Helm HELMPAK User Manual

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HelmPak Press Control

HELMPAK™

Press Control

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

Users Guide

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Page 1 HelmPak Press Control HELMPAK™ Press Control Helm Instrument Co. • 361 West Dussel Drive • Maumee, Ohio USA • 419-893-4356 Users Guide...
Page 2 HelmPak Press Control Users Guide...
Page 3: Table Of Contents
HelmPak Press Control SECTION 1: INTRODUCTION............................4 THE HELM-PAK SYSTEM..........................4 WARNINGS ..............................5 SECTION 2: WHAT IS CLUTCH / BRAKE SOFTWARE?....................6 POSITION MONITORING..........................6 PROGRAMMABLE LIMIT SWITCH AND DIE MONITORING BASICS............6 SECTION 3: BASIC OPERATION ............................ 12 MODE OF OPERATION ..........................
Page 4 HelmPak Press Control Users Guide...
Page 5: Introduction
At HELM, quality is inherent not only in the design of our products but in the attitudes of our employees as well. We’re working together to give you the best. After all, that’s what our business is all about - providing innovative instrumentation to help make your manufacturing processes more productive and your operations more efficient.
Page 6: Warnings
Do not remove modules under power. The module location in a specific rack is critical to proper operation of the Helm-Pak press control. If a module is replaced, ensure that the proper module is inserted into the proper slot in the rack. If it is not the ladder programming will not recognize the module and the Helm-Pak control will become unstable and unsafe to operate.
Page 7: What Is Clutch / Brake Software
SECTION 2: CLUTCH / BRAKE SOFTWARE The HelmPak Clutch/Brake Control System is a bundle of hardware, software, and engineering documents designed to control the clutch and/or brake mechanism on a mechanical stamping press that has a part-revolution friction clutch and/or brake. This system uses two processors for clutch/brake control.
Page 8 HelmPak Press Control PROGRAMMABLE LIMIT SWITCH OPERATION PLS software is a group of engineered press-control products for PLC processors. This software controls the operation-of: • Programmable Limit Switch (PLS) for crankshaft synchronization WHAT IS A PROGRAMMABLE LIMIT SWITCH? The Programmable Limit Switch is ladder logic for a PLC -based control system that times or sequences outputs according to precise and repeatable positions of a crankshaft.
Page 9 HelmPak Press Control APPLY DM SENSORS TO A STAMPING PROCESS IN A VARIETY OF WAYS. Typical PLS / DM / Load Monitoring Application RESOLVER LIGHT PART-EJECTION BUCKLE CURTAIN LIGHT DETECT LUBRICATOR STOCK END OF MATERIAL LIGHT MATERIAL PROGRESSION CURTAIN STRAIGHTNER...
Page 10 HelmPak Press Control Mode: Signal must be seen as follows, or function sets an output action: static continuously cyclic Thru a preset angular window once every cycle. Intermittent cyclic Thru a preset angular window after a preset number of press cycles...
Page 11 HelmPak Press Control In-position (POS) N.O. Use this mode to verify that the sensor signal remained ON within the entire window once each stroke. The signal must cycle OFF outside the window. Use it to detect if an ejector and other automation parts are retracted to home position.
Page 12 HelmPak Press Control OUTPUT RESPONSES FOR DIE MONITORING CHANNELS When the 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:...
Page 13: Basic Operation
HelmPak Press Control SECTION 3: BASIC OPERATING INSTRUCTIONS • Turn power on • Set CONTROL POWER to ON • Press CONTROL POWER RESET, to reset the safety relay • Start the Oil/Coolant pumps, button will turn green when all pumps running •...
Page 14: Mode Of Operation
The press will wait at top for an amount of time determined in the Job Recipe. SHUT DOWN SYSTEM To shut down the Helm-Pak: • Stop the press • Shut off Main Motor •...
Page 15: Screen Navigation
HelmPak Press Control SECTION 4: SCREEN NAVIGATION MAIN MENU The MAIN SCREEN provides a display of pertinent information about the current run, including the FAULT description when a machine stop occurs. If recipe is incorporated into your system, the current job number is displayed. If shutheight monitoring is installed, the current shutheight is displayed.
Page 16: Login
HelmPak Press Control Login Runtime Version – displays the current version of the HMI Application Login – will bring up a user/password message, which will allow for value entry. Logout – will log a user out and return the system to the “Default” user.
Page 17: Motor Control
HelmPak Press Control Motor Control This screen allows the user to Start and Stop the Filter Motor, as well as displaying the current status of the motor. Users Guide...
Page 18: Tonnage Main
HelmPak Press Control Tonnage Main The 4 channels of Tonnage are all displayed individually, along with corresponding trending displays, and the Total Tonnage. The Monitor Parts/Peak Push Button Determines the mode of the Tonnage Module Peak Mode – capacity alarms are active, trend alarms are inactive Monitor Mode –...
Page 19: Tonnage Alarms
HelmPak Press Control Tonnage Alarms High Capacity – displays the current High Capacity Alarm Setpoint. These values are set for each channel and are typically established as press capacity alarms. Each channel is typically set based on the formula: Press Capacity divided by number of strain gage channels.
Page 20: System Setup
HelmPak Press Control SECTION 5: System Setup On the main System Setup screen, the user has 5 entry options, 4 page buttons, and an exit to configuration screen button. The Exit to Configuration screen button exits out of the current running application, to the built in HMI interface.
Page 21: Tonnage Calibration
HelmPak Press Control Tonnage Calibrate This screen should only be accessed by Service Technicians when the press needs to be calibrated. The 4 channels of Tonnage are all displayed individually The Setup/Peak Push Button Determines the mode of the Tonnage Module...
Page 22: Shutheight Setup
