Wrap Control Panel. Installation Guide and User Manual - Version 1.0. Sales: icscarwashsystems.

Transcription

1 Wrap Control Panel Installation Guide and User Manual - Version 1.0 Corporate Office: Jacobsburg Jacobsburg Road, Road, Wind Wind Gap, Gap, PA PA Production Production Facility: Facility: Fox Fox Hill Hill Road, Road, Easton, Easton, PA PA Sales: sales@icscarwashsystems.com icscarwashsystems.com

2 Mounting the Wrap Control Panel IMPORTANT: Fork Extensions are highly recommended. 1. Locate an area on the wall in your equipment room. 2. Hang the Wrap Control Panel on the wall according to Figure 1. Figure 1. Wrap Control Panel Dimensions This document is intended to provide instructions to properly use the Wrap Control HMI. The Wrap Control Panel must be installed exactly as described in this manual to ensure its reliability and proper operation. Information in this manual is subject to change without notice. The example companies, organizations, products, domain names, addresses logos, people, places and events depicted herein are fictitious. No association with any real company, organization, product, domain name, address, logo, person, place or event is intended or should be inferred unless otherwise noted. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Innovative Control Systems, Inc. Innovative Control Systems and its product trademarks in this manual are trademarks of Innovative Control Systems, Inc. All other marks are property of their respective owners Innovative Control Systems, Inc. All rights reserved. 2

3 3. Power the Wrap Control Panel according to Figure 2. VFD Cabinet in Equipment Room Hydraulic Motor* D.S. Wrap Motor* Encoder ACCUWRAP CONDUIT and POWER DETAIL THIS DRAWING IS ONLY INTENDED TO SHOW THE CONDUITS NECESSARY, AS A MINIMUM, TO COMPLETE THE INSTALLATION OF THE ICS EQUIPMENT PURCHASED. ALL PERMANENT SITE WIRING CONNECTIONS MUST BE PERFORMED BY A LICENSED ELECTRICIAN THAT MUST COMPLY WITH ALL LOCAL AND NATIONAL CODES. THIS DRAWING IS NOT TO SCALE. P.S. Wrap Motor* Encoder ADDITIONAL CONDUITS MUST BE INSTALLED FOR OTHER EQUIPMENT SUCH AS LIGHTS, MENU SIGNS, CAMERAS, INTERCOMS, AND ALL OTHER NON-ICS EQUIPMENT. WIRING, OTHER THAN THE WIRING SHOWN FOR ICS EQUIPMENT, MAY NOT BE RUN IN THE CONDUITS INSTALLED FOR ICS EQUIPMENT. DEVIATIONS FROM ICS SPECIFICATIONS MAY RESULT IN THE VOIDING OF ANY AND ALL WARRANTIES OF ICS EQUIPMENT. LOW VOLTAGE CONDUIT HIGH VOLTAGE POWER CONDUIT Single Wrap Control Panel Scan Arch Ultrasonics X 4 D.S. Wrap* 120 V AC 20 Amp Breaker Inclinometer Home Sensor Tunnel Master wbc Good Car Conveyor Motor Pulses Gate Signal Wheel Treadle P.S. Wrap* 120 VAC MAIN SERVICE ELECTRICAL PANEL NOTE: * If site has dual Accuwraps, then double each piece of equipment. Inclinometer Home Sensor Figure 2. Power and Conduit Detail for the Accuwrap 3

4 Accuwrap User Manual List of Terms: Cam Inclinometer Lenze Drive Multi-state Indicator HMI PLC Momentary Push The rotary part on the stepper motor shaft that will position the wrap arm at the proper distance from the car. A device that is used to measure the angle of the wraps in both the x and y axis. An inverter that is used to move the stepper motor to actuate the cam into the correct position. A visual display function give the state of a setting, parameter, or indicator. In a lot of cases, it will let the user know if a device is on or off. Human Machine Interface Programmable Logic Controller A momentary push button is only engaged while its being depressed as opposed to a typical on/off switch. Ex. Ex. Usually fault or off Usually good or on Light Blue display color: represents the driver s side wrap. Purple display color: represents the passenger s side wrap. Main Screen Figure 3. Main Screen On the Accuwrap Control Panel HMI, the Main Screen is present a majority of the time. It is one of two screens that can be accessed without a password. The Main Screen is intended to give a quick, visual status of the system in real time. 4

