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HelmPak Press Control

Users Guide

Helm Instrument Co. • 361 West Dussel Drive • Maumee, Ohio USA • 419-893-4356

HELMPAK™

Press Control

Summary of Contents for HELMPAK

Page 1: ...HelmPak Press Control 1 Users Guide Helm Instrument Co 361 West Dussel Drive Maumee Ohio USA 419 893 4356 HELMPAK Press Control...

Page 2: ...HelmPak Press Control 2 Users Guide...

Page 3: ...RING BASICS 6 SECTION 3 BASIC OPERATION 12 MODE OF OPERATION 13 SHUT DOWN SYSTEM 13 SECTION 4 SCREEN NAVIGATION 14 LOGIN 15 COUNTERS 15 MOTOR CONTROL 16 TONNAGE MAIN 17 TONNAGE ALARMS 18 SECTION 5 SYS...

Page 4: ...HelmPak Press Control 4 Users Guide...

Page 5: ...rol processors magnetics and Human Machine Interface HMI These components are laid out for the maximum operator efficiency The control enclosure s contain Allen Bradley SLC PLC s operating pushbuttons...

Page 6: ...t the ladder programming will not recognize the module and the Helm Pak control will become unstable and unsafe to operate TURNING SYSTEM ON SAFETY FIRST Check all light curtains barriers safety shiel...

Page 7: ...The other processor is designed to follow suit Dual processors control outputs to clutch brake valve Chapter 1 Clutch Brake Modes The operator can select the mode of control system operation with the...

Page 8: ...ankshaft positions are monitored by a resolver You can use PLS to integrate auxiliary press machinery such as lifters grippers blow off valves and inter press automation into your stamping press contr...

Page 9: ...ENT OF A PART part in position part ejected feed coil misfeed SENSORS TO DETECT STATIC CONDITIONS lube end of feed die clamps air pressure DESCRIPTION OF MODES The purpose of DM channels is to verify...

Page 10: ...ed here the software generates a fault signal We graphically define these window inputs as follows DEFINITION OF DIE MONITORING WINDOW Cyclic CYC N O Use this mode to verify that a pulse from the sens...

Page 11: ...position Transition Diagram For These Expected Transitions Input is NOT ALLOWED When the Sensor Signal Which Results in a Fault signal Sent After Sensor turns OFF before and ON after window 1 turns ON...

Page 12: ...software detects a channel fault it displays the channel number and type of fault on the Operator Interface screen The software also sets a fault response that you select from the following Warning di...

Page 13: ...switch to FORWARD Press Main Motor Start Verify that the current job recipe matches the part being produced Set the press MODE selector switch Inch single or Continuous The Main Menu screen is the in...

Page 14: ...Continuous is being used to operate the press in a Single On Demand mode Press CONTINUOUS SETUP button Press both RUN buttons within 5 seconds of pressing the CONTINUOUS SETUP button Hold the RUN butt...

Page 15: ...y touching the field for entry area on the screen A data entry field will pop up and you will use the numeric or alphanumeric keys to enter the value Use the ENTER key to store the value All Setup scr...

Page 16: ...and return the system to the Default user A user will automatically be logged out if there is no screen activity for 30 minutes Counters Parts Per Stroke Identifies the number of parts each counter wi...

Page 17: ...HelmPak Press Control 17 Users Guide Motor Control This screen allows the user to Start and Stop the Filter Motor as well as displaying the current status of the motor...

Page 18: ...de of the Tonnage Module Peak Mode capacity alarms are active trend alarms are inactive Monitor Mode both capacity and trend alarms are active The Reverse Load Off On Push Button Determines the mode o...

Page 19: ...ed on the formula Press Capacity divided by number of strain gage channels This value can be set lower that press capacity on each channel but no higher than 195 of scale factor High Low Trend Display...

Page 20: ...allow Die Monitoring Inch Bypass to be enabled or disabled Enabled by Default Inch Stop On Top This buttons will allow Inch Stop On Top to be enabled or disabled disabled by Default Top Stop Setup Run...

Page 21: ...nputs The Low Alarm Inhibit Count displays the number of consecutive machine cycles where low alarm is inhibited Used in a process where machine cycles several times before running speed is establishe...

