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ABB straight servo press installation manual

1. Z lt z LLI I O gt z Z E lt A E 2 BE N Picture NO 4 e O O 4 5 SERVO DRIVE FIXING HOLES TEMPLATE AND MOUNTING To fix the AMP servo drive Microflex e 150 on the backplane is necessary drill four holes for screw M5 or in alternative UNC 10 24 or W7 32x24 with the centre to centre distance as indicated in template below 63 1225 Le top holes holes template 90 mm bottom slot mount the servo drive oriented with the holes to the top and the slot to the bottom an tight the screw until the drive will be secure on the backplane 34 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS SERVO PRESS MODULE INSTALLATION sm Lin rasa 5 1 SERVO PRESS MODULE MOUNTING Follow the next raccomandations to install correctly the servo press modules The servo press housing must be mounted without tension or contorsion The servo press housing must be precisely aligned to the load direction of motion The servo press accept only the lateral force declared by the manufacturer 5 1 1 SERVO PRESS FLANGE MOUNTING The easiest and most economic method of mounting is using the available mounting thru holes on the servo press flange Make sure that the mounting surface is level and that the servo press is mounted on the surface without tension and contorsion This method of mounting is only possible if the top side of the mounting surface is accessible See Picture
2. Pump a quantity of 13 cm3 to lubricate the bearing by the Nipples NO 1 Pump a quantity of 4 cm3 to lubricate the bearing by the Nipples NO 2 Pump a quantity of 4 5 cm3 to lubricate the bearing by the Nipples NO 3 Pump the grease ONLY when the spindle s supply current is cut off The relubrication shall be effectuated only by skilled personnel MN0010 VERSION 1 0 DATE 2014 10 17 59 MAINTENANCE sma LLL rasa STRAIGHT PRESS nipples 1 nipples NO 2 nipples NO 3 10 3 ANTY TWIST GUIDE RELUBRICATION The anti twist guide has to be greased at least every 1500 hours of working according to the maintenance plan To lubricate the anti twist guide is raccomended the grease NULON L 80 DO NOT use different type of grease and DO NOT introduce different kind of grease and mix with the grase present in the device Use the nipples NO 4 5 6 7 8 9 10 11 12 to pump the grease to lubricate the anti twist guide See the pictu re NO 10 im nipples 7 nipples NO 8 nipples nipples NO 10 TIT D S m 4 at p Hs nipples NO 12 nipples NO 9 amp P am EE La pic NO 10 nipples NO 6 nipples nipples NO 4 Procedure 1st step Positioning the Rod in home position totally inn Pump
3. SHIELD SHIELD CONDUCTOR PE MNO0010 VERSION 1 0 DATE 2014 10 17 2 N PLANNING THE ELECTRICAL STRAIGHT PRESS mp ic ana For AC power cabling is allowed also a four conductor system as three phase conductors and a protective conductor See below SHIELD PE PE 3 4 PROTECTING THE CONTACTS OF RELAY OUTPUTS AND ATTENUATING INDUCTIVE LOADS Inductive loads relays contactors motors cause voltage transients when switched off Equip inductive loads with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances might connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system Install the protective component as close to the inductive load as possible Do not install protective components at the I O terminal block 230 V AC EE 230 24 V DC 0 V DC 28 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS PLANNING THE ELECTRICAL m INSTALLATION ALL 0 V DC 24 V DC Relay outputs Varistor RC filter Diode 3 5 ROUTING THE CABLES Route the motor cable away from other cable routes Motor cables of several drives may be run in parallel installed next to each other It is recommended that the motor cable input power cable and force sensor cables are installed on sep
4. 3 Attach the metal P clip or clamp to the exposed area of braided shield 4 Ensure that the P clip is securely attached to an unpainted area of the metal backplane On painted panels remove paint to expose bare metal Make a single circular cut in the cable s outer sheath ensuring that the cable s braided shield is not damaged Slide the section of outer sheath towards the end of the cable to expose an area of braided shield Carefully remove the excess sheath at the end of the cable from MicroFlex e150 Continuation of motor power cable shielding When using a motor contactor or extending the motor cable through a terminal box ensure that the motor cable shielding is continued all the way to the motor o M contactor La je l a Nm he a m 4 il i zi j k ats Uo h N h E i r a from MicroFlex e150 Shielding 46 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS ELECTRICAL INSTALLATION sm LL iL rona 7 4 5 MOTOR CIRCUITS CONTACTOR If required by local codes or for safety reasons an M Contactor motor circuit contactor can be installed to provide a physical disconnection of the motor windings from the MicroFlex e150 Opening the M Contactor ensures that the MicroFlex e150 cannot drive the motor which might be necessary during equipment maintenance
