320 15 9 m Ductor Status 3 4 4 20 4 20 0 Operational Mode auto 4 50 3 360 a 236 Ductors Auto ON ON af co A s A 282 te 7 2 400 2 2889 ductors Manual Control wz so 420 4 32 fa meme mA mame my mE s s x 440 x 38 Ducters ONANI Ductors OEF AII System Message All Faults Normal ONLINE 10 7 2003 9 44AM 7 Note For virtually all fields that allow the user to adjust a setting the user may either use the increment decrement control or simply select the field and enter in a number Once a value has been changed or the Enter key pressed the new value is validated for proper range and then written to the M4508 HSL DC5 User s Manual SYSTEMS Electronics Group 232 HSL DC5 User s Manual SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE Color Control Parameters The label number On duration and Cycle duration are used to adjust the color control settings in the M4508 The following is a description of each of these settings 1 2 3 4 Label Number The M4508 is capable of storing the settings for up to 100 labels 0 99 Select desired label number to adjust the On and Cycle duration settings Note The user may only adjust the Label Number when the machine is at Zero Speed main drive off and no motion detected On Duration The On du
5. m Lifetime Count x1000 Bad Can Blow off 0 Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 4 40PM 7 HSL DC5 User s Manual SYSTEMS Electronics Group 43 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 4 1 GENERAL DESCRIPTION Title Bar At the top of the window is the Title Bar The title bar is used to display the name of the working Set up Data file as well as the name of the active Window The title bar is dark if the window is active and grayed if another window is active The color depends on the settings of the Display Properties of the Control Panel Status Bar At the bottom of the window is the Status Bar The status bar is used to display system messages online or offline mode as well as the current time and date as set by the operating system The system messages panel displays general information about operation of the system The Online Offline mode panel displays the status of the current set up program mode of operation The mode of operation can be changed by simply double 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
6. Comm Port Port Speed Com1 9600 C Com2 C 19200 C Com3 C Com4 Cancel Once selected a dialog box requesting the user to select a Comm Port and Baud Rate will be displayed The default setting is COMI at 9600 baud The option to select the 19200 baud rate is to allow the user to communicate with the processor via the S4516 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 Settings folder SYSTEMS Electronics Group 54 HSL DC5 User s Manual SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 4 3 3 COLOR CONTROL PASSCODE The edit Color Control Passcode is an Online function only This allows the user the ability to directly change the value of the Color Control Passcode Once selected an input box is displayed allowing the user to view the current Passcode setting and to change the value if necessary If the passcode is set to zero passcode entry is disabled The operator can press the Color Control key on the Keypad Display and simply press the ENTER
7. cans blown off for every mis loaded can infeed open blow offs restart blow offs manual blow offs select a can QC blow offs etc Mis loads This is the total number of mis loaded cans trips These would be the actual number of damaged cans that did not load properly on the machine This gives an indication of conveying can handling problems Restart Blow offs This is the total number of cans blown off when the infeed opened and from the print station and varnish station at machine restart Manual Blow offs This is the total number of cans blown off by the operator using the Manual Blow off PB or selector switch QC Blow offs This is the total number of cans blown off by the operator with the Select A Can QC station or QC Blow off key on the D4591 keypad for quality verification Trips Mis loads per Spindle 1 24 or 36 This is the total trips mis loads for each spindle A disproportionately high count for a particular spindle indicates a loading problem for that spindle SYSTEMS Electronics Group 34 HSL DC5 User s Manual SECTION 3 USING THE KEYPAD DISPLAY 3 2 3 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 Refer to section 3 2 2 Current Shift Data Using the Keypad
8. key to gain access to the color control settings without having to enter a zero If the value of the Color Control Passcode is set somewhere between 1 and 65 000 Passcode Entry is enabled This requires the operator to enter in the Correct passcode to gain access to the color control parameters Note Passcode entry is only in effect when the Set up Enable selector switch is in the Disable position If an invalid value is entered the passcode value will not be reset and a message box notifying the user of the error is displayed SYSTEMS Electronics Group 55 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE HSL DC5 User s Manual 4 4 THE VIEW MEN U 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 APMDEC unnamed Main Display File Edit View Window Help lal x v Online Data Offline Data Machine CPM r Varnish RPM Q C Blow off Spindle Number 9 9 P Blanket Blow off L _ 1 9 Good Cans r Blow offs 400 148 41 69 Mandrel Blowoff Lifetime Count x1000 Bad Can Blow off 0 Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 5 01PM 7 4 4 1 TARGET BOARD INTERFACE This function allows the user to
9. save Data rnish RPM Q C Blow off Download Program 997 Spindle Number Download restore Data gt 39 m Blanket Blow off MULUS ACE 2 1 m Print Report Ctrl P 3 Mandrel Blowoff Exit L Lifetime Count x1000 Bad Can Blow off 0 Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 4 56PM 7 SYSTEMS Electronics Group 5 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 2 This will display a dialog box allowing the user to select the data to be printed in the report E APMDEC unnamed Main Display Report Set up 3 Again from the File menu select Print Report or press Ctrl P This displays the Print Setup dialog box allowing the user to select a printer as well as the paper size and orientation Once the user selects OK the report is generated and sent to the specified printer device This function makes use of the windows print manager which allows the user to continue with their work while the document is being printed HSL DC5 User s Manual SYSTEMS Electronics Group 152 HSL DC5 User s Manual SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 4 3 THE EDIT MENU The Edit menu allows the user to perform the following functions e Enable Disable Offline Editing e Set up the Comm Port e Edit the Color Control Passcode amp APMDEC unnamed Main Display
10. 04 trips Spindle 16 trips Spindle 05 trips Spindle 17 trips Spindle 06 trips Spindle 18 trips Spindle H07 trips Spindle 19 trips Spindle 08 trips Spindle 20 trips Spindle 09 trips Spindle 21 trips Spindle 10 trips Spindle 22 trips Spindle 11 trips Spindle 23 trips Spindle 12 trips Spindle 24 trips Spindle 25 Spindle 26 Spindle 827 Spindle 28 Spindle 29 Spindle 30 Spindle 31 Spindle 32 Spindle 33 Spindle 34 Spindle 35 Spindle 36 Coco coco coco coco 000 Cc coco coco 00 00cm Cocco coco coco 000 To set the spindle trip offset select 1 and enter the required offset see section 2 9 8 Set Spindle Trip Shift Offset Tuning the HSL DC5 To reset the spindle trip counts press 2 The counts will be reset in the M4508 To return to the main menu press lt ESC gt Spindle xx Trips This is the total number of trips for each spindle This data is displayed and updated continuously in the respective field for each spindle A disproportionately high count for a particular spindle indicates a loading problem for that spindle SYSTEMS Electronics Group 83 SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE 5 6 CURRENT SHIFT DATA This selection is used to view the Current Shift data and is the totals so far into the shift This data is transferred to the Last shift when the end of shift input transfers from a 0 to a
11. 4 5 3 The Shift Data Window 4 5 4 The Color Control Window CONTENTS SYSTEMS Electronics Group diis HSL DC5 User s Manual CONTENTS 5 HSLDC5 DOS Based Set up Program Reference __75 5 1 Set Speed Parameters 76 5 2 Set Ductor Parameters 77 5 3 Set Pin Chain QC Blow off Parameters 79 5 4 Adjusting Timing Set points 82 5 5 Number of Trips per Spindle Data 83 5 6 Current Shift Data 84 5 7 Last Shift Data 85 5 8 Download Program to Module 86 5 9 Download restore Set up Data to Module 87 5 10 Upload save Set up Data from Module 88 6 Pneumatic Ductor Color Control 89 6 1 Features 89 6 2 Functional Description 90 6 3 Ductor Feedback 91 6 4 Operator Adjustable Parameters 91 6 5 Set up Pneumatic Ductor Parameters 92 6 5 1 Default Ductor Configurations Settings 94 6 6 Manual Off Auto Control 94 6 7 Overview of Keys Relating to the Color Control 95 6 8 Recommended Procedure for Using the Color Control 1 96 6 9 Selecting the Label Number 97 6 10 Light Dark Color Adjustment 97 6 11 Changeover Using an Existing Label 99 7 Recommended Spare Parts 101 LIST OF FIGURES Recommended Panel Door Cut out 8 Machine Zero Position 18 Location of Can No Can Sensor 21 Location of Blow off timing ON Position 22 Keypad Display Legend 31 APPENDICES Drawings Appendix A SYSTEMS Electronics Group iii HSL DC5 User s Manual SECTION 1 GENERAL DESCRIPTION This section describes the features of the M4508 APM Decorator High Sp
12. Display for definitions of the data fields in the Last Shift data menu 3 2 4 DISPLAY LIFETIME CAN COUNT The lifetime can count is used to display the total number of cans printed by the machine This count is never reset and displays in 1 000 can increments SYSTEMS Electronics Group 35 SECTION 3 USING THE KEYPAD DISPLAY HSL DC5 User s Manual 3 3 SET UP KEY This selection is used to invoke the primary set up menu This consists of the following selections 1 SET SPEED PARAMETERS 2 SET PNEUMATIC DUCTOR PARAMETERS 3 SET PIN CHAIN QC BLOW OFF PARAMETERS 4 SET MACHINE TIMING SET POINTS ETC 5 ZERO MACHINE SET RESOLVER OFFSET 6 VERIFY CAN PRX1 LOCATION TIMING When selected each of the above selections will bring up a sub menu with the corresponding set up parameters The following sections describe these sub menus and the definitions of the corresponding variables To select the respective set up sub menu simply press the corresponding numeric key 1 through 6 Note The Set Up Enable input is used to enable the primary set up menu When this input is on the primary set up menu is enabled through the Keypad Display If the Set Up Enable input is off then the primary set up menu is bypassed 3 3 1 SET SPEED PARAMETERS This menu is activated when the 1 key SET SPEED PARAMETERS is pressed while the primary set up menu is active The following four set up parameters
13. Infeed Open This is the number of cans which will be blown off when the infeed is first opened To blow off no cans at infeed open set equal to 0 to blow off one can set equal to 1 etc of Cans to Blowoff from Print at Restart This is the number of cans which will be blown off from the print station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc of Cans to Blowoff from Varnish at Restart This is the number of cans which will be blown off from the varnish station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc Set Number of Pins to Pin Chain Blow off Port This is the number of pins from the spindle wheel to disk transfer location to the first can blown off at the Pin Chain blow off port minus two This can be a number from 0 to 999 SYSTEMS Electronics Group 80 SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE 4 Set Qc Select A Can Blow Off QC Can Blowoff Solenoid ON Response Time This is the time used as the on response time of the QC blow off port time from on solenoid actuation to first air out port in milliseconds The M4508 will activate the solenoid ON this amount of time ahead of the QC blow off timing ON position usually set at 15 to 20 milliseconds QC Can Blowoff Solenoid Off Response Time This is the time used as the
14. Program download should not be performed while the decorator is running All outputs on the M4508 are turned off and no program execution is performed The decorator should therefore be stopped before the download takes place 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4508 2 Select 8 Download Program to Module from the Main Menu The current program ident revision and checksum for both the program on disk and already loaded in the module will be displayed A prompt will be displayed asking to continue or abort Press any key to continue or press the lt ESC gt key to abort If a prompt stating that the file could not be opened is displayed then the application program is not installed in the current directory TTE Bl x Systems M4500 Program Dump Version 1 0 Copyright C Systems Electronics Group 1997 all rights reserved Program to be loaded to module on disk Program Ident C Program Revision 253 Program Checksum 36 Program already loaded in module Program Ident APMDEC Program Revision 253 Program Checksum 36 Entire program file will be dumped to M4500 All outputs are turned off while program dump occurs Press ESC to abort program dump or any other key to continue HSL DC5 User s Manual SYSTEMS Electronics Group 86 HSL DC5 User s Manual 3 4 5 SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE Once program do
15. Setpoints Bad Can blowoff ON position 180 Q C blowoff timing ON position 185 Can Gate timing ON position 0 HSL DC5 User s Manual SYSTEMS Electronics Group 18 HSL DC5 User s Manual SECTION 2 INSTALLATION 2 9 2 SET MACHINE ZERO To zero the machine set resolver offset perform the following 1 2 3 4 5 Enter the Set Up menu by pressing the SET UP key of the Keypad Display Select 6 VERIFY CAN PRX1 LOCATION TIMING and observe the ACTUAL ABSOLUTE POS field Verify that as the machine is rotated forward either jogged or barred that the position increases linearly from 0 through 1079 for Rotary Trip Machines or 0 through 719 for interposer trip machines If not swap the S1 and S3 leads of the resolver at the M4508 resolver connector Then verify that the position then indeed does increase with forward movement Press lt ESC gt to return to the primary set up menu Position the machine at machine zero A trip cam follower just past A trip cam see figure below C TRIP CAM B TRIP CAM A TRIP CAM C TRIP CAM FOLLOWER B TRIP CAM FOLLOWER A TRIP CAM FOLLOWER Auto zero the resolver by selecting 5 ZERO MACHINE from the primary set up menu of the Keypad Display Enter 0 to zero the resolver The VERIFY CAN PRX menu will be displayed now showing the ACTUAL ABSOLUTE POS at zero The M4508 will calc
16. Slot0 2 slot next to 84573 of the M4508 chassis 5 Install 84573 SLOTO 3 Set the slot address dip switches SW1 on the S4573 to the following positions slot3 4573 SWI switchl ON SWI switch2 ON Install the 4573 in Slot0 3 slot next to S4573 of the M4508 chassis 6 Install the cover back over the M4508 making sure all the board connectors protrude 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 M4508 chassis 7 Connect the display ribbon cable to the connector on the back of the M4508 the connector on the cable is polarized and should mate with the connector on the M4508 only one way 8 Mount the M4508 chassis to the HSL DCS back panel using four 8 32 screws 9 With power to the P4500 off install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4508 the connector on the cable is polarized and should mate with the connector on the M4508 only one way 10 Install the respective field wiring arms on all the I O boards of the M4508 I O slotsO thru 3 resolver connector and INO IN1 connector Make sure all field wiring connectors are fully mated in the M4508 HSL DC5 User s Manual SYSTEMS Electronics Group 28 HSL DC5 User s Manual SECTION 2 INSTALLATION 2 10 2 P4500 POWER SUPPLY INSTALLATION To install the P4500 perform the following steps 1 Mount the P4500 to the HSL D
