/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED TABLE OF CONTENTS DESCRIPTION PAGE 1 INTRODUCTION........................................................................................................................................... 3 2 THEORY OF OPERATION ......................................................................................................................... 3 2.1 MECHANICAL ASSEMBLY............................................................................................................
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED RECEIVING INSPECTION BEFORE REMOVING UNIT FROM ITS PACKAGING, CHECK FOR VISUAL DAMAGE, ESPECIALLY IF CRATE, SKID, OR CARTON HAS BEEN DAMAGED IN TRANSIT. ANY DAMAGE CAUSED IN SHIPMENT SHOULD BE IMMEDIATELY REPORTED TO THE CARRIER. IF UNIT APPEARS IN SATISFACTORY CONDITION, REMOVE ALL PACKING AND WIPE RUST PREVENTIVE FROM ROLLERS WITH MILD SOLVENT.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED ALL ULTRA ADVENTAGE SERVO ROLL FEED CONTROLS ARE CONVENIENTLY LOCATED ON THE FRONT SIDE OF THE ELECTRICAL ENCLOSURE CONTROL/DEVICE DESCRIPTION Power On/Reset button Turns controller on, resets the servo drive. In Position indicator light, white Turns on when move is complete and motor is holding position. Cycle Start illuminated button, green Turns controller into “Auto” mode from “Manual” mode, starts cycling.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Example: If a feed pitch/length of 11.138 inches is entered into the feeder, this will result in exactly one revolution of the feed rolls. The motor will accelerate and turn 10.24 turns. This will produce (10.24 x 8000 = 81,920) pulses of the encoder. The feeder will decelerate and stop, when 81,920 pulses are detected. The feeder is now in position. The result is an accurately positioned strip exactly 11.138 inches from its starting point.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED The encoder then turns into the incremental mode, sending the count signals to the servo drive proportionally to the angle of the move (1024 counts per revolution). The servo drive software, having the start point position of the encoder shaft, constantly calculates (updates) its current position.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED 3 PROGRAMMING THE ULTRA ADVANTAGE SERVO ROLL FEED SYSTEM OVERVIEW NOTE: Before attempting any programming, make sure that the “PROGRAMMING LOCKED / UNLOCKED” key switch is in the “Unlocked” position. NOTE: After power shutdown, WAIT for 10 seconds before powering up the Feed. Turn on the main power disconnect switch. This applies power to the control power supply. Press the green Power On push-button.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED 3.1 “OPER” KEY “OPER” key controls appearance of two screens: STATUS screen and OPERATOR screen. STATUS screen shows: Tool#1 Pos:182 Manual Mode 30 / Cont.Run Press a Mode Key • • • • Active tool number. In case there is no active tool “No Tool!” message is displayed instead Current press position in degrees.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Position the pointer on desired line, using “↑” and “↓” keys , and press the “ENTER” key. Enter in the tool number or select it from the tool list using “↑” and “↓” keys and press the “ENTER” key again. Edit Tool#1 Arrow keys to scroll Press TOOLS to exit Activate Tool#1 Arrow keys to scroll Press TOOLS to exit Create Tool# Press TOOLS to exit NOTE: Tool number can contain up to seven digits.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Edit Tool# Arrow keys to scroll Press TOOLS to exit Or Activate Tool# Arrow keys to scroll Press TOOLS to exit If “Edit Tool” or “Create New Tool” operation is chosen, then the next three (nine - with PLS option) screens will allow editing of the tool parameters. Position the cursor on desired line, using “↑” and “↓” keys , enter in the desired value, and press the “ENTER” key. Press “TOOLS” to open the next screen or “BKSP” – the previous. Tool#1 Length 60.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED NOTE: Each of the following six PLS screens (Feed Cam, Reset Cam, Pilot Release, Auxiliary 1,2,3) has a press current position shown at the top right corner. Tool#1 Pos:354 FeedCam On 260 FeedCam Off 90 TOOLS-next BKSP-Prev FeedCam On indicates the position of the press when the feed cam switch turns on and the feed starts feeding the material. FeedCam Off indicates the position of the press where the feeding must be completed.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Auxiliary 1 (2, 3) Off indicated the position of the press when the auxiliary cam switch turns off. Tool information can be saved on the next screen. NOTE: Up to 200 tools can be saved. Tool# Save < Save as TOOLS-next BKSP-Prev Use SAVE to save the tool being edited. Press the “ENTER” key. Tool#1 Saved Use SAVE AS to create a new tool using the one being edited. Press the “ENTER” key, enter desired tool number, and press the “ENTER” key again.