/14/2003 ULTRA EDGE SERVO ROLL FEED TABLE OF CONTENTS DESCRIPTION PAGE 1 INTRODUCTION............................................................................................................................................................................3 2 THEORY OF OPERATION...........................................................................................................................................................3 2.1 MECHANICAL ASSEMBLY .............................................
2/14/2003 ULTRA EDGE 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 EDGE 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 EDGE SERVO ROLL FEED The result is an accurately positioned strip exactly 11.138 inches from its starting point. This entire process happens in milliseconds. 2.4 TOOL STORAGE OPERATION The tool storage feature allows for storing of parameters that are different from tool to tool. It takes just a few seconds to activate feeding parameters associated with a certain tool number. Maximum 200 tools can be stored.
2/14/2003 ULTRA EDGE SERVO ROLL FEED encoder shaft, constantly calculates (updates) its current position. The position of the press crankshaft is determined through the offset parameter, which is the position of the encoder shaft when the press is in its 0 degree position (TDC). Thus, at every point of the stroke, the servo drive knows where the crankshaft is. The servo drive controls six cams simultaneously, turning them on and off accordingly to the cam settings.
2/14/2003 ULTRA EDGE SERVO ROLL FEED 3 PROGRAMMING THE ULTRA EDGE 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 5 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 EDGE 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 displayed instead • Current press position in degrees.
ULTRA EDGE SERVO ROLL FEED 2/14/2003 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 EDGE SERVO ROLL FEED 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 60.000 Count Cont.
2/14/2003 ULTRA EDGE SERVO ROLL FEED 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. Otherwise, the servo drive will generate Synch Fault Signal, display the corresponding message in the screen, and stop feeding.
2/14/2003 ULTRA EDGE SERVO ROLL FEED 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. Save As Tool# Press TOOLS to Abort Save As #1234567 Tool#1234567 Saved The display will show the STATUS screen. Tool#1 Spd:384 Auto Mode 30 / Cont.
2/14/2003 ULTRA EDGE 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.
ULTRA EDGE SERVO ROLL FEED 2/14/2003 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. Priority is a parameter that selects whether the feeder indexes before the press starts “FBP” or the press starts before the feeder indexes “PBF”. Entering a “0” selects “PBF” mode and a “1” selects “FBP” mode.
2/14/2003 ULTRA EDGE SERVO ROLL FEED 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. It is a numeric entry, with a range of 0 to 1 inch.
2/14/2003 ULTRA EDGE SERVO ROLL FEED LINEAR ACCELERATION S-CURVED ACCELERATION NOTE: To exit setup editing at any time, press the “OPER” key. Changes will be saved. 4 HOW TO … NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position. If the current screen is one of the tool editing screens (they all have the message on the last line “Press TOOLS for next”), press the “OPER” key to exit tool editing. 4.1 HOW TO CREATE A NEW TOOL Press the “TOOLS” key.
2/14/2003 ULTRA EDGE SERVO ROLL FEED 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 EDGE SERVO ROLL FEED Tool#1 Pos:354 PilotRel On 125 PilotRel Off 225 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 Aux1 On 0 AuX1 Off 120 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 Aux2 On 120 AuX2 Off 240 TOOLS-next BKSP-Prev Press “TOOLS” to open the next screen.
2/14/2003 ULTRA EDGE SERVO ROLL FEED Edit Tool < Activate Tool Create New Press TOOLS to Exit Enter desired tool number or select it from the tool list using “↑” and “↓” keys and press the “ENTER” key again. Edit Tool# Arrow keys to scroll Press TOOLS to exit Edit Tool#1 Arrow keys to scroll Press TOOLS to exit Position cursor next to desired parameter, enter the new value, and press the “ENTER” key. Tool#1 Length 20.000 Count Cont.Run Press TOOLS for next Press “TOOLS” key to open next screen.
2/14/2003 ULTRA EDGE 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 EDGE SERVO ROLL FEED Tool#1 Saved NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position. If the current screen is one of the tool editing screens (they all have message on the last line “ Press TOOLS for next”), press the “OPER” key to exit tool editing. Press “TOOLS” key, position the pointer next to EDIT TOOL command and press the “ENTER” key.