17. View Window Help Trips Per Spindle Current Shift Last Shift r Spindle Tri b in 36 Spindle 1 Trip Offset 0 4d w 23 Tripped Spindle 22 13 10 Reset Trips 3 e ee A E SC ed omni E12 ESTERI sis 22 7 SEEDS sb oat 12 11 System Message All Faults Normal ONLINE 10 6 2003 5 03PM 7 This window utilizes a TAB control to divide the set up parameters into three categories similar to that of the Keypad Display These sections are as follows Trips per Spindle The Number of trips per spindle display is provided to aid in the trouble shooting of a loading problem with a spindle or spindles The total number of trips for each spindle since the last reset or end of shift is displayed The operator can reset these counts at anytime to aid in the trouble shooting process The following data is displayed in the Trips per Spindle section 1 Spindle 1 Trip Offset The Spindle Trip Offset can be entered from this section This is used to compensate for the location of the can no can sensor and the spindle 1 I D sensor location Use the Tripped Spindle display to adjust the offset value Follow the procedure outlined section 3 2 8 Set Spindle Trip Shift Offset SYSTEMS Electronics Group 69 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 2 Spindle xx Trips This is the total number of trips for each spindle This data is displayed and
18. blow off port 03 QC select a can Blow off Blow off solenoid on response time nsec 015 Blow off solenoid off response time msec 028 QC can blow off port shift offset 001 1 Set Bad Can Pin Chain Blow off Response Times Bad Can Blowoff Solenoid ON Response Time This is the time used as the on response time of the pin chain blow off port time from on solenoid actuation to first air out port in milliseconds The M4508 will activate the solenoid ON this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds Bad Can Blowoff Solenoid Off Response Time This is the time used as the off response time of the pin chain blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4508 will activate the solenoid OFF this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids SYSTEMS Electronics Group 79 inl x SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE 2 HSL DC5 User s Manual Set Number of Cans to Blow off Pin Chain of Bad Cans to Blowoff for Misload This is the number of cans blown off at the pin chain port when one mis loaded can is detected typically set at 1 can of Cans to Blowoff from
19. hour shift or label run however the shift collection is set up This allows data collection and diagnostics to take place automatically over a two shift period E APM File Edit View Windos d ow Help Trips Per Spindle Current Shift Last Shift Last Shift Total Good Cans 765 533 Total Blow offs 14 113 ti 258 ma 74 um 0 2 122 ta 181 0 3 121 5 015 rE Bad Can Blow offs 9 696 Eom fon M Blow off 3 026 K a sins 39 s a anual Blow offs EM ECH mm Q C Blow off 394 2i M aid 34 dem E Blow offs e 70 sean lt 0 ea Restart Blow offs 333 7 58 maf 7 sm 0 3 6 20 8 32 0 9 59 21 110 33 0 mof 8 22 194 34 0 m s 23 85 35 0 Mo ea 123 wef 0 System Message All Faults Normal ONLINE 10 6 2003 5 03 PM HSL DC5 User s Manual SYSTEMS Electronics Group 71 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 4 THE COLOR CONTROL WINDOW The Color Control window is used to view and adjust any of the color control settings This window is selected from the Window menu or by pressing the F8 function key amp APMDEC unnamed Color Control P x File Edi View Window Help m Color Control m Solenoid Response Time Label Number fo 2 Station Number i ON CYCLE Solenoid ON Response Time msec 1555 en uen icd Solenoid OFF Response Time msec EEE
20. is empirically set by selecting spindle 1 for blow off and adjusting this value until the can from spindle 1 is the can that is blown off Spindle Trip Shift Offset This is the number of spindle difference from the detection of the spindle 1 flag to the Can No Can sensor This is a number between 0 and 23 or 35 and is empirically such that a mis loaded can on spindle 1 increments the spindle 1 count in the Trips per spindle menu see section 2 9 8 Set Spindle Trip Shift Offset Tuning the HSL DC5 SYSTEMS Electronics Group 38 HSL DC5 User s Manual SECTION 3 USING THE KEYPAD DISPLAY 3 3 4 SET MACHINE TIMING This selection brings up the timing set point menu which displays the following fields channel description ON POSITION XXX RPM yyyy POS zzz OFFSET www SCALE 360 Each field is defined as follows Field POSITION xxx channel description RPM yyyy POS zzz OFFSET www SCALE 360 39 Definition Leading Edge of the ON Position for the Timing Setpoint Selected Timing Set point Description Current Main Drive Speed where yyyy is in Main Motor RPM Current Resolver Position where zzz is in Degrees 0 359 degrees Resolver Offset where www is the Offset in Degrees Resolver SCALE FACTOR 360 degrees per Mandrel SYSTEMS Electronics Group SECTION 3 USING THE KEYPAD DISPLAY Bad Can Blowoff ON Position Set this signa
21. is from 140 to 650 and defines the upper limit or the longest amount of time between ductor cycles Care should be taken not to set this parameter too low as this would restrict the operators range of adjustment The Cycle duration is set individually for each ink station and is the rate at which ink is transferred from the fountain roll Maximum On Duration The maximum On duration is set to 1 10 of a can resolution The range of this parameter is from 0 to 200 and defines the upper limit or the longest amount of time the ductor roll can be in contact with the fountain roll The On duration is set individually for each ink station and is the amount of time the ductor roll is in contact with the fountain roll SYSTEMS Electronics Group 92 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL Response Time Compensation The response time compensation parameters is used to adjust the On duration based on the difference between the ON and off response time of the ductor solenoid As and example if the ON response time were 40 msec and the off response time was 15 msec then this parameter would need to be set to 25 msec The ON response time is defined as the time ductor is activated to the time it comes in contact with the fountain roll The off response time is the time the ductor is deactivated to the time it lifts off of the fountain roll If the optional feedback sensors are to be used t
22. key is passcode protected when the Set Up Enable switch is not disabled When the Color Control key is depressed the label selection screen is displayed The operator may enter in a new label number or press either the lt NEXT gt or lt ENTER gt keys to advance to the next station lt NEXT gt Pressing this key moves to the next adjustment field Holding this key depressed for one second will move to the next field continuously If selection has reached bottom of the order this key will have no effect lt PREV gt Previous Pressing this key moves to the previous adjustment field Holding this key depressed for one second will move to the previous field continuously If selection is returned to the top of the order this key will have no effect INC Increment Pressing this key once increments the currently selected value by one Holding this key depressed for one second will increment the currently selected value continuously This key is only active in the Color Control mode DEC Decrement Pressing this key once decrements the currently selected value by one Holding this key depressed for one second will decrement the currently selected value continuously This key is only active in the Color Control mode HSL DC5 User s Manual SYSTEMS Electronics Group 95 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 8 RECOMMENDED PROCEDURE FOR USING THE COLOR CONTROL With a mechanically cammed d
23. lol x File Edit View Window Help Comm Port Ctrl M Color Control Passcode r Machine CPM Vamish RPM Q C Blow off Spindle Number 0 100 Blanket Blow off B l 1 r Good Cans r Blow offs 400 148 41 69 1 Mandrel Blowoff Lifetime Count x1000 Bad Can Blow off 0 Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 4 58PM 7 4 3 1 ENABLE OFFLINE EDITING This function allows the user to perform Offline editing on the currently loaded set up data file This allows the user the ability to make any necessary changes to the set up parameters or label data values while not online with the processor If offline editing is not enabled the user is only able to view the set up parameters and shift data When the program is first invoked the default setting is offline editing disabled The user will need to specifically select Enable Offline Editing from the edit menu or press function key F2 to enable disable this feature SYSTEMS Electronics Group 53 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE HSL DC5 User s Manual 4 3 2 SETUP COMM PORT This function allows the user to specify the serial communications port and rate to talk to the M4508 The programming port of the M4508 is set to 9600 baud ia Comm Port Settings x r
24. may then be adjusted or viewed Canfeed Enable Speed The Canfeed Enable Low Speed and Canfeed Enable High Speed are used in conjunction with one another to define a window within which the can gate can be opened or closed This allows the flow of cans to be controlled whenever the machine speed is inside this window This window should be set for optimal loading conditions O Varnish Roll Speed Calibrate The O Varnish drive speed input is a 0 10VDC signal from the O Varnish drive if available The roll speed calibrate is used to scale this signal to display the O Varnish RPM The number entered here should equal the O Varnish roll speed when the drive is at full speed input 10VDC SYSTEMS Electronics Group 36 HSL DC5 User s Manual SECTION 3 USING THE KEYPAD DISPLAY 3 3 2 SET PNEUMATIC DUCTOR PARAMETERS This menu is activated when the 2 key SET PNEUMATIC DUCTOR PARAMETERS is pressed while the primary set up menu is active See section 6 Pneumatic Ductor Color Control for a complete description of set up and tuning of the ductor control system 3 3 3 SET PIN CHAIN QC BLOW OFF PARAMETERS This menu is activated when the 3 key SET PIN CHAIN QC BLOW OFF PARAMETERS is pressed while the primary set up menu is active The following blow off set up parameters may then be adjusted or viewed Cans to Blow off at Infeed Open This is the number of cans that will be blown off
25. off response time of the QC blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4508 will activate the solenoid OFF this amount of time ahead of the QC blow off timing ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids QC Can Blowoff Port Shift Offset This is the number of spindles difference from detection of the spindle 1 flag to the QC blow off port This is a number between 1 and 24 and is empirically set by selecting spindle 1 for blow off and adjusting this value until the can from spindle 1 is the can that is blown off HSL DC5 User s Manual SYSTEMS Electronics Group 81 SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE HSL DC5 User s Manual 5 4 ADJUST TIMING SET POINTS The following is a general description of the timing signals and the locations they should be set at f HSLDC5 EXE _ nl x Systems APM Decorator Set up Menu Version 2 1 Machine Timing Set points Set Bad Can Blow off ON Position Set Q C Blow o ON Position Set Can Gate Timing ON Position whore Enter Selection ESC to exit Bad Can Blow off ON Position degrees 180 Q C Blow off ON Position degrees 185 Can Gate Timing ON Position degrees 000 1 Bad Can Blowoff ON Position Set this signal to turn ON when the pin
26. parameters in the M4508 This section contains the following selections amp APMDEC unnamed Set Up File Edit View Window Help anl x Speed Parameters D Cycling Parameters Maximum Cycle Duration 0 1 cans 500 a Maximum ON Duration 0 1 cans 200 E Response Time Compensation msec 25 E Color Gain CG 100 per 2000CPM 100 E r Feedback Enable Bie M EN DM E INI II IH Enable All Disable All Blow off Parameters Machine Timing System Message All Faults Normal 63 ONLINE 10 6 2003 5 02PM _ SYSTEMS Electronics Group SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE HSL DC5 User s Manual 1 2 3 4 5 Maximum Cycle Duration 0 1 cans The maximum cycle duration is the maximum cycle time in 0 1 cans for one cycle of the ductor This parameter limits the upper value that the operator can enter for the cycle duration Ifthe operator attempts to enter a value higher then this limit the value will default back to the original number The range of this parameter is 140 999 Maximum ON Duration 0 1 cans This parameter limits the upper value that the operator can enter for the ON duration The cycle duration is the total cycle time in 0 1 cans that the ductor roll is in contact with the fountain roll If the operator attempts to enter a number higher than the maximum ON duration the value will defaul
27. position of the port to the blow off timing will vary as the take up moves causing partial blow offs to occur SYSTEMS Electronics Group 2203 SECTION 2 INSTALLATION HSL DC5 User s Manual 2 9 8 SET SPINDLE TRIP SHIFT OFFSET Set the Spindle Trip Shift Offset as follows 1 2 3 4 5 Initially set the Spindle Trip Offset to zero Wrap a piece of tape around spindle 1 such that cans will not load on this spindle Run the machine very slowly with the can gate open and verify that indeed cans do not load on spindle 1 and that the 1 spindle is tripped Observe the trips per spindle data and determine which spindle number is being incremented every time the 1 spindle trips The spindle number that should be incrementing is spindle 1 If it is not subtract 1 from the spindle number that is being incremented and enter this value as the spindle trip offset this variable must be a number between 0 and 23 or 35 Now verify that the spindle 1 count is incremented every time the 1 spindle trips If it still increments another spindle number other than 1 continue adjusting the Spindle Trip Offset until it does then stop the machine and remove the tape from spindle 1 2 9 9 SET QC BLOW OFF OFFSET Set the QC Can Blowoff Port Shift Offset as follows 1 2 3 4 Dial in spindle 1 on the select a can thumb wheel switch Run the machine slowly and mark cans printed on sp
28. sensor should be located axially on the spindle such that the sensor will See the top open end of can only if it is fully loaded on the spindle CAN NO CAN SENSOR NX l CAN f MANDREL Location of Can No Can Sensor 6 If necessary adjust the Can No Can sensor to achieve the location relative to an A spindle as described above SYSTEMS Electronics Group HSL DC5 User s Manual 2 SECTION 2 INSTALLATION 2 9 4 SET PIN CHAIN BLOW OFF TIMING ON POSITION This timing signal should just turn ON when the pin chain blow off port is centered between pins on the pin chain To set either the Bad Can Blow off or Q C Blow off timing ON position perform the following 1 Locate the machine with the blow off solenoid centered between pins on the pin chain as shown below PREVIOUS GOOD CAN PIN CHAIN BLOW OFF PORT BAD CAN TO BE BLOWN OFF ON Position of Pin Chain Blow off Solenoid 2 This is the ON position for the blow off solenoid This position will be different for the Bad Can Blow off and Q C Blow off solenoids HSL DC5 User s Manual SYSTEMS Electronics Group 2 27 HSL DC5 User s Manual SECTION 2 INSTALLATION 2 9 5 SET CAN GATE TIMING ON POSITION This signal is used to open and close the can gate Adjust the ON position for proper can gate operation 2 9 6 SET CANFEED ENABLE SPEED
29. updated continuously in the respective field for each spindle A disproportionately high count for a particular spindle indicates a loading problem for that HSL DC5 User s Manual spindle Current Shift Data This section is used to view the Current Shift data This data is the totals so far into the shift This data is transferred to the Last shift at the end of either an 8 or 12 hour shift or alternatively could be done at label changes such that the data collected would be for label runs rather than complete shifts This data can be reset by the user from this section File Edit View Window E APMDEC unnamed Shift Data Help Current Shift Trips Per Spindle Current Shift Last Shit Manual Blow offs D C Blow offs Restart Blow offs Total Good Cans 400 148 Total Blow offs 4 153 Bad Can Blow offs 2 795 640 176 558 m End of Shift Transfer Data s E s2 83 wT 44 wf 4 wT 42 Eze 72 go m nf 36 ya sro eain srt eed m2 50 a 2 mp e 5 33 mef 46 e FERE tig 30 my 47 20 3 21 58 Sa I 23 50 af 5 Son RED 25 REDE saa o son oem anm 0 san Rei SOT EDENDI nar pe as 0 wa o0 5 0 36 0 System Message All Faults Normal ONLINE 10 6 2003 5 03PM _ Note The Transfer Data command button is only active while Online 1 Total Good Cans This is