5 The following table describes the Main Screen: SCANARCH SCANNING CONVEYOR RUNNING SCANARCH TCARS PER HOUR PULSE COUNT LEFT WRAP WRAPS ACTIVE RIGHT WRAP - WRAPS ACTIVE TUNNEL SETTINGS OUT-IN (Light Blue) DS TARGET IN-OUT (Purple) PS TARGET VALID CAR COUNT PASSWORD LEFT WRAP ON REAR This is a multi-state indicator that indicates if there is a car at the scan arch. Green means a car is present. Red means there is no car present. If the car is under the minimum length and the Gate photo-eye is blocked, the multi-state indicator will display that the system is in a scanning mode. Green means scanning is on. Red means that scanning is off. This is a multi-state indicator that will tell the user if the system is receiving the pulses that indicate that the conveyor is running. Conveyor running is a multi-state indicator that will be green when the PLC is receiving pulses and red when it is not. This is a multi-state indicator that will tell the user if the car has engaged the wheel treadle. It will only turn on if the wheel treadle is engaged while the conveyor is running and the Gate is blocked as well. Green indicates all of these conditions are met. Red indicates that this state is not met. This is a numerical display that represents the number of cars going through the tunnel in an hour. This value will only be displayed when the conveyor is running. It is calculated using the current conveyor speed and the last known full car length (car length + space between cars). Used to display the consistency of conveyor pulses. It is a numeric display that will count individual conveyor pulses from Indicates when the wrap is spinning on the left front\side of the car. It is a multi-state indicator that will display green when active and red when not active. Indicates when the wrap is spinning on the right front\side of the car. It is a multi-state indicator that will display green when active and red when not active. This button will take the user to the Tunnel Settings Screen which displays parameters for the system that do not require the user to enter a password. This is a series of (3) multi-state indicators. The first and third multi-state indicators will inform the user if the inclinometer angle for the driver side wrap is out of range in the positive or negative ranges. Green indicates that it is in range and red indicates that it is out of range. The second multi-state indicator is the state of the cam positioning. Green indicates that the cam is at the correct location while red indicates that it is not. This is a numeric display that will indicate to the user the target position for the driver s side cam. DS POS IN. This is the actual position of the driver s side cam. This is a series of (3) multi-state indicators. The first and third multi-state indicators will inform the user if the inclinometer angle for the passenger side wrap is out of range in the negative or positive ranges. Green indicates that it is in range and red indicates that it is out of range. The second multi-state indicator is the state of the cam positioning. Green indicates that the cam is at the correct location while red indicates that it is not. This is a numeric display that will indicate to the user the target position for the passenger s side cam. This is a counter for the number of cars inducted into the wrap system. The counter will be reset at the start of the day or upon recycling power. This is a concealed numeric display. When the ICS logo is touched on the screen, a keypad will pop up. The user must enter in the correct password to gain access to the higher function screens of the wrap positioning program. When the password is correctly entered, the System Setup Screen Navigation screen appears.. Indicates when the wrap is spinning on the left rear of the car. It is a multi-state indicator that illuminates green when active and illuminates red when not active. 5

6 Tunnel Settings Screen Figure 4. Tunnel Settings Screen The following table describes the Tunnel Settings Screen: SCANARCH SCANARCH SCANNING MAX CAR LENGTH INCHES MIN CAR LENGTH INCHES INCHES PER MIN CONVEYOR SIGNAL DEBOUNCE SECONDS TYP CAR LENGTH INCHES This is a multi-state indicator that indicates if there is a car at the scan arch. Green means a car is present. Red means there is no car present. This is a multi-state indicator that will tell the user if the car has engaged the wheel treadle. It will only turn on if the wheel treadle is engaged while the conveyor is running and the Gate is blocked as well. Green indicates all of these conditions are met. Red indicates that this state is not met. If the car is under the minimum length and the Gate photo-eye is blocked, the multi-state indicator will display that the system is in a scanning mode. Green means scanning is on. Red means that scanning is off. This is a numeric data display where the user can enter in the maximum car length in inches. The system will calculate the length of the car using the number of pulses from the conveyor movement while the Gate PE is blocked. It then compares this value to the maximum car length to determine if there is a valid car present. This value is used in calculating cars per hour. This is a numeric data display where the user can enter in the minimum car length. The system will calculate the length of the car using the number of pulses from the conveyor movement while the Gate PE is blocked. It then compares this value to the minimum car length to determine if there is a valid car present. This is the speed of the conveyor in inches per minute. It is a calculated value based up the inches per pulse cycle and the number of pulses from the conveyor movement. This is a numeric data display where the user can enter in the amount of time that the pulse from the conveyor movement needs to be either high or low to be considered a valid pulse. This is a numeric data display where the user can enter in the typical car length. This value added to the space between cars will yield the car full length value used in calculating the number of cars per hour. 6

