InDisplay Keypad for Rapid Machinery RP type machines with servo driven foil/hologram feeder Rev 1 1/12/97

Transcription

1 InDisplay Keypad for Rapid Machinery RP type machines with servo driven foil/hologram feeder Rev 1 1/12/97 The new InDisplay keypad fitted to this machine has many enhancements over the "Burr-Brown" terminal fitted to older machines from Rapid Machinery. These include: English language prompts. Context sensitive help screens. Values are entered in millimetres, not in one hundreths of a millimetre as before. Machine diagnostics built in. SBSC drive reprogramming facility built in. The Keypad has a 2 x 40 character LED backlit LCD display and 16 keys, 4 of which are "soft" function keys. The function of each of the four function keys is indicated on the bottom line of the display in angle brackets. The remaining keys are the digits 0 to 9, a decimal point and a delete key which may be used to delete the digit to the left of the cursor or if no digits exist, to back up through the menu structure. There is a display contrast adjustment accessible from the rear in the centre. This may be adjusted with a small flat blade screwdriver. The LCD contrast is affected by temperature changes and may require adjustment to suit you operating conditions. This adjustment also affects the optimum viewing angle of the display. New keypads may be retrofitted to older machines by simply replacing the keypad and cable assembly. The old keypad derived its power (5 V) from connector X6 on the SBSC, the new keypad must be supplied with 10 to 30 volts on its green screw terminals. 24 volts is available from the scanner switch on the control panel, refer to the schematics supplied with your machine. After fitting the new keypad the SBSC must be reprogrammed using the facility built in to the new keypad. Also older machines may need the start pull input rewired from the STEP input to the START input. These instructions are laid out according to the order that the different menus and screens appear on the display, following each one to its bottom level before moving to the next one. With this particular version most of the settings are prefixed with either Main or Holo. This indicates whether the setting is for the main web pull drive or the foil (or hologram) pull drive. The particular drive addressed can be changed by pressing the <Main/Holo> button. This selection is modal i.e. once Main is selected all subsequent setting will be for main and vice versa. When the machine is powered up you are presented with the following screen: InDisplay by Industronics Version: RPH 1.01 Date: 26/02/97 The version number and date may change however these instructions should be valid for all RPH V1.xx versions. If all is well this screen should be replaced with the following main menu. If the first screen remains for more than 10 seconds refer to troubleshooting guide. Page 1 of 8

2 Main Menu Rapid Machinery - Made in Australia <Length> <Speed> <Skip> <Next> <F1> Selects Length Entry Screen <F2> Selects Speed Entry Screen <F3> Selects Skip Menu <F4> Selects Menu 2 <DEL> No Action This is the main menu. You can always get back to here by repeated pressing of the <DEL> key or selecting the <MAIN> option available in most menus. Length Entry Screen Main Length (mm) _ <Main/Holo> Now: xx.xx <Main Menu> <Enter> <DEL> Selects Main Menu In this screen you enter the pull length you require in fixed length (Scanner Off) mode. This value is also used in registration (Scanner On) mode. Unlike with the old terminal you enter the exact repeat length here and the +2mm and -3mm are automatically calculated. These +/- values are adjustable elsewhere. If you require a pull length of 102mm simply key in 102 and press <F4> to enter. If you require more accuracy you can enter up to 2 decimal places e.g The value currently set is displayed on the top right. Speed Entry Screen Main Speed (mm/s) _ Now: xxxx <Main/Holo> <Main Menu> <Enter> <DEL> Selects Main Menu Enter the speed of the pull here. The units are millimetres per second as with the old terminal. You can enter a speed as high as 9999mm/s however the speed is effectively limited by the acceleration and the length of the pull. The value currently set is displayed on the top right. Page 2 of 8

3 Skip Menu Main Skip Menu - Skip Mode Off <Length 2><Skip No.><Norm No.><MainMenu> <F1> Selects Skip Length Entry Screen <F2> Selects Number of Skip Moves Entry Screen <F3> Selects Number of Normal Moves Entry Screen <F4> Selects Main Menu <DEL> Selects Main Menu This menu is available by pressing <F3> from the main menu. When selecting this menu the top line of the display indicates whether or not skip mode is active. Skip mode is an advanced feature that while not often used is invaluable for overprinting on non regularly printed stock. Some printers that have intermitant feeding mechanisms can print a set of labels accurately spaced but then have a larger or smaller gap (or inaccurate gap) to the next label set. By using the skip mode it is possible to print on this type of preprinted stock. In short this allows you to pull a programmable amount of standard size pulls then a programmable amount (usually only one) of another size pulls and then the process repeats indefinately. Skip Length Entry Screen Main Length2 (mm) _ Now: xx.xx <Main/Holo> <Help> <Main Menu> <Enter> <F2> Display Help Screen <DEL> Selects Skip Menu In this screen you enter the length of pull in millimetres of the skip or second size move. This value is ignored if skip mode is off. The value currently set is displayed on the top right. Number of Skip Moves Entry Screen Holo Skip Number: _ Now: xx <Main/Holo> <Help> <Main Menu> <Enter> <F2> Display Help Screen <DEL> Selects Skip Menu In this screen the number of skip moves is entered. If zero is entered skip mode is off and the number of normal moves is forced to one. For this reason the number of skip moves must be set before attempting to enter the number of normal moves. The value currently set is displayed on the top right. Page 3 of 8