HelmPak Press Control Shutheight Setup The Set Initial Config button is used to setup the shutheight module for the first time, or if the module has been replaced. The Set Zero button is used to clear the internal offset value of the shutheight resolver module, which should be done anytime the resolver needs to be recalibrated, for example if the coupling breaks and the slide or resolver shaft have been moved even slightly.
Page 23: Motor Setup
HelmPak Press Control Motor Setup The Setup Speed Enable/Disable is used to manually control the speed of the Main Motor, when enabled what ever percentage entered in the manual speed will be used as the speed reference. Manual Speed – displays the speed reference percentage used when speed setup is enabled.
Page 24: Robot Setup
HelmPak Press Control Robot Setup The Robot Interface Enable/Disable is used to Enable or Disable the Robot system operating with the press. If Disabled, the ok and enable signals will not be sent to the robot control, which cause the robots not to cycle if the press is stroked.
Page 25: Recipe Setup And Download
HelmPak Press Control SECTION 6: Recipe Setup and Download Touch the Select button for the job number to create, edit or download parameters to the PLC. Once recipe data is stored, enter this Recipe screen to select a job for downloading.
Page 26 HelmPak Press Control Enter or Change Recipe Die Monitoring Settings Press Blue Die Monitoring button at the bottom of the overview screen to jump to DM Recipe screen Touch the yellow field indicated by channel select, to enter the desired channel, or use the arrow keys Touch the Name Button select the desired name, these names need to be set in the HMI Application and downloaded to the HMI .
Page 27 HelmPak Press Control Enter or Change Recipe PLS Settings Press Blue PLS button at the bottom of the overview screen to jump to PLS Recipe screen Touch the fields indicated by CH1, CH2, etc. to select each PLS channel. Touch the Mode window to select the desired mode, these are explained on page 7.
Page 28 HelmPak Press Control Enter or Change Robot Recipe Settings Press Blue Robot button at the bottom of the overview screen to jump to Robot Recipe screen Robot Setup: Robot Cycle – The on and off angles represent the OK to enter press window Robot in press E-stop –...
Page 29 HelmPak Press Control Downloading Recipe Settings Press should be in safe position, and not operating, when a recipe is downloaded Press the Select button next to the Job that is to be loaded, the Job number will appear in the job selected box in the screen banner.
Page 30: Active Job Setup
HelmPak Press Control Active Job 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 job recipe by pressing the “Save to Recipe” button.
Page 31 HelmPak Press Control Change Active Die Monitoring Settings Press Die Monitoring button at the bottom of the Active Overview screen to jump to Active DM screen Touch the yellow field indicated by channel select, to enter the desired channel, or use the arrow keys.
Page 32 HelmPak Press Control Change Active PLS Settings Press PLS button at the bottom of the Active Overview screen to jump to Active PLS screen Touch the fields indicated by CH1, CH2, etc. to select each PLS channel, the current status of the output is displayed below in the ON/OFF box.
Page 33 HelmPak Press Control Change Active Job Settings Press JOB button at the bottom of the Active Overview screen to jump to Active Job screen Press yellow text area under Main Motor to enable a numeric keyboard to enter the speed reference.
Page 34 HelmPak Press Control Change Active Job Settings Press JOB button at the bottom of the Active Overview screen to jump to Active Job screen Yellow windows represent area values that can be changed. Green Text boxes display values that are currently being used in the PLC.
Page 35: Alarm Explanations
HelmPak Press Control Appendix A: Alarm Explanations BATCH COUNTER FULL This fault occurs when all of the following events occur: • The actual batch count is greater than the preset specified on the Counter Screen Clearing fault: 1. Press the fault reset push button; this will clear the actual count.
Page 36 HelmPak Press Control CHANNEL (1, 2, 3, 4) LOW TREND This fault occurs when all of the following events occur: • When the current peak load has met or become below the low tolerance percentage or tonnage setting from the sample tonnage.
Page 37 HelmPak Press Control COOLANT PUMP CONTACTOR FAULT This fault occurs when all of the following events occur: • The contactor output and aux contact input did not match Clearing fault: 1. Function check the contactor 2. Press the fault reset push button...
Page 38 HelmPak Press Control GREASE LOW LEVEL This fault occurs when all of the following events occur: • The low level input B I:6/4 is present • A three second timer was satisfied Clearing fault: 1. Verify the grease level, add if needed.
Page 39 HelmPak Press Control NO CLUTCH/BRAKE AIR PRESSURE This fault occurs when all of the following events occur: • The C/B Pressure switch input is not present for more than one second, I:0/4 Clearing fault: 1. Check air pressure 2. Press the fault reset push button...
Page 40 HelmPak Press Control OVERLOAD PRESSURE This fault occurs when all of the following events occur: • The input from the Oil Overload Pressure Switch is not present, Processor B I:6/1 • A three second timer has been satisfied Clearing fault: 1.
Page 41 HelmPak Press Control ROBOT FAILED TO CYCLE This fault occurs when all of the following events occur: • The press has completed a stroke in Continuous Mode • The robot has not cycled to initiate another stroke • The robot wait timer has been satisfied Clearing fault: 1.
Page 42 HelmPak Press Control SLIDE ADJUST IN ON POSITION This fault occurs when all of the following events occur: • The slide adjust key switch is in the on position Clearing fault: 1. Turn the slide adjust key switch OFF 2. Press the fault reset push button...
Page 43: Limited Warranty
This warranty shall extend for the one (1) year period from date of shipment from our factory or authorized dealer, provided that the product is returned, freight prepaid, to Helm within the one (1) year warranty period within specific written authorization to perform repairs. Helm’s obligations and the exclusive remedy of customer under this warranty are limited to repairing or replacing any defective Product at no additional charge and returning Product to customer freight paid.