7 SPACE BETWEEN CARS INCH E-STOP INCHES PER PULSE CYCLE This is a numeric data display where the user can enter in the space between cars. It is entered in inches and is used with the typical car length in inches to yield the car full length value used in calculating the number of cars per hour. This is a two position toggle switch with an indicator. When the button is green, the system is not in E-STOP. When the user taps the button, it will turn red and put the wrap positioning system into an E-STOP condition. When the E-STOP is engaged, the wrap cams will stop at the current position. As long as the E-STOP is active, the cams can not be moved manually or automatically. Pressing this button allows the operator to enter the number of inches between the pulses from the conveyor pulse generator as defined by the conveyor manufacturer. (SEE THE CONVEYOR DATA SHEET FOR THIS VALUE.) This value is used in conjunction with the Distance to scan arch values to trigger the wraps as well as providing the conveyor speed in feet per minute. When the user taps this button, the screen will return to the Main Screen. 7

8 Scan Arch Sensor Setup Screen Figure 5. Scan Arch Sensor Setup Screen The following table describes the Scan Arch Sensor Setup Screen: ULTRASONIC TEST DS BOT OUTPUT MINIMUM DS BOT OUTPUT MAXIMUM INCHES This is a user enabled switch. It is green when enable (on) and blue when disabled (off). When enabled, it will actively take the analog input from the ultrasonic sensors and convert them to a measurement. This allows the installer to check the values being produced by the ultrasonic sensors without having to have a car in the scan arch. Normally this button is DISABLED. This is a numeric data display where the user can enter in the minimum distance from the driver side bottom ultrasonic to the driver side of the vehicle and have it considered a valid distance. This is a numeric data display where the user can enter in the maximum distance from the driver side bottom ultrasonic to the driver side of the vehicle and have it considered a valid distance. In each occurrence of this numeric data display, the measurement from the ultrasonic sensor to the side of the car is displayed. This calculated distance is in relation to the inside rail of the conveyor guide. Warning: The following settings correspond to the Ultrasonic Sensor settings loaded by ICS and should not be changed! DS TOP OUTPUT MINIMUM DS TOP OUTPUT MAXIMUM PS BOT OUTPUT MINIMUM PS BOT OUTPUT MAXIMUM PS TOP OUTPUT MINIMUM PS TOP OUTPUT MAXIMUM This is a numeric data display where the user can enter in the minimum distance from the driver side top ultrasonic to the driver side of the vehicle and have it considered a valid distance. This is a numeric data display where the user can enter in the maximum distance from the driver side top ultrasonic to the driver side of the vehicle and have it considered a valid distance. This is a numeric data display where the user can enter in the minimum distance from the passenger side bottom ultrasonic to the passenger side of the vehicle and have it considered a valid distance. This is a numeric data display where the user can enter in the maximum distance from the passenger side bottom ultrasonic to the passenger side of the vehicle and have it considered a valid distance. This is a numeric data display where the user can enter in the minimum distance from the passenger side top ultrasonic to the passenger side of the vehicle and have it considered a valid distance. This is a numeric data display where the user can enter in the maximum distance from the passenger side top ultrasonic to the passenger side of the vehicle and have it considered a valid distance. 8

9 PHOTO EYE ANTIBNCE 10=1 SEC DS SCAN ARCH TO WRAPS INCHES PS SCAN ARCH TO WRAPS INCHES DRIVER SIDE PASSENGER SIDE This is a numeric data display where the user can enter in the time in seconds that the photo eye needs to be blocked or cleared for to be considered a valid state. When the user taps this button, the Main Screen appears. This is a numeric data display where the user will need to enter in the distance from the scan arch to the DS Wraps. This is a numeric data display where the user will need to enter in the distance from the scan arch to the PS Wraps. This is a numeric data display where the user will need to enter in the distance from the scan arch on the driver side to the inner rail of the conveyor guide. This is a numeric data display where the user will need to enter in the distance from the scan arch on the passenger side to the inner rail of the conveyor guide. 9