5. The process analisys result OK in each program s steps Analisys NOK The process analisys result NOK in any program s steps Cycle running Press cycle is running This output will be off when press reach to home The Servo drive output Slave shall be connectet from the Input connectors OPT1 and X3 located in the Micro flex e 150 servo drive to the input PLC connector as indicated in the diagram below USER S PLC MASTER SERVO DRIVE CONNECTOR CYCLE RUNNING CYCLE NOK DOUT4 DOUT3 1 SERVO DRIVE CONNECTOR OO O a N OO O N STATUS DOUT2 DOUT1 PRESS READY CYCLE OK MOTOR BREAK PLC INPUT SERVO DRIVE OUTPUT Use shielded cable to connect the servo drive input connector to the user s PLC output connector 52 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS ELECTRICAL INSTALLATION sm EL iL rona 7 8 ETHERNET CONNECTION Auloma s servo press through the Ethernet network executes two functions Servo press set up Process monitoring data management The Auloma Process Monitoring APM PC tool kit installed in a hosted PC has the possibility of set up all servo press parameters and also can download in run the process data analysis elaborated by the Servo Drive This two operations are effectuated through the Ethernet network Servo Servo Servo Servo Host PC us drive drive drive drive External switch E1 E1 E1 E1 ig If the s
6. sm LL IL rona SPECIFICATIONS STRAIGHT PRESS Calculation of ball screw life per total travel L 106 where Ls Fatigue life total travel km ball screw lead mm Auloma provide a service for calculate the ball screw lifetime of its products 13 5 ROLLER BEARING LIFETIME Roller bearings specifications The spindle mount only original SKF roller bearings To calculate the lifetime of roller bearing utilised it is necessary use the calculation program provided on internet by the manufacturer at the web site address www skf com Ask to Auloma which kind of bearings are arranged in your press The roller bearings assembly it is visible in the picture NO 14 Rod side Motor side pic NO 14 72 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS SPECIFICATIONS sm LL iL rona To calculate correctly the roller bearings lifetime is necessary consider the right viscosity value of the grease utilised to lubricate the roller bearing The grease utilised to lubricate the spindle s bearings is the NULON L 80 with the follow features Base oil viscosity 40 ASTM D445 185 cSt Auloma provide a service for calculate the roller bearing lifetime of its products MNO0010 VERSION 1 0 DATE 2014 10 17 73 mm ORDER CODE STRAIGHT PRESS 14 ORDER CODE 74 DATE 2014 10 1
7. GENERAL HAZARDS 6 1 2 2 RISK ANALYSIS T 1 2 3 INTENDED USE 8 1 2 4 IDENTIFYING RESIDUAL DANGERS AND HAZARDOUS AREAS 8 1 2 5 WORKING SAFELY 9 1 2 6 SAFETY INSTRUCTION FOR COMPANY THAT USING THE SYSTEM 9 1 2 7 SAFETY INSTRUCTIONS FOR OPERATING PERSONNEL 9 1 2 8 SAFETY INSTRUCTIONS FOR ELECTRICAL COMPONENTS INSTALLATION 10 1 3 MANUFATURER S DECLARATION 13 1 4 PACKAGING STORAGE TRANSPORT 14 1 4 1 SPECIAL NOTE ON TRANSPORT 14 1 5 WARRANTY CONDITIONS 15 1 6 CONDITIONS OF UTILIZATION 15 1 6 SCOPE OF DELIVERY 16 1 7 MECHANICAL STRUCTURE 17 1 8 SAFETY LABELS 18 1 9 TRADE MARKS 18 2 PRESS FIT MESUREMENT 19 2 1 STANDARD PRESS FIT OPERATION 19 2 2 MULTIPLE PRESS FIT OPERATION 20 3 PLANNING THE ELECTRICAL INSTALLATION 23 3 1 ELECTRICAL CIRCUIT PLANIFICATION 23 3 1 1 SELECTING THE SUPPLY DESCONNETTING DEVICE 23 3 1 2 EMERGENCY STOP DEVICE 24 3 2 THERMAL OVERLOAD AND SHORCICUIT PROTECTION 24 3 2 1 SERVO DRIVE THERMAL OVERLOAD PROTECTION 24 3 2 2 PROTECTING AGAINST SHORT CIRCUIT IN THE SUPPLY CABLE OR DRIVE 24 3 2 3 MOTOR THERMAL PROTECTION 25 3 2 4 BRAKE OUTPUT SHORT CIRCUIT PROTECTION 25 3 3 SELECTING POWER CABLES 25 3 3 1 ALTERNATIVE POWER CABLE TYPES 26 3 4 PROTECTING THE CONTACTS OF RELAY OUTPUTS AND ATTENUATING INDUCTIVE LOADS 27 3 5 ROUTING THE CABLES 28 3 6 EMC STANDARD COMPLIANCE WITH EN 61800 3 30 4 SERVO DRIVE MECHANICAL INSTALLATION 31 4
