Operation Manual Series P40-SN002 Application metal shears Programmable controller LCD Display Simple handling Manual inching function Single set operation Program memory Digital outputs Analog Output
Contents Content 1. General Information....................................................................................................... 4 1.1. Information Operation Manual ............................................................................. 4 1.2. Explanation of Symbols ......................................................................................... 4 1.3. Statement of Warranties ....................................................................................... 5 1.4.
Contents 7. Operation ....................................................................................................................... 36 7.1 Operation Modes .............................................................................................................. 36 7.1.1 Manual mode .................................................................................................................... 36 7.1.2 Single mode ............................................................................
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. The manual should be kept accessible at anytime.
General Information Hints and commendations ADVERT! ...highlights helpful hints and recommendations for efficient and failure-free operation. Specific safety instructions The following symbols in conjunction with safety instructions are used in order to point out possible hazards: DANGER! ...marks perilous situations by electricity. By non-observance of the safety instructions the possibility of death or severe injuries exist. The operations have to be carried out only by an electrician. 1.3.
General Information 1.4. Demounting and Disposal Unless otherwise authorized, dispose the item considering the safety instructions.
Safety 2. Safety 2.1. General Cause of Risks This chapter gives an overview about all important safety aspects to guarantee an optimal protection of employees. 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. Therefore: Change into protective clothing before beginning the work process.
Conventional use, Transport, Storage 2.3. Conventional Use The controller P40 is for the limited purpose as described in this manual: The controller P40 is constructed for positioning uses only. CAUTION! Danger through non-conventional use! Non-intended use and non-observance of this operation manual can lead to dangerous situations.
Conventional use, Transport, Storage 3.3. Check of Transport Examine delivery immediately after receiving for completeness and transport damages. In case of externally recognizable transport damages: Do not accept the delivery or do accept under reserve Note extent of damages on the transportation documents or on the delivery note File complaint immediately ADVERT! Claim any damages you recognize as soon as possible. The claims for damage must be filed in the lawful reclaim periods. 3.4.
Product Features 4. Product Features Essential features: Analog or digital outputs for 1 - 3 speed operation 16 free programmable digital in-/outputs Program memory (1000 sets) Angle control / gap control / backgauge Limitation of the cutting length Material List for angle and gap control The single axis controller of P40 series is applicable to easy positioning tasks. An important feature is the easy structured function menu.
Technical Data 5. Technical Data P40 – ELGO-position controller Input supply voltage 24 VDC Power input 24 VDC; max. 150 mA (no-load condition) Rotary encoder supply unit 24 VDC or 5VDC ; max. 130 mA Analog input (option) 12 Bit resolution ; 3,3 V Supply measuring system Input signals The Pin assignment of the inputs and the input logic are programmable Minimum pulse duration: 300 ms Input current /Pin: max.
Technical Data 5.1.
Configuration and Functions 6. Configuration and Functions 6.1. Elements 6.1.1. Control Elements Escape Menu navigation Manual/Single Forward/backward/Enter Program-Mode Function keys Input Start Stop 6.1.2.
Configuration and Functions 6.1.3. Function of Keys Change Operation mode between „Manual“ and „Single“ Operation Mode “Program” Leaving an 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 ...
Configuration and Functions 6.2. Menu, sections and parameters Main menu Due to the display size only five menu levels are visible. The further (momentarily invisible) levels are located beneath.
Configuration and Functions 6.2.1. 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 analog Access to parameters concerning the analog output. General Parameters Axes Access to general parameters concerning the axes.
Configuration and Functions 6.2.1.1. Distance / Longitudes Parameters Slow speed/Creep speed/Correction Slow speed/slow speed (r) = middle speed Distance to the demand position at which the controller switches from high speed to slow speed. The output high speed will be switched off. Creep speed/creep speed (r) = slow speed Distance to the demand position at which the controller switches from slow speed to creep speed. The output slow speed will be switched off.
Configuration and Functions Positioning with two speeds Slow speed = Creep speed > Correction stop Slow speed/Slow speed (r) Creep speed/Creep speed (r) Correction/Correction (r) = 10.0 = 10.0 = 1.0 Position reached Fast Slow speed/Creep speed 100,0 Correction stop 90,0 99,0 Slow Positioning with three speeds Slow speed > Creep speed > Correction stop Slow speed/Slow speed (r) Creep speed/Creep speed (r) Correction/Correction (r) = 20.0 = 10.0 = 1.
Configuration and Functions Tolerance window It is possible to enter a value in this register that represents an acceptable tolerance. When the actual position is within the tolerance the actual position displayed is aligned with the demand position. The entered range of tolerance is always active in the + and – range around the demand value. The real actual value is saved in the processor, i.e. no positioning errors through adding up occur. Example: Entered value = 0.2 (tolerance +/ 0.