10 DS Wrap Angle Window Settings Figure 6. DS Wrap Angle Window Settings Screen The following table describes the DS Wrap Angle Window Settings Screen: ADJUST FREQUENCY 0-10 ANG OUT DS X NEG ANGLE DS WRAP ANGLE WINDOW SETTINGS INDICATOR DS Y NEG ANGLE WRAPS ACTIVE ANG IN (Y AXIS ONLY) DS INCLINE ADJ. ENAB. This is a numeric data display where the user can enter in the frequency that the cam will attempt to adjust the wrap arm. By adjusting the wrap arm, the wrap material will move to the proper angle for the proper penetration on the vehicle. This is a momentary push button. When pressed, it illuminates green, when not pressed, it remains gray. Pressing this button will adjust the DS Y Wrap Angle Window by positive 1 on both the minimum and maximum values. Pressing this button decreases the desired angle. This is a numeric data display where the user can enter in the lower value of the DS Wrap Angle Window on the x axis. This value is used strictly for providing the user with a quick, visual diagnostic of the wrap angle. This is a multi-state indicator that will provide the user with a visual diagnostic of whether or not the angle being reported by the inclinometer for the wrap is in the DS Wrap Angle Window. When the wrap angle is in the window, the indicator will be green and when it is out of the window, the indcator will be red. This is a numeric data display where the user can enter in the lower value of the DS Wrap Angle Window on the y axis. If the value from the inclinometer is less than this value, the wrap angle will move more positive.. This is a multi-state indicator the will provide the user with a visual diagnostic of whether or not the driver side wrap is currently active. Active is defined as the wrap arm is not in the home position and the system is actively adjusting the cam based on position table and inclinometer measurements. This is a momentary push button. When pressed, it illuminates green, when not pressed, it remains gray. Pressing this button will adjust the DS Wrap Y Angle window by negative 1 on both the minimum and maximum values. Pressing this button increases the desired wrap angle using the inclinometers. This button is setup as a two position switch. When it is on, the button will light up green. When it is off, the button will light up blue. This button functions to turn on or turn off the system s ability to adjust the driver s side wrap angle. 10

11 WRAP TARGET ANGLE DS X POS ANGLE DS E-STOP NEG ANGLE DS Y POS ANGLE DS Y ADJUST VAL GOTO PS CURRENT ACTUAL X DEG This is a numeric data display where the user can view the desired angle of the wrap. This angle plays an important role in determining how much physical penetration the wrap material has on the vehicle. This is a numeric data display where the user can enter in the higher value of the DS Wrap Angle Window on the x axis. This value is used strictly for providing the user with a quick, visual diagnostic of the wrap angle. This is a numeric data display where the user can enter in the maximum angle as reported by the inclinometer before the system will send out a panic stop. This is used as a protection feature to stop the system if the wrap begins riding up the hood of a vehicle. This is a numeric data display where the user can enter in the higher value of the DS Wrap Angle Window on the y axis. If the value from the inclinometer is greater than this value, the wrap angle will move more negative.. This is a numeric data display where the user can enter in the incremental value to adjust the cam to fine tune the angle of the wraps for penetration on the Driver Side of the vehicle. When the user taps this button, the screen will return to the Main Screen. When the user taps this button, the screen will go to the PS Wrap Angle Window Settings. This is the setup screen for the passenger side wrap. This is a numeric data display that will display the current angle of the wrap in the x axis as reported by the inclinometer for the driver side wrap. CURRENT ACTUAL Y DEG This is a numeric data display that will display the current angle of the wrap in the y axis as reported by the inclinometer for the driver side wrap. 11

12 System Setup Navigation Screen Figure 7. System Setup Navigation Screen The following table describes the System Setup Navigation Screen: SCAN ARCH SENSORS WRAP TABLES REAR CONTROLS VISUAL DIAGNOSTIC SCREEN DS INCLINE SENSOR SETUP PS INCLINE SENSOR SETUP INCLINOMETER VALUE SCREEN OVER ANGLE DELAY 10=1S OVER ANGLE STOP DISABLE DS VFD MANUAL AND SETUP PS VFD MANUAL AND SETUP VFD STATUS DATA MANUAL HOME RST SEQUENCE When the user taps this button, the screen will go to the Scan Arch Sensor Setup Screen. When the user taps this button, the screen will go to Driver Side Wrap Configuration Table Values Screen. When the user taps this button, the screen will go to Rear of Car Speeds and Start Values. When the user taps this button, the screen will go to the a screen that allows the technician to view all 10 queues and the status of the car in each queue in sequence.. When the user taps this button, the screen will return to the Main Screen. When the user taps this button, the screen will go to DS Wrap Angle Window Settings Screen. When the user taps this button, the screen will go to PS Wrap Angle Window Settings Screen. When the user taps this button, the screen will go to the Inclinometer Actual Values Screen. This is a numeric data display where the user can enter in the amount of time the wrap needs to exceed the E-Stop angle before the system will send out a panic stop. 10 = 1 second. This is a multi-state indicator that will toggle the system s ability to send out a panic stop in the event that the time set for the over angle is exceeded. When the Over Angle Stop Disable is enabled, the button will be illuminated green, when it is in a disable status, it will be illuminated red. When the user taps this button, the screen will go to Driver Side Wrap Manual Control.. When the user taps this button, the screen will go to Passenger Side Wrap Manual Control. When the user taps this button, the screen will go to the VFD Status Screen. When the user taps this button, the system will conduct a reset of the home position on the Lenze Inverter by moving the cam out to a predetermined position and then returning it to the home position. This is used in the event that a recoverable fault has occurred in the Lenze Inverter. 12

