IM-110007-2004 C.E.S. Stamping Press Controller INSTRUCTION MANUAL (Revised 07/04) DRIVE SOURCE INTERNATIONAL INC. 7900 Durand Avenue, P.O. Box 0361 Sturtevant, WI USA 53177 Toll Free: (800) 548-2169 Phone: (262) 554-7977 - Fax: (262) 554- 7041 Email: sales@drivesourceusa.
DANGER HIGH VOLTAGE Motor control equipment and controllers are connected to hazardous line voltage. When servicing drives and electronic controllers, there may be exposed components with their cases and protrusions at or above line potential. Extreme care should be taken to protect against shock. Stand on an insulating pad and make it a habit to use only one hand when checking Components. Always work with another person In case an emergency occurs.
TABLE OF CONTENTS SECTION 1 - GENERAL INFORMATION Introduction Safety Training Receiving and Damage Claims Warranty Handling Storage Long Term Storage Removing from Storage Electrical Part Numbering System Category Number and Description Symbols Used in Illustrations Page No.
GENERAL INFORMATION Training programs are an essential part of safe and correct operation. Training provides the knowledge necessary to obtain top performance from your equipment. DSI/Dynamatic recognizes this fact and conducts training schools to educate your plant personnel in safe maintenance and operating procedures. INTRODUCTION This instruction manual relates specifically to the CES Stamping Press Controller.
is abbreviated by dropping zeros, i.e., 15-825-1. The number printed on the board and in the technical instruction material is the abbreviated form. However, the actual bill of material and order paper work for that board would use, the complete number 15-000825-0001. vibration. Electrical components are delicate and easily damaged - provide adequate protection for them. Ambient temperature should not exceed 25ºC. (77ºF.) on a continuous basis or 40ºC. (104ºF.) on an intermittent basis.
70 71 72 73 74 75 Insulated mounting boards Master bill of material Engineering data sheets Reworked or exchanged assemblies The middle six digits describe a basic type of part, such as physical or electrical characteristics of a group or family of parts. As an example, a resistor family of 1/2 watt carbon resistors have the number 000045. The part number of one specific resistor in this family is a 54000045-0102.
CES STAMPING PRESS CONTROLLER DESCRIPTION CONSTRUCTION The CES Stamping Press Controller is a solid state, closed loop velocity controller designed specifically for use with Dynamatic® eddy-current press drives. The controller is built with analog, digital and microprocessor circuitry. All components of the CES Controller are contained on a sub-panel, except for an autotransformer that is mounted separately. The panel measures 74" by 31.25". Special sizes are made to order upon request.
Clutch excitation provides up to 180 Amps peak at 70% duty cycle. Brake excitation provides up to 90 Amps peak at 30% duty cycle. LOGIC INTERFACE INDICATOR PCB (15-242-57): Refer to Figure 2-2 for the identification of the LEDs found on this printed circuit board. KEYPAD PROGRAMMING The keypad is mounted integrally with the DMR. It is connected to the main DMR through a ribbon cable and is used for viewing and modifying various parameters within the system.
operation of the CES controller. Parameters are scaled in user units when applicable. CES DIGITAL MASTER REGULATOR (DMR) The DMR Controller is a microprocessor based solid state electronic control system operating in conjunction with a CES press drive controller. It provides the interface with the press manufacturer's control. It also provides the safety circuits necessary to ensure proper Upon power-up in the field, the values will be set by the factory.
The enable signals consist of two press control contact closures that put the 115 VAC of the press control into the I/O board. numbers for a specific control may vary, see your Control Data Master. PRESS CONTROL INTERFACE - COMMANDS ACCEPTED The CES controller will accept nine different input command signals from the press controller that are available for the operator to make, They are as follows: two Enables, Clutch Contactor ON, Inch, Micro Inch, Reverse, Control Power ON, Stop-On-Top and Fault Reset.
closure that puts the 115 VAC of the press control into the I/O board. Fault, Stop Now Fault, Stop-on-Top Fault, Control Failure Fault, Clutch ON and TD Relay REVERSE: The reverse command is sent to the press control to indicate that the press is to operate in the inch or micro inch mode in the reverse direction. The CES controller uses this information with other signals to establish either the inch-reverse or micro inch-reverse mode.
1. 2. 3. 4. The I/O board of the CES controller opens a solid state relay contact for the control failure fault signal to the press control. CLUTCH ON (SIGNAL): The clutch ON is a 115 volt output that drives the CR1 relay. A NO CR1 relay contact is in series with the 115 VAC power provided by the press control and a TD contact. Activating the CR1 relay and the TD relay will allow the clutch contactor to pull in after the press control has given the clutch ON command.
