Operation Manual Series P40-000 Programmable controller LCD Display Simple handling Manual function Single set operation Program memory Digital outputs Analogue output
1 GENERAL INFORMATION ........................................................................................................................ 4 1.1 1.2 1.3 2 SAFETY................................................................................................................................................... 6 2.1 2.2 2.3 3 INFORMATION OPERATION MANUAL ............................................................................................................... 4 EXPLANATION OF SYMBOLS ............
8 DIAGNOSTICS / ERROR SEARCH ............................................................................................................ 40 8.1 8.2 9 DIAGNOSTICS ............................................................................................................................................ 40 ERROR MESSAGE ....................................................................................................................................... 40 INTERFERENCE ...................................
General Information 1 General Information 1.1 Information Operation Manual The manual contains important information regarding the handling of the controller. Precondition for safe operation is the compliance with the specified safety and handling instructions. Moreover, observe the existing local accident prevention regulation and general safety rules. Please read the operation manual carefully before starting to work.
General Information Tips and recommendations: NOTE! Here you can see highlights, useful tips, information recommendations for efficient and interference-free operation. and 1.3 Statement of Warranties The warranty conditions are in a separate document in the sales documents. Guarantee The producer guarantees the functional capability of the process engineering and the selected parameter. The period of warranty is one year and begins with the date of delivery.
Safety 2 Safety 2.1 General Cause of Risk This chapter gives an overview about all important safety aspects to guarantee an optimal protection of employees as well as a safe and transference-free operation. Non-observance of the instructions mentioned in this operation manual can result in hazardous situations. 2.2 Personal Protective Equipment Employees should wear protective clothing during installation of the device to minimize the risk of accidents.
Safety 2.3 Conventional Use The controller P40 is for the limited purpose as described in this manual: CAUTION! Danger through non-conventional use! An ELGO position control of the series P40 is not a safe control in the sense of the norm EN 61508. Safety-relevant shutdowns like emergency stop cannot be realised with the controller. Non-intended use and non-observance of this operation manual can lead to dangerous situations.
Transport and Storage 3 Transport and Storage 3.1 Safety Instructions for Transport/Unpacking and Loading ATTENTION! Professional transport only. Do not throw, hit or fold the package. 3.2 Handling of Packaging Material Adverts for proper disposal refer to chapter General Information. 3.3 Check of Transport Examine delivery immediately after receiving for completeness and transport damages.
Product Features 4 Product Features Essential features: Single or Two Axis-Controller Analogue or digital outputs for 1 - 3 speed operation 16 free programmable digital in-/outputs (optional 8 digital in-/outputs) Program memory for up to 1000 sets General: The single axis controller of P40 series is applicable to easy positioning tasks. An important feature is the easy structured function menu.
Configuration / Functions 5 Configuration / Functions 5.1 Elements 5.1.1 Control Elements Escape Menu Navigation Operation Mode Function keys Start Input 5.1.2 Stop Display Elements (two-axes-version in the Program-Mode is displayed here) Program Number Set Number Symbol operating mode Absolute / Incremental Position Actual Value Target Value Auxiliary Function Counter Program-Counter Page through the data sets ADVICE! Display elements can vary depending on control mode and configuration.
Configuration / Functions 5.1.3 Function of Keys Change Operation mode between „Manual“ and „Single“ Operation Mode “Program” (only at activated program mode) Activating (pressing 3 sec.) or exiting the Operation Mode or a Sub menu. Select or Confirm Cursor navigation „up“ Cursor navigation „down“ ... Function keys (addicted to Menu or Operation mode) Clear or reset an input Change of Sign ...
Installation / Initial Operation 6 Installation / Initial Operation 6.
Installation / Initial Operation 6.1.1 Axis Menu / Distances Relevant distances for the axes can be set in this menu. Axis distances Access to parameters concerning distances e.g. speeds etc. Axis times Access to parameters concerning times e.g. position reached, zero speed monitoring, rotary encoder etc. Axis analogue Access to parameters concerning the analogue output. Axis settings Access to general parameters concerning the axes.
Installation / Initial Operation 6.1.1.1 Distance / Longitudes Parameters Slow forward/slow backward = middle speed This parameter serves the input of the distance, at which the controller switches from high speed to slow speed before reaching the target position. Creep forward/creep backward = slow speed This parameter serves the input of the distance, at which the controller switches from slow speed to creep speed before reaching the target position.