13 PS Wrap Angle Window Settings Screen Figure 8. PS Wrap Angle Window Settings Screen The following table describes the PS Wrap Angle Window Settings Screen ADJUST FREQUENCY 0-10 ANG OUT (Y AXIS ONLY) PS X NEG ANGLE PS WRAP ANGLE WINDOW SETTINGS INDICATOR PS Y NEG ANGLE WRAPS ACTIVE ANG IN This is a numeric data display where the user can enter in the frequency that the cam attempts to adjust the wrap arm. By adjusting the wrap arm, the wrap material moves to the proper angle for the proper penetration on the vehicle. This is a momentary push button. When pressed, it illuminates green, when not pressed, it remains gray. Pressing this button adjusts the PS Y Wrap Angle Window by positive 1 on both the minimum and maximum values. This button decreases the desired angle. This is a numeric data display where the user can enter in the lower value of the PS Wrap Angle Window on the x axis. This value is used strictly for providing the user with a quick, visual diagnostic of the wrap angle. This is a multi-state indicator that provides the user with a visual diagnostic of whether or not the angle being reported by the inclinometer for the wrap is in the PS Wrap Angle Window. When the wrap angle is in the window, the indicator illuminates green and when it is out of the window, the indicator illuminates red. This is a numeric data display where the user can enter in the lower value of the PS Wrap Angle Window on the Y axis. If the value from the inclinometer is less than this value, the wrap angle moves more positive. This is a multi-state indicator the provides the user with a visual diagnostic of whether or not the driver side wrap is currently active. Active is defined as the wrap arm is not in the home position and the system is actively adjusting the cam based on position table and inclinometer measurements. This is a momentary push button. When pressed, it illuminates green, when not pressed, it remains gray. Pressing this button adjusts the PS Wrap Angle Window by negative 1 on both the minimum and maximum values using the inclinometers. Pressing this button increases the desired wrap angle. 13

14 PS INCLINE ADJ. ENAB. WRAP TARGET ANGLE PS X POS ANGLE PS E-STOP POS ANGLE WRAP ANGLE ADJUST PS Y POS ANGLE PS Y ADJUST VAL GOTO DS CURRENT ACTUAL X DEG CURRENT ACTUAL Y DEG This button is setup as a two position switch. When it is on, the button illuminates green. When it is off, the button illuminates blue. This button functions to turn on or turn off the system s ability to adjust the Passenger Side wrap angle using the inclinometers. This is a numeric data display where the user can view the desired center angle of the wrap within the window setup by the POS and NEG Y values. This angle plays an important role in determining how much physical penetration the wrap material has on the vehicle. This is a numeric data display where the user can enter in the higher value of the PS Wrap Angle Window on the x axis. This value is used strictly for providing the user with a quick, visual diagnostic of the wrap angle. This is a numeric data display where the user can enter in the maximum angle as reported by the inclinometer before the system sends out a panic stop. This is used as a protection feature to stop the system if the wrap begins riding up the hood of a vehicle. This is a multi-state indicator that enables the system s ability to adjust the position of the cam based upon the angle being reported by the inclinometer. This is a numeric data display where the user can enter in the higher value of the PS Wrap Angle Window on the y axis. If the value from the inclinometer is greater than this value, the wrap angle moves more negative. This is a numeric data display where the user can enter in the incremental value to adjust the cam to fine tune the angle of the wraps for penetration on the side of the vehicle. When the user taps this button, the Main Screen appears. When the user taps this button, the DS Wrap Angle Window Settings screen appears. This is the setup screen for the Driver Side Wrap. This is a numeric data display that shows the current angle of the wrap in the x axis as reported by the inclinometer for the passenger side wrap. This is a numeric data display that shows the current angle of the wrap in the y axis as reported by the inclinometer for the passenger side wrap. 14