Configuration and Functions Software-end position MIN/MAX These two values can be used if no mechanical limit switches are present or additionally for already existing mechanical limit switches. End position min.: This value should be between the smallest length/position that hast o be worked off and zero (and shortly before the mechanical limit switch respectively). End position max.
Configuration and Functions 6.2.2. Axis menu / times The times relevant for the respective axes can be entered from 0.1 to 99.9 seconds. 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 analog Access to parameters concerning the analog output. General Parameters Axes Access to general parameters concerning the axes.
Configuration and Functions Parameter of time Position reached The 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. The appropriate output signal becomes active if: Actual value = demand value +/– stop offset By reached position the signal is switched to pulsed if a value (0.1 … 99.9 sec) is entered into the register „position reached“. Spindle compensation In the peak of the loop drive, the drive signals drop-out.
Configuration and Functions 6.2.3. Axis menu / analog The axis relevant analog 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 analog Access to parameters concerning the analog output. General Parameters Axes Access to general parameters concerning the axes.
Configuration and Functions 6.2.3.1. Analog parameters Velocity The maximum speed is set in this register, in rpm. The speed is monitored by the encoder speed (0 – 10000 rpm). Should there be gearing between the motor and the encoder this has to be considered in the calculations. EXAMPLE! Demanded motor speed rpm = 3000 Gearing ratio i = 10 V = RPM/i = 3000/10 = 300 Edge multiplier and impulse multiplication factor has not to be considered.
Configuration and Functions D-portion Differential voltage: setting 1...1000 General: The D-controller (differential controller) provides the control value from the derivative with respect to time oft he offset. P40: By 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).
Configuration and Functions 6.2.4. Axis menu / General System relevant general parameters can be entered in this register. 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 analog Access to parameters concerning the analog output. General Parameters Axes Access to general parameters concerning the axes.
Configuration and Functions 6.2.4.1. System parameters Positioning measurement system The type of measurement system is defined in this parameter. Axis deactivated Microcontroller PID Controller Analog potentiometer Direction change manual The allocation of the direction for the corresponding keys can be set as inverted in this parameter. normal inverted Drive signals With configuration of the motor signals different starting combinations for the different speeds can be set.
Configuration and Functions Drive signals = Mode 3 2 speeds speed = output signals 2 + 3 output 4 set direction reverse Output signals Creep speed forward Slow speed forward Fast speed forward Creep speed backward Slow speed backward Fast speed backward 1 X 2 X X X X 3 4 X X X X X Drive signals = Mode 4 2 speeds Independent outputs for direction and speed Output signals Creep speed forward Slow speed forward Fast speed forward Creep speed backward Slow speed backward Fast speed backward
Configuration and Functions Drive signals = Mode 6 3 speeds Binary coded output 1 = forward output 4 = backward outputs 2+3 = speed Output signals Creep speed forward Slow speed forward Fast speed forward Creep speed backward Slow speed backward Fast speed backward 1 X X X 2 X X X 3 4 X X X X X X X X 2 3 4 X X X Drive signals = Mode 7 3 speed Forward/backward separately Output signals Creep speed forward Slow speed forward Fast speed forward Creep speed backward Slow speed backward Fa
Configuration and Functions Mode reference The mode for referencing is defined in this parameter. Mode 1 = Calibration through reference parameter Mode 2 = Calibration through demand value Mode 3 = Reference run positive with index impuls Mode 4 = Reference run negative with index impuls Mode 5 = Reference run positive to input “reference point” Mode 6 = Reference run negative to input “reference point” Backlash compensation The different types of backlash compensation (loop) are defined in this parameter.
Configuration and Functions 6.2.5 Material Table In this table the material specific experienced values for cut angle and gut gap can be entered in this parameter. The more inputs are made the more precise the non-existing values in the table can be calculated through interpolation. By operating one set or more sets the only values that have to be entered are the kind of material (material no.) and the metal sheet thickness. The buttons F1 and F3 are used to scroll through the material table.
Configuration and function 6.2.6 Menu / System Adjustment Access to system parameters.
Configuration and Functions Language German English Axes active Backgauge + Gap + Angle Backgauge + Gap Backgauge + Angle Backgauge Mode pieces counter single block The mode pieces counter for the single mode can be defined here. Without counter Automatically subtracting Automatically adding Mode pieces counter program The mode counter fort he program mode can be defined in this parameter.