8. Use crimp connections where possible If the drive is subjected to high potential hipot testing only DC voltages may be applied AC voltage hipot tests could damage the drive For further information please contact your local ABB representative The safe integration of the servo drive for servo press into a machine system is the responsibility of the machine designer Be sure to comply with the local safety requirements at the place where the machine is to be used In Europe these are the Machinery Directive the ElectroMagnetic Compatibility Directive and the Low Voltage Directive In the United States this is the National Electrical code and local codes To comply with CE directive 2004 108 EC an appropriate AC filter must be installed Motor overtemperature sensing is required to satisfy UL 508C The drive has no provisions for motor overtemperature protection so external provisions are required MNO0010 VERSION 1 0 DATE 2014 10 17 11 sma EL iL rona INTRODUCTION STRAIGHT PRESS A Both the AC supply and the 24 V DC supply must be fused The 24 V DC control circuit supply must be installed so that the 24 V DC supplied to the unit is isolated from the AC supply using double or reinforced insulation or by using basic insulation with a protective earth The input of the control circuit must be limited to Safety Extra Low Voltage circuits Permanet magnet motor drives These are additional warnings concerning per
9. None being damaged Ball screw wear damage Thrust bearing wear damage Ball screw coupling loosened m Gearbox wear damage ForcetTransducer destroyed through excessive load Cable breakage force transducer Cable breakage proximity switches Cable breakage motor encoder Cable breakage power cable 1 2 3 INTENDED USE The servo press has a specific uses compression spindle for force compression measuring machines Since the component can be used in a wide range of applications the user is responsible for its use in specific applications Please make sure that the mounting of parts or tools will not pose a threat to persons or cause damages to any parts or devices The servo press must only be used in areas that are not accessible to persons during operation If the servo press is used in areas accessible to people it must be installed in such a manner that no one can be endangered during operation 1 2 4 IDENTIFYING RESIDUAL DANGERS AND HAZARDOUS AREAS If there are still residual dangers present to persons or property from the servo press in spite of operating it in a safe manner the user must make reference to these residual dangers through signs and written rules requiring appropriate procedures The following safety signal words are used Danger Indicates that an imminent hazardous situation may lead to death or serious bodily harm if not prevented using appropriate safety measures Warning
10. SETTING DIGITAL INPUT IN2 CALIBRATION GREEN CABLE SHIELD CONNECTED TO HOUSING In the force sensor the supply voltage OV whire black and output signal OV whire gray are connected internally The inputs outputs of the force sensor are protected against short circuits and reverse polarity 7 5 3 FORCE SENSOR POWER SUPPLY CONNECTION Connect the force sensor to a stabilized power supply as indicated in the follow diagram FORCE SENSOR 24 V BLUE 230 V 400 V STABILIZED POWER SUPPLY DO NOT use the same 24V power supply to supplying the voltage to the force sensor The force sensor is based on wisteon bridge and measure the variation of resistance in the bridge circuit The 24V supplied to the sensor pass through the wisteon bridge and is the base of the force measurement To have a correct force measure it is necessary supply a dedicated 24V power stabilized A variation of the supply voltage means a va riation of the force value output at the same load stress 48 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS ELECTRICAL INSTALLATION sm LL iL rona 7 5 4 FORCE SENSOR ANALOG OUTPUT CONNECTION The force sollecitations against the spindle are transformed by the force sensor in an analog output of 0 to 10 Volts The analog signal is elaborated by the servo drive for analysing The analog signal is acquired through the connector X4 of the servo drive as indicated in the diagram below FORCE S
11. The size of the fuses depends by the power of the servo drive units The Auloma s servo press drove by the ABB Micro flex e 150 can be equipped by different size of servo drive Cheek in the servo drive label beside the written CAT see the Picture NO 3 the alphanumeric number corresponding to the size of your servo drive an choose the right fuses according the label below ABB O lli 152 0 _ SNo 00316010002 TAA Desc MicroFiek e150 Drive US INPUT 105 250 AC 50 60 Hz 16 30 sscesnisnozsovse sa Servo drive code Cont Input fuse Circuit Minimum wire gauge outputs type E152A03EIOA Ferraz Shawmut 8A 14 8A 6x32 FA series 8A V084313P or BS88 2 5 URGS 7A M076647J E152A06EIOA 6A 30 Ferraz Shawmut 12 5A 14 8A 6x32 serie FA 12 5 A X084315P oppure BS88 2 5 URGS 12A P076649J MNO0010 VERSION 1 0 DATE 2014 10 17 PLANNING THE ELECTRICAL STRAIGHT PRESS INSTALLATION Servo drive code Cont Input fuse Circuit Minimum wire gauge outputs Nu braker Amp type C type E152A09EIOA Ferraz Shawmut 14 6x32 FA series 20 A084318P or BS88 2 5 URGS 20A LO97507J The fuses protect the input cable in short circuit situations restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive Circuit breakers It is highly recommended that fuses are us