2. 3. 4. 5. 6. 7. A setting of 360 degrees on any angle will cause the control to skip the speed setting that immediately follows. Parameter Locations Table 2-3 Parameter Number Data 30 Angle No. 1 31 Speed No. 1 (manual)* 32 Angle No. 2 33 Speed No. 2 34 Angle No. 3 35 Speed No. 3 36 Angle No. 4 37 Speed No. 4 38 Angle No. 5 39 Speed No. 5 40 Angle No. 6 41 Speed No.
The micro inch forward mode will be indicated by the "Micro Inch" LED on the keypad and display board. III. INCH REVERSE MODE (RUN AT) The CES controller will be in the inch reverse mode if the following conditions exist: V. MICRO INCH REVERSE MODE (RUN AT) The CES controller will be in the micro inch reverse mode if the following conditions exist: 1. Enable signal is present 2. No fault is present 3. Reverse is present 4. Inch is present 5. Micro inch is not present 6.
When a level 0100, 0200 or 0300 fault exists it will be indicated by an LED on the keypad and display board. A control fault will be indicated by the absence of the "control fault" LED on the I/O PCB. 0207 Loss of Line Fault - Loss of an input phase or greater than 20% drop in ac line for a period of 100 milliseconds. 0208 Enable Without Clutch Contactor ON Fault Clutch contactor ON is not present within 170 milliseconds of receiving enable (see Fault No. 0226).
0228 Creep Speed Not Reached Before Stop Angle Fault - During a stop-on-top sequence, the creep speed is not reached before the press reaches the stop angle. 0318 Micro Inch Change Fault - If the micro inch command is changed while enable is present, a micro inch change fault will exist. 0319 Reverse Change Fault - If the reverse command is changed while enable is present, a reverse change fault will exist.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 1. Issuing a brake ON command 2. Setting reference to 0% 3. Setting feedback to 100% CES controller power is applied Enable is not present No fault is present Test mode parameter No.
7. The press run data should have the format indicated in Table 2-5. which will represent faults corresponding to these numbers. Zeros are used to complete the 68-character packet. Press Run Data Format Table 2-5 Packet Number Data Par No. 1 through 2 AA 3 through 6 Angle No. 1 30 7 through 10 Speed No. 1 31 11 through 14 Angle No. 2 32 Monitor data will be sent by the DMR on request of the press control. The two ASCII characters of the "Request to Send Monitor Data" will be CC.
A typical program to run a press with a Manual Speed pot and use the slowdown function to get good parts would be set up as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Angle No. 1 = 180 degrees Manual Speed pot = 16 SPM Angle No. 2 = 115 degrees Speed No. 2 = 10 SPM Angle No. 3 = 360 degrees Speed No. 3 = 10 Angle No. 4 = 360 degrees Speed No. 4 = 10 Angle No. 5 = 360 degrees Speed No. 5 = 10 Angle No. 6 = 360 degrees Speed No. 6 = 10 Creep Angle = 305 degrees Stop Angle = 356.
OPERATION PURPOSE Driving torque is developed through an electromagnetic The CES Stamping Press Controller is easy to operate. force between the flywheel and clutch rotor. Braking We believe that some knowledge of how the controller is torque is developed through a similar force between the supposed to function will help you obtain the best stationary brake field assembly and the brake rotor. performance with minimum down time.
velocity control and another one for current limit. simple closed loop system is shown in Figure 3-1. A POWER AMPLIFIER The power amplifier is a high current capacity SCR power section capable of supplying four times rated voltage (field forcing) to the clutch and brake coils. Field forcing reduces the effective coil time constant. One time constant is defined as the time required for the current in a coil to reach 63% of its final value with a step change in voltage.
85% rated line voltage or missing phase. For the brake, it can be caused by the brake contactor not being pulled in; 120% rated brake coil current; or 85% rated line voltage or missing phase. The link with the DMR is a 26-line ribbon cable. This cable also connects to the interface indicator board; however, this board is not required in order to run. A separate 8-pin cable, PL-Fault, connects to the DMR and converts various logic state conditions.
through 25. The remaining parameters can be modified from the keypad. Parameters that can be downloaded through a serial interface are numbered 30 through 43. Some parameters have built in limits. Refer to Table 3-2 for the parameter numbers have limits set. to the desired number with the up arrow (↑) or down arrow (↓). A list of all parameter numbers is included in Table 3-3 and 3-4 to serve as a quick reference during operation.
78 Gear box ratio 79 Tach pulses per revolution 80 Pot selector KEYPAD PROGRAMMING The keypad is mounted integrally with the DMR. It is connected to the main DMR through a ribbon cable and is used for viewing and modifying various parameters within the systems. The module consists of the following: a 20-button keypad; two independent sets of 8-digit, 7-segment LED displays; and a row of 8 individual status LEDs. The keypad is illustrated in Figure 2-1.
Fast auto-repeat is also accomplished by pressing the Asterisk button and then pressing and holding one of the arrow buttons down. After releasing the arrow button (↓) for a period longer than one second, the up/down function will revert back to normal speed of operation. A faster up/down function is also available. By first pressing the (#) key and then either the Up or Down arrow button (↑↓), the increment of change will be by 100 units per increment.