30. user to upload the label information from one processor and download it to another without altering any of the other set up parameters or shift data registers SYSTEMS Electronics Group 50 HSL DC5 User s Manual SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE All This option allows the user to completely download All of the set up parameters shift data and label data registers to the M4508 Note Only the values contained within the current data file are downloaded If unsure of the validity of the current data file review the set up parameters shift data and label data in an Offline edit mode prior to download 4 2 5 PRINT REPORT The Set up program allows the user to generate a Report printout of all set up parameters shift data and label data settings This function is accessed from the File menu At the top of each page the report displays the name of the set up program and 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 report of the settings contained in the set up Data File perform the following 1 From the File menu select Report Setup amp APMDEC unnamed Main Display File Edit View Window Help New Ctrl N Open Ctrl O Save Ctrl S Save As Export Shift Data Ctrl Upload
31. view fault codes S3000 network communication error codes and review the current Ident and Revision of the application program This is accessed by the View menu by selecting Target Board Interface Once invoked the set up program will prompt the user to select a program to compare with the one existing in the processor the setup program will then attempt to communicate with the M4508 If unsuccessful or 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 still be displayed SYSTEMS Electronics Group 56 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE Target Board Interface Erogram Ident Fievision Set Network Address Set Time amp Date No Internal Fault has Ocurred No Internal Fault has Ocurred No Network Comm Error No Network Comm Error Target Board Interface GER HSL DC5 User s Manual SYSTEMS Electronics Group 57 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE HSL DC5 User s Manual 4 4 2 VIEW ONLINE DATA This function allows the user to place the set up program Online with the processor This is accessed from the View menu by selecting Online Data or by simply pressing the F3 function key Note The program can be toggled between Offline and
32. when the infeed is first opened Valid range 0 to 99 Cans to Blow off from Print at Restart This is the number of cans that will be blown off from the print station when the machine is restarted Valid range 0 to 99 Cans to Blow off from Varnish at Restart This is the number of cans that will be blown off from the varnish station when the machine is restarted Valid range 0 to 99 Cans to Blow off for each Misload This is the number of cans blown off at the pin chain port when a mis loaded can is detected typically set at 1 can Any additional cans entered will be blown off every 12 can later cans that would be have been printed on the same blanket Pins to Pin Chain Blow off Port This is the number of pins from the spindle wheel to disk transfer location to the first can blown off at the Pin Chain blow off port minus two This can be a number from 0 to 999 SYSTEMS Electronics Group 37 SECTION 3 USING THE KEYPAD DISPLAY HSL DC5 User s Manual Pin Chain bad can Solenoid on Response Time msec This is the time used as the on response time of the pin chain blow off port time from on solenoid actuation to first air out port in milliseconds The M4508 will activate the solenoid ON this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds Valid range 5 to 60 msec Pin Chain bad can Solenoid off Response Time msec This is
33. 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 This data is reset at the end of shift input transition To return to the main menu press lt ESC gt The following data is displayed in the Current Shift menu es HSLDC5 EXE lal x Systems APM Decorator Set up Menu Version 2 1 Current Shift Totals so far Press ESC to return to main menu Total Good Cans Total Blow offs Total Misloads Restart Blow offs Manual Blow offs QC Blow offs Spindle H01 trips Spindle H02 trips Spindle H03 trips Spindle 04 trips Spindle 05 trips Spindle 06 trips Spindle H07 trips Spindle H08 trips Spindle H09 trips Spindle H10 trips Spindle H11 trips Spindle H12 trips 25 aoe 26 Spindle 827 Spindle 28 Spindle 29 Spindle 30 Spindle 31 Spindle 32 Spindle 33 Spindle 34 Spindle 35 Spindle 36 trips trips trips trips trips trips trips trips trips trips trips Spindle trips Cocco cocco coc 000 Cocco coco cocco 00cm Cocco coco coco 000 Total Good Cans This is the total number of good cans printed so far into the shift This is essentially a can counter Total Blow offs This is the total number of cans blown off the machine This includes all types of blow offs cans blown off for every mis loaded can infeed open blow offs re
34. BASED SETUP PROGRAM REFERENCE HSL DC5 User s Manual Solenoid Response Time The Solenoid Response time is an indication of the reaction time of pneumatic ductor The response times are only valid when the optional feedback sensors are used The response times for each ink station can be easily viewed by adjusting the station number The following is a description of each of these settings 1 Station Number The ink station mask to view the response time of the ductor solenoid 2 Solenoid On Response Time msec This displays the amount of time msec from first activation of the solenoid to contact with the fountain roll 3 Solenoid Off Response Time msec This displays the amount of time msec from first deactivation of the ductor solenoid to lift off from fountain roll Ductor Status The ductor Status gives the user an indication of the status of the input signals used to control the pneumatic ductor these are as follows 1 Operational Mode A three position selector switch is used to set the operation mode of the ductors auto off manual This display reflects the position of the selector switch 2 Ductors Auto On This displays the state of the ductors Auto On input to the M4508 Ductors Manual Control The ductors Manual control allows the user to toggle individual ductor solenoids when the ductors operational mode is Manual and the machine is at Zero speed main driv
35. C5 User s Manual e Based on high performance M4508 PLC PLS module which allows easy trouble shooting and user customization using SYSdev DOS based programming package e Built in PLS provides all machine timing eliminating need for an additional PLS 1 2 FUNCTIONAL DESCRIPTION The HSL DC5 is an electronic upgrade for the APM Decorator Basecoater that detects miss loaded cans performs speed compensated trip cam control and single can bad can blow off at speeds in excess of 2400 CPM In addition a select a can pin chain blow off function is used to perform print quality verification of each blanket The control system interfaces directly to the machine mounted resolver can no can sensor trip and blow off solenoids as well as the host PLC via discrete DC I O Alarm detection is provided including e Infeed Track Jam e No Can Transfer can on mandrel e Timing Signal Failure Data collection both for the current shift and last shift includes e Total Good Can Count e Blow Off Counts e Trips Per Spindle The control system is not a dedicated black box but is instead implemented using the high performance SYSTEMS M4508 PLC PLS module This allows easy customization by either SEA or the end user The M4508 module is programmed using the DOS based SYSdev programming package which allows the module to be programmed in any combination of Ladder or High level subset of C as well as perform on line monitoring an
36. C5 in the mounting holes next to the M4508 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 M4508 the connector on the cable is polarized and should mate with the connector on the M4508 only one way 2 10 3 D4591 KEYPAD DISPLAY INSTALLATION To install the D4591 perform the following steps 1 With the gasket installed on the mounting studs of the D4591 install the D4591 in the cut out in the user s existing control cabinet 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 M4508 only one way SYSTEMS Electronics Group 29 SECTION 2 INSTALLATION 2 10 4 DOWNLOAD HSLDC5 PROGRAM AND SET UP DATA TO M4508 Once the M4508 P4500 D4591 are installed perform the following to download the HSLDCS5 application program to the M4508 as well as download the previously saved set up data and timing channel set points 1 Power up the M4508 and the PC used to interface with the HSL DCS 2 Connect an RS 232 cable from the computer COM port to the PROG port on the M4508 3 Initiate the respective setup program APMDEC for Windows systems HSLDCS5 exe for DOS systems 4 Download the HSLDCS application program to the M4508 See se
37. Data Set up Data Download Program Shift Data Download restore Data gt Label Data Q C Blow off Spindle Number Blanket Blow off EN B i Report Setup Print Report Ctrl P 7 Mandrel Blowoff Exit Lifetime Count x1000 Bad Can Blow off Test Trip Blow off System Message All Faults Normal ONLINE f 0 6 2003 H PM 4 HSL DC5 User s Manual SYSTEMS Electronics Group 47 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE Set up Data This option uploads only the Set up data from the M4508 without changing any values for the shift data or label data parameters Shift Data This option uploads only the Shift Data from the M4508 This will retrieve the Trips per Spindle data the Current Shift data the Last Shift data as well as the Lifetime Can Count data Label Data This option uploads only the Label Data used for the pneumatic ductor color control from the M4508 Once selected the user is prompted to either upload all 100 labels or specify a range This allows the user to upload the label information from one processor and download it to another without altering any of the other set up parameters or shift data registers All This option allows the user to completely upload All of the set up parameters shift data and label data registers from the M4508 4 2 3 DOWNLOAD PROGRAM The Se
38. HSL DC5 APM Decorator High Speed Front End User s Manual Systems Engineering Associates Inc 14989 West 69th Avenue Arvada Colorado 80007 U S A Telephone 303 421 0484 Fax 303 421 8108 WWW Sea seg com 03 2004 HSL DC5 APM Decorator High Speed Front End User s Manual Copyright 2001 Systems Engineering Associates Inc All Rights Reserved Revised 15 March 2004 WARNING To ensure the equipment described by this User Manual as well as the equipment connected to and used with it operates satisfactorily and safely all applicable local and national codes that apply to installing and operating the equipment must be followed This includes the National Electric Code in the USA and other applicable legislation regulations and codes in practice elsewhere Since codes can vary geographically and can change with time it is the user s responsibility to determine which standards and codes apply and to comply with them FAILURE TO COMPLY WITH APPLICABLE CODES AND STANDARDS CAN RESULT IN DAMAGE TO EQUIPMENT AND OR SERIOUS INJURY TO PERSONNEL Persons supervising and performing installation or maintenance must be suitably qualified and competent in these duties and should carefully study this User Manual and any other manuals referred to by it prior to installation and or operation of the equipment The contents of the User Manual are believed to be correct at the time of printing however no responsibility is assumed f
39. Location of Can No Can Sensor 7 View the Number of Trips per Spindle 8 View the Current Shift Data 9 View the Last Shift Data 10 View Lifetime Can Count 11 Activate the select a can QC blow off 12 Adjust the Color Control Parameters The definitions of the keypad commands and menus are described in the following sections SYSTEMS Electronics Group 31 SECTION 3 USING THE KEYPAD DISPLAY HSL DC5 User s Manual Note For virtually all the menus the NEXT and PREV keys can be used to advance to the next or previous parameter respectively To change the currently displayed parameter simply enter the new value on the numeric keypad and press ENTER The value will be entered and the next parameter will automatically be displayed When the last parameter in a section is entered the primary set up menu is again displayed Pressing lt ESC gt at anytime will exit back to the primary set up menu 3 1 DEFAULT SCREEN The default screen displayed when no other commands are active contains the following data MACHINE CPM 0000 O VARNISH RPM 000 GOOD CANS 0 BLOWOFFS 0 Machine Speed is the current speed of the decorator O Varnish RPM is the current speed of the varnish unit Good Cans field is the total number of good cans printed so far into the current shift and the Blow offs field is the total number of cans blown off the machine scrap so far into the current shif
40. MS Electronics Group 26 SECTION 2 INSTALLATION 2 10 M4508 P4500 D4591 INSTALLATION The following is provided only as a reference These steps are performed by the factory prior to shipping the HSL DCS These steps need only be performed in the event either the M4508 module P4500 power supply or D4591 display need to be replaced Refer to the M4500 User s Manual for general details on installing the M4508 P4500 and D4591 2 10 1 M4508 MODULE INSTALLATION To install the M4508 module perform the following 1 Remove the cover from the M4508 chassis retained with three captive screws on the lower front of the cover and two captive screws on each side of the M4508 chassis 2 Install S4563 SLOTO 0 Set the slot address dip switches SW1 on the S4563 to the following positions slot 4563 SWI switchl OFF SWI switch2 OFF Install the 4563 in Slot0 0 furthest left slot of the M4508 chassis 3 Install S4573 SLOTO 1 Set the slot address dip switches SW1 on the S4573 to the following positions slot1 4573 SWI switchl ON SWI switch2 OFF Install the 4573 in Slot0 1 slot next to 4563 of the M4508 chassis HSL DC5 User s Manual SYSTEMS Electronics Group Ug SECTION 2 INSTALLATION 4 Install S4573 SLOTO 2 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
41. O Varnish RPM This display is only active while Online and displays the current speed to the over varnish roll speed in Revolutions Per Minute Good Cans This display is the Current Shift good can count SYSTEMS Electronics Group 60 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE Blow offs This display is the Current Shift total blow off count Lifetime Count x1000 This is the total number of good cans produced since the control system was installed module replaced or the data register restored This value is in Thousands of cans and is never reset Q C Blow off This function is only active while Online and it allows the operator to perform a QC Select A Can blow off e A Single blow off can be performed by entering in the desired spindle number and clicking the Single Blow off command button e A Blanket blow off can be performed by clicking the Blanket Blow off command button The blanket blow off will initiate a blow off sequence such that a can printed by each blanket is blown off at the QC blow off port starting with a can printed by blanket 1 e A Mandrel Blow off can be performed by clicking the Mandrel Blow off command button The mandrel blow off will initiate a blow off sequence such that a can printed on each mandrel will be consecutively blown off at the QC blow off port starting with mandrel 1 Bad Can Blow off This function
42. 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 M4508 If the set up program is unsuccessful a warning message will be displayed prompting the user to either Retry or Cancel the operation If the operation is canceled and communication with the processor cannot be established the system will be placed in an Offline edit mode Note Anytime while the set up program is Online with the processor and communication is interrupted a warning message will be displayed prompting the user to either Retry or Cancel the operation 4 4 3 VIEW OFFLINE DATA This function allows the user to place the set up program in an Offline mode This is accessed from 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 M4508 SYSTEMS Ele
43. S 232 cable from COM1 on the computer to the PROG PORT on the M4508 Note The set up program is an on line communications program used to interface with the M4508 module The data displayed in the menus and set in the menus is communicated directly to the module Therefore prior to selecting any of the selections make sure an RS 232 cable is connected from the COM port on the computer to the PROG port on the M4508 The following sections are a complete description of the set up program selections and menus SYSTEMS Electronics Group 235 SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE HSL DC5 User s Manual 5 1 SET SPEED PARAMETERS This selection is used to set the canfeed enable speed window and the calibration of the O Varnish roll speed in the M4508 When selected the Set Speed Parameters Set Up menu is invoked The Set Speed Parameters Set Up Menu contains the following selections HSLDC5 EXE _ gl x Systems APM Decorator Set up Menu Version 2 1 Speed Parameters set up Set Canfeed Enable Low Speed Set Canfeed Enable High Speed Set 0 VYarnish Roll Speed Calibrate Ne Enter Selection ESC to exit Canfeed Enable Speeds Canfeed Enable Low Speed CPM 0600 Canfeed Enable High Speed CPM 1000 Q Varnish Unit O Varnish Roll Speed Calibrate RPM at 10V 380 1 Set Canfeed Enable Low Speed This is the minimum speed the