Installation / Initial Operation Example: Positioning with two speeds For the adjustment of the parameters generally applies: Slow speed = Creep speed > Correction stop Slow speed: Creep speed: Correction stop: 10,0mm 10,0mm 1,0mm Fast Position reached: 100,0mm Slow speed/Creep speed Correction Stop Slow 99,0mm 90,0mm 100,0mm Example: Positioning with three speeds Here for the adjustment of the parameters generally applies: Slow speed > Creep speed > Correction stop Slow speed: Creep speed: Correc
Installation / Initial Operation Tolerance window If the current actual position of the target position corresponds + / - to the value of "tolerance window", the corresponding output "tolerance zone" (see the main configuration) is set. Manipulation It is possible to adjust the indicator of the actual value of the corresponding axis to the target value within the entered tolerance window. The entered range of tolerance is always active in the + and – range around the demand value.
Installation / Initial Operation Software-end position minimum/maximum These two values can be used if no mechanical switch end-positions are present or additionally for already existing mechanical switch end-positions. End position min.: This value should be between the smallest length/position that has to be proceeded and zero (respectively shortly before the mechanical switch end-position). End position max.
Installation / Initial Operation 6.1.2 Axis menu / Times The times relevant for the respective axis can be entered here. Axis distances Access to parameters concerning distances e.g. speeds etc. Axis times Access to parameters concerning times e.g. position reached, zero speed monitoring, rotary encoder etc. Axis analogue Access to parameters concerning the analogue output. Axis settings Access to general parameters concerning the axes.
Installation / Initial Operation 6.1.2.1 Parameters of Time Position reached The output signal is based on a variable time during input of a time value or statically/maintained (axis in position) if the value is set to 0. It is set if the according axis has reached the target position. Spindle compensation In the peak of the loop drive, the drive signals decline. The controller returns to the target value when the parameterized time has expired (adjustment range 0.0 sec. … 99.9 sec.).
Installation / Initial Operation 6.1.3 Axis menu/analogue The axis relevant analogue parameters can be set in this menu. Axis distances Access to parameters concerning distances e.g. speeds etc. Axis times Access to parameters concerning times e.g. position reached, zero speed monitoring, rotary encoder etc. Axis analogue Access to parameters concerning the analogue output. Axis settings Access to general parameters concerning the axes.
Installation / Initial Operation 6.1.3.1 Analogue Parameters Velocity The maximum speed is set in this parameter, in rpm. Should there be gearing between the motor and the measuring system, this has to be considered in the calculations (e.g. gear or spindle) Example! Demanded (below the maximum possible !) motor speed rpm = 3000 Gearing ratio i = 10 V = rpm/i = 3000 rpm/10 = 300 rpm Acceleration The acceleration during positioning is set in this parameter in revolutions per square second ( [U ] ).
Installation / Initial Operation D-portion Differential voltage: setting 1...1000 General: The D-controller (differential controller) determines the control value from the derivative with respect to time of the offset. P40: At offset a short voltage pulse proportional to the rate of change will be put out to compensate quickly without sacrificing the stability of the control loop permanently. The value of the voltage pulse is entered. (max + / - 10 V).
Installation / Initial Operation 6.1.4 Axis menu/general parameters System relevant general parameters can be entered in this parameter. Axis distances Access to parameters concerning distances e.g. speeds etc. Axis times Access to parameters concerning times e.g. position reached, zero speed monitoring, rotary encoder etc. Axis analogue Access to parameters concerning the analogue output. Axis settings Access to general parameters concerning the axes.
Installation / Initial Operation 6.1.4.1 System Parameters Axis type The type of axis is defined. Digital + CPU (use with positioning through digital drive signals) Digital + PID (use with PID version) Button manual mode The function of the keys in manual mode is defined in this parameter. off (The buttons F1, F3 on the control are deactivated for the according axis. This axis can only be moved via the correspondingly assigned inputs.
Installation / Initial Operation Drive signals Æ Mode 3 2 speeds speed = output signals 2 + 3 output 4 set direction reverse Output signals Creep forward Slow forward Fast forward Creep backward Slow backward Fast backward 1 X X X 2 X 3 4 X X X X X X Drive signals = Mode 4 2 speeds Independent outputs for direction and speed Output signals Creep forward Slow forward Fast forward Creep backward Slow backward Fast backward 1 X 2 3 4 Signal configuration: Forwards: Forwards fast: Backw
Installation / Initial Operation Drive signals = Mode 6 3 speeds Binary coded output 1 = forward output 4 = backward outputs 2+3 = speed Output signals Creep forward Slow forward Fast forward Creep backward Slow backward Fast backward 1 X X X 2 X X X X 3 4 X X X X X X X Drive signals = Mode 7 3 speed Forward/backward separately Output signals Creep forward Slow forward Fast forward Creep backward Slow backward Fast backward 1 X X X 2 3 X X X X X X 4 X X X Reference mode (see 7.