15 Rear of Car Speeds and Start Values Screen Figure 9. Rear of Car Speeds and Start Values Screen The following table describes the Rear of Car Speeds and Start Values Screen DRIVER SIDE CAM SPEED TO HOME: CAR HOME SPEED CAR END ADJUST DS & PS PASS. SIDE CAM SPEED TO HOME: CAR HOME SPEED This is a numeric data display where the user can enter in the speed of the driver s side stepper motor for returning the cam to the home position. This is a numeric data display where the user can enter in the distance in inches from the car end value before the cam starts its movement back to the home position. When the user taps this button, the user returns to the Main Screen. This is a numeric data display where the user can enter in the speed of the passenger s side stepper motor for returning the cam to the home position. 15

16 Driver Side Wrap Manual Control Screen Figure 10. Driver Side Wrap Manual Control Screen The following table describes the Driver Side Wrap Manual Control Screen DS MOVE DS WRAP POSITION 1 TO 290 ACTUAL DS CAM POSITION DS JOG FWD DS JOG REV DS WRAP SPEED 1 TO 1000 PS MANUAL VFD READY DS VFD RST HOME POSITION OK This is a momentary push button. When depressed, the button illuminates green and the cam moves to the DS Wrap Position as entered in the data display below. When not depressed, the button remains blue. This is a numeric data display that allows the user to enter a position value to move the cam to when the DS MOVE button is pressed. This is a numeric data display that allows the user to view what the actual position of the Driver Side cam is as reported by the encoder input into the Lenze drive. This is a momentary push button. When depressed, the button illuminates green and the cam moves forward. It continues to move until the button is no longer pressed. When not depressed, the button remains blue. This is a momentary push button. When depressed, the button illuminates green and the cam moves backwards. It continues to move until the button is no longer pressed. When not depressed, the button remains blue. This is a numeric data display that allows the user to set the speed to move the Driver Side cam. When the user taps this button, the user is returned to the Passenger Side Wrap Manual Control screen. When the user taps this button, the screen returns to the Main Screen. This is a multi-state indicator that gives the user a visual diagnostic that shows if the Lenze Drive is in a ready state or not. Green means ready, Red means not ready. This is a momentary push button When depressed, the button illuminates green. When not depressed, it remains blue. When the user presses this switch, it sends a reset message to the Lenze Drive. This is a multi-state indicator that allows the user to view a visual diagnostic as to whether or not the cam is in the home position. When illuminated green, the proximity photo eye is seeing the cam and the cam is in the home position. When illuminated red, the cam is not in the home position meaning that the proximity photo eye is not seeing the cam. 16

17 DS GO HOME E-STOP This is a momentary push button. When pressed, it illuminates green and the Driver Side cam stops what it is doing and moves to the home position. When not pressed, it remains Blue. This is a two position toggle switch with an indicator. When the button illuminates green, the system is not in E-STOP. When the user taps the button, it illuminates red and places the wrap positioning system into an E-STOP condition. Passenger Side Wrap Manual Control Screen Figure 11. Passenger Side Wrap Manual Control Screen The following table describes the Passenger Side Wrap Manual Control Screen: PS MOVE PS WRAP POSITION 1 TO 310 ACTUAL PS CAM POSITION PS JOG FWD PS JOG REV PS WRAP SPEED 1 TO 1000 DS MANUAL This button acts like a switch. When depressed, the button illuminates green and the cam moves to the PS Wrap Position as entered in the data display below. When not depressed, the button remains blue. This is a numeric data display that allows the user to enter a value in which to move the cam to when the PS MOVE button is pressed. This is a numeric data display that allows the user to view what the actual position of the cam is as reported by the encoder input into the Lenze drive. This button acts like a switch. When depressed, the button illulminates green and the cam moves forward. It continues to move until the button is no longer pressed. When not depressed, the button remains blue. This button acts like a switch. When depressed, the button illuminates green and the cam moves backwards. It continues to move until the button is no longer pressed. When not depressed, the button remains blue. This is a numeric data display that allows the user to set the speed to move the Passenger Side cam. When the user taps this button, the Driver Side Wrap Manual Control screen appears. When the user taps this button, the user returns to the Main Screen. 17

