CMF Power Select Installation And Operation Instructions Manual

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CUSTOM METAL FABRICATORS, INC.

Installation / Operation Instructions

Power Select

Ver. 3.0

(For serial # 80396 and above)

(PLC VERSION 4.87)

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Page 1 CUSTOM METAL FABRICATORS, INC. Installation / Operation Instructions Power Select Ver. 3.0 (For serial # 80396 and above) (PLC VERSION 4.87)
Page 2: Table Of Contents
Installation / Operation Instructions CMF Power Select Ver. 3.0 Table of Contents Chapter 1 Introduction ................. Chapter 2 Installation ................Chapter 3 Operation ................Chapter 4 Advanced HMI Operations ..........Chapter 5 Integration ................. Chapter 6 Maintenance ..............Chapter 7 Troubleshooting ..............
Page 3: Chapter 1 Introduction
From a controls standpoint, all of the CMF series distributors are identical. This allows for simple integration of multiple units at the same facility. The following sections describe how to install various configurations of the Power Select and how to operate and maintain the system.
Page 4: Chapter 2 Installation
CMF Power Select Ver. 3.0 Installation The CMF Power Select can be ordered as a complete unit factory installed on a new distributor, or by itself to be retrofit to an existing “TH” distributor installation in the field. Section 2.2 details a factory prepared unit. Section 2.3 details a field installation.
Page 5 CMF Power Select Ver. 3.0 TH Series Field Installation 2.3.1 Upon receipt of the Power Select, check for visible signs of damage that may have occurred during shipment. These include scratched paint, dented housing, oil leaking from the unit, etc.
Page 6 2.3.13 In order to make the adjustments needed for the system to function properly, it will be necessary to manually operate the unit. Manually moving (jogging) the Power Select is accomplished by starting the hydraulic pump and then pushing or pulling the red manual override disks located on the ends of the solenoid valves.
Page 7 Fig. 3: Proximity Sensors 2.3.16 Jog the Power Select (UP) until the lift cylinder is fully extended (up position), check the up proximity sensor as outlined above. REV 6.3...
Page 8: Chapter 3 Operation
Installation / Operation Instructions CMF Power Select Ver. 3.0 2.3.17 Jog the Power Select (ROTATING) until the inner spout is aligned with the number one outlet (dwg 503003-G). Jog the inner spout (DOWN) until the lift cylinder is fully retracted (down position). Ensure that the inner spout has engaged the locator ring and the outlet stub.
Page 9 There are also textboxes to display and input data. Just like a button, touch the textbox to edit the value. The “CMF” logo at the bottom of the screen with either take you to the “MENU” screen, or back to the “HOME” screen depending on what screen is currently displayed.
Page 10 Installation / Operation Instructions CMF Power Select Ver. 3.0 3.2.3 If the machine is booting up for the first time, or if any fault has occurred, the operator may see the “Machine Stop” alarm banner and a popup window with pertinent information about the fault.
Page 11 Installation / Operation Instructions CMF Power Select Ver. 3.0 Selecting an Outlet 3.3.1 To change the position of the spout, press the button on the “Home” screen that corresponds to the spout you want to move. 3.3.2 From the “Outlet Selection” screen (Fig. 6), choose the outlet number that the spout should move to and press the button for at least 1 second.
Page 12: Chapter 4 Advanced Hmi Operations
“MANAGER” in upper case, and then press the “Enter” button. Touch the “Password” textbox and type the word “CMF” in upper case. Touch the “padlock” icon to login and confirm that the “Current User” field has changed to “MANAGER”.
Page 13 Installation / Operation Instructions CMF Power Select Ver. 3.0 Fig. 8: Login Screen 4.1.2 After successfully logging in, a button will show up on the “Home” screen. Use it to enter the “Setup” screen. REV 6.3...
Page 14 Installation / Operation Instructions CMF Power Select Ver. 3.0 Teaching Outlets 4.2.1 In order for the PLC to direct the spout to the proper outlet, it is required to “teach” each position and store these set points into memory. 4.2.2 From within the “Setup” screen, touch the “Maintenance Mode” checkbox to disable the machine automation.
Page 15: Chapter 5 Integration
Installation / Operation Instructions CMF Power Select Ver. 3.0 Integration If required, the power select can be controlled by 3 party hardware. There are 4 options available for communicating with the on board PLC. 1. Modbus RTU (serial) 2. Modbus TCP/IP (Ethernet) 3.