Configuration and Functions 6.3. Machine setting ATTANTION! First check end-switch function! 6.3.1. Gap Setup (Cut gap) Minimum gap: Enter the small cut gap of the shear (e.g. 0.5 mm) and after that drive manually to the smallest position by using F1-key or F3-key. When reached this position press the F2-key (teach). The incremental measurement value is assigned to the gap and entered in the field “min.” is saved. Maximum gap: Enter the large cut gap of the shear (e.g. 10.
Configuration and Functions Configuration of inputs and outputs With the controller P40 it is possible to configure feely the inputs and outputs with their associated logic. 6.4.1. Link-up the inputs with functions In the menu “Input functions” you will find an overview of all functions of the inputs which can be assigned. After dialing a function by using the navigation buttons you can select this function by pressing the Enter key.
Operation 7. Operation 7.1 Operation Modes 7.1.1 Manual mode With the keys F1 & F3 the axis shown in the display can be driven manually or with the inching function. In register “delay hand” a time (in sec) can be set. If the hand mode is selected and the entered time value is worked off the manual mode will automatically switch from creep speed to fast speed. 7.1.2 Single mode Using the single mode (single set mode) a single set can be processed. The arrow keys can be used for navigation.
Operation 7.1.3.2. Handle of a program The program mode can be select directly by using the program button. First, choose a program by entering a program number, and confirmed with the Enter key. With the keys F1 and F3 you can scroll again through all the sets. The automatic positioning starts by pressing the Start button. Now, all sets will be processed until the end marker of the program is reached. The positioning process can be intercepted by pressing the stop button at any time.
Operation 7.2 Connector pin assignment ST1 ST2 ST3/ST4 ST5/ST6 ST7 ST9 MCC1 P1 = = = = = = = = Encoder input Backgauge Encoder input Angle and Gap Digital Inputs Digital Outputs Analog Output (PID) Power supply Analog Output/Motor Drive Controller (MCC) PC Interface Advert! The Analog Output is only available for devices with Option PID.
Operation 7.2.1 Overview Terminal Assignment ST1 Encoder Backgauge 1 2 3 4 5 6 7 8 9 ST2 Encoder Gap and Angle GND 5VDC/24VDC A‐Channel B‐Channel Earth /A‐Channel /B‐Channel Z‐Channel (Index pulse) /Z‐ Channel (Index pulse) 1 2 3 4 5 6 7 8 9 GND 3,3VDC Supply Analog Input Gap 0..3,3VDC Earth Analog Input Angle 0..3,3VDC ST3 Inputs 1 GND 2 24VDC (Output) 3 Limit Switch Min. Axis 1 4 Limit Switch Min. Axis 2 5 Limit Switch Min. Axis 3 6 Limit Switch Max. Axis 1 7 Limit Switch Max.
Operation 7.3 Diagnostics The modules for inspecting, maintenance, control and safety/security are provided in this register: (1) (2) (3) (4) Input test – The inputs can be inspected with this function. Output test – The outputs can be inspected with this function. Keyboard test – The functioning oft he keys can be ensured in with this test. Version info – The installed software version is displayed with this function.
Interferences 8. Interferences The following chapters describe possible causes for malfunction and the instructions to correct them. If you encounter problems check for proper installation first. Make sure that power is supplied to the system. If you observe recurring errors you might consider electrical interference suppression measures as described in section 8.2 If errors cannot be corrected with the following instructions please contact the manufacturer (see last page). 8.
Interferences Shielding: All external signal wires have to be installed shielded: 1. Rotary encoder wires and analog 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 (earth potential), connect only one sided at the controller. ADVERT! Do not connect the controller / measuring system GND to PE (protective earth).
Interferences 8.4 EMC information A trouble-free operation of the control devices of the company ELGO Electric GmbH 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.
Maintenance 9 Maintenance The unit works maintenance-free.
Type Designation 10 Type Designation P40 – XXX – 024 – XX – XX - XXXX Positioning controller Single axis with program memory Construction 000 = standard 001 = special version … Supply voltage 024 = 24 VDC (+/- 20%) Encoder inputs X = Not equipped 0 = A, B (PNP) 24 VDC supply voltage for encoders/24 VDC – 20 KHz 1 = A, B, 0 (PNP) 24 VDC supply voltage for encoders/24 VDC – 20 KHz 2 = A,/A, B, /B (TTL) 24 VDC supply voltage for encoders 5 V-TTL – 100 KHz 3 = A, /A, B, /B, 0, /0 (TTL) 24 VDC supply voltage
Accessories 11 Accessories NG 13.0 Power supply Primary: 115/230 V AC Secondary: 24 V DC/600 mA Relay outputs over separate relay card RP16K and connector cable available Document- No.: 799000348 / Rev. 1 DocumentP40-002-E_30-10 Name: Subject to change - © 2010 ELGO Electronic GmbH & Co.