2/14/2003 ULTRA EDGE SERVO ROLL FEED 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. Position cursor next to desired parameter, enter new value, and press “ENTER” key.
2/14/2003 ULTRA EDGE SERVO ROLL FEED Press “TOOLS” key to open next screen. To save changes as a new tool, choose the SAVE AS command and press the “ENTER” key. Tool# Save Save as < TOOLS-next BKSP-Prev Enter the new tool number and press the “ENTER” key again. Save as Tool# Press TOOLS to Abort Save as #5 Tool#5 Saved 4.4 HOW TO DELETE A TOOL NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position.
2/14/2003 ULTRA EDGE SERVO ROLL FEED Tool#1 Length 20.000 Count Cont.Run Press TOOLS for next Press the “TOOLS” key four (ten – with PLS option) times scrolling through the editing screens. Tool#1 Speed 72 Dwell 150 TOOLS-next BKSP-Prev Tool#1 Accel 400.0 Decel 400.
2/14/2003 ULTRA EDGE SERVO ROLL FEED 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 4.5 HOW TO ACTIVATE A TOOL NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position.
2/14/2003 ULTRA EDGE SERVO ROLL FEED 4.6 HOW TO EDIT “SETUP” PARAMETERS NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position. If the current screen is one of the setup screens (they all have message on the last line “ Press “SETUP” for next”), press the “OPER” key to exit setup screens. Press “SETUP” key three times, position cursor next to desired parameter, enter in new value, and press the “ENTER” key. Jog Speed % 5 JogAccel 10.0 JogDecel 10.
2/14/2003 ULTRA EDGE SERVO ROLL FEED 4.10 HOW TO SYNCHRONIZE PRESS AND PLS Open SetUp screens, find Press offset parameter, and verify its value is set to “0” and if it is not, set it so. Recycle the power. PLS Counts/Rev Press Offset 1024 0 SETUP-Exit BKSP-Prev Jog the press to its “0” degree (TDC) position, open status screen and read PLS position. Tool# Pos:324 Manual Mode 30 /Cont.Run Press a Mode Key Go back to Press offset parameter and change it to match PLS reading.
2/14/2003 ULTRA EDGE SERVO ROLL FEED OPERATOR screen is the only one that is Operator editable. This screen displays Length, Count, and Length Adjustment. Length and Count can be changed only when cycling is stopped, although Length can be adjusted by using the LENGTH ADJUSTMENT command even while the feed is running.
2/14/2003 ULTRA EDGE SERVO ROLL FEED The “Permit Press” relay remains activated until the automatic cycling is stopped by either “Cycle Stop” button, “Batch Complete” internal command, “Sync Fault” or any other drive related error. Under “Cycle Stop” or “Batch Complete” stopping, the output will turn off at the beginning of the Feed Cam Signal. This should allow the press to stop near the top of the stroke.
2/14/2003 ULTRA EDGE 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 72.00 400.00 Feed Time(sec) 90 0.070 0.091 0.107 0.120 0.161 0.193 0.220 0.244 0.265 0.285 0.303 0.320 0.336 0.366 0.394 0.422 0.450 0.478 0.506 0.533 0.561 0.589 0.617 0.686 0.756 0.825 0.894 0.964 1.
2/14/2003 ULTRA EDGE SERVO ROLL FEED 5.6 TROUBLESHOOTING GUIDE The chart that follows contains the most frequently encountered issues. Symptom No power indication when Power On button is pressed No display on power up 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 Cause or Remedy 1. Check the main power supply for proper voltage. 2. Check the supply circuit breakers. 3.
2/14/2003 ULTRA EDGE 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 EDGE 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. Route the encoder cable away from potential noise sources.
2/14/2003 ULTRA EDGE SERVO ROLL FEED WARNING This equipment offers various means of operating or controlling machines. The operator must not be in or near the point-ofoperation 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.