Page 22: ...lide or resolver shaft have been moved even slightly The Zero should be set at the maximum shutheight or just before the maximum limit is reached Set Max by moving slide position to near maximum enter...

Page 23: ...peed reference percentage used when speed setup is enabled Drive Status displays if the drive is moving forward reverse or is off The Job Drive Push Button will send a signal to the drive to manually...

Page 24: ...rface is Enabled or not The Manual OK Push Button is used to send initiate the ok to enter press signal to the robots as long as the press is not moving and all necessary conditions are met Robot Prog...

Page 25: ...PLC to move values to the PLC registers Enter or Change Job Descriptions Press yellow text area under Part No or Die No to enable keyboard for entry of alphanumeric characters Press yellow text area...

Page 26: ...page 8 Static Cyclic Intermittent Cycle In Position Intermittent In Position Touch the Input Button select if the sensor is Normally Open or Normally Closed Touch the Output Button to select the nece...

Page 27: ...ndicated by CH1 CH2 etc to select each PLS channel Touch the Mode window to select the desired mode these are explained on page 7 Touch Angle On Off to enter values Touch Timer window to enter value i...

Page 28: ...If the robot is in the press within this window the press well immediately stop Robot Program Program is used by the robot control to compare the current job running in the press with the current job...

Page 29: ...appear If the Shutheight is different from the current setpoint and Auto adjust is Enabled the Auto Adjust Confirmation message will appear on the HMI If is did not appear verify Auto Adjust is enable...

Page 30: ...b Setup From the main menu select the Active Overview From this screen the user can select to edit any of the four current job recipe sections Once changes are made they can be saved to the current jo...

Page 31: ...tion Intermittent In Position Touch the Input Button to select if the sensor is Normally Open or Normally Closed Touch the Output Button to select the necessary response from the press control Bypass...

Page 32: ...layed below in the ON OFF box Touch the Mode window to select the desired mode these are explained on page 7 Touch Angle On Off to enter values Touch Timer window to enter value if Timer Mode is selec...

Page 33: ...enter the speed reference Press yellow text area under Shut Height to enable a numeric keyboard to enter the Shut Height setpoint The current Shut Height is being displayed above the setpoint Press th...

Page 34: ...E stop If the robot is in the press within this window the press well immediately stop Robot Program Program is used by the robot control to compare the current job running in the press with the curr...

Page 35: ...reen and observe the current BRAKE STOP TIME and the current limit 2 Press the fault reset push button CHANNEL 1 2 3 4 HIGH CAPACITY ALARM This fault occurs when all of the following events occur The...

Page 36: ...or B A thirty second timer has be satisfied Clearing fault 1 Verify they Coolant Fault Input B I 6 0 2 Press the fault reset push button CLUTCH VALVE FAULTED This fault occurs when all of the followin...

Page 37: ...input B I 4 6 is ON or the Main Drive Running B I 0 8 is NOT ON A thirty second timer has been satisfied Clearing fault 1 Press the fault reset push button EMERGENCY STOP This fault occurs when all o...

Page 38: ...d the selector switch is set to test Clearing fault 1 Verify the switch position and the limit input 2 Press the fault reset push button LUBE SENSOR 1 7 warning only This fault occurs when all of the...

Page 39: ...1 Check that the Key Switch is in a definite position Off Inch Single or Auto 2 Verify that one of the inputs is being received OIL PUMP 1 CONTACTOR FAULT This fault occurs when all of the following...

Page 40: ...on bit from the resolver is not present The resolver angle is not between 0 30 or 320 359 Clearing fault 1 Place Key Switch into Inch mode and inch press to between 320 and 30 degrees 2 Press the faul...

Page 41: ...s occur The resolver module has determined there is a fault with the resolver or cabling Clearing fault 1 Press the fault reset push button 2 If fault persists check resolver cable connection and cycl...

Page 42: ...was satisfied Clearing fault 1 Verify Tank Lube Level add if needed 2 Verify Level switch input B I 6 3 3 Press the fault reset push button TONNAGE CHANNELS SCALE FACTOR EQUALS 0 This fault occurs wh...

Page 43: ...at no additional charge and returning Product to customer freight paid Repair parts and replacement Products shall be furnished on an exchange basis and shall be either new or reconditioned All repla...

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