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Delete Tool#1 Press 1 to confirm Another key to abort The corresponding message on the next screen confirms the chosen command execution. Tool#1 Deleted or Aborted! Display will show STATUS screen. Tool#1 Spd:384 Auto Mode 30 / Cont.Run Press a Mode Key NOTE: To exit tool editing at any time, press the “OPER” key. Changes will not be saved. 3.3 “SETUP” KEY “SETUP” key controls the appearance of setup screens.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED InPosition 0.0200 Priority (1/0) FBP AdjustmentStep 0.001 SETUP-Next BKSP-Prev InPosition is a tolerance window around the final position. This is used to verify the feed index accuracy is within acceptable limits before continuing onto the next function. It is a numeric entry with a range of 0 to 100 inch. Normally set 0.02 inch.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Back Length 0.000 Kerf 0.000 MaxLength 60.000 SETUP-Next BKSP-Prev Back Length is used for Cut-to-Length application to protect the material against bending up by the blade. If any value is assigned for this parameter, the feed will move material back for the distance that equals Back Length when Reset Cam input is turned “On” by the blade bottom position sensor. The Back Length is compensated on the next move, so it has no affect on the Length parameter.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Bandwidth is a tuning parameter, before changing its value consult the P/A Industries Service Department Kp Multiplier is a parameter that defines a proportional gain of the position loop of the Strip Encoder and based on the value of the motor encoder's Kp proportional gain. This is a tuning parameter, before changing its value, consult the P/A Industries Service Department.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Create Tool# Press TOOLS to Exit Create #1 Tool Created Position cursor next to desired parameter, enter appropriate value, and press the “ENTER” key. Tool#1 Length 1.000 Count Cont.Run Press TOOLS for next Press “TOOLS” key to open next screen. Position cursor next to desired parameter, enter appropriate value, and press the “ENTER” key. Tool#1 Speed 72 Dwell 0 TOOLS-next BKSP-Prev Press “TOOLS” key to open next screen.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Tool#1 Pos:354 FeedCam On 260 FeedCam Off 90 TOOLS-next BKSP-Prev Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER” key. Tool#1 Pos:354 ResetCam On 180 ResetCam Off 200 TOOLS-next BKSP-Prev Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER” key.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Tool#1 Saved 4.2 HOW TO EDIT AN EXISTING TOOL NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position and OPERATOR screen is displayed. If the current screen is not OPERATOR one then press the “OPER” key to bring it up. Press “TOOLS” key, position the pointer next to EDIT TOOL command and press the “ENTER” key.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Tool#1 Accel 400.0 Decel 400.0 TOOLS-next BKSP-Prev NOTE: The following six screens are part of the optional PLS package and displayed only if the corresponding software is loaded. Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and then press “ENTER” key. Tool#1 Pos:354 FeedCam On 260 FeedCam Off 90 TOOLS-next BKSP-Prev Press “TOOLS” to open the next screen.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Tool#1 Pos:354 Aux3 On 240 AuX3 Off 0 TOOLS-next BKSP-Prev Press “TOOLS” key to open next screen. To save changes choose SAVE command and press the “ENTER” key. Tool# Save < Save as TOOLS-next BKSP-Prev Tool#1 Saved 4.3 HOW TO CREATE A NEW TOOL USING AN EXISTING ONE NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position and OPERATOR screen is displayed.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Press “TOOLS” key to open next screen. Position cursor next to desired parameter, enter new value, and press the “ENTER” key. Tool#1 Speed 72 Dwell 150 TOOLS-next BKSP-Prev Press “TOOLS” key to open next screen. Position cursor next to desired parameter, enter new value, and press the “ENTER” key. Tool#1 Accel 400.0 Decel 400.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER” key. Tool#1 Pos:354 Aux2 On 120 AuX2 Off 240 TOOLS-next BKSP-Prev Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER” key. Tool#1 Pos:354 Aux3 On 240 AuX3 Off 0 TOOLS-next BKSP-Prev Press “TOOLS” key to open next screen.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED 4.3 HOW TO DELETE A TOOL NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position and OPERATOR screen is displayed. If the current screen is not OPERATOR one then press the “OPER” key to bring it up. Press “TOOLS” key, position the pointer next to EDIT TOOL command and press the “ENTER” key.