SHEETLINE MINI-PLC STANDARD APPLICATION

User’s Manual Rev Date 9/2/00

1. OPERATION
This program functionally controls different elements of the sheetline, which
require timing functions in their sequencing. By taking on the functions using
the mini-plc, we eliminate the discrete timers required as well as numerous
latch-in relays, which were also required. There is also the added benefit of
“consistency of operation” which comes with using a master program. The
following sections detail how the program sequence controls each element. I/O
will be referenced by terminal #, not address in order to make it more readable
when referencing the print (the wire#’s are still the address per our
standard). Inputs will be IN 0 through IN 23, while Outputs will be OUT 0
through OUT 15.

1.1 LINE START/STOP

The following I/O are sequenced by the program for line run operation:

• IN 0 Emergency stop status. 1=RESET

• IN 1 Line start request
• IN 2 Line stop request/ fault status
• IN 22 Line drives running status
• IN 23 System up to pressure input
• OUT 5 Line run command relay(s)
• OUT 6 Motion warning horn

1.1.1 Initial conditions

Initially, before a line start is allowed IN 0 (E-stop) and IN 2 (stop/fault)
and IN 23 (System up to pressure) need to be active. At this point, a LINE
START may be initiated. This will first start a motion warning trial time, OUT
6, motion warning horn.

1.1.2 Motion warning trial

Prior to running the line drives, the motion warning horn will sound for 5
seconds. This will warn other operators of the pending motion. After the delay
the Line run relays will be activated (OUT 5). This relay will start all line
drives. At this point, the motion warning horn will de-activate while the line
is running for obvious reasons.

1.1.3 Maintain run

The Line run will now be maintained until one of the following occurs:

1. Emergency stop (IN 0 off)

2. Line stop requested, drive fault (IN 2 off)

3. Line drives not running (IN 22 off) buffered with timer.

4. Low system pressure (IN 23 off)

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 SHEETLINE MINI-PLC STANDARD APPLICATION

User’s Manual Rev Date 9/2/00

1.1.4 Stopping
The drives should be wired to respond to the loss of the run command by ramping
to a controlled stop. The only exception to this is stopping because of
Emergency stop in which case the drives should be brought to a dynamic stop as
soon as physically possible.

1.2 HEAT EXCHANGER PUMPS

The following I/O are sequenced by the program for heat exchanger pump
operation:

• IN 3 Zone #1 Pump start request

• IN 4 Zone #1 Pump stop request/pump running status
• IN 5 Zone #2 Pump start request
• IN 6 Zone #2 Pump stop request/pump running status
• IN 7 Zone #3 Pump start request
• IN 8 Zone #3 Pump stop request/pump running status
• IN 9-11 FLOW SENSORS FOR 3 ZONES ABOVE, RESPECTIVELY
• OUT 0-2 Zone #1-3 pump starter, heat enable.

1.2.1 Initial conditions

This description applies to all 3 pumps. There are no initial requirements to
allow starting any pumps. A start request will initiate a trial for the
stop/Maux input to go high (IN 4,6,8). Once high, loss of this input will stop
the pump immediately (stop request or starter trip.)

1.2.2 Maintain run

The pump run will now be maintained until one of the following occurs:

1. Pump stop requested, loss of M-aux (IN 4,6,8 off)

2. Loss of flow inputs for 10 seconds continuously (IN 9,10,11)

The circuit will then de-energize until a pump start is initiated again.

1.2.3 Temp control interlock

The running of the heat exchanger pump is required to allow heating of the
zone. The output, which drives the starter (OUT 0,1,2), should be used to
supply the line side of the temperature controller heat outputs for the
respective zone.

1.3 HYDRAULIC SUPPLY PUMP

On lines with high PLI requirements, the opening and closing of the rolls on
the sheet stack ((2) top and bottom typically) requires a hydraulic power
supply. The opening and closing of the first two rolls (Roll #1, Roll #2) in
this program are interlocked with the hydraulic pump circuit see section 1.4
for info on roll open/close sequence. The pump itself has sequence requirements
detailed below.

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 SHEETLINE MINI-PLC STANDARD APPLICATION

User’s Manual Rev Date 9/2/00

The following I/O are sequenced by the program for hydraulic pump operation:

• IN 12 Pump start request

• IN 13 Pump stop request/pump running status
• OUT 3 Pump starter

The following I-O need to be wired external to the mini PLC:

• Dump Solenoid, Energize with pump.

• Relief Solenoid, E-Stopped, energize with pump running and selector switch
• Remote Drain, E-Stopped, energize with pump running.

1.3.1 Initial conditions

Initially, before a hydraulic system start is allowed, IN 0 (E-stop) needs to
be active. At this point, a PUMP START may be initiated.