12. be cause of mechani cal rupture and healt injuries Warning Proxmity switch pic NO 8 58 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS MAINTENANCE sm LL iL rona The ballscrew drive the screw support bearing internal slide and rod must be relubricated from time to time MAINTENANCE PLAN COMPONENT MAINTENANCE INTERVAL ACTION RAM ROD If required cleaning BEARINGS 3800 hours lubricated ANTI TWIST GUIDE 1500 hours lubricated BALL SCREW 1500 hours lubricated FORCE SENSOR 1 YEAR calibration GREASE SCHEDULE APPLICATION GREASE MANUFACTURER ROD BEARINGS ANTI TWIST GUIDE L 80 Nulon BALL SCREW High Lub LFB 2000 Bechem Multipurpose EP grease NLGI Grade 2 10 1 CLEANING If necessary the ram should be cleaned to prevent damage of bushing and bearings caused by sticking dust Therefore remove leaking grease from the rod with a soft cloth Grease emission is operational and is not considered as failure 10 2 BEARING RELUBRICATION The bearings spindle has to be greased at least every 3800 hours of working according to the maintenance plan To lubricate the bering spindle is raccomended the grease NULON L 80 DO NOT use different type of grease and DO NOT introduce different kind of grease and mix with the grase present in the device Use the nipples NO 2 3 4 to pump the grease to lubricate the bearings See the picture NO 9
13. change approach m flaring home position 0 tool change position idle stroke flaring stroke back stroke idle time for tool fast foward until slow forward fast bakward until changing workpiece to the target home position value In this programming mode the functions of the individual position sets are determined by servo drive with APM Home position the ram return in home position and then stop Idle stroke end the ram approach workpiece Introduction stroke the ram insert slowly the workpiece Fitting to the target value the ram fit the workpiece to the target value and then stop Home position the ram goes home posi tion and then stop for tool changing Idle stroke end 4 no the ram approach the workpiece Flaring to the target value 5 yes the ram fit the workpiece to the target value and then stop The user s PLC starts position set 0 of the 1st program The required speed reduction at the end of the respective target positions is performed by the APM servo drive without standstill and without additional activation by the PLC The following records from 1 2 3 are executed by APM Only when the tool hange position set 0 is reached the servo drive will signal the reaching of the position and stop the drive Then the operator change the tool a sensor confirm the presence of the flaring tool Now the system is able to perform the 2nd part of the program after the start executed by the operator As previous program the
14. even damages must be expected 16 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS INTRODUCTION sm LL iL rona Compare the operating data with the stated limit values especially with reference to Stroke length and setting of the encoder those must be set so that there is a sufficient safety travel at both ends of the travel stroke The brushless must be set according to suitable values before operation Thrust and traction force in the effective direction Lateral force e g as a component of the effective force but also due to own weight on horizontal mounting especially with longtravel strokes Velocity Acceleration Environmental conditions e g temperature contamination Please do take possible pulses caused by moved masses into consideration for the operating data Even small abrupt loads can cause damage especially if they occur rather often at the same place The limit values for the thrust and traction force lateral force speed and acceleration are partly influenced by several factors and can change depending on The servo press size Ball screw pitch Direct drive transmission Gearbox trasnsmission ratio Mounting method Mounting orientation vertical or horizontal resp inclined Travel stroke The lifetime of the servo press depends strongly on the degree of power exploitation and on impermissible operating states occurring even if only for a short time The internal mechanical end stops of