18 VFD READY PS VFD RST HOME POSITION OK PS GO HOME E-STOP This is a multi-state indicator that allows the user to view a visual diagnostic that shows if the Passenger Side Lenze Drive is in a ready state or not. Green means ready, red means not ready. This a momentary push button. When depressed, the button illuminates green. When not depressed, the button remains blue. When the user presses this switch, it sends a reset message to the Lenze Drive. This is a multi-state indicator that allows the user to view a visual diagnostic as to whether or not the cam is in the home position. When illuminated green, the proximity photo eye is seeing the cam and the cam is in the home position. When illuminated red, the cam is not in the home position meaning that the proximity photo eye is not seeing the cam. This button is acting like a switch. When pressed, the button illuminates green and the Passenger Side cam stops what it is doing and moves to the home position. If not pressed, the button remains blue. This is a two position toggle switch with an indicator. When the button is green, the system is not in E-STOP. When the user taps the button, it turns red and places the wrap positioning system into an E-STOP condition. Visual Diagnostics Screen Figure 12. Visual Diagnostics Screen The following table describes the Visual Diagnostics Screen Column 1 Column 2 Column 3 18 The multi-state indicators in this column illuminate green when a vehicle is active for that queue number. When indicator illuminates red, there is no vehicle in the specific queue number. This is a multi-state indicator for the Drivers Side wrap. When illuminated green, the wrap is active for that vehicle in the queue. When illuminated red, it is inactive for that car in the queue. This is a multi-state indicator for the Driver Side wrap. When illuminated green, the wrap for the vehicle in the queue has reached the Driver Side wrap based on the distance from the scan arch to the driver side wrap.

19 Column 4 Column 5 Column 6 Column 7 CONV CAR@ARCH WHL@ARCH SCANNING GOOD WBC CAR SIZE LAST QUE This is a numeric data display that allows the user to view the position of the car as it moves toward the driver s side wrap. As the car moves forward, the number should increment. This is a multi-state indicator for the passenger s side wrap. When illuminated green, the wrap is active for that vehicle in the queue. When illuminated red, it is inactive for that car in the queue. This is a multi-state indicator for the passenger s side wrap. When illuminated green, the wrap for the vehicle in the queue has reached the passenger side wrap based on the distance from the scan arch to the passenger side wrap. This is a numeric data display that will allow the user to view the position of the car as it moves toward the passenger s side wrap. As the car moves forward, the number should increment. This is a multi-state indicator that shows the user if the system is receiving the pulses that indicate that the conveyor is running. Conveyor running is a multi-state indicator that illuminates green when the PLC is receiving pulses and illuminates red when it is not. This is a multi-state indicator that indicates if there is a car at the scan arch. The indicator illuminates green when a car is present, and red when there is no car present. This is a multi-state indicator that shows the user if the car has engaged the wheel treadle. When illuminated green, the wheel treadle is engaged while the conveyor is running and the Gate is blocked as well. The indicator illuminates red when this state is not met. If the car is under the minimum length and the Gate photo-eye is blocked, the multi-state indicator shows that the system is in a scanning mode. When illuminated green, the scanning is on. When illuminated red, the scanning is off. This is a multi-state indicator shows the user if the Good Car Signal from the Tunnel Master WBC is active or not. When illuminated green, the wrap PLC is receiving the signal. When illuminated red, there is no signal being received. This is a numeric data display that shows the user the size of the last car as measured by the PLC. The PLC looks at the duration of the Gate photo-eye being block in relation to how many conveyor pulses are received. This is a numeric data display that allows the user to view which queue position was used by the last vehicle through the wrap positioning system. When the user taps this button, the user returns to the Main Screen. 19

20 Driver Side Wrap Configuration Table Values Screen Figure 13. Driver Side Wrap Configuration Table Values Screen The following table describes the Driver Side Wrap Configuration Table Values Screen DRIVER SIDE WRAP CONFIGURATION TABLE VALUES ADJ OUT-ADJ IN (Light Blue) PS TABLES ACTUAL DS CAM POSITION LAST POS TRIGGERED The numeric data display buttons are the positioning settings for the cam. When the driver side of the car is calculated to x inches from the inside rail by the feedback from the ultrasonic sensors, the system moves the cam to the position indicated in this table. These values are not set and need to be adjusted based upon physical placement of the tunnel and the wrap material that is being used. This is a series of (3) multi-state indicators. The first and third multi-state indicators will inform the user if the inclinometer angle for the wrap is out of range in the positive or negative ranges. Green indicates that it is in range and red indicates that it is out of range. The second multistate indicator is the state of the cam positioning. Green indicates that the cam is at the correct location while red indicates that it is not. When the user taps this button, the Main Screen is returned. When the user taps this button, the screen will go to the Passenger Side Wrap Configuration Table Values. This is a numeric data display that will allow the user to view the position of the Driver Side wrap in reference to cam position. This number is generated from feedback of the encoder located in the gear box. This is a test table data display that represents the last value the motor was to direct the cam to. 20