1.3.2 Maintain run

The pump run will now be maintained until one of the following occurs:

1. Pump stop requested, loss of M-aux (IN 13 off)

2. E-stop after 10 seconds continuously (IN 0)

The pump will be shut-off with E-stop tripped after 20 seconds. This will
ensure adequate system pressure to open the rolls. The roll close circuit is
disabled instantly on E-stop obviously.

1.3.3 Roll Close interlocks

The running of the hydraulic pump is required to allow closing of Roll #1, Roll
#2. For pneumatic system with no hydraulics, just jumper IN 13 and bypass
hydraulics up to pressure swtch to allow roll close operation. See section 1.4
for more information.

1.4 ROLL OPEN/CLOSE

The code in this standard program is designed to sequence the opening and
closing of (3) rolls. Rolls 1 and 2 have added interlocks assuming a hydraulic
system. These interlocks may be bypassed if the system is pneumatic (see pump
sequence description above.) The third roll is assumed to be pneumatic.

The following I/O are sequenced by the program for Roll Open/Close operation:

• IN 0 E-stop status
• IN 13 Hydraulic Pump stop request/pump running status
• IN 23 System up to pressure
• IN 14 Roll #1 Close request
• IN 15 Roll #1 Open request
• IN 16 Roll #2 Close request
• IN 17 Roll #2 Open request

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 SHEETLINE MINI-PLC STANDARD APPLICATION

User’s Manual Rev Date 9/2/00

• IN 20 Nip Roll Close request
• IN 21 Nip Roll Open request
• OUT 6 Motion warning horn
• OUT 8,9,10 Rolls closing/closed lights
• OUT 11,12,13 Rolls close solenoids

1.4.1 Initial conditions

Initially, before a roll may be closed, IN 0 (E-stop), and for rolls 1,2->IN
13,IN 23 (hydraulic pump ON/up to pressure) need to be active. At this point, a
ROLL CLOSE may be initiated. This will first start a motion warning trial time,
OUT 6, motion warning horn. An exception to this is for up to 12 seconds AFTER
THAT ROLL WAS OPENED, instant operation is allowed.

1.4.2 Motion warning trial

Prior to closing the roll, the motion warning horn will sound for 5 seconds.
This will warn other operators of the pending motion. After the delay the nip
CLOSE (OUT 11-13) will activate depending on what was selected. The horn will
then cease sounding while the roll is closed.

1.4.3 Maintain close

The roll close will now be maintained until one of the following occurs:

1. Roll open requested, (IN 15,17,21 off)

2. E-stop occurs (IN 0)

For rolls #1 and #2 only:

3. Hydraulics off (IN 13 off)

4. System pressure low (IN 23 off)

These conditions will cause the circuit to de-energize which will open the
roll.

1.4.4 Opening
As soon as the circuit is de-energized, the “instant-ON” trial time of 12
seconds begins. If motion is re-initiated within this time frame, the close
solenoids will be actuated immediately. If the roll has been opened for longer,
the trial delay will be active again. As opposed to locomotion, the motion
warning horn only needs to sounded during the delay, not while closing or
closed.

1.5 LOCOMOTION
The following I/O are sequenced by the program for locomotion operation:

• IN 0 Emergency stop status. 1=RESET

• IN 18 Locomotion request

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 SHEETLINE MINI-PLC STANDARD APPLICATION

User’s Manual Rev Date 9/2/00

• OUT 14 Enable relay
• OUT 6 Motion warning horn

1.5.1 Initial conditions

Initially, before locomotion is allowed, IN 0 (E-stop) needs to be active. At
this point, locomotion may be initiated. This will first start a motion warning
trial time, OUT 6, motion warning horn. An exception to this is for up to 12
seconds AFTER locomotion has ceased, instant operation is allowed.

1.5.2 Motion warning trial

Prior to moving the line, the motion warning horn will sound for 5 seconds.
This will warn other operators of the pending motion. After the delay the
Enable (OUT 14) will activate. THE HORN WILL CONTINUE TO SOUND DURING ALL
LOCOMOTION, NOT JUST THE TRIAL DELAY!

1.5.3 Maintain run

As long as input is maintained, locomotion will continue. The locomotion drive
should be setup with a long ACCEL time and a short (as possible) DECEL time.
This will allow fine adjustment of the line when in close to the die while
speeding it up for long moves.

1.5.4 Stopping
As soon as the selector is released, The locomotion relay will de-activate to
stop the line. This will start the “instant-ON” trial time of 12 seconds. If
motion is re-initiated within this time frame, the run relays will be actuated
immediately. If the locomotion drive has been inactive for longer, the trial
delay will be active again.

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