15. form any other mechanical function Connector X1 contains earth terminals but these must not be used as protective earth since the connector does not guarantee earth connection first disconnection last Earthing methods are shown in Typical installation example on page 29 When using unearthed ungrounded distribution systems an isolation transformer with an earthed grounded secondary is recommended This provides three phase AC power that is symmetrical with respect to earth ground and can prevent equipment damage Protection class User protection has been achieved using Protective Class EN 61800 5 1 which requires an earth connection to the unit whenever hazardous voltages are applied The equipment provides protection against electric shock by Means of connection of protective earth to accessible live conductive parts Basic insulation Earth leakage Maximum earth leakage from the MicroFlex e150 is 3 4 mA per phase 230 V 50 Hz supply This value does not include the earth leakage from the AC power filter which could be much larger If the MicroFlex e150 and filter are mounted in an enclosure it is recommended the enclosure is earthed using a 10 mm2 conductor 7 2 2 INPUT POWER CONDITIONING Certain power line conditions must be avoided an AC line reactor an isolation transformer or a step up step down transformer might be required for some power conditions If the feeder or branch circuit that provides power to the Mic
16. in roller thrust bearings and through the bearing housing is connected to the force sensor The nut is firmly screwed in the ram through the anti twist device that save the ram against twisting If the ball bearing spindle is running free the ram moves upward downward If the ram encounters resistance a force is produced which is transmitted from the ram through the nut on the ball screw spindle This force is transmitted through the roller thrust bearing to the force sensor which is allocated between the bea ring housing and the body press The load cell connection is plug in An encoder is integrated in the motor so that approach to reference point after voltage failure will not be required if the servo press is provided by an absolute ancoder 1 8 SAFETY LABELS Various labels are used on the servo press to warn of possible harm or injury These labels should be taken very seriously Refer to the following page for label location DANGER HIGH VOLTAGE Do not touch exposed connector terminal May cause electric shock Disconnect power before servicing CAUTION HOT SURFACE Do not touch heatsink May cause burn 1 9 TRADE MARKS WINDOWS VISTA Is registered trademarks of the Microsoft Corporation Microflex e 150 Is registered trademarks of the ABB Group Corporation Is a registered trademarks of the ABB Group Corporation BALDOR Is a registered trademarks of the ABB Group Corporation MNO0010 VERSION 1 0 DAT
17. ndicates a potentially hazardous situation which if not avoided using appropriate safety measures could result in serious or minor injury MNO0010 VERSION 1 0 DATE 2014 10 17 9 INTRODUCTION STRAIGHT PRESS Caution Indicates a potentially hazardous situation which if not avoided using appropriate safety measures may result in minor injury or damage Hint Provides important information about the product how to handle the product or about the part of the manual to which particular attention must be paid 1 2 5 WORKING SAFELY Heed the Instructions The informations such as instructions and notes contained in this manual must be heeded for all work involved in installing commissioning setting up operating changing operating conditions and modes servicing inspecting and repairing the unit The manual must be available close to the servo press during the performance of all tasks It is impermissible to operate the servo press if it is not in perfectly functional condition Operating personnel The following jobs must only be performed by appropriately trained and authorized personnel Installation and set up tasks on the servo press Attaching safety transmitter switches Connecting the drive and testing the motion direction Instructions for Special Hazards The servo press must be fixed or supported in accordance with the indications in this manual The operator must ensure that operation of the servo
18. press does not cause any danger If the servo press moves in hazardous areas these areas can be safeguarded with safety transmitter switches 1 2 6 SAFETY INSTRUCTION FOR COMAPNY THAT USING THE SYSTEM Supervisors must also become familiar with the entire chapter entitled Safety and handling required on the servo press Supervisors must ensure that installation and operating personnel have read and understand all chapters entitled Safety and the description of how to work with the machine and that they observe the instructions The manual must be available close to the servo press during the performance of all tasks It is impermissible to operate the servo press if it is not in perfectly functional condition 1 2 7 SAFETY INSTRUCTIONS FOR OPERATING PERSONNEL Any work step that has a negative effect on the operating safety of the servo press must be omitted Operating and supervisory personnel are required to check the servo press or machine at least once per shift for externally visible damage or defects Changes that have occurred including the operating behaviour that could have a negative effect on the operating safety must be reported immediately Components and accessories are designed especially for this product When purchasing spare and wearing parts use only original Auloma parts We note here explicitly that we are unable to check or release spare parts or accessories that were not provided by us Installing and or using such