OPTIONAL FEATURES OPERATING THE PRESS-ON-HOP This term is used in reference to a press that is basically operating in the single stroke mode. When the press is about to stop, if all limit switches and sensing devices indicate that the mechanical handling equipment is in a GO condition, the press is told not to stop but to continue running. Speed into the next stroke. This is the equivalent of the continuous mode of operation. If the signal is not present at this point, the press will go to Creep Speed.
Typical DMR Parameter and Fault Number Reference Chart PARAMETER NUMBER 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 PARAMETER Not Used Average Speed Feedback - SPM Speed Reference - SPM Average Speed Error (+/-) - SPM Effective Resolver Position AC Line Voltage - Volts Not Used Not Used Clutch Current Feedback - Amps Brake Current Feedba
Special DMR Parameter and Fault Number Reference Chart for DMR with Stop-On-Bottom Feature Table 3-4 PARAMETER NUMBER 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 PARAMETER Not Used Average Speed Feedback - SPM Speed Reference - SPM Average Speed Error (+/-) - SPM Effective Resolver Position AC Line Voltage - Volts Not Used Not Used Clutc
START-UP AND ADJUSTMENT 6. Provides clutch "free wheel" command signals to prevent damage to the clutch SCRs. 7. Provides brake "free wheel" command signals to prevent damage to the brake SCRs 8. Control amplifiers that compare the clutch and brake current reference signals to current feedback signals. 9. Phase shifter microprocessors in the clutch and brake circuit, which control the firing angles of the clutch and brake amplifier SCRs.
i. 3A. Older controls have two EPROM’s provided with each control. The test mode will be indicated by the "Test" LED on the keypad and display board. 5. Enter the clutch test mode. a. One EPROM protects certain parameters that are adjustable from the keypad from accidental changes. These parameters are: 26 Maximum Speed 27 Line Voltage 28 Clutch Current 29 Brake Current 72 Number of Speed Feedback Periods 73 Baud Rate 78 Gear Box Ratio 79 Tach Pulses Per Revolution 80 Potentiometer Selector b.
rotating, it will not get to the creep angle or the stop angle; therefore, a stop now fault will be generated. Check this LED on the 1/0 board. 6) Send the clutch contactor ON signal without the enable signal. A stop now fault will be generated. 7) Send the enable signal without the clutch contactor ON signal. A stop now fault will be generated. the size of the mechanical unit, +/-1 amp. Adjust the Brake Current Limit potentiometer only if necessary for the proper Amps. d.
8) 9) 10) 11) 12) 13) Enter Creep Angle, parameter 42. Enter Stop Angle, parameter 43. Enter Creep Speed, parameter 44. Enter Max Speed, parameter 26. Enter Initial Accel Rate, parameter 49. Enter the Wrong Direction Limit, parameter 70. APPROXIMATE PARAMETER SETTINGS Approximate parameter settings, which are furnished for trial only, are indicated in Table 4-1. Actual settings will be determined during the press set-up.
Typical Parameter Settings Parameter Number 26 27 28 29 30 31 32 83 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 58 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 Table 4-1 Value Max press speed 480.00 Same as CL Meter Same as BR Meter 180.0 20.0* 90.0 10.0 170.0 20.0 360.0 20.0 360.0 20.0 360.0 20.0 300.0 354.0 5.0 5.0 10.0 100.0 3.0 100.0 100.0 100.0 100.0 5.0 5.0 100.0 100.0 100.0 5.5 5.5 Off Off Off Clear 10.0 10.0 300.0 2.0 2.0 10.0 3.0 .1 1.
MAINTENANCE AND TROUBLE SHOOTING the factory for the coil resistance. Resistance to ground should be about 20 megohms. When using a megger, make sure both coil leads are disconnected from the controller. Do not megger any portion of the controller. MAINTENANCE Very little maintenance is required to keep the CES stamping press controller in service. Periodically, we suggest that you check the controller to make sure all terminal screws and other connections are tight.
29 72 73 78 79 80 Brake Current No. of Speed Feedback Periods Averaged Baud Rate Gear Box Ratio Tach Pulses Per Revolution Pot Selector RENEWAL PARTS AND SERVICE Some renewal parts for the CES Stamping Press Controller are stocked at the factory. We suggest you stock renewal parts to minimize down time. You alone can evaluate the cost of down time compared to the cost of stocking spares. If you need help in establishing an appropriate list and stock levels, contact your local sales office.
DRIVE SOURCE INTERNATIONAL INC. 7900 Durand Avenue, P.O. Box 0361 Sturtevant, WI USA 53177 Toll Free: (800) 548-2169 Phone: (262) 554-7977 - Fax: (262) 554- 7041 Email: sales@drivesourceusa.