44. STORE DATA The Set up program allows the user to download parameters and shift data to the M4508 from 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 APMDEC unnamed Main Display Pm x Fie Edit View Window Help New Ctrl N Open Ctrl O Save Ctl S Save As Export Shift Data Ctrlex Upload save Data linish RPM Download Program ooi Download restore Data Set up Data Q C Blow off Spindle Number Blanket Blow off EN neisa Shift Data ea Sup Label Data Print Report eee So 7 1 Mandrel Blowoff Exit E Lifetime Count x1000 Bad Can Blow off 0 Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 4 49PM 7 Set up Data This option downloads only the Set up data to the M4508 without changing any values for the shift data or label data parameters Shift Data This option downloads only the Shift Data to the M4508 This will restore the Trips per Spindle data the Current Shift data the Last Shift data as well as the Lifetime Can Count data Label Data This option downloads only the Label Data used for the pneumatic ductor color control to the M4508 Once selected the user is prompted to either download all 100 labels or specify a range This allows the
45. TION 6 PNEUMATIC DUCTOR COLOR CONTROL This Page Intentionally Left Blank HSL DC5 User s Manual SYSTEMS Electronics Group 100 HSL DC5 User s Manual SECTION 7 RECOMMENDED SPARE PARTS The following are recommended spares for the HSL DCS These parts are available through Systems Engineering Assoc Inc Quantity lea lea lea lea lea Part Number M4508 P4500 4563 84573 D459 101 Description PLC PLS Processor Chassis 4 Slot Power Supply 16 Point 10 30VDC Input Board 16 point 10 30VDC Output Board Display Keypad SYSTEMS Electronics Group
46. V PROGRAM DEVELOPMENT SOFTWARE INSTALLATION The SYSdev Program Development software is used to perform on line trouble shooting and program modifications to the HSL DC5 If SYSdev was purchased with the HSL DC5 package and is not already installed on the your computer install SYSdev onto the hard drive of your computer following the steps in outlined in the SYSdev Program Development manual HSL DC5 User s Manual SYSTEMS Electronics Group 13 SECTION 2 INSTALLATION HSL DC5 User s Manual 2 7 4 APPLICATION PROGRAM INSTALLATION The application program is a SYSdev based program loaded into the M4508 module and performs the HSL DC5 logic The program is written in a combination of Ladder logic and High level If the user desires to make program changes or perform on line monitoring of the program execution the files which constitute the HSLDCS5 program will have to be loaded onto the hard drive of the PC used to support the system The SYSdev Program Development Software will also have to be loaded on the PC To install this program perform the following 1 Install the PROGRAMS disk into the drive 2 For each of the HSLDEC directories created in section 2 7 2 copy all the files from the disk to each of these subdirectories 2 8 MODIFY EXISTING PLC PROGRAM Modify the existing control system PLC program to interface with the HSM DC5 by incorporating the following into the existing PLC ladder logic 1 T
47. Watch the Color Density to see how your adjustments change this value Once again think of the On duration as a Course adjustment and the Cycle duration as a Fine adjustment 5 Check the color quality and continue to increase or decrease the Color Density until the desired color quality is achieved 6 Perform steps 2 through 4 above for all ink stations used as necessary 7 Once the label quality is satisfactory press the lt ESC gt key to exit the adjustment mode and save the changes for the selected label HSL DC5 User s Manual SYSTEMS Electronics Group 98 HSL DC5 User s Manual SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 11 CHANGEOVER USING AN EXISTING LABEL When a label is run again perform following to set up the label at change over 1 Select the respective label number on the Keypad Display 2 Set the keys open predefined number of turns a number which is used for all ink stations on all labels on the areas of the can that will have ink and closed on areas that will not have ink 3 Run the machine and verify that ink is being distributed on the can correctly The ink will be metered at the same rate as previously set the last time the label was run Only minor adjustments to the keys may be necessary to assure that ink is not distributed to areas where no color is applied resulting in slinging due to ink build up SYSTEMS Electronics Group 99 SEC
48. a message box 1s 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 amp APMDEC unnamed Main Display BEEN 1al xl File Edit View Window Help Messages Program Download M 9 Program to be loaded into module on disk 2 Program Ident APMDEC E z Program Revision 253 c T Program Checksum 36 Machine EM Target Board M4500 PLC 0 Program currently loaded in module Blanket Blow off Program Ident APMDEC Good Cans Program Revision 252 100148 Program Checksum 36 Mandrel Blowoff J Entire program file will be dumped to the PLC Lifetime Count x1000 All outputs are off while program dump occurrs Do You Wisth to Continue Yes No Cancel System Message All Faults Normal ONLINE 4 0 6 2003 4 43 PM Ui 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 SYSTEMS Electronics Group 49 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE HSL DC5 User s Manual 4 2 4 DOWNLOAD RE
49. adjustment Observe how changing either the On duration or Cycle duration changes the relative Color Density Note If an ink station is not used simply set its On duration to zero to disable the cycling operation Use the Color Density display as an indication of the amount of ink being transferred by the ductor Different settings of the On and Cycle durations will achieve the same Color Density SYSTEMS Electronics Group 97 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL Note To reduce Light and Dark variations in print between cycle times adjust both the On duration and Cycle duration down to achieve the same Color Density For a new label or existing label that needs color adjustment perform the following 1 Press the COLOR CONTROL key to enter the adjustment mode if not already in adjustment mode 2 To select the desired ink station for adjustment press the lt NEXT gt or lt PREV gt keys until the desired ink station is displayed 3 To lighten the color start by decreasing the On duration or increasing the Cycle duration Watch the Color Density to see how your adjustments change this value Remember think of the On duration as a Course adjustment and the Cycle duration as a Fine adjustment 4 To darken the color start by increasing the On duration or decreasing Cycle duration
50. ains the following selections fe HSLDC5 EXE nl x Systems APM Decorator Set up Menu Version 2 1 Ductor Parameters set up Set Maximum Cycle Duration Set Maximum On Duration Set Solenoid Response Time Compensation Set Color Gain Enable Disable Ductor Feedback Fault Enter Selection ESC to exit C1 Oho Maximum Cycle Duration 0 1 Cans 900 Maximum On Duration 0 1 Cans 200 Solenoid Response Time Compensation msec were 025 Color Gain ColorGain 100percent per 2000CPM 100 Ductor Feedback Fault Enable Disable Ductor 1 Feedback Fault Enabled Ductor 82 Feedback Fault Ductor 3 Feedback Fault Ductor 4 Feedback Fault Ductor 5 Feedback Fault Ductor 6 Feedback Fault Ductor 4 amp 7 Feedback Fault Ductor 8 Feedback Fault 1 Set Maximum Cycle Duration 0 1 Cans The maximum cycle duration is the maximum cycle time in 0 1 cans for one cycle of the ductor This parameter limits the upper value that the operator can enter for the cycle duration If the operator attempts to enter a value higher then this limit the value will default back to the original number The range of this parameter is 140 999 SYSTEMS Electronics Group 293 SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE 2 Set Maximum On Duration 0 1 Cans This parameter limits the upper value that the operator can enter for the ON duration The cycle du
51. 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 this user s manual is contained within the help file Pressing Ctrl H will display the help file window Pressing the F1 key will display the contents file Hot spots allow jumps to other topics to display additional information as desired Selecting About APMDEC 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 DC5 User s Manual SYSTEMS Electronics Group 44 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 4 2 THE FILE MENU The File menu allows the user to perform the following functions Create a New set up Data File e Open an existing Data File e Save any changes made to the current Data File to disk e Upload save Data from the Processor e Download a SYSdev sdv program to the processor e Download restore Data from the current set up Data File to the processor e Print a Report of the current set up parameters e Exit the set up progr
52. am amp APMDEC unnamed Main Display File Edit View Window Help Open k Ctl O Save Ctl S Save As Export Shift Data Ctrl Upload save Data Imish RPM Q C Blow off Download Program Spindle Number 38 P Download restore Data gt Blanket Blow off Report Setup i n Print Report Ctrl P I Mandrel Blowoff Exit Lifetime Count x1000 Bad Can Blow off 0 Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 4 41PM 4 HSL DC5 User s Manual SYSTEMS Electronics Group 45 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE HSL DC5 User s Manual 4 2 1 THE SET UP DATA FILE The set up Data File sdt is a binary access file designed for fast file I O operation When the set up program is first invoked the default set up parameters are loaded into memory If changes are made to any of the set up parameters either online or offline as well as shift data the user will be flagged to Save Changes upon exit of the program Note Any windows based 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 wo
53. can gate is allowed to open to enable cans to be loaded into the machine This defines the lower limit of the canfeed enable window As the machine speed increases above this threshold the can gate will be enabled to be opened 2 Set Canfeed Enable High Speed This is the maximum speed the can gate is allowed to open or close to enable cans to be loaded into the machine This defines the upper limit of the canfeed enable window With the machine operating at production speed the M4508 will only activate deactivate the can gate solenoid within the canfeed enable window When the machine goes to a stand by condition the speed of the machine will need to be decreased below this threshold for the can gate solenoid to be deactivated The M4508 will activate and deactivate the can gate solenoid on the Can Gate Timing ON signal SYSTEMS Electronics Group 76 HSL DC5 User s Manual SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE 3 Set O Varnish Roll Speed Calibrate The O Varnish drive speed input is a 0 10VDC signal from the O Varnish drive if available The roll speed calibrate is used to scale this signal to display the O Varnish RPM The number entered here should equal the O Varnish roll speed when the drive is at full speed input 10VDC 5 2 SET DUCTOR PARAMETERS This selection is used to set the ductor solenoid control parameters in the M4508 The Set Ductor Parameters menu cont
54. chain blow off port is centered between pins on the chain see figure below PREVIOUS GOOD CAN a PIN CHAIN BLOW OFF PORT BAD CAN TO BE BLOWN OFF 2 Q C Blow off Timing ON Position Set this signal to turn ON when the select a can chain blow off port is centered between pins on the chain see figure above SYSTEMS Electronics Group 82 HSL DC5 User s Manual SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE 3 Can Gate Timing ON Position This signal is used to open and close the can gate Adjust the ON Position for proper can gate operation 5 5 NUMBER OF TRIPS PER SPINDLE DATA The Number of trips per spindle menu is provided to aid in the trouble shooting of loading problems with decorator The total number of trips for each spindle since the last reset or end of shift is displayed and can be reset at anytime to aid in the trouble shooting process In addition the Spindle Trip Offset is used to compensate for the location of the spindle 1 I D sensor location The following data is displayed in the Trips per Spindle menu HSLDC5 EXE _ gl x Systems APM Decorator Set up Menu Version 2 1 Trips per Spindle Menu 1 Set Spindle 1 trip offset 2 Reset Spindle trip counts Enter Selection ESC to exit Spindle 1 trip offset 00 Spindle 01 trips Spindle 13 trips Spindle 02 trips Spindle 14 trips Spindle 03 trips Spindle 15 trips Spindle
55. ction 4 2 3 for Windows based systems see section 5 8 for DOS 6 Download the previously saved set up data to the M4508 See section 4 2 4 for Windows based systems section 5 9 for DOS 7 The M4508 is now ready to run loaded with HSLDCS application program timing set points and set up data Note Double check the machine zero position and re zero the resolver if necessary prior to running the machine HSL DC5 User s Manual SYSTEMS Electronics Group 30 HSL DC5 User s Manual SECTION 3 USING THE KEYPAD DISPLAY The D4591 Keypad Display contains 24 keys consisting of data display commands set up commands and a numeric keypad 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 adjust the timing and all set up parameters activate the select a can QC blow off and adjust the pneumatic ductor color control parameters SYSTEMS QB ELECTRONICS GROUP INC MACHINE CPM 0000 O VARNISH_ RPM 000 GOOD CANS O BLOWOFFS O el d 12 53 e mu f 4 s e Gee The Keypad Display allows the following to be viewed or adjusted 1 Set Speed Parameters 2 Set Pneumatic Ductor Parameters 3 Set Pin Chain QC Blow off Parameters 4 Set Machine Timing 5 Set Machine Zero 6 Verify
56. ctronics Group 58 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 THE WINDOW MENU The Window menu allows the user to select one of four different Display Set up windows to modify set up parameters view shift data adjust color control parameters or receive feedback about the current status of the control system lal x A APMDEC unnamed Main Display File Edit View window Help r Messages 2 Set up Parameters F6 3 Shift Data F7 4 Color Control F8 r Machine CPM O Varnish RPM QC Blow off Spindle Number 3 P Blanket Blow off ls E E 1 9 Good Cans r Blow offs A Em 400 1 48 41 69 i i Mandrel Blowoff Lifetime Count x1000 Bad Can Blow off 0 Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 amp 02PM 7 HSL DC5 User s Manual 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
57. d setup programs and PLC application program on a PC used to support the HSL DC5 control system 2 7 1 WINDOWS BASED SETUP PROGRAM INSTALLATION The APMDEC setup program is compatible with Windows 95 98 ME 2000 XP operating systems and is used to Setup tune the user adjustable variables Adjust the timing channel set points Download the application program to the M4508 module Download restore or upload save the user setup variables from the M4508 View Shift and Trips per Spindle data To install the set up software perform the following steps 1 2 3 4 5 HSL DC5 User s Manual Insert the HSL DC5 CD into the drive From the Windows desktop Click Start and then select run From the Run dialog box Click the Browse button Select the drive with HSL DC5 CD Select the setup exe file and Click Open and then Ok This will initiate the installation process Follow the instructions that appear on the screen to complete the installation process The APMDEC setup program can be executed from the Systems folder located in Programs SYSTEMS Electronics Group 1 SECTION 2 INSTALLATION 2 7 2 DOS BASED SETUP PROGRAM INSTALLATION The HSLDCS set up software is used to e Setup tune the user adjustable variables e Adjust the timing channel set points e Download the application program to the M4508 module e Download restore or upload save the user setup var