19. products may cause negative changes in the required design properties in some circumstances which in turn could negatively effect the active and or passive operating safety of the product The manufacturer is unable to accept any liability for damage caused by using nonoriginal parts and accessories Safety and protection devices are strictly NOT to be removed or bypassed or set out of order Applicable requirements and national accident prevention regulations must always be observed when installing and operating our servo press 10 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS INTRODUCTION sma LL rana 1 2 8 SAFETY INSTRUCTIONS FOR ELECTRICAL COMPONENTS INSTALLATION Electrical safety in installation and maintenance These safety instructions are intended for all who work on the drive motor cable or motor Ignoring the following instructions can cause physical injury or death or damage to the equipment Only qualified electricians are allowed to install and maintain the drive Be sure the system is properly earthed grounded before applying power Do not apply AC power before earths grounds are connected Never work on the drive motor cable or motor when input power is applied After is connecting the input power always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive motor or motor cable Always ensure by measuring with a multimeter impedance a
20. the instructions given in this manual 4 Maximum cable length is 30 meters A drive of category C3 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expectedif the drive is used on such a network Warning MNO0010 VERSION 1 0 DATE 2014 10 17 31 SERVO DRIVE MECHANICAL STRAIGHT PRESS mp Ein rasa 4 1 SERVO DRIVE REQUIREMENTS FOR INSTALLATION SITE The safe operation of the APM servo drive MicroFlex e 150 depends upon its use in the appropriate environment The following points must be considered The MicroFlex e150 must be installed indoors permanently fixed and located so that it can only be accessed by service personnel using tools When installed in a cabinet the cabinet must have a volume of at least 0 19 m3 6 84 cu ft If no installed in a cabinet barriers around the equipment are required The MicroFlex e150 must be secured by the slots in the flange The protective earth ground the threaded hole on the top of the MicroFlex e150 must be bonded to a safety earth ground using either a 25 A conductor or a conductor of three times the peak current rating whichever is the greater Avoid locating the MicroFlex e150 immediately above or beside heat generating equipment or directly below water steam pipes Avoid locating the MicroFlex e150 in the vicinity of corrosive substances or vapors metal particles and dust Failure to mee
21. 0 is designed to be powered from standard single or three phase lines that are electrically symmetrical with respect to earth ground The power supply module within the MicroFlex e150 provides rectification smoothing and current surge protection Fuses or circuit breakers are required in the input lines for cable protection For three phase supplies connect the supply to L1 L2 and L3 as shown above For single phase supplies connect the supply and neutral to any two line inputs for example L1 and L2 40 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS ELECTRICAL INSTALLATION sma EL For CE compliance an AC filter must be connected between the AC power supply and the MicroFlex e150 If local codes do not specify different regulations use at least the same gauge wire for earth ground as used for L1 L2 and L3 The X1 mating connector is a Phoenix COMBICON MSTB 2 5HC 11 ST 5 08 Tightening torque is 0 5 0 6 N m 4 4 5 3 Ib in The threaded hole in the top or bottom of the case may be used as an additional functional earth ground connection for signals on connector X3 The threaded holes may also be used to attach shield or strain relief clamps The holes are threaded for M4 bolts no longer than 11 mm 0 43 in 7 2 1 EARTING GROUNDING A permanent earth ground bonding point is provided on the heat sink which must be used as the protective earth It is labeled with the protective earth symbol in the casting and does not
