hmc2420 Press Control
hmc2420 Press Control
hmc2420 Press Control
Press Control
Helm Instrument Co. • 361 West Dussel Drive • Maumee, Ohio USA • 419-893-4356
HMC2420 PRESS CONTROL
SECTION 1 ................................................................................................ 2
INTRODUCTION ..................................................................................................................................................... 2
THE HMC2420 SYSTEM .......................................................................................................................................... 2
WARNINGS............................................................................................................................................................... 3
REPLACING MODULES ......................................................................................................................................... 4
FUSES ...................................................................................................................................................................... 4
SECTION 2 ................................................................................................ 5
WHAT IS CLUTCH / BRAKE SOFTWARE? ............................................................................................................ 5
SECTION 3 ................................................................................................ 6
QUICK START GUIDE ............................................................................................................................................ 6
SHUT DOWN SYSTEM ............................................................................................................................................ 6
SECTION 4 ................................................................................................ 7
START UP SCREENS ............................................................................................................................................... 7
SYSTEM OVERVIEW ............................................................................................................................................... 8
RESOLVER SETUP .................................................................................................................................................. 9
RESOLVER SETUP(CONTINUED) .......................................................................................................................10
RESOLVER SETUP(CONTINUED) ........................................................................................................................11
TOP STOP SETUP .................................................................................................................................................12
LIGHT CURATIN SETUP .......................................................................................................................................13
SYSTEM MENU .......................................................................................................................................................14
LUBE CONTROL ....................................................................................................................................................15
SYSTEM ALARMS ...................................................................................................................................................16
SECTION 5 .............................................................................................. 17
ACTIVE DIE MONITORING ..................................................................................................................................17
DIE MONITORING MODES ...................................................................................................................................18
DIE MONITORING SENSOR STATUS ...................................................................................................................19
ACTIVE PROGRAMMABLE LIMIT SWITCHES (PLS) ..........................................................................................20
RECIPE MENU .......................................................................................................................................................21
RECIPE DIE MONITORING ..................................................................................................................................22
RECIPE PROGRAMMABLE LIMIT SWITCHES (PLS) .........................................................................................23
HOW PLS AND DIE MONITORING OPERATE ............................................................................................. 23-28
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HMC2420 PRESS CONTROL
SECTION 1
INTRODUCTION
You have just purchased the most advanced press control system available. HELM
INSTRUMENT COMPANY, INC. manufactures a complete line of press control solutions
for use on metal stamping, forging, compaction and assembly presses.
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 process more productive and your operation more effective.
The main control enclosure contains MicroLogix processors, magnetics, relays, power
supply and fusing.
.
The Run Station T-Stand is supplied with operating push buttons, lamps and the
PanelView operator Interface, run/inch buttons, armed continuous, Top Stop, Cycle Stop
and E-Stop push buttons.
The dual MicroLogix rack configurations provide the redundant control of the clutch and
brake system. Both controllers monitor all clutch/brake I/O and exchange information
about machine status. They are linked by hardwired I/O so if one controller detects a
condition different from that detected by the other, the control logic is designed to declare
a fault and turn off all outputs to press valves. The other controller is designed to follow
suit.
Compliance:
The package uses two redundant MicroLogix 1500 processors with application software
for self testing and verification to meet the safety requirements of ANSI B11.1, OSHA
1910.217 and CAN/CSA Z142-M90 press safety regulations for mechanical stamping
presses.
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WARNINGS
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REPLACING MODULES
The module location in a system 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 position. If it is not the ladder
programming will not recognize the module and the Helm-Pak control will become unstable and unsafe to
operate.
FUSES
The fuse for the Helm-Pak System is located in the front of the enclosure on a terminal
strip in the center of the enclosure. Replacement is 5-amp Buss fuse.
SAFETY FIRST Check all light curtains, barriers, safety shields and
personnel safety devices to ensure that they are present and functioning
properly. If they are not, do not proceed with starting the press. Authorized
personnel should make any repairs that are required before starting the press.