58. d trouble shooting The M4508 module incorporates a built in PLS which interfaces directly with the machine mounted resolver and provides all machine timing eliminating the need for an external PLS SYSTEMS Electronics Group HSL DC5 User s Manual SECTION 1 GENERAL DESCRIPTION 1 3 MANDREL TRIP CONTROL Trip cam control at speeds in excess of 2400 CPM is incorporated in the M4508 The appropriate trip cam is accurately extended for the spindle of the miss loaded can and retracted back prior to the spindle following the miss loaded can at all speeds This reduces scrap by providing an accurate single mandrel retract at all speeds This eliminates inside litho problems by assuring that the miss loaded spindle is completely skipped 1 4 BAD CAN AND SELECT A CAN PIN CHAIN BLOW OFF Both the Bad Can Pin Chain Blow Off and Select A Can Pin Chain Blow Off incorporate speed compensation to compensate for the response time of the solenoid regardless of machine speed This allows accurate rejection of a single can from the pin chain at all speeds The bad can blow off is activated automatically to reject miss loaded cans from the pin chain The Select A Can feature allows the user to dial in a mandrel number either at a remote PB station or from the Keypad Display and blow off one can printed on that mandrel This provides a way to verify the print quality of each mandrel Two other Select A Can Blow Off modes are availabl
59. e off when the drive is disabled this includes auto stop conditions This is true for jog modes as well 6 Add the Alarm Reset output This signal should be on as long as the system reset push button is depressed 7 Add the Pin Chain Manual Blow off output to the PLC logic When on the bad can pin chain blow off is on When off the pin chain blow off functions normally blowing off detected bad cans restart cans etc 8 Add the PLC Clock timing channel CH06 input to the PLC logic This is a general purpose PLC clock timing signal pulsed once per can 9 Add the Blow off Data Clock timing channel CH07 input to the PLC logic This is used to clock the blow off data bits 0 1 and 2 Use the leading edge of this signal to increment the PLC blow off data counters The blow off data is encoded into a 3 bit binary code according to the following chart BLOWOFF 2 BLOWOFF 1 BLOWOFF 0 None 0 0 j 0 Restart Blow off 0 0 1 J QCBowot 0 o Manual Bowo 0 1 1 BadCanBowof 1 o o GoodCan 1 o 1 HSL DC5 User s Manual SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION 10 The following alarms are available to the host PLC via the discrete encoded alarm bits according to the following chart ALARM BIT 1 ALARM BIT 0 Timing Signal Fail O0 1 No Can Transfer 1 o infeed Track Jam
60. e The Consecutive Blanket mode blows off consecutive cans printed on each blanket starting with mandrel 1 The Consecutive Spindle mode blows off consecutive cans printed on all mandrels starting with mandrel 1 The following variables can be set by the user for the Bad Can pin chain blow off e Number of shifts from machine to blow off port up to 999 e Number of cans to blow off for each bad can one is normal can be up to 5 e Both the on and off solenoid response time used by the speed compensation algorithm SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSL DC5 User s Manual The following variables can be set by the user for the Select A Can blow off e Q C shift offset this is used to match the actual mandrel number to the selected mandrel number e Both on and off solenoid response times 1 5 ALARM DETECTION The following alarms are detected Infeed Track Jam The infeed track jam alarm occurs when 7 consecutive empty mandrels are detected by the Can No Can Sensor after the can gate is opened No Can Transfer The no can transfer alarm occurs when the No Can Transfer sensor detects a can on the mandrel after the disk transfer location Timing Signal Fail The timing signal fail occurs when any of the timing signals generated in the PLS section fail to change state while the machine is running The Encoded Alarm outputs of the M4508 are a
61. e off machine not in motion The individual solenoids can be toggled On and Off by clicking on the individual stations The user may also toggle All the ink stations On by clicking the Ductors ON All command or toggle all Off by clicking the Ductors OFF All command button SYSTEMS Electronics Group 74 HSL DC5 User s Manual SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE The HSLDCS5 DOS based set up program is menu driven that allows the user to easily view data or alter set up variables using a laptop or PC In addition to adjusting the set up variables the set up program 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 M4508 to match the configuration and performance of the specific decorator see section 2 9 Tuning the M4508 The main menu of the set up program incorporates the following menu selections le HSLDC5 EXE B x Systems APM Decorator Set up Menu Version 2 1 Main Menu Set Speed Parameters Set Ductor Parameters Set Pin Chain QC Blow off Parameters Set Machine Timing Number of Trips per Spindle Data Current Shift Data Last Shift Data Download Program to Module Download Set up data to Module Upload Save Set up data from Module Enter Selection ESC to exit OLSUNN e NOTE Before selecting one of the ten selections listed above connect an R
62. ed Valid range 0 to 99 SYSTEMS Electronics Group 25 SECTION 2 INSTALLATION 2 9 11 SET PIN CHAIN BLOW OFF SOLENOID RESPONSE TIMES Pin Chain bad can and QC Blow off Solenoid ON Response Time msec This is the time used as the ON response time of the pin chain blow off port time from solenoid actuation to first air out port in milliseconds The M4508 will activate the solenoid this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds Valid range 5 to 60 msec Pin Chain bad can and QC Blow off Solenoid off Response Time msec This is the time used as the off response time of the pin chain blow off port time from solenoid off actuation to air stopping at port in milliseconds The M4508 will activate the solenoid off this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Valid range 5 to 60 msec 2 9 12 SET O VARNISH ROLL SPEED CALIBRATE The O Varnish drive speed input is a 0 10VDC signal from the O Varnish drive if available The roll speed calibrate is used to scale this signal to display the O Varnish RPM The number entered should equal the O Varnish roll speed when the drive is at full speed input 10VDC THE MACHINE IS NOW SET UP AND READY TO RUN HSL DC5 User s Manual SYSTE
63. eed Logic Module This includes the functional description alarms detected etc 1 1 FEATURES e Performs high speed control functions of the APM Decorator to speeds in excess of 2400 CPM e High speed front end upgrade package which interfaces with existing control system e Accurate detection of misloaded cans and trip cam control eliminates inside deco and varnish problems e Accurate speed compensated single can bad can pin chain blow off reduces scrap and eliminates silver cans down the line e Single select a can QC pin chain blow off allows operator to blow off a can from a selected spindle or blanket to verify print quality of each blanket with machine running at full production speeds e Can gate open close control e Alarm detection infeed track jam no can transfer can on mandrel and timing signal fail detection e Data Acquisition Total number of good cans printed total number of blow offs trips per spindle etc for both current shift and last shift e Built in 2 Line X 40 character sealed display with 24 key membrane keypad allows local viewing of collected data can count blow off count trips per spindle by operator and set up of all user variables passcode protected or key switch enabled by authorized personnel e Interfaces directly with machine mounted resolver can no can sensor and all trip and blow off solenoids SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION HSL D
64. eel to disk transfer location to the first can blown off at the Pin Chain blow off port minus two This can be a number from 0 to 999 2 Number of Cans to Blow off for Each Mis load This is the number of cans blown off at the pin chain port when one mis loaded can is detected typically set at 1 can 3 Number of Cans to Blow off at Infeed Open This is the number of cans which will be blown off when the infeed is first opened To blow off no cans at infeed open set equal to 0 to blow off one can set equal to 1 etc SYSTEMS Electronics Group 65 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 4 Number of Cans to Blow off from Print at Restart This is the number of cans that will be blown off from the print station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc 5 Number of Cans to Blow off from Varnish at Restart This is the number of cans that will be blown off from the varnish station when the machine is restarted To blow off no cans at restart set equal to 0 to blow off one can set equal to 1 etc 6 Q C Can Blow off Port Shift Offset This is the number of spindles difference from detection of the spindle 71 flag to the QC blow off port This is a number between 1 and 24 and is empirically set by selecting spindle 1 for blow off and adjusting this value until the can from spindle 1 is the can that is blown off 7 Bad Can Blo
65. elections 1 Canfeed Enable Low Speed This is the minimum speed the can gate is allowed to open to enable cans to be loaded into the machine This defines the lower limit of the canfeed enable window As the machine speed increases above this threshold the can gate will be enabled to be opened HSL DC5 User s Manual SYSTEMS Electronics Group 62 HSL DC5 User s Manual 3 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 2 Canfeed Enable High Speed This is the maximum speed the can gate is allowed to open or close to enable cans to be loaded into the machine This defines the upper limit of the canfeed enable window With the machine operating at production speed the M4508 will only activate deactivate the can gate solenoid within the canfeed enable window When the machine goes to a stand by condition the speed of the machine will need to be decreased below this threshold for the can gate solenoid to be deactivated The M4508 will activate and deactivate the can gate solenoid on the Can Gate Timing ON signal O Varnish Roll Speed Calibrate The O Varnish drive speed input is a 0 10VDC signal from the O Varnish drive if available The roll speed calibrate is used to scale this signal to display the O Varnish RPM The number entered here should equal the O Varnish roll speed when the drive is at full speed input 10VDC Ductor Parameters This section is used to set the ductor solenoid control
66. en the select a can chain blow off port is centered between pins on the chain see figure above 3 Can Gate Timing ON Position This signal is used to open and close the can gate Adjust the ON Position for proper can gate operation Note View the Machine Position field when adjusting the above timing setpoints Machine position will increase linearly from 0 to 359 360 degrees per mandrel as the machine is rotated forward 4 Zero Resolver To set the Machine Zero position set resolver offset follow the procedure outlined in section 2 9 2 Set Machine Zero Verify that as the machine is rotated forward either jogged or barred that the Absolute Position field increases linearly from 0 to 1079 for Rotary Trip machines and from 0 to 719 for Interposer Trip machines Note The Zero Resolver command button is only active at Zero Speed main drive off amp no motion detected Once the user has clicked the command button a message box will be displayed confirming their choice to Zero the resolver HSL DC5 User s Manual SYSTEMS Electronics Group 68 HSL DC5 User s Manual SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 3 THE SHIFT DATA WINDOW The Shift Data window is used to view the shift data collected by the M4508 This window is selected from the Window menu or by pressing the F7 function key amp APMDEC unnamed q BEER lol x File Edi
67. er supply should be adequate SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 3 MOUNTING AND WIRING THE HSL DC5 Mount the back panel in the existing control cabinet Referring to the figure below create a cut out in the existing control cabinet door and mount the D4591 Keypad Display L 4475 T 4415 0 250 e 9 eo i 8 000 sins 4 875 d 1 875 0 475 1 775 4 450 i ECAT I PEACES HSL DC5 User s Manual D4591 Recommended Panel Door Cut out Note The D4591 must be located within 6 feet of the M4508 module to avoid EMI pick up on the display ribbon cable Connect the ribbon cable from the M4508 module to the D4591 module SYSTEMS Electronics Group SECTION 2 INSTALLATION Referring to the electrical control schematic at the back of this manual wire the HSL DCS to the existing control system as follows Note Keep all 24VDC wiring resolver cable and sensor cable wiring away from high voltage wiring Wire the machine mounted resolver directly to the 8 pin resolver input connector of the M4508 1 Incoming Power 115VAC 230VAC to FUI neutral to 900 and ground to GND Logic power 24VDC to 501 and common to 500 Control power 24VDC to 601 and common to 600 2 Interlocks from existing control system terminals I12 through I17 amp 142 3 Interlocks to existing control system terminals O10 through O19 4 Module fault inte
68. et up required at label change is to set the keys open and closed at the required areas on the can The following sections describe the recommended procedure for setting up a label and the recommended procedure for a label change over using a label which has previously been programmed into the color control HSL DC5 User s Manual SYSTEMS Electronics Group 96 HSL DC5 User s Manual SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 9 SELECTING THE LABEL NUMBER To select a label perform the following 1 Press the COLOR CONTROL gt key to enter the adjustment mode 2 If the prompt ENTER PASSCODE is displayed enter the corresponding 1 to 5 digit passcode on the numeric keypad and press ENTER If the prompt ENTER PASSCODE INCORRECT PASSCODE is displayed enter the correct passcode and press lt ENTER gt 3 The LABEL field is displayed Enter a new label 0 99 on the numeric keypad and press lt ENTER gt or press the lt NEXT gt key to use the existing label Note The decorator must be stopped in order to change the label number 4 Ifno further changes are to be made to the ink stations settings press lt ESC gt to exit 6 10 LIGHT DARK COLOR ADJUSTMENT The On duration and Cycle duration for each ink station can be set individually for each label number The On duration can be viewed as a Course adjustment and the Cycle duration can be viewed as a Fine
69. f a can press the QC BLOW OFF key The display will then prompt Enter Spindle to Blow Can off Enter the desired spindle number 1 24 or 1 36 and press enter One can from that spindle will be blown off at the Pin Chain QC blow off port 3 5 SET COLOR CONTROL KEY PASSCODE The Set Passcode input to the M4508 is used to set or view the passcode of the Color Control menu Normally this input is off To set the passcode jumper 24VDC to this input and press the Color Control key The ENTER PASSCODE prompt will be displayed as well as the current 5 digit passcode This allows the passcode to be viewed if necessary To change the passcode enter any number from 1 to 64999 and press ENTER Note Set the passcode to 0 to disable passcode protection When the passcode is prompted for after the Color Control key is pressed simply press lt ENTER gt to proceed to the color control menu To enable passcode protection set the passcode to a number from 1 to 64999 When the Color Control key is pressed the actual valid passcode number will have to be entered in order to gain access to the color control menu Once the passcode is set turn the Set Passcode input off and the set up menu will be passcode protected with the number entered SYSTEMS Electronics Group 4 SECTION 3 USING THE KEYPAD DISPLAY This Page Intentionally Left Blank HSL DC5 User s Manua
70. he HSM DC5 now controls e The Can Gate Solenoid e Pin Chain Blow Off Solenoids e Trip Cam Solenoids e Ductor Solenoids If the existing host PLC was controlling these functions this logic can optionally be removed from the existing host PLC if desired In most cases this logic can be left in the program as connecting the respective solenoids to the HSM DCS5 will effectively defeat the logic 2 The Test Mode can be an output from the PLC or from a push button or selector switch The cans will then be blown off at the Bad Can pin chain blow off port as long as this input is ON SYSTEMS Electronics Group 4 SECTION 2 INSTALLATION 3 The End of Shift can be an output from the PLC or from a push button When the End of Shift input goes ON the current shift data is transferred to the last shift and all data registers for the current shift as well as the trips per spindle will be reset to Zero 4 Add the Can Feed Enable output to the PLC logic When turned on while running the infeed is timed open with the can feed timing signal When turned off while running the infeed is timed closed with the can feed timing signal When the machine is stopped turning this input on and off will respectively open and close the can stop 5 Add the Main Drive On output to the PLC logic This should be on when the drive is enabled running and should b