22. 1 SERVO DRIVE REQUIREMENTS FOR INSTALLATION SITE 31 4 2 REQUIRED TOOLS FOR MOUNT THE SERVO DRIVE 31 4 3 SERVO DRIVE AMBIENT CONDITION 32 4 4 PRECAUTIONS TO COOLING THE SERVO DRIVE 32 4 4 1 EFFECTS OF MOUNTIG SURFACE AND PROXIMITY BETWEEN SEVERAL SERVO DRIVE 32 4 5 SERVO DRIVE FIXING HOLES TEMPLATE AND MOUNTING 33 5 SERVO PRESS MODULE INSTALLATION 34 5 1 SERVO PRESS MODULE MOUNTING 34 9 1 1 SERVO PRESS FLANGE MOUNTING 34 9 1 2 SERVO PRESS HORIZONTAL MOUNTING 35 9 1 3 SERVO PRESS VERTICAL MOUNTING 35 9 1 4 MOUNTING PAYLOAD 35 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS LJ RR 6 ACTIVATION AND SIGNAL 36 6 1 SCHEMATIC DIAGRAM USING APM SERVO DRIVE MICROFLEX e 150 36 6 2 ELECTRICAL CONNECTION DIAGRAM USING APM SERVO DRIVE MICROFLEX e 150 37 6 3 INPUT OUTPUT CHARTS IN STANDARD PRESS FIT OPERATION 38 7 ELECTRICAL INSTALLATION 39 1 CHEEKING THE INSULATION OF THE ASSEMBLY 39 2 CONNECTING THE SERVO DRIVE POWER CABLE 39 2 1 EARTING GROUNDING 40 2 2 INPUT POWER CONDITIONING 40 2 3 POWER SUPPLY FILTERS 41 2 3 1 HARMONIC SUPPRESSION 41 2 3 2 REVERSING THE FILTER 41 2 4 POWER DISCONNECT AND PROTECTION DEVICE 41 3 24V CONTROL CIRCUIT SUPPLY 42 4 MOTOR CONNECTIONS 42 4 3 MOTOR WHIRES TERMINATOR 43 4 1 MOTOR POWER CONNECTIONS 43 4 2 MOTOR THERMAL SWITCH CONNECTIONS 43 4 4 MOTOR POWER CABLE SHIELDING 44 4 5 M
23. 2014 10 17 INTRODUCTION STRAIGHT PRESS Lift Operations Use the four holes M8 NO 1 2 3 4 to fix eyebolts for lift the servo press See the picture NO 1 2 The holes holes have depth of 1 5 fold the diameter In case the threaded length of the eyebolts exceed this measure use a spacer with a thickness enough high to bear at the eyebolt of working properly Use eye bolts DIN 580 1972 or with the same load capacity if are made according diffe rent standards Picture 1 Picture NO 2 The spacer shall be conform to the technical requirements suggested by the eye bolts manufacturers DO NOT let the load swing while handling it Could be causes of collision and failing down of the spindle 1 5 WARRANTY CONDITIONS User Conversions and Changes are Not Permitted The servo press must not be changed in its design or in terms of safety without our approval Any change as defined here made by the user excludes any liability on our part 1 6 CONDITIONS OF UTILIZATION General introductory notes With the Auloma s servo press you bought a product which was manufactured and tested before delivery with the utmost care Please take your time to read the following notes which you ought to follow closely during setup and operation The operation of the servo press is only permitted within the limit values stated in this manual Unless all claims under the warranty will become void and a reduced service life or
24. 6 5 IS lt lt 12 15 gt I I v o gt O Z Z O I amp o or a gt lt lt gt x S C x A O 12 o lu o O 1 gt 2 9 i2 lt p O w 5 Z x Z I O Ja I lt 5 w 5 LL DIGITAL INPUT DIGITAL OUTPUT PC LAPTOP WITH APM PC TOOL INSTALLED PC SERVER WITH APM PC TOOL INSTALLED OPTIONAL PROXIMITY FORCE SENSOR SENSOR OTPTICAL MAGNETIC CAPACITIVE SERVO PRESS MOTOR OPTIONAL ETHERNET SWITCH ENCODER sma MN0010 VERSION 1 0 DATE 2014 10 17 37 sm LL iL rona ACTIVATION AND SIGNAL STRAIGHT PRESS 6 2 ELECTRICAL CONNECTION DIAGRAM USING APM SERVO DRIVE MICROFLEX e 150 MN E1 ETHERNET E2 Cycle running 1 xe Force sensor calibration 8 1 lt Analysis NOK 2 mu 11 Press ready 2 3 12 Analysis OK JOg 4 motor brake OPT1 14 Workpiece present Motor temperature 12 5 J OO 15 Cycle start 13 6 7 16 14 T 17 Home position command 8 SUPPLY POWER CABLES 18 STO OPTIONAL 9 19 STO OPTIONAL MOTOR POWER CONNECTION 10 20 REGENERATIVE R1 1 RESISTOR optional EM R2 5 2 X4 6 24V POWER 0 EM X2 CIRCUITS SUPPLY 24 3 5 SENSOR 0V AIN7 10VDC T 4 8 lt 38 DATE 2014 10 17 MN0010 VERSION 1 0 sma iL rana ACTI
25. 7 MNO0010 VERSION 1 0 STRAIGHT PRESS ORDER CODE mpm MN0010 VERSION 1 0 DATE 2014 10 17 19 INDEX STRAIGHT PRESS sma iL rana A ACTIVATION AND SIGNAL 36 ALLOWED LATERAL FORCE 68 ALTERNATIVE POWER CABLE TYPES 26 ANTY TWIST GUIDE RELUBRICATION 59 B BALL SCREW LIFETIME 70 BALL SCREW RELUBRICATION 60 BEARING RELUBRICATION 58 BENEFITS OF THE SINUSUAL FILTERAT MOTOR EFFICENCY 46 BRAKE OUTPUT SHORT CIRCUIT PROTECTION 25 C CHEEKING THE INSULATION OF THE ASSEMBLY 39 CLEANING 58 CONDITIONS OF UTILIZATION 15 CONNECTING THE SERVO DRIVE POWER CABLES 39 CONTROL CIRCUIT SUPPLY 24V 42 D DIGITAL INPUT OUTPUT COMMUNICATION CONNECTION 49 E EARTING GROUNDING 40 ELECTRICAL CIRCUIT PLANIFICATION 23 EFFECTS OF MOUNTIG SURFACE AND PROXIMITY BETWEEN SEVERAL SERVO DRIVE 32 ELECTRICAL CONNECTION DIAGRAM USING APM SERVO DRIVE MICROFLEX e 150 37 ELECTRICAL INSTALLATION 39 ELECTRICAL INSTALLATION CHEEK LIST 55 EMC STANDARD COMPLIANCE WITH EN 618003 30 EMERGENCY STOP DEVICE 24 ETHERNET CONNECTION 52 ETHERNET CONNECTORS AND ROUTING 53 F FORCE SENSOR ANALOG OUTPUT CONNECTION 48 FORCE SENSOR CALIBRATION 62 FORCE SENSOR CONNECTION 46 FORCE SENSOR DIGITAL INPUT CONNECTION 48 FORCE SENSOR PIN ASSIGNMENT 47 FORCE SENSOR POWER SUPPLY 46 FORCE SENSOR POWER SUPPLY CONNECTION 47 G GENERAL HAZARDS 6 GENERAL INFORMATIONS 68 76 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PR