Installation / Initial Operation Spindle compensation mode No spindle compensation Negative spindle compensation Positive spindle compensation + With forced loop With forced loop + Software end-position all end positions active end position min deactivated end position max deactivated all end positions deactivated Hardware end-position all end positions active end position min (defined input) deactivated end position max (defined input) deactivated all end positions deactivate
Installation / Initial Operation - With the function “Counter increment”, it is counting up from the current actual value. - With the function “Counter decrement”, it is counting towards zero. - With the function “counter decrement/increment”, it is decrementing if a certain number of items have been assigned. If it reaches zero, the number of units corresponding to the time stored in the parameter “times-axes-quantity reached” is set for a time and not static. Then the counter is incrementing.
Installation / Initial Operation 6.1.5 Reference In the manual mode and single mode the axes can be referenced. Depending on the setting in „AxesParameters -> General Parameters -> Mode reference“ the following applies: Mode 1, 3, 5, 7: The “F2” key has to be pressed for at least 2 sec.
Installation / Initial Operation 6.1.6 Menu / System Setup Access to system parameters. System-times Access to system parameters concerning times.
Installation / Initial Operation 6.1.6.1 Menu / System Parameter Language German English French Spanish Axes active (only with two-axes-version) X-Axis X-Axis and Y-Axis Piece counter program With this parameter the piece counting mode is terminated in the option “program”.
Installation / Initial Operation Next set stepping For the program mode, you can select the following for the next set stepping: without no next step setting activated quantity reached after expiration of the piece counter of the current set, the next set will be loaded quantity, set 1 same as “quantity reached”, additionally set 1 will be loaded after program end Auxiliary functions (see 5.1.2 Display Elements) off on Auxiliary functions are activated.
Installation / Initial Operation 6.1.6.2 System-Times Setup Access to system parameters. System-times Access to system parameters concerning times. I/O Configuration Here the inputs and outputs are assigned. Default parameter Reset the parameters Next set stepping Clamping off Edit-mode timeout Piece counter program Clamp auxiliary function Next set stepping This is the time setting in seconds (0.0 – 9.
Installation / Initial Operation 6.2 Functioning of the inputs/outputs 6.2.1 Functioning of the inputs INFORMATION! At the inputs „Extern Enable“, “External Stop” and „switch end-pos min/max“, the input logic is per default/factory setting set on “low active” for security reasons (failsafe). External enable The extern enable input is monitored during the positioning.
Installation / Initial Operation Switch endposition min/max switch end-pos. min switch end-pos. max The switch end-position inputs are monitored during the positioning. If a switch end-position input is activated, no positioning in the corresponding direction is possible respectively the positioning will be cancelled.
Installation / Initial Operation Reference drive This output is set during a reference drive Tool enable In manual mode: the output is set when changing into the manual mode and is reset during a positioning. In single- and program-mode: the output is reset when changing in one of these modes and is set after each positioning. The output can be reset with the stop-key. Program-end The output is set, after the set with end marker has been proceeded.
Installation / Initial Operation 6.3 Configuration of Inputs and Outputs The inputs and outputs can be configured freely with their associated logic 6.3.1 Linking the Inputs with Functions In the menu “Input functions” you will find an overview of all functions which can be assigned to the inputs. After dialling a function by using the navigation buttons you can select an input for this function by pressing the Enter key.
Operation 7 Operation With the arrow buttons the input fields can be selected consecutively depending on the operating mode. With the numeric keypad, the corresponding values can be changed and with the enter-key they can be selected. Depending on the configuration and operation mode the different values can be changed and the function buttons can be used differently. With the manual/single-button you can change between manual and single mode and with the programbutton you can change into the program-mode.
Operation 7.1.3.1 Entering a Program The program mode is selected through the program key. To be able to generate a program, you first have to assign a program number and confirm with the enter key. On this Program you then load the corresponding data sets. The keys “F1” and “F3” serve to navigate through the various program data sets. It is also possible to select a data set directly, by entering the set number in the corresponding input field and pressing the enter key.