71. his parameter should be set to zero Color Gain This parameter allows the color density to be increased proportionately up or down as a function of machine speed The valid range of this parameter is 50 to 150 per 2000 CPM When set to 100 no increase or decrease as a function of speed will occur When set to 50 the color density will drop 50 from 0 to 2000CPM When set to 150 the color density will increase by 50 from 0 to 2000CPM This parameter is used to compensate for ink atomization misting as a function of speed higher speed proportionately higher ink misting Feedback Enable stations 1 8 This parameter enables the individual feedback faults and should only be used when the optional feedback sensors are used Once enabled the M4508 will verify that the ductor is cycling properly If a ductor is not detected as cycling properly the Ductor Feedback Fault is energized indicating a problem with the ductor cycling control If a Ductor Feedback Fault does occur the ductors should be manually activated to verify proper cycling operation as well as the sensor for proper feedback operation The feedback sensor should be set such that it is only ON when the ductor is in contact with the fountain roll HSL DC5 User s Manual SYSTEMS Electronics Group 93 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 5 1 DEFAULT DUCTOR CONFIGURATION SETTINGS As shipped the ductor configuration settings are as follows
72. iables from the M4508 to disk e View Shift and Trips per Spindle data To install the DOS based set up software perform the following steps 1 Create a directory off the root for each decorator These will be used to store the HSLDCS EXE setup program and set up data for each decorator Create a directory for each machine HSLDECI line 1 Decorator HSLDEC2 line 2 Decorator HSLDEC3 line 3 Decorator etc 1 Install the PROGRAMS disk into the drive For each HSLDEC directory you created at a DOS prompt e Switch to that directory e Install the HSLDCS set up program by typing the following Line 1 decorator is shown CD HSLDECI lt ENTER gt A INSTALL lt ENTER gt HSL DC5 User s Manual SYSTEMS Electronics Group 12 SECTION 2 INSTALLATION 3 Add each decorator s set up program to your computer s menu software by creating a selection for each decorator called e SET UP DECO LINE for the line 1 decorator e SET UP DECO LINE2 for the line 2 decorator etc The DOS commands executed for these selections should be Line decorator is shown For the SET UP DECO LINET selection CD MHSLDECI HSLDC5 HSLDC5 CD 4 To execute the respective decorator s set up program simply select the corresponding SET UP DECO LINE selection from the menu software s menu 5 Alternatively a PIF file for each HSLDC5 EXE could be setup on the Windows desktop 2 7 3 SYSDE
73. indle 1 so they can be identified while they are on the chain Press the select a can push button and observe the can blown off with the location of a can printed on spindle 1 Add the number of cans difference between the can actually blown off and the can printed on spindle number one to the QC can blowoff port shift offset SYSTEMS Electronics Group 24 HSL DC5 User s Manual SECTION 2 INSTALLATION Note This variable must be a number between 1 and 24 or 36 as there is always a can printed on spindle 1 every 24 or 36 cans Once set up verify that a can from spindle 1 is blown off when 1 is dialed in on the thumb wheel and the select a can push button is pressed 2 9 10 SET NUMBER OF CANS TO BLOW OFF Set the number of cans to blow off as desired Cans to Blow Off for Each Mis Load This is the number of cans blown off at the pin chain port when a mis loaded can is detected typically set at 1 can Any additional cans entered will be blown off every 12 can later cans printed on the same blanket Cans to Blow off at Infeed Open This is the number of cans blown off when the infeed is first opened Valid range 0 to 99 Cans to Blow off from Print at Restart This is the number of cans blown off from the print station when the machine is restarted Valid range 0 to 99 Cans to Blow off from Varnish at Restart This is the number of cans blown off from the varnish station when the machine is restart
74. is only active while Online and it allows the operator to test the action of the control system by electronically inducing a mis loaded or Bad Can into the system By clicking on the Test Trip Blow off command button a Bad Can will be electronically induced into the system to test the response of the control system due to a Mis Loaded can HSL DC5 User s Manual SYSTEMS Electronics Group 61 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 4 5 2 THE SETUP PARAMETERS WINDOW The Set up Parameters window is used to view and adjust any of the set up parameters This window is selected from the Window menu or by pressing the F6 function key A APMDEC unnamed Set Up File Edi View Window Help Speed Parameters Ductor Parameters Blow off Parameters Machine Timing Set Speed Parameters Canfeed Enable Low Speed 600 Canfeed Enable High Speed 1000 a D Varnish Roll Speed Calibrate 380 Roll RPM at 10 DC O Vamish Roll Speed RPM 33 System Message All Faults Normal ONLINE 10 6 2003 amp 02PM 7 This window utilizes a TAB control to divide the set up parameters into five categories similar to that of the Keypad Display These sections are as follows Speed Parameters This section is used to set the canfeed enable speed window and the calibration of the O Varnish roll speed in the M4508 This section contains the following s
75. k up perform the following to set up and tune the HSL DC5 The set up is performed using either the Keypad Display or a PC running the set up program See section 3 of this manual for a description of the Keypad commands and menu displays of the Keypad Display See sections 4 and 5 for a description of menus and variables and how to use the set up programs SYSTEMS Electronics Group 17 SECTION 2 INSTALLATION 2 9 1 DEFAULT SET UP VARIABLES As shipped the user variables for the M4508 are set the following defaults Speed Parameters Canfeed Enable Low Speed 600 Canfeed Enable High Speed 1000 O Varnish Roll Speed Calibrate 380 Pneumatic Ductor Parameters Maximum Cycle Duration 0 1 cans 500 Maximum On Duration 0 1 cans 200 Response Time Compensation msec 25 Color Gain CG 100 per 2000cpm 10096 Feedback Enabled 1N 2N 3N 4N 5N 6N 7N 8N Bad Can pin chain Blowoff of cans to blowoff from infeed open 012 of cans to blowoff from print at restart 000 of cans to blowoff from varnish at restart 000 of bad cans to blowoff for misload 001 of pins to pin chain blowoff port 032 Blowoff solenoid on response time msec 015 Blowoff solenoid off response time msec 028 QC Can select a can Blowoff Blowoff solenoid on response time msec 015 Blowoff solenoid off response time msec 028 QC can blowoff port shift offset 001 Spindle Trip Offset 000 Timing
76. l SYSTEMS Electronics Group 42 SECTION 4 APMDEC 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 HSL DC5 to match the configuration and performance of the specific decorator see section 2 9 Tuning the HSL DC5 Installation Note The set up program is an on line communications program used to interface with the M4508 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 M4508 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 APMDEC unnamed Main Display O 4i xl File Edit View Mindow Help Messages Machine CPH _ O Varnish RPM Q C Blow off Spindle Number 9 9 E Blanket Blow off foots EH Good Cans r Blow offs 400 148 4163 Single Blow off Mandrel Blowoff
77. l to turn ON when the pin chain blow off port is centered between pins on the chain see figure below PREVIOUS GOOD CAN a PIN CHAIN BLOW OFF PORT BAD CAN TO BE BLOWN OFF Q C Blow off Timing ON Position Set this signal to turn on when the select a can chain blow off port is centered between pins on the chain see figure above Can Gate Timing ON Position This signal is used to open and close the can gate Adjust the ON Position for proper can gate operation 3 3 5 ZERO MACHINE SET RESOLVER OFFSET This selection is used to auto zero the resolver Follow the instructions in section 2 9 2 Set Machine Zero M4508 Set Up to position the machine at machine zero Press the 0 key on the numeric keypad to set the resolver offset The M4508 will calculate the actual offset value required to make this the 000 position and display this number in the offset field of the machine timing menu HSL DC5 User s Manual SYSTEMS Electronics Group 40 HSL DC5 User s Manual SECTION 3 USING THE KEYPAD DISPLAY 3 3 6 VERIFY CAN PRX LOCATION TIMING This selection is used to verify the location of the Can No Can sensor See section 2 9 3 Verify Location of Can No Can Sensor for setting the location and timing of the Can No Can sensor 3 4 QC BLOW OFF KEY This key is used to blow off a can from a selected spindle at the pin chain QC Blow off port To blow of
78. le Disable Ductor Feedback Fault This selection is used to enable or disable the feedback fault detection When the optional feedback sensors are installed the ductor feedback faults should be enabled The feedback sensor verifies the cycling of the ductor and resets the ON duration as the speed of the machine changes based on the response time of the solenoid HSL DC5 User s Manual SYSTEMS Electronics Group 78 HSL DC5 User s Manual SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE 5 3 SET PIN CHAIN QC BLOW OFF PARAMETERS This selection is used to set the pin chain QC blow off parameters in the M4508 When selected the Pin Chain QC Blow off Set up menu is invoked The Pin Chain QC Blow off Set up menu contains the following selections HSLDC5 EXE Systems APM Decorator Set up Menu Version 2 1 Pin Chain QC Blow off set up Set Bad Can pin chain blow off response times Set number of cans to blow off pin chain Set number of pins to pin chain blow off port Setup QC select a can blow off Enter Selection ESC to exit Pin Chain Bad Can Blow off FON low off solenoid on response time nsec 015 Blow off solenoid off response time msec 028 of bad cans to blow off for misload 001 of cans to blow off from infeed open 012 of cans to blow off from print at restart 000 of cans to blow off from varnish at restart 000 of pins to pin chain
79. lor control replaces the mechanically cammed ductors with pneumatically controlled ductors The ductors are now activated by air cylinders controlled by solenoids driven by the M4508 This allows the cycle duration number of cans between one complete ductor cycle and the duty cycle the time the ductor is in contact with the fountain roll or On duration to be adjusted independently for each ink station This allows the ink flow rate of each station to be adjusted based on the amount of ink required for each particular color on the label The maximum Cycle duration maximum On duration and Response Time compensation are set using the Keypad Display These values are used with all labels The color control allows up to 100 labels to be saved This allows the operator to perform quick label changes by recalling the settings used the last time the particular label was run Thus when a label change is made the corresponding label number is selected and settings for each ink station used for that label previously are used again When the machine first starts up the ductors are staged ON in one can increments At the beginning of each cycle the ductor solenoid is activated and the ductor roll comes in contact with the fountain roll Once the On duration is complete the solenoid is deactivated and the ink is transferred to the first steel roll At the completion of the cycle there is a 5 can dwell period before the ne
80. mber of Cans to Blow off 25 2 9 11 Set Pin Chain Blow off Solenoid Response Times 26 2 9 12 Set O Varnish Roll Speed Calibrate 26 2 10 M4508 P4500 D4591 Installation 27 2 10 1 M4508 Module Installation 27 2 10 2 P4500 Power Supply Installation 29 2 10 3 D4591 Keypad Display Installation 29 2 10 4 Download HSLDC5 Program and Set up Data to M4508 30 HSL DC5 User s Manual SYSTEMS Electronics Group HSL DC5 User s Manual 3 Using the Keypad Display 4 3 1 3 2 3 3 3 4 3 5 Default Screen Display Data Key 3 2 1 Trips per Spindle Data 3 2 2 Current Shift Data 3 2 3 Last Shift Data 3 2 4 Display Lifetime Can Count Set up Key 3 3 1 Set Speed Parameters 3 3 2 Set Pneumatic Ductor Parameters 3 3 83 Set Pin Chain QC Blow off Parameters 3 3 4 Set Machine Timing 3 3 5 Zero Machine set resolver offset 3 3 6 Verify Can PRX Location Timing QC Blow off Key Set Color Control Key Passcode APMDEC Windows Based Set up Program Reference 4 1 4 2 4 3 4 4 4 5 General Description The File Menu 4 2 1 The Set Up Data File 4 2 2 Upload save Data 4 2 3 Download Program 4 2 4 Download restore Data 4 2 5 Print Report The Edit Menu 4 3 1 Enable Offline Editing 4 3 2 Setup Comm Port 4 3 3 Color Control Passcode The View Menu 4 4 1 Target Board Interface 4 4 2 View Online Data 4 4 3 View Offline Data The Window Menu 4 5 1 The Main Display Window 4 5 2 The Setup Parameters Window
81. menu le HSLDC5 EXE Systems APM Decorator Set up Menu Version 2 1 Last Shift Total for shift Press ESC to return Total Good Cans 0 Total Misloads Manual Blow offs 0 Spindle 801 Spindle 02 Spindle 03 Spindle 04 Spindle 05 Spindle 06 Spindle 07 Spindle 08 Spindle 09 Spindle 10 Spindle 11 Spindle 12 trips trips trips trips trips trips trips trips trips trips trips trips OOOO Spindle Spindle Spindle Spindle Spindle Spindle Spindle Spindle Spindle Spindle Spindle Spindle 85 13 14 15 16 17 18 19 20 21 22 23 24 to main menu Total Blow offs 0 Restart Blow offs 0 QC Blow offs 0 trips 0 Spindle 25 trips 0 Spindle 26 trips 0 Spindle 827 trips 0 Spindle 28 trips 0 Spindle 29 trips 0 Spindle 830 trips 0 Spindle 831 trips 0 Spindle 32 trips 0 Spindle 33 trips 0 Spindle 34 trips 0 Spindle 35 trips 0 Spindle 836 trips trips trips trips trips trips trips trips trips trips trips trips Cocco coco cocco coc 0c SYSTEMS Electronics Group SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE 5 8 DOWNLOAD PROGRAM TO MODULE This selection is used to download the application program to the M4508 module This should only be performed when replacing the module or when the program has been changed To download the program perform the following Note
82. n milliseconds The M4508 will activate the solenoid OFF this amount of time ahead of the QC blow off timing ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Machine Timing This section is used adjust the timing channel setpoints This section contains the following selections amp APMDEC unnamed Set Up Bl x File Edit View Window Help Set Machine Timing Bad Can Blow off ON Position degrees 180 a D C Blow off ON Position degrees 185 Can Gate Timing ON Position degrees 0 a Test Blow off r Machine Position Bad Can Blow off 206 B C Can Blow off System Message All Faults Normal ONLINE 10 6 2003 amp 03PM 4 Note The Bad Can Blow off command button will electronically induce a mis loaded can into the system as well as the Q C Can Blow off will blow off a can printed on spindle 1 at the QC blow off port HSL DC5 User s Manual SYSTEMS Electronics Group 67 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 1 Bad Can Blowoff ON Position Set this signal to turn ON when the pin chain blow off port is centered between pins on the chain see figure below PREVIOUS GOOD CAN ze PIN CHAIN BLOW OFF PORT BAD CAN TO BE BLOWN OFF 2 Q C Blow off Timing ON Position Set this signal to turn on wh
83. or inaccuracies In the interests of a commitment to a policy of continuous development and improvement the manufacturer reserves the right to change the specification of the product or it s performance or the contents of the User Manual without notice Copyright 2001 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description 1 Features Functional Description Mandrel Trip Control Bad Can and Select A Can Pin Chain Blow off Alarm Detection Data Collection i X X Xo Xx OnKRwWNM o gt aRWWN 2 Installation _7 2 1 What s Included 7 2 2 Power Required 7 2 3 Mounting and Wiring the HSL DC5 8 2 4 Mounting the HSL QCSTA 10 2 5 Mounting the RSV34 MS1 Resolver 10 2 6 Mounting the Mandrel 1 Mark I D Sensor 10 2 7 HSL DC5 Software Installation 11 2 7 1 Windows Based Setup Program Installation 11 2 7 2 DOS Based Setup Program Installation 12 2 7 3 SYSdev Program Development Software Installation 13 2 7 4 Application Program Installation 14 2 8 Modify Existing PLC Program 14 29 Tuning the HSL DC5 17 2 9 1 Default Set up Variables 18 2 9 2 Set Machine Zero 19 2 9 3 Verify Location of Can No Can Sensor 20 2 9 4 Set Pin Chain Blow off Timing ON Position 22 2 9 5 Set Can Gate Timing ON Position 23 2 9 6 Set Canfeed Enable Speed 23 2 9 7 Set Number of Pins to Pin Chain Blow off Port __ 23 2 9 8 Set Spindle Trip Shift Offset 24 2 9 9 Set QC Blow off Shift Offset 24 2 9 10 Set Nu