21 Passenger Side Wrap Configuration Table Values Screen Figure 14. Passenger Side Wrap Configuration Table Values Screen The following table describes the Passenger Side Wrap Configuration Table Values Screen PASSENGER SIDE WRAP CONFIGURATION TABLE VALUES ADJ OUT-ADJ IN (Purple) DS TABLES ACTUAL PS CAM POSITION LAST POS TRIGGERED The numeric data display buttons are the positioning settings for the cam. When the passenger side of the car is calculated to x inches from the inside rail by the feedback from the ultrasonic sensors, the system will move the cam to the position indicated in this table. These values are not set and will need to be adjusted based upon physical placement of the tunnel and the wrap material that is being used. This is a series of (3) multi-state indicators. The first and third multi-state indicators will inform the user if the inclinometer angle for the wrap is out of range in the positive or negative ranges. Green indicates that it is in range and red indicates that it is out of range. The second multistate indicator is the state of the cam positioning. Green indicates that the cam is at the correct location while red indicates that it is not. When the user taps this button, the screen will return to the Main Screen. When the user taps this button, the screen will go to the Driver Side Wrap Configuration Table Values Screen. This is a numeric data display that will allow the user to view the position of the passenger s side wrap in reference to cam position. This number is generated from feedback of the encoder located in the gear box. This is a text table data display that represents the last value the motor was to direct the cam to. 21

22 Inclinometer Actual Values Screen Figure 15. Inclinometer Actual Values Screen The following table describes the Inclinometer Actual Values Screen: WRAPS ACTIVE (Blue) DRIVER SIDE CURRENT ACTUAL X DEG (Blue) DRIVER SIDE CURRENT ACTUAL Y DEG (Blue) DRIVER SIDE HI & LOW WRAPS ACTIVE (Purple) PASSENGER SIDE E-STOP This is a multi-state indicator the will provide the user with a visual diagnostic of whether or not the driver side wrap is currently active. Active is defined as the wrap arm is not in the home position and the system is actively adjusting the cam based on position table and inclinometer measurements. This is a numeric data display that will display the current angle of the wrap in the x axis as reported by the inclinometer for the driver s side wrap. This is a numeric data display that will display the current angle of the wrap in the y axis as reported by the inclinometer for the driver s side wrap. All of these are multi-state indicators that will let the user know if the wrap angle as reported by the inclinometer is higher or lower than the target angle. If the display is red, it is either higher or lower than the high or low value. When the display is green, the angle is not higher or lower than the high or low value. This is a multi-state indicator the will provide the user with a visual diagnostic of whether or not the passenger side wrap is currently active. Active is defined as the wrap arm is not in the home position and the system is actively adjusting the cam based on position table and inclinometer measurements. When the user taps this button, the screen will return to the Main Screen. This is a two position toggle switch with an indicator. When the button is green, the system is not in E-STOP. When the user taps the button, it will turn red and put the wrap positioning system into an E-STOP condition. 22

23 VFD Status Screen Figure 1. VFD Status Screen The following table describes the VFD Status Screen: ACTIVE QUE DS LAST TABLE POS TRIGGERED PS LAST TABLE POS TRIGGERED VFD STATUS DRIVER SIDE VFD STATUS MESSAGES PASSENGER SIDE VFD STATUS MESSAGES This is a numeric data display that will show the user which vehicle in the queue is active to the wrap positioning system. This is a text table data display that represents the last value the motor was to direct the cam to for the driver s side. This is a text table data display that represents the last value the motor was to direct the cam to for the passenger s side. DS (Driver s Side) & PS (Passenger s Side) All of these are multi-state indicators that show status of the VFD. POWER DISABLED When the display is green, there is power to the VFD. Red indicates no power. SPEED IS ZERO Green indicates that the motor is not turning the cam. Red means the motor is turning the cam. CONTROLLER INHIBIT Green indicates that there is no condition present that will prevent the VFD from causing the motor to turn. Red indicates that either the VFD is inhibited or a condition exists that would prevent the VFD from causing the motor to turn. WARNING Red indicates that the VFD is in a warning state. Green indicates no warnings are presetn.. TROUBLE Red indicates a trouble response from the VFD. Green indicates no trouble response from the VFD. When the user taps this button, the user is returned to the Main Screen. This is a text table data display that will give a text based message on the current status of the driver side VFD. This is a text table data display that will give a text based message on the current status of the passenger side VFD. 23