Diagnostics/Error Search 8 Diagnostics / Error Search 8.1 Diagnostics Here function to test the hardware and to display the current installed hard- and software versions are offered. Inputs Outputs Keypad Version/Info 8.2 Error Message Check the signals/wires of the corresponding input or deactivate the according input function (see section 6.3.
Interference 9 Interference The following chapters describe possible causes for malfunction and the instructions to correct them. If you observe recurring errors you might consider electrical interference suppression measures as described in section 9.2 Electrical interference suppression. If errors cannot be corrected with the following instructions please contact the manufacturer (see last page). 9.
Interference Shielding All external signal wires have to be installed shielded: 1. Rotary encoder wires and analogue input wires 2. Wires for all other input signals 3. Wires for all output signals 4. Wires from the power supply to the controller All shields have to be connected centrally low ohm to PE (connect only one-sided at the controller). INFORMATION! Do not connect the controller / measuring system GND to PE (protective earth). Do not connect the shielding on both sides to PE (protective earth).
Interference/Maintenance 9.4 EMC Information An interference-free operation of the control devices of the company ELGO Electronic GmbH & Co. KG can only be guaranteed if in assembly, wiring and operating the following basic rules are observed and adhered to: • • • • • • • use only shielded signal lines with a minimum diameter of 0.15 mm² to protect against electrical fields, connect the cable shield unilaterally, low resistance and low inductive with the operating lightning protection.
Technical Data 11 Technical Data Input supply voltage 24 VDC +10/-20% Power consumption Rotary encoder supply unit +24 VDC; max. 150 mA (no-load condition)-permitted current on all consumer (incl. own consumption) is 1A 24 VDC (optional 5VDC); max. 130 mA Analogue input (optional) 12 Bit resolution at 3,3 V Supply measuring system Input signals The Pin assignment of the inputs and the input logic (high/low active) are programmable. Minimum pulse duration: 300 ms Input voltage/Pin: max.
Technical Data 11.2 Tables of parameters 11.2.1 Parameter of axes Slow forward Creep forward Correction stop forward Slow backward Creep backward Correction stop backward Tolerance window Manipulation Spindle compensation Forced loop Reference value Retract length End position min. End position max.
Technical Data 11.2.
Technical Data 11.3.
Technical Data 11.4 Connector pin assignment S 16 ST9 S1 S12 2 MCC 1 M MCC 2 C C 2 ST 8 ST8 ST1 ST1 ST2 ST3/ST4 ST5/ST6 ST7 ST8 ST9 MCC1 MCC2 S12 ST2 ST7 ST3 ST4 ST5 ST6 Measuring system connection Measuring system connection (only at 2-axes-version) digital inputs digital outputs Analogue output (PID) Analogue output 2 (PID) (only at 2-axes-version) Power supply Control signal 1 (PID) (e.g. in combination with the Motor Drive Controller P100 MCC) Control signal 2 (PID) (e.g.
Technical Data 11.4.
Technical Data MCC1 Analogue output /motor drive controller MCC Control enable (+24V) 1 NC 2 3 !! do not wire !! 4 !! do not wire !! 5 !! do not wire !! 6 !! do not wire !! Analogue output, max. +/- 10V 7 8 GND (0V) S12 1 2 3 6 7 8 MCC2 1 2 3 4 5 6 7 8 Analogue output /motor drive controller Control enable (+24V) NC !! do not wire !! !! do not wire !! !! do not wire !! !! do not wire !! Analogue output, max.
Technical Data 11.
Type Designation 12 Type Designation P40 – XXX – 024 – XX – XX – CXXX Positioning controller Series P40 Version 000 = standard 001 = customized version … Supply voltage 024 = 24VDC (+/‐ 20%) Encoder inputs X = input is not available 1 = A, B, Z (PNP) 2 = A, A´, B, B´, Z, Z´ 3 = A, A´, B, B´, Z, Z´ 4 = one analogue input 5 = two analogue inputs 6= A, B, Z (PNP) one analogue input 24V supply / 24V ‐ 100 KHz 24V supply / 5V‐TTL ‐ 100 KHz 5V supply / 5V‐TTL ‐ 100 KHz 3,3V supply / 0..
Accessories/Document History/Company Information 13 Accessories NG 13.0 Power supply Primary: 115/230 V AC Secondary: 24 V DC/600 mA Relay output over separate relay card and connector cable possible Document- Nr.: 799000347 / Rev.6 Document- Name: P40-000-E_09-11 Subject to change - © 2011 ELGO Electronic GmbH & Co.