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Tool#1 Pos:354 PilotRel On 125 PilotRel Off 240 TOOLS-next BKSP-Prev Tool#1 Pos:354 Aux1 On 0 AuX1 Off 120 TOOLS-next BKSP-Prev Tool#1 Pos:354 Aux2 On 120 AuX2 Off 240 TOOLS-next BKSP-Prev Tool#1 Pos:354 Aux3 On 240 AuX3 Off 0 TOOLS-next BKSP-Prev Tool#1 Save Save as < TOOLS-next BKSP-Prev Tool#1 Delete Tool < TOOLS-next BKSP-Prev Press “ENTER” key. Delete Tool#1 Press 1 to confirm Another key to abort Press “1” key. Tool#1 Deleted 4.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Edit Tool Activate Tool < Create New Press TOOLS to exit Activate Tool# Arrow keys to scroll Press TOOLS to exit Enter desired tool number or select it from the tool list using “↑” and “↓” keys and press the “ENTER” key again. Activate #1234567 Arrow keys to scroll Press TOOLS to exit Tool Activated 4.5 HOW TO EDIT “SETUP” PARAMETERS NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position and OPERATOR screen is displayed.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED 4.8 HOW TO EDIT COUNT FROM OPERATOR SCREEN Locate the OPERATOR screen, position cursor next to the Count, enter new value, and press the “ENTER” key. Enter “0” for continuous run. Length 1.000 Count Cont.Run Length Adjustment < Press OPER to exit 4.9 HOW TO MICRO ADJUST LENGTH USING LENGTH ADJUSTMENT Locate the OPERATOR screen, position pointer next to the Length Adjustment and press the “ENTER” key. Length 1.000 Count Cont.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Tool# Pos: 0 Manual Mode 30 /Cont.Run Press a Mode Key At this point the press and PLS are synchronized and you can start setting cam On/Off parameters. 4.11 HOW TO SET CAM “ON”/“OFF” PARAMETER Open the screen that displays desired cam settings, jog the press to position where cam should turn on, read the exact value of the press current position and enter this value for Cam On parameter.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED The “Jog Forward” Operator button will function until the end of the “Feed Length” is reached. During “JTL” mode, the bottom line on the display will show “Waiting for Jog”. When the “Feed Length” is reached, the jog buttons become inactive and the message on display will show “Waiting for Press”. The jog buttons will not become active again until after the press has made a cycle. 5.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Length Mode Control Length Check 0.01 Strip Scale 3386.30 SETUP-Next BKSP-Prev Profile Linear Bandwidth 300 Kp Multiplier 1.3 SETUP-Next BKSP-Prev NOTE: The following speed performance charts represent theoretical calculations based on parameter values most commonly used. Higher performance for specific applications can be reached by custom tuning the control.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Figure 6 SPEED PERFORMANCE CHART Velocity (in/sec) 2 Accel (in/sec ) Feed(in) 0.25 0.50 0.75 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 12.00 14.00 16.00 18.00 20.00 22.00 24.00 26.00 28.00 30.00 35.00 40.00 45.00 50.00 55.00 60.00 Velocity (in/sec) 2 Accel (in/sec ) Feed(in) 0.25 0.50 0.75 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 12.00 14.00 16.00 18.00 20.00 22.00 24.00 26.00 28.00 30.00 35.00 40.00 45.00 50.00 55.00 60.00 72.00 400.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED 5.6 TROUBLESHOOTING GUIDE The chart that follows contains the most frequently encountered issues. Symptom Cause or Remedy No power indication when Power On button is pressed 1. 2. 3. 4. 5. No display on power up 1. 2. 1. 2. Feed will not jog Power On indicator is lit. Feed will not operate. Feed will not accept new “Feed Length” or other parameters Inaccurate feeding Feed runs backwards Drive Fault Check the main power supply for proper voltage.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED 5.7 ERROR CODES Error Code Problem or Symptom 04 Motor Over Temperature 05 IPM Fault 09 Bus Under Voltage 10 Bus Over Voltage 11 Illegal Hall State 20 Motor Encoder State Error Possible Cause(s) Action/Solution Motor thermostat trips due to: High motor ambient temperature, and/or Excessive RMS torque. Bad encoder cable or connection. Motor cables shorted. Motor winding shorted internally. Ultra5000 Servo drive temperature too high.
2/14/2003 ULTRA ADVANTAGE SERVO ROLL FEED Error Code Problem or Symptom Possible Cause(s) Action/Solution 21 Auxiliary Encoder state Error The auxiliary encoder encountered an illegal transition. 22 Motor Thermal Protection Fault 23 IPM Thermal Protection Fault The internal filter protecting the motor from overheating has tripped. The internal filter protecting the IPM at slow speed has tripped. Use shielded cables with twisted pair wires.
WARNING This equipment offers various means of operating or controlling machines. The operator must not be in or near the point-of-operation of the machine, or the operating parts of any equipment installed on the machine, or bodily injury could result. The EMPLOYER must post adequate warning signs onto the machine with proper warnings for his machine and the specific application to which the machine and equipment are being applied. Occupational Safety and Health Act (OSHA) Sections 1910.211, 1910.