TURNING
Always wearSYSTEM ONprotection when operating a stamping press.
eye and ear
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SECTION 2
INTRODUCING CLUTCH / BRAKE SOFTWARE
Clutch/Brake Modes:
The operator can select the mode of control system operation with the selector
switch located on a control panel.
Mode Operation
Inch Jog the press through successive parts of the cycle by pressing
and releasing the pair of INCH buttons. If INCH buttons are
held, the press will stop at the top of its stroke.
Single-stroke Run the press through one complete cycle by holding both RUN
buttons until completion of the down stroke.
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SECTION 3
Go to Main Menu
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SECTION 4
Startup Screen
Status
Screen help and information about Helm Instrument Company.
Control
No control
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System Overview
Status
Strokes Per Minute (SPM)
Angle
Date/Time
Active Job Number
Part and Batch Counters Setpoint and Actual displays
System OK/System Alarm Status
4 Channel Tonnage Display
Die Monitoring Status
Control
Touching either the Part or Batch Counter will display the Counter Screen
Touching the Header (System Overview) will display the Main Menu
Touching System OK/System Alarm will display the Active Alarms
Touching the tonnage area will display the tonnage main screen
Fault conditions are indicated on the screen on the System OK/System Alarm Button. Clear any faults by
pressing the FAULT RESET button on the operator station.
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Resolver Setup
Controls resolver
setup function
Status
Strokes Per Minute (SPM)
Date/Time
Displays Brake Fault Preset time
Displays Actual Brake Stopping time
Resolver Rotation Direction*
Control
Setup AMCI Resolver pushbutton – Displays Setup AMCI Verify Screen
Zero AMCI Resolver pushbutton – Displays Zero AMCI Verify Screen
Brake Fault Preset – Alarm value for Brake Stopping time
Die Monitoring Inch Bypass Off/On pushbutton – If selected to On, the Die Monitoring will be
bypassed in Inch mode
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Setup Verify
Status
Setup AMCI Resolver pushbutton – Used only when replacing AMCI module or changing the
resolver count direction. The initial setup is done at Helm Instrument Company before the
unit shipped.
Control
Setup AMCI Resolver pushbutton – Configures AMCI Resolver Module
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Zero Verify
Status
Strokes Per Minute (SPM)
Date/Time
Control
Zero AMCI Resolver pushbutton – Configures the AMCI Resolver to 180°
Resolver Rotation
Status
Setup AMCI Resolver pushbutton – Used only when replacing AMCI module or changing the
resolver count direction. The initial setup is done at Helm Instrument Company before the
unit shipped.
Control
Resolver rotation – To reverse the resolver rotation select the FWD/REV pushbutton
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Sets up calculated
Top Stop Angle on
Initial startup.
Status
90° Brake Test – Indicates if 90° brake test is enabled.
Calculated Top Stop Angle – Displays Calculated Top Stop Angle.
PLC Scan Time – Displays PLC scan time in milliseconds.
Control
+/- Degree(s) – Adjust Top Stop Angle +/- 10°.
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Status
Die Monitoring Inch Bypass – Bypasses the die monitoring alarms while in inch mode.
Upstroke muting – Bypasses the light curtains from 181°-359° in single stroke mode. When
selected the light curtain auto reset is turned on.
Light Curtain Auto reset – Automatically reset the light curtain fault when the light curtain
beam has been broken.
Minimum light curtain distance – The calculated distance for the light curtains to be mounted
from the bed of the press by OSHA standards.
Control
Upstroke muting – Bypasses the light curtains from 181°-359° in single stroke mode. When
selected the light curtain auto reset is turned on.
Light Curtain Auto reset – Automatically reset the light curtain fault when the light curtain
beam has been broken.
Status
Counter on/off selector – Indicates if the counter function is on or off.
Actual – Displays actual part count.
Control
Setpoint – The press will top stop when the actual equals the setpoint.
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System Menu
Status
Strokes Per Minute (SPM)
Angle
Date/Time
Control
Selection of what screen to display
o Main Screen
o System Setup
o Lube Control
o Active Control
o Recipe Control
o Tonnage
o Top Stop Adjust
o DM Sensor Status
o Help Screen
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Lube Control
Status
Press Cycles Actual – Displays actual press cycles.