Page 16 Installation / Operation Instructions CMF Power Select Ver. 3.0 Required Memory Objects Address Symbol Description Access Spout 1 outlet select. Set this MW to the corresponding %MW1 S1_OUTLET_SELECT READ/WRITE outlet position (101-130) to change the position of the spout. Fault code for diagnostics. Gets reset by the system...
Page 17 Type of input control. 0, 1, or 2 Gets set by sending “RESET” from respective device. Set to “3” %MW0 CONTROL_TYPE Manually for “Modbus / Other”. READ/WRITE (CMF / HMI = ”0”, Ethernet/IP = ”1”, Cam/Relay = ”2”, Modbus / Other = “3”). %MW5 NUM_INNERSPOUTS Total number of inner spouts. READ/WRITE Total number of outlets.
Page 18 Installation / Operation Instructions CMF Power Select Ver. 3.0 Ethernet 5.6.1 The default network parameters for the Ethernet connection are shown below. These parameters can be changed by connecting the PLC to a switch/hub and entering the IP address in a standard web browser such as Google Chrome or Mozilla Firefox.
Page 19 Installation / Operation Instructions CMF Power Select Ver. 3.0 Fig. 10: PLC network settings Note: Notice the parameters are separated by commas and NOT periods. The file will be ignored if periods are used. For the new settings to take effect, a power cycle of the PLC is required.
Page 20 “MANAGER” to the HMI. This process is described in section 4.1.1. After logging in, from the “Home” screen of the HMI, touch the CMF logo at the bottom of the screen to enter the “Menu” screen. Touch the “Network Settings” button. To modify the local network settings for the HMI, touch the “This HMI Network...
Page 21 The web interface will now be visible. Fig. 11: Web Control Panel 5.7.2 To commission the machine, touch the CMF logo at the bottom to view the menu. Login as “MANAGER” with a password of “CMF” and then press the “Setup”...
Page 22 Installation / Operation Instructions CMF Power Select Ver. 3.0 Modbus TCP/IP 5.8.1 The supported functions for this connection are the same as Modbus RTU. However, the communication cable is plugged into the green Ethernet port directly on the front of the PLC.
Page 23 “RESET” from respective device. Set to “3” Manually for CONTROL_TYPE “Modbus / Other”. GET/SET (CMF / HMI = ”0”, Ethernet/IP = ”1”, Cam/Relay = ”2”, Modbus / Other = “3”). Spout 1 outlet select. Set this to the corresponding outlet S1_OUTLET_SELECT GET/SET position (101-130) to change the position of the spout.
Page 24 Installation / Operation Instructions CMF Power Select Ver. 3.0 5.11 Ethernet/IP optional instance data Description Access Channel Symbol NUM_INNERSPOUTS Total number of inner spouts. NUM_OUTLETS Total number of outlets. Type of distributor. (Flat Back= ”1”, Full Round= ”2”, DISTRIBUTOR_TYPE Pendulum= ”3”, Head House= ”4”).
Page 25 5.12.1 In order for the machine to automate, there are a few parameters that need to be configured. If the Power Select was purchased with a distributor, this step would be done at the factory. These settings can be modified via Modbus or the built in web server.
Page 26 PLC, cam switch, relay block, or other equipment to convert it to a BCD format and send that signal back to the Power Select PLC. This option provides basic machine control; however, any advanced functions or commissioning will have to be done using the built in web interface or the HMI.
Page 27: Chapter 6 Maintenance
6.3.4 Remove any accumulation of dust or material from the inside bottom of the distributor housing. 6.3.5 Inspect all mounting bolts on Power Select for signs of loosening and tighten as required. 6.3.6 Check the level of hydraulic fluid in the reservoir.
Page 28: Chapter 7 Troubleshooting
Installation / Operation Instructions CMF Power Select Ver. 3.0 Troubleshooting In the event of an error, the operator will be notified via the “Alarm Banner” and/or the “Fault Code” popup on the HMI (Section 3.2.3). The text will give suggestions on how to correct the problem.
Page 29 502950-E • Damaged communication wiring • Damaged equipment Fig. 14: No communications In the case that none of the above suggestions has returned the system to normal operating conditions, it is recommended to contact CMF for further assistance. REV 6.3...
Page 30 Installation / Operation Instructions CMF Power Select Ver. 3.0 Fault Codes Code Description Possible Cause Possible Solution Normal operating condition When power is restored, Restart after power failure Loss of power press “RESET” Encoder is offline, loss of Inspect CAN bus wiring...
Page 31 Installation / Operation Instructions CMF Power Select Ver. 3.0 REV 6.3...
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Page 40 Installation / Operation Instructions CMF Power Select Ver. 3.0 Custom Metal Fabricators Inc. 3194 R Ave. Herington, KS 67449 Phone: 785-258-3744 Fax: 785-258-2584 Website: www.cmfmfg.com Email: sales@cmfmfg.com REV 6.3...