4 Number of Normal Moves Entry Screen Main Norm Number: _ Now: xx <Main/Holo> <Help> <Main Menu> <Enter> <F2> Display Help Screen <DEL> Selects Skip Menu In this screen the number of normal sized moves is entered. If zero is entered in the number of skip moves screen this value is forced to one. The value currently set is displayed on the top right. Menu 2 Rapid Machinery - Menu 2 <Complex> <Diagnose> <Reprog><Main Menu> <F1> Selects the Registration Setup Entry Screens <F2> Selects the Diagnostics Menu Screen <F3> Selects the SBSC Reprogramming Facility <F4> Selects the Main Menu <DEL> Selects Main Menu This menu is accessed from the main menu by pressing <F4>. This menu allows access to the less often used functions of the keypad. Scan Length Entry Screen Main Scan Length _ Now: xx <No Mark> <Help> <Main Menu> <Enter> <F1> Selects the No Mark Length Entry Screen <F2> Selects the Help Screen <F3> Selects the Main Menu <F4> Sends the typed in value to the SBSC drive <DEL> Selects Menu 2 This entry screen can be accessed from Menu 2 by pressing <F1>. The value entered here is subtracted from the pull length entered and used as the distance to move after a registration mark is encountered by the sensor. Or another way to look at it is that the pull will stop this distance short of the following registration mark. The value currently set is displayed on the top right. Page 4 of 8

5 No Mark Length Entry Screen Main No Mark (mm) _ Now: xx <Minus> <Help> <Main Menu> <Enter> <F1> Minus Key <F2> Selects the Help Screen <F3> Selects the Main Menu <F4> Sends the typed in value to the SBSC drive <DEL> Selects Menu 2 This entry screen can be accessed from the scan length entry screen by pressing <F1>. The number entered here is added to the pull length entered elsewhere. It is possible to enter a negative number here by pressing <F1> before entering any digits. If no mark is encountered by the sensor in registration mode the pull length will be this long. A value of zero is most commonly used when the marks are relatively evenly spaced. However, if the original registration is poor it may be of benefit to enter a small negative number. The value currently set is displayed on the top right. Diagnose Menu Diagnose Menu <Scanner><Scanner Sw><Start In> <Main> <F1> Selects the Scanner Input Test Screen <F2> Selects the Scanner Switch Input Test Screen <F3> Selects the Start Pull Input Test Screen <F4> Selects the Main Menu <DEL> Selects Menu 2 This menu may be reached by pressing <F2> from Menu 2. When this menu is displayed some basic checks of the SBSC are performed. If an error is detected the appropriate error message is displayed. Scanner Input Test Screen Main Scanner Off Mark Operate Input to Test<Main/Holo> <Back> <F1> No Action <F3> Selects either Main Drive or Holo (Foil) drive <F4> Selects the Diagnose Menu <DEL> Selects the Diagnose Menu This screen can be accessed by pressing <F1> from the diagnose menu. It is used to test for the correct operation of the registration scanner input on the SBSC. Operate the scanner input by moving some material by hand under the scanner. The scanner input status is indicated on the top line of the display. It is possible to set the "Light on/dark on" switch on the scanner correctly using this screen. Page 5 of 8