Control
Mode – Off, Pushbutton, cyclic, or timer mode can be used to control the lube output.
Timer on time/off time – Enter on and off times to control the lube output when timer mode is
selected.
Setpoint – Enter setpoint for number of press cycles to control the lube output.
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System Alarms
Status
System alarms – Displays active alarms and trigger month, date, and time
When an alarms occurs the fault reset light on the enclosure will light red.
Control
View History alarms
Status
History alarms – Displays history alarms and trigger month, date, and time
Control
Scroll up or down the history alarms
Clear all history alarms
Return to active alarms
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SECTION 5
Active Die Monitoring
Status
Indicates current selected channel
Displays current channel Name, Mode, Input, and Output
Displays current channel On Angle, Off Angle, and Intermittent Cycles Setpoints
Control
Mode pushbutton – Selects operating mode for channel (Bypass, Static, Cyclic, In-Position)
Input pushbutton – Selects whether the input wired is normally open or normally closed
Output pushbutton – Selects what action will take place if the channel faults (Top Stop,
Emergency Stop, Warning)
Cyclic Mode - Use this mode to verify that a pulse from the sensor (OFF-ON-OFF) occurred within
the window once each stroke. For example, use it to detect that a part moved past a monitor.
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In-Position Mode - 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.
For These Input is NOT ALLOWED Which Results in a
Transition Expected When the Sensor Signal: Fault signal Sent
Diagram Transitions After:
Sensor turns ON 1. turns OFF before window sensor turns OFF
before, goes OFF
and OFF after window
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Status
Displays current channel On Angle, Off Angle values (indicates angles at which the sensor
actually turns on and off, used to setup sensor)
Displays current channel setpoint for the on/off angles.
Displays Sensor Status On/Off
Control
Selection of DM Channel 1-6
Status
Displays Active Job#
System OK/System Alarm Status
Active Job Number
Strokes Per Minute (SPM)
Angle
Control
Save Active settings to Recipe
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Status
Indicates current selected channel
Displays current channel Mode
Displays current channel On Angle, Off Angle, Intermittent Cycles, and Timer Setpoints
Control
Mode pushbutton – Selects operating mode for channel (Bypassed, Timer, Angle)
On Angle Setpoint – Degree angle the PLS output turns On
Off Angle Setpoint – Degree angle the PLS output turns Off
Intermittent Cycles Setpoint – Number of rotations before the On and Off angle setpoints are
looked at
Save Changes pushbutton – Saves the screen changes to the active registers
Display Active Die Monitoring screen pushbutton
Return pushbutton – Displays Active Die Monitoring/PLS Menu
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Status
Current Recipe Job
System OK/System Alarm Status
Recipe Job Number
Strokes Per Minute (SPM)
Angle
Control
Recipe Job Setpoint – Enter Recipe number (1-100)
Display Recipe Die Monitoring screen pushbutton
Display Recipe PLS screen pushbutton
Load to PLC pushbutton – Loads current Recipe selected to the PLC
Return pushbutton – Displays System Overview screen
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Status
Indicates current selected channel
Displays Recipe channel Name, Mode, Input, and Output
Displays Recipe channel On Angle, Off Angle, and Intermittent Cycles Setpoints
Control
Name pushbutton – Selects a pre-programmed name for the channel
Mode pushbutton – Selects operating mode for channel (Bypass, Static, Cyclic, In-Position)
Input pushbutton – Selects whether the input wired is normally open or normally closed
Output pushbutton – Selects what action will take place if the channel faults (Top Stop,
Emergency Stop, Warning)
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Status
Indicates current selected channel
Displays Recipe channel Mode
Displays Recipe channel On Angle, Off Angle, Intermittent Cycles, and Timer Setpoints
Control
Mode pushbutton – Selects operating mode for channel (Bypassed, Timer, Angle)
On Angle Setpoint – Degree angle the PLS output turns On
Off Angle Setpoint – Degree angle the PLS output turns Off
Intermittent Cycles Setpoint – Number of rotations before the On and Off angle setpoints are
looked at
Save Changes pushbutton – Saves the screen changes to the current Recipe
Display Recipe Die Monitoring screen pushbutton
Return pushbutton – Displays Recipe Die Monitoring/PLS Menu
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0°
Near Top Zone
Angular preset to
turn output ON
270° 90°
Up Stroke Zone Down Stroke Zone
Angular or Time
preset to
turn output OFF 180°
Bottom
Then, you can program your application-specific output response, such as using the PLS output bit as a
trigger to:
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DESCRIPTION OF MODES
The purpose of DM channels is to verify that predictable conditions in your press
operation take place. When the software detects a fault condition, it sets a
selected output response. You select the type of mode for each channel from the
following:
Bypassed
Static
Cyclic
In Position
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Use the following table to help you select the types of channel modes
required for your application.