84. plete press any key to return to the main menu HSL DC5 User s Manual SYSTEMS Electronics Group 88 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL This section describes the features of the pneumatic ductor color control This includes the functional description the user and operator selectable parameters etc 6 1 FEATURES e Replaces the mechanically cammed ductors on the decorator e Directly controls the cyclic ductor solenoids to a resolution of one tenth of a can at speeds up to 2400CPM e Enables the operator to perform quick label changes by recalling the ductor Cycle and On duration used the last time the particular label was run e Incorporates optional ductor feedback sensor inputs to compensate for the response time of the solenoid and verify that the ductors are cycling e Keypad adjustment of label parameters label number cycle duration and on duration e Stores label parameters for up to 100 labels e User selectable ductor configuration parameters including maximum Cycle duration maximum On duration response time compensation and individual ductor feedback enable e Passcode security access for adjusting label parameters e Manual Off Auto modes of operation e Provides control for up to 8 ink station machines HSL DC5 User s Manual SYSTEMS Electronics Group 89 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 2 FUNCTIONAL DESCRIPTION The pneumatic ductor co
85. ration can be individually set for each ink station for each label The On duration is the amount of time cans the ductor roll is in contact with the fountain roll Follow the procedure outlined in the Pneumatic Ductor Color Control section 6 10 Light Dark Color Adjustment to properly adjust the On duration Note The user cannot adjust the On duration to within 14 cans 140 tenths of the Cycle duration To disable a ductor from cycling set this variable to zero Cycle Duration The Cycle duration can be individually set for each ink station for each label The Cycle duration is the frequency at which the ductor is activated This is the duration number of cans between one complete cycle Follow the procedure outlined in the Pneumatic Ductor Color Control section section 6 10 Light Dark Color Adjustment to properly adjust the Cycle duration Note The user cannot adjust the Cycle duration to within 14 cans 140 tenths of the On duration Color Density The Color Density display is used as an indication of the amount of ink being transferred by the ductor Different settings of the On and Cycle durations will achieve the same Color Density Follow the procedure outlined in the Pneumatic Ductor Color Control section 6 8 Recommended Procedure for Using the Color Control SYSTEMS Electronics Group 73 SECTION 4 APMDEC WINDOWS
86. ration is the total cycle time in 0 1 cans that the ductor roll is in contact with the fountain roll If the operator attempts to enter a number higher than the maximum ON duration the value will default back to the previous value The range of this parameter is 0 200 3 Set Solenoid Response Time Compensation Msec This parameter is the difference in msec between the ON and off response times of the ductor solenoid This is used to adjust the ON duration to compensate for the mechanical response time of the whole mechanism As an example if the ON response time was 40 msec and the off response time was 15 msec Then the value entered for this parameter would be 25 msec Note If the optional feedback sensors are used set this parameter to 0 The feedback sensors will automatically adjust the ON duration based on the response time of the solenoids 4 Set Color Gain This parameter allows the color density to be increased proportionately up or down as a function of machine speed The valid range of this parameter is 5096 to 150 per 2000 CPM When set to 100 no increase or decrease as a function of speed will occur When set to 50 the color density will drop 50 from 0 to 2000CPM When set to 150 the color density will increase by 50 from 0 to 2000CPM This parameter is used to compensate for ink atomization misting as a function of speed higher speed proportionately higher ink misting 5 Enab
87. rd processing file When the program first starts a default file is loaded and the user is able to make any changes as desired The set up program is unaware of the settings and parameters that exist within the M4508 Therefore to normalize the set up program with the processor the user should define or open an existing file then upload All variables from the processor This allows the user to either create a backup of the data or maintain an existing file The user can even open a data file for another decorator save the file to a new name make the necessary changes and simply download the new parameters to another processor The following functions can be accessed any time from any set up or display windows New To create a New data file select New from the File menu or press Ctrl N This creates a completely new file loaded with the default variables and the word unnamed is displayed in the title bar If any changes were made to the existing file the user is prompted to save changes to the existing file Open To Open and existing data file select Open from the File menu or press Ctrl O This displays a dialog box allowing the user to select an existing data file to open The name of the file will be displayed in the title bar If any changes were made to the existing file the user will be prompted to save any changes before terminating the program SYSTEMS Electronic
88. rlock FLT 24VDC sink output 5 Can Gate Bad Can Blow off and Q C Can Blow off solenoids FU2 FU3 amp FU4 6 Trip Cam ON and off solenoids FU5 through FU10 7 Ductor solenoids FU11 through FU18 8 Can No Can sensor Mandrel No 1 Mark sensor Can on Mandrel sensor terminals 109 110 amp I11 and Ductor Feedback sensors terminals 140 through 147 using three conductor shielded cables The shields of the sensor cables should be tied to earth ground at a terminal inside the existing control cabinet and left floating at the sensors 9 Set Up Enable key switch if desired to allow entry to set up variables through Keypad Display 10 Resolver cable from resolver or existing PLS to 8 pin resolver input connector on the M4508 using a three pair two conductor shielded cable The shield of the resolver cable should be tied to the SHLD terminal of the M4508 resolver input connector Make sure the resolver cable shield is left floating at the resolver SYSTEMS Electronics Group HSL DC5 User s Manual SECTION 2 INSTALLATION HSL DC5 User s Manual 2 4 MOUNTING THE HSL QCSTA The HSL QCSTA is used to blow off a can from a selected spindle or blanket from the pin chain for quality verification If the optional HSL QCSTA remote select a can PB station was purchased mount it in the vicinity of the pin chain QC blow off port in a convenient location for the operator Wire the HSL QCSTA to the HSL DC5 referring
89. s Group 46 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE Save To Save data file 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 already exists and 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 Export Shift Data This function allows the user to export the shift data to a Tab Delimited text file This allows the user to easily use the shift data to produce production reports 4 2 2 UPLOAD SAVE DATA The Set up program allows the user to upload set up parameters and shift data from the M4508 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 APMDEC unnamed Main Display B x Fie Edit View Window Help New Ctrl N Open Ctrl Save Ctrl S Save As Export Shift Data Cha lt Upload save
90. s follows None 0 0 Timing Signal Fail 0 1 No Can Transfer 1 0 Infeed Track Jam 1 1 SYSTEMS Electronics Group HSL DC5 User s Manual SECTION 1 GENERAL DESCRIPTION 1 6 DATA COLLECTION The following data is collected for both the current shift and the previous last shift e Total Number of Good Cans Printed e Total Number of Cans Blown Off e Total Number of Miss Loaded Cans bad cans e Total Number of Restart Blow Offs e Total Number of Manual Blow Offs e Total Number of Select A Can QC Blow Offs e Total Trips per Spindle for each spindle This data can be viewed locally on the Keypad Display or sent to the host PLC via RS 232 communications MODBUS or Allen Bradley DF1 protocols using the optional S4516 communication board This information is updated Current shift transferred to Last shift based on the change of state of the End of Shift input This can be activated on an 8 or 12 hour basis or alternatively based on label run depending on the user s preference A separate buffer is used to collect Trips per Spindle counts as a diagnostic to aid in trouble shooting a loading problem Unlike the shift data these counts can be reset at will This allows one to note an abnormally high count on a specific mandrel The collected data is available via encoded Blow off Data outputs from the M4508 as follows Blow off Data None Restart Blow offs QC Blow offs Manual Blo
91. s for the respective spindles Screens for the rest of the spindles are shown in this fashion each for a time delay of 10 seconds The final screen prompts the user to reset the counts by pressing 0 or press ESC to return to the main menu This provides the operator with the opportunity to reset the counts if desired The ESC key can also be used at any time to abort the trips per spindle data display and return to the default screen SYSTEMS Electronics Group 33 SECTION 3 USING THE KEYPAD DISPLAY HSL DC5 User s Manual 3 2 2 CURRENT SHIFT DATA The Current Shift data is the totals so far into the current shift The data is transferred to the Last shift 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 This data cannot be reset by the operator only at the end of shift transition Note The Current shift Good Cans and Blow offs is displayed as part of the default screen see section 3 1 Default Screen Using the Keypad Display The Current Shift data is defined as follows Good Cans This is the total number of good cans printed so far into the shift This is essentially a can counter Blow offs This is the total number of cans blown off the machine This includes all types of blow offs
92. start blow offs manual blow offs select a can QC blow offs etc Total Mis loads This is the total number of mis loaded cans trips These would be the actual number of damaged cans that did not load properly on the machine This gives an indication of conveying can handling problems HSL DC5 User s Manual SYSTEMS Electronics Group 84 HSL DC5 User s Manual SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE Restart Blow offs This is the total number of cans blown off when the infeed opened and from the print station and varnish station at machine restart Manual Blow offs This is the total number of cans blown off by the operator using the Manual Blow off PB or selector switch QC Blow offs This is the total number of cans blown off by the operator with the Select A Can QC station or QC Blow off key on the M4508 keypad for quality verification Spindle 01 through 24 or 36 trips This is the total trips mis loads for each spindle A disproportionately high count for a particular spindle indicates a loading problem for that spindle 5 7 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 over a two shift period Refer to the previous section for definitions of the data fields in the Last Shift data
93. t This display effectively replaces a speed meter and two can counters This screen is always returned to when no commands are active 3 2 DISPLAY DATA KEY This selection is used to invoke the primary display data menu This consists of the following selections 1 DISPLAY TRIPS PER SPINDLE DATA 2 DISPLAY CURRENT SHIFT DATA 3 DISPLAY LAST SHIFT DATA 4 DISPLAY LIFETIME CAN COUNT When selected each of the above selections will bring up a sub menu with the corresponding data The following sections describe these sub menus and the definitions of the corresponding data To select the respective sub menu simply press the corresponding numeric key 1 through 4 SYSTEMS Electronics Group 332 HSL DC5 User s Manual SECTION 3 USING THE KEYPAD DISPLAY 3 2 1 TRIPS PER SPINDLE DATA The Number of trips per spindle menu is provided to aid in the trouble shooting of a loading problem with a spindle or spindles The total number of trips for each spindle since the last reset or end of shift is displayed The operator can reset these counts at any time to aid in the trouble shooting process The data can be viewed simply by pressing this key The display shows a series of screens each with four spindles from 1 through 24 or 36 as shown below TRIPS MIS LOADS PER SPINDLE 1 XXXX 2 XXXX 3 XXXX 4 XXXX Where the numbers 1 through 4 are the first 4 spindles and the xxxx would be the actual count
94. t back to the previous value The range of this parameter is 0 200 Response Time Compensation msec This parameter is the difference in msec between the ON and off response times of the ductor solenoid This is used to adjust the ON duration to compensate for the mechanical response time of the whole mechanism As an example if the ON response time was 40 msec and the off response time was 15 msec Then the value entered for this parameter would be 25 msec Note Ifthe optional feedback sensors are used set this parameter to 0 The feedback sensors will automatically adjust the ON duration based on the response time of the solenoids Color Gain This parameter allows the color density to be increased proportionately up or down as a function of machine speed The valid range of this parameter is 50 to 150 per 2000 CPM When set to 100 no increase or decrease as a function of speed will occur When set to 50 the color density will drop 50 from 0 to 2000CPM When set to 150 the color density will increase by 50 from 0 to 2000CPM This parameter is used to compensate for ink atomization misting as a function of speed higher speed proportionately higher ink misting Enable Disable Ductor Feedback Fault This selection is used to enable or disable the feedback fault detection When the optional feedback sensors are installed the ductor feedback faults should be enabled The feedback sensor
95. t up program allows the user to Download any SYSdev program file to the M4508 APMDEC unnamed Main Display File Edit View Window Help New Ctrl N Open Ctrl Save DtrleS Save As Export Shift Data Ctrl x Upload save Data d B C Blow off Spindle Number Download restore Data gt Blanket Blow off EH EE Report Setup Print Report Ctrl P i Mandrel Blowoff Exit Lifetime Count x1000 m Bad Can Blow off 0 Test Trip Blow off System Message All Faults Normal ONLINE 10 6 2003 H PM 4 HSL DC5 User s Manual SYSTEMS Electronics Group 48 HSL DC5 User s Manual SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE Note To Download a SYSdev program to the processor the program must be Online If Online mode cannot be achieved program download will not be executed If the program is currently Offline the user will be prompted to first go Online Once selected and the set up program Online with the processor a dialog box will be displayed allowing the user to select the SYSdev file to download Note Only the files with the sdv file extension will be displayed It is important to keep in mind that only a valid M4508 PLC SYSdev file can be downloaded through the set up program Care should be taken when selecting a program to download Once selected
96. the time used as the off response time of the pin chain blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4508 will activate the solenoid OFF this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Valid range 5 to 60 msec QC Blow off Solenoid on Response Time msec This is the time used as the on response time of the QC blow off port time from on solenoid actuation to first air out port in milliseconds The M4508 will activate the solenoid ON this amount of time ahead of the QC blow off timing ON position usually set at 15 to 20 milliseconds Valid range 5 to 60 msec QC Blow off Solenoid off Response Time msec This is the time used as the off response time of the QC blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4508 will activate the solenoid OFF this amount of time ahead of the QC blow off timing ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids Valid range 5 to 60 msec QC Blow off Shift Offset This is the number of spindles difference from detection of the spindle 1 flag to the QC blow off port This is a number between 1 and 24 or 36 and