6 Scanner Switch Input Test Screen Holo Scanner Switch Off Operate Input to Test<Main/Holo> <Back> <F1> No Action <F3> Selects either Main Drive or Holo (Foil) drive <F4> Selects the Diagnose Menu <DEL> Selects the Diagnose Menu This screen can be accessed by pressing <F2> from the diagnose menu. It is used to test for the correct operation of the scanner switch input on the SBSC. Operate the scanner switch on the control panel of the machine. The switch input status is indicated on the top line of the display. Start Input Test Screen Main Start Input Off Operate Input to Test<Main/Holo> <Back> <F1> No Action <F3> Selects either Main Drive or Holo (Foil) drive <F4> Selects the Diagnose Menu <DEL> Selects the Diagnose Menu This screen can be accessed by pressing <F3> from the diagnose menu. It is used to test for the correct operation of the start input on the SBSC. Operate the start input by jogging the machine until the appropriate reed relay is activated in the cam bank attached to the main motor. The single pull button may also be tested with this screen. The start input status is indicated on the top line of the display. SBSC Reprogramming Facility Downloading I Parameters <Main Menu> <F1> No Action <F3> No Action <F4> Selects the Main Menu <DEL> Selects Menu 2 This screen is accessed from Menu 2 by pressing <F3>. Once selected the process starts automatically. The top line of the display indicates the progress and changes from I Parameters to C Definitions to M Definitions to P Variables to Programme and finally to Finished! This facility is used when the keypad is first installed to setup the SBSC for use with the keypad. It can also be used when the system is malfunctioning and the validity of the programme in the SBSC is suspect. Page 6 of 8

7 Fault Message Screens 24 Volts missing from SBSC terminals! Check 24V X2/14, 0V X2/9,11,12 <Back> This fault message indicates that the hardwired 24 volt connections to terminals on SBSC connector X2 have come loose or that the 24 volt wiring is faulty elsewhere. The test for this condition is only done on selecting the diagnose menu. Pressing either <F4> or <DEL> takes you back to Menu 2. Error communicating with SBSC! No response from SBSC Drive. <Retry> This fault message indicates that no response was recieved from the SBSC following a command or query issued by the keypad. This would normally indicate a faulty connecting cable or failure of the keypad or SBSC. Pressing <F4> retries the communications. Error communicating with SBSC! Following Error or No Power. <Retry> This fault message also indicates that no response was recieved from the SBSC following a command or query however this could be caused by the same reasons as above but it is more likely that the drive has tripped on following error or that power has been lost to the SBSC. Pressing <F4> retries the communications. Help Screens The following are the various help screens shown after pressing the help soft function key. They need no further explanation here as this manual describes the functions under the various screen instructions. Pressing <F4> or <DEL> takes you back to the screen help was called from. Distance you would like to scan for the mark. Usually set to 3mm. <Back> Distance to move when mark not detected. Value entered added to length. <Back> Enter length of skip or 2nd size index here in mm. <Back> Enter number of skip or 2nd size indexes here. Enter 0 to stop skip mode <Back> Enter number of normal size indexes here Enter no. of skip moves first. <Back> Page 7 of 8

8 Troubleshooting Problem: Keypad fails to show Main Menu on power up or shows following error message. A following error is the end result of a number of different problems. It is caused by either the motor moving when it wasn't supposed to or not moving when it was supposed to move. Fault finding sequence: Check LED's on SBSC If Ready LED is green and Following Error LED is off, problem is probably a faulty cable between keypad and SBSC. If Ready LED is green and following error LED is on, this could have the following causes: Web causing to much load on pull motor. Reduce load. Thermal switch in motor open or wiring to it open circuit. Reset drive with button and immediately check decimal point in Monitor display on SBSC. If it is off and following error LED is now off this is the problem. Check motor temperature and thermal wiring. No 24 volts on SBSC connector X2/14. Reset drive and go to diagnose menu if this is the problem it will be shown here. Check wiring to connector X2. If Ready LED is red and a number is displayed on monitor display check number in the table below. 1. Overvoltage. Mains voltage too high or regeneration resistor connected to X7/Rx faulty. 2. Undervoltage. Internal power supplies are low. Replace SBSC. 3. Overcurrent. Internal short circuit. Replace SBSC. 4. Overtemperature. Internal temperature exceeds 82 deg C. Allow SBSC to cool. 5. Resolver Fault. Check wiring between connector X3 and resolver on rear of motor. 6. Electronic Fusing. Check motor power wiring for shorts or motor for jammed shaft. 7. It Limit. After 4 seconds changes to 6 (see above). If Ready LED is off there is no power on SBSC or it has failed. If SBSC has wires in terminals U1 and V1 on X7 check for 100 to 250 volts AC here. If the SBSC has wires in terminals L+ and L- on X7 check for 140 to 350 volts DC here. Problem: No backlight on display Cause: No power on green terminals on rear of keypad. Check for 10 to 30 volts DC. Problem: Input tests under diagnose menu fail. Cause: Sensors/switches or wiring to them faulty. Check for +24V DC on connector X2 pin 14 or X8 pin 2. The sensors/switches switch to 0 volts. The registration scanner is connected to X8 pin 12. The scanner switch must be on to test this. One contact of the scanner switch is connected to X8 pin 15, the other supplies 24V to the scanner. The start reed switch and single pull button are connected to X8 pin 3. Page 8 of 8