Window Input signals for Cyclic (CYC) and In-position (POS) modes are
synchronized with the rotation of the crankshaft, and must be detected within a
zone of crankshaft rotation. We call this zone a window. For example, a part-
detect signal could be expected within a window of 80-110º to indicate that a part
was inside a die before it was hit by a stroke.
When the software detects input signals that are different from those described
here, the software generates a fault signal. We graphically define these (window)
inputs as follows:
Cyclic (CYC) N.O. Use this mode to verify that a pulse from the sensor (OFF-
ON-OFF) occurred within the window once each stroke. For example, use it to
detect that a part moved past a monitor.
For These Input is NOT ALLOWED Which Results in a
Transition Diagram Expected Transitions When Sensor: Fault Signal Sent After:
Sensor turns ON then OFF 1. stays ON beyond window window goes OFF
within window
Cyclic (CYC) N.C. Use this mode to verify that a pulse from the sensor (ON-
OFF-ON) occurred within the window once each stroke. For example, use it to
detect that a part moved past a monitor.
For These Input is NOT ALLOWED Which Results in a
Transition Diagram Expected Transitions When Sensor: Fault Signal Sent After:
Sensor turns OFF then ON 1. stays OFF beyond window window goes OFF
within window
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.
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In-Position (POS) N.C. Use this mode to verify that the sensor signal
remained OFF within the entire window once each stroke. The signal must cycle
ON outside the window. Use it to detect if an ejector and other automation parts
are retracted to home position.
For These Input is NOT ALLOWED Which Results in a
Transition Diagram Expected Transitions When the Sensor Signal: Fault signal Sent After:
Sensor turns OFF before, 1. turns ON before window goes ON sensor turns ON
and ON after window
Static Mode (STC) Use this mode to detect that an event occurred
independent of the press stroke. When a static-mode input turns Off, the
programmed output is turned On. For example, use it to detect end of stock.
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LIGHT
CURTAIN BUCKLE PART-EJECTION
DETECT LUBRICATOR LIGHT
STOCK
MATERIAL END OF LIGHT
MATERIAL PROGRESSION CURTAIN
STRAIGHTNER
PART SHORT PARTS
BLOW OFF FEED BIN
ELECTRONIC
FEED
SLC PROCESSOR
FOR EXAMPLE:
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LIMITED WARRANTY
Helm Instrument Co., Inc. (“HELM”) hereby warrants that the instruments and sensors (collectively the
“Product”) manufactured by it and sold to customer, are free from defects in material and/or workmanship
under normal use subject to the following conditions. This warranty shall not apply to any Product which
has been subjected to improper installation, misuse, negligence, accident, alteration, where service has
been performed by other than an authorized Helm serviceman, or where the serial number has been
defaced or altered. 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. Repair parts and
replacement Products shall be furnished on an exchange basis and shall be either new or reconditioned.
All replaced parts and Products shall become the property of Helm.
Should you have any questions concerning this Warranty, you may contact Helm by writing or calling:
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HELM Instrument Co., Inc. 361 W. Dussel Drive Maumee, OH 43537 U.S.A. (419) 893-4356