97. the total number of good cans printed so far into the shift This is essentially a can counter 2 Total Blow offs This is the total number of cans blown off the machine This includes all types of blow offs the can s blown off for each mis load infeed open blow offs restart blow offs manual blow offs select a can QC blow offs etc 70 SYSTEMS Electronics Group SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 3 Total Bad Cans or Mis loads This is the total number of mis loaded cans trips These would be the actual number of damaged cans that did not load properly on the machine This gives an indication of conveying can handling problems 4 Manual Blow offs This is the total number of cans blown off by the operator using the Manual Blow off PB or selector switch 5 QC Blow offs This is the total number of cans blown off by the operator with the Select A Can QC station or QC Blow off key on the M4508 keypad for quality verification 6 Restart Blow offs This is the total number of cans blown off when the infeed opened and from the print station and varnish station at machine restart 7 Spindle 01 through 24 or 36 trips This is the total trips mis loads for each spindle A disproportionately high count for a particular spindle indicates a loading problem for that spindle Last Shift Data The Last Shift data is identical to the current shift data except it is for the previous 8 12
98. tion is not ceased therefore data download can be performed while the machine is running Once set up data download is complete press any key to return to the main menu SYSTEMS Electronics Group 87 SECTION 5 HSLDC5 DOS BASED SETUP PROGRAM REFERENCE 5 10 UPLOAD SAVE SET UP DATA FROM MODULE This selection is used to save set up variables from the M4508 module to the hard drive current directory selected This should be performed anytime any of the set up variables have been changed Note When the set up variables are changed they are changed directly in the module not on the file in the computer By uploading saving the set up variables to disk they can be downloaded to the module in the event the module must be replaced The set up data consists of the speed parameters pin chain QC blow off parameters ductor label data and the spindle trip shift offset To upload the set up data perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4508 2 Select 0 Upload Save Set up data from Module A prompt will be displayed asking to continue or abort Press any key to continue press the lt ESC gt key to abort 3 Once data upload is initiated the current address being uploaded will be displayed Note M4508 program execution is not ceased therefore data upload can be performed while the machine is running 4 Once set up data upload is com
99. to adjust and enter in a new value or use the increment or decrement controls to change the value by 1 unit SYSTEMS Electronics Group 59 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE HSL DC5 User s Manual 4 5 1 THE MAIN DISPLAY WINDOW The Main Display window is used to display the general state of the control system This window is selected from the Window menu or by pressing the F5 function key APMDEC unnamed Main Display File Edit Vie Mindow Help Messages pau aser m Machine CPM Varnish RPM Q C Blow off Spindle Number ii Blanket Blow off Good Cans Blow offs i 400 148 4 158 Single Blow off Mandrel Blowoff m Lifetime Count x1000 Bad Can Blow off 0 Test Trip Blow off System Message All Faults Normal 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 M4508 as well as the current Online or Offline status of the set up program By simply scrolling the display the user is able to view all active alarm and status messages If no alarm or status messages are active a default message is displayed Machine CPM This display is only active while Online and displays the current speed of the machine in Cans Per Minute
100. to the electrical control schematic at the back of this manual 2 5 MOUNTING THE RSV34 MS1 RESOLVER The HSL DC 5 is designed to interface to a resolver not encoder for machine timing If the machine is not already equipped with a resolver then the existing encoder will have to be removed and a resolver mounted in its place Note The resolver must make 1 revolution per 2 spindles interposer trip 1 revolution per 3 spindles rotary trip Route the resolver cable in a separate conduit away from all other high voltage and control wiring Wire the cable directly to the 8 pin resolver connector on the M4508 see section 2 3 2 6 MOUNTING THE MANDREL 1 MARK I D SENSOR If the machine has not been provided with a spindle 1 I D sensor then one will have to be mounted This sensor is used to determine which spindle is the 1 spindle for both the QC select a can blow off and the trips per spindle count This must see a target once every revolution of the spindle wheel once every 24 spindles Any non discriminating 10 30VDC proximity sensor can be used and can be mounted anywhere around the periphery of the spindle wheel The target should be either a large steel bolt head or 1 by 1 square steel target mounted on the spindle wheel in the vicinity of spindle 71 SYSTEMS Electronics Group 10 SECTION 2 INSTALLATION 2 7 HSL DC5 SOFTWARE INSTALLATION Follow the steps below to install either the Windows or DOS base
101. uctor the keys on the fountain are used to control the areas the ink is applied as well as the color quality light or dark The keys are adjusted proportionally to where the color was located as well as how much area the color covered and how dark the color was With the pneumatic ductor the color quality is now controlled by the frequency and duty cycle of the ductor as set through the Keypad Display The fountain keys are simply used to define the locations top bottom middle etc the color is located on the can The keys should not be adjusted proportional as before but should be either closed at areas where there will be no color on the can or opened a predefined number of turns on areas where the color is located on the can This allows label changes to occur quicker by simply setting the keys open or closed at the locations required on the can and selecting the label number for the respective label on the Keypad Display thus setting the color quality to the same level as previously set for that label The M4508 is capable of saving the settings for up to 100 labels in the internal memory As different labels are run on the machine different labels can be programmed and added to the internal database When a label which has already been programmed is run again simply recall the label number and the ductors will oscillate at the same frequency and duty cycle they did the last time the label was run The only additional s
102. ulate the actual offset value required to make this the 000 position and will display this number in the offset field SYSTEMS Electronics Group SECTION 2 INSTALLATION HSL DC5 User s Manual 6 Return to the primary set up menu by pressing the lt ESC gt key Return to the default screen by pressing the lt ESC gt key again 2 9 3 VERIFY LOCATION OF CAN NO CAN SENSOR Verify the location of the Can No Can sensor by placing a can on an A spindle and performing the following 1 2 3 4 Enter the Set Up menu by pressing the SET UP key of the Keypad Display Select 6 VERIFY CAN PRX1 LOCATION TIMING Locate the machine with an A spindle approximately under the Can No Can sensor The Can No Can sensor is located approximately at the One O clock position of the spindle wheel see sheet 2 of the electrical timing procedure drawing at the back of this manual Locate the machine to the exact location defined as follows Interposer Trip Type Machines Locate the machine at exactly 630 degrees as displayed in the Actual Absolute POS field of the Keypad Display Rotary Trip Type Machines Locate the machine at exactly 270 degrees as displayed in the Actual Absolute POS field of the Keypad Display SYSTEMS Electronics Group 20 SECTION 2 INSTALLATION 5 The Can No Can sensor should be centered radially over an A spindle at this position The
103. ut is ON then passcode protection is disabled otherwise passcode protection is enabled If passcode protection is enabled the operator must enter the proper passcode in order to make adjustments to the color control parameters If the Set Passcode input is ON then a new passcode can be entered If a passcode is not entered the value is reset to zero HSL DC5 User s Manual SYSTEMS Electronics Group 9 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL HSL DC5 User s Manual 6 5 SET UP PNEUMATIC DUCTOR PARAMETERS This menu is activated when the 2 key SET PNEUMATIC DUCTOR PARAMETERS is pressed while the primary set up menu is active using the Keypad Display The following four set up parameters may then be adjusted or viewed Note For virtually all the menus the lt NEXT gt and lt PREV gt keys can be used to advance to the next or previous parameter respectively To change the currently displayed parameter enter the new value on the numeric keypad and press lt ENTER gt The value will be entered and the next parameter will automatically be displayed When the last parameter in a section is entered the primary set up menu is again displayed Pressing lt ESC gt at anytime will exit back to the primary set up menu The following parameters are used to define the ductor configuration Maximum Cycle Duration The maximum Cycle duration is set to 1 10 of a can resolution The range of this parameter
104. verifies the cycling of the ductor and resets the ON duration as the speed of the machine changes based on the response time of the solenoid SYSTEMS Electronics Group 64 HSL DC5 User s Manual SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE Blow off Parameters This section is used to set the Pin Chain QC Blow off parameters in the M4508 This section contains the following selections APMDEC unnamed Set Up Bl x File Edit View Window Help Speed Parameters Ductor Parameter i Machine Timing Blow off Set up Number of Pins to Pin Chain Blow off Port 32 y Number of Cans to Blow off for Each Mis load 1 a Number of Cans to Blow off at Infeed Open 12 y Number of Cans to Blow off from Print at Restart 3 Number of Cans to Blow off from Varnish at Restart 0 y Q C Can Blow off Port Shift Offset 1 y Solenoid Response Times Test Blow off ON OFF msec msec Bad Can Blow off Bad Can Blow off Solenoid 15 C Can Blow off Q C Blow off Solenoid 15 28 Aetna System Message All Faults Normal ONLINE 10 6 2003 amp 02PM 7 Note The Bad Can Blow off command button will electronically induce a mis loaded can into the system as well as the Q C Can Blow off will blow off a can printed on spindle 1 at the QC blow off port 1 Number of Pins to Pin Chain Blow off Port This is the number of pins from the spindle wh
105. w off Solenoid ON Response Time This is the time used as the ON response time of the pin chain blow off port time from ON solenoid actuation to first air out port in milliseconds The M4508 will activate the solenoid ON this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds 8 Bad Can Blow off Solenoid Off Response Time This is the time used as the off response time of the pin chain blow off port time from off solenoid actuation to air stopping at port in milliseconds The M4508 will activate the solenoid OFF this amount of time ahead of the Pin Chain blow off ON position usually set at 15 to 20 milliseconds for double acting solenoids and set at 25 to 30 milliseconds for single acting solenoids 9 Q C Can Blow off Solenoid ON Response Time This is the time used as the on response time of the QC blow off port time from ON solenoid actuation to first air out port in milliseconds The M4508 will activate the solenoid ON this amount of time ahead of the QC blow off timing ON position usually set at 15 to 20 milliseconds HSL DC5 User s Manual SYSTEMS Electronics Group 66 SECTION 4 APMDEC WINDOWS BASED SETUP PROGRAM REFERENCE 10 Q C Can Blow off Solenoid Off Response Time This is the time used as the off response time of the QC blow off port time from off solenoid actuation to air stopping at port i
106. w offs Bad Can Blow offs Good Cans SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION This Page Intentionally Left Blank HSL DC5 User s Manual SYSTEMS Electronics Group HSL DC5 User s Manual SECTION 2 INSTALLATION The standard HSL DC5 control system is provided for back panel mounting inside the existing control cabinet 2 1 WHAT S INCLUDED Verify that the following items are included when unpacking the HSL DCS lea M4508 PLC PLS module lea P4500 Power Supply lea D4591 Display with ribbon cable for mounting in the existing control cabinet door lea HSL DC5 User s Manual lea M4500 User s Manual lea HSL DC5 Program Disk The following items are optional items and can be purchased separately as required or desired lea HSL QCSTA Remote Select A Can PB station lea RSV34 MSI Resolver lea RSV RSCBLE XX Resolver Cable 2 2 POWER REQUIRED The HSL DCS is powered from 115VAC 230V AC 50 60HZ and 24VDC The 115VAC 230V AC is used to power the M4508 module while the 24VDC is used to power the 24VDC I O sensors trip and blow off solenoids Note 24VDC solenoids must be used for all trip and blow off solenoids These provide a more consistent and repeatable response time than 115VAC solenoids If 24VDC solenoids were used in the existing system the 24VDC current required by the HSL DC5 is no more than the existing systems 24VDC current requirement therefore the existing 24VDC pow
107. wnload is initiated program execution will cease the current address being downloaded will be displayed and the RUN LED on the module will flash continuously Once the download is complete the RUN LED on the module will illuminate solid and program execution in the M4508 will resume Press any key to return to the main menu This selection can also be used to verify the program ident revision and checksum without downloading the program Perform steps 1 and 2 above but instead of initiating the download in step 2 press the lt ESC gt key to abort the download once the ident revision and checksum have been displayed 5 9 DOWNLOAD RESTORE SET UP DATA TO MODULE This selection is used to download the previously uploaded saved set up variables to the M4508 module This should only be performed when replacing the module Note The set up data consists of the speed parameters pin chain QC blow off parameters ductor label data and the spindle trip shift offset To download the set up data perform the following 1 2 3 4 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4508 Select 9 Download Set up data to Module A prompt will be displayed asking to continue or abort Press any key to continue press the lt ESC gt key to abort Once data download is initiated the current address being downloaded will be displayed Note M4508 program execu
108. xt cycle starts During this dwell period ductor cycling operation is checked and adjustments made to the On duration for the response time of the solenoids HSL DC5 User s Manual SYSTEMS Electronics Group 90 SECTION 6 PNEUMATIC DUCTOR COLOR CONTROL 6 3 DUCTOR FEEDBACK Sensors mounted on the machine sense the actuation of the ductor arm verifies that the ductor is cycling and compensates for the response time of the solenoid As the speed of the machine changes the feedback sensor is used to adjust the amount of time the ductor is in contact with the fountain roll This allows consistent ink transfer throughout the entire speed range of the machine If a ductor is not detected as cycling an output is activated to indicate a fault in the ductors cycling operation Note The feedback sensor must go ON when the ductor is in contact with the fountain roll 6 4 OPERATOR ADJUSTABLE PARAMETERS The following parameters can be adjusted through the Color Control key on the Keypad Display e Label Number 0 99 e Ink Station On Duration e Ink Station Cycle Duration Note The above values are passcode protected to prevent unauthorized personnel from making adjustments Also the On duration and Cycle duration cannot be set with in 14 cans of one another Passcode protection can be enabled or disabled via the passcode itself If the passcode is set to zero or the Set Up Enable inp

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