26. A00 should be installed to isolate the MicroFlex e150 from the rest of the system Alternatively a ferrite sleeve can be attached to the supply cable near connector X2 24 V Filter SERVO DRIVE Customer supplied Optional Ferrite Slave CONNECTOR 24VDC Eusa twisted pair cable Incoming safety with ferrite sleeve attached earth ground PE close to connector X2 Star Point Recommended fuse Bussman 5504 20 x 5 mm anti surge 2 A Recommended ferrite sleeve Fair Rite part 0431164281 or similar 7 4 MOTOR CONNECTIONS The motor outputs are fully short circuit proof according to EN 61800 5 1 The drive trips on a motor phase short circuit and will not restart unless AC power is removed Hazardous voltages can exist on the motor output connections Do not touch the motor output connections before you first ensure there is no high voltage present The motor cables U V and W must be connected to their corresponding U V or W terminal on the motor Misconnection will result in uncontrolled motor movement Do not connect supply power to the MicroFlex e150 UVW outputs The MicroFlex e150 might be damaged For CE compliance the motor earth ground should be connected to the drive earth ground The motor power cable supplied in the kit are shielded The connector or gland used at the motor has 360 degree shielding The maximum cable length available is 30 5 m 100 ft MNO0010 VERSIO
27. APM perform the entire flaring cycle until reach the target value and then drive the ram press to the home position and stop 22 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS home position PLC start V mm s Position set 0 PLC start V mm s Position set 0 PRESS FIT MEASUREMENT Position set 1 Idle stroke Back stroke Idle stroke Back stroke sm LL iL rona Position set 2 Stop E 15 1 121 Fitting I Program 1 Po i Position set 3 Measurement Position set 4 Stop Flaring Program 2 Position set 5 Measurement MN0010 VERSION 1 0 DATE 2014 10 17 23 PLANNING THE ELECTRICAL STRAIGHT PRESS INSTALLATION sma iL rana 3 1 ELECTRICAL CIRCUIT PLANIFICATION The servo press are equipped with servo drive servo motor and brake resistor optional manufactured by ABB Further this manual for the servo press commisioning is necessary read also the ABB original user manual for each specific components used in our servo press system The skilled personnel in charge to execute the commisioning shall read the user manual as indicated in the follow list Manuals and guide title Reference Number Code User s Manual Microflex e 150 servo drive MN1961WEN MicroFlex e150 Quick Installation Guide LT0307 Safety Manual Safe Torque Off STO function
28. E 2014 10 17 19 sm EL iL rona PRESS FIT MEASUREMENT STRAIGHT PRESS The press fit operation must be defined from the user Positions speed of movement The press fit operation is controlled by the APM servo drive The user s PLC through discrete I O shall provide the command to the servo drive The position sets Positions speed of movement are programmed and stored at the user s PC with the APM PC tool kit and transferred to the APM servo servo drive The PLC selects and starts the required pro gram set The positioning of the spindle is now performed by the servo drive which displays a signal message as soon as the target position or force is reached at the ends of the press fit operation In case of complex press fit operation where different press fit program come in succension the user s PLC shall be programmed to select the different programs stored in the APM servo drive This allows breakpoints manual interventions by the operator parts exchange etc All differents programs activated by the user s PLC provide se parated analysis result related to each programs of the sequence At each PLC starting input the APM start to record in synchronous y Force vs x Displacement data to analyse and doing that as soon as the approach stroke is terminated By user defined tolerance windows the evaluation of the measured trace will be done and a definite detection of OK and NOK process is performed 2 1 SANDARD PR
29. ENSOR SERVO DRIVE CONNECTOR AIN0 AINO 7 5 5 FORCE SENSOR DIGITAL INPUT CONNECTION The force sensor own two digital inputs used for the set up Through the red wire is possible reset the zero force value and define the start of the scale of measure Through the green whire is possible calibrate the scale of mea sure The APM software own a procedure to execute both operations The force sensor s green and red wire shall be connected as indicated in the diagram below on the I O connector on the top of the servo drive FORCE SERVO DRIVE SENSOR CONNECTOR DOUT6 DOUT5 O a N 7 6 PROXIMITY CONNECTION Special version mount resolver in the motor for ram feedback The servo press in this case is provided by a proxi mity switch to identify the home position of the press ram The incremental encoder that control the ram movement need of this reference point to count the ball screw revolutions The proximity is a NPN device with contact Normal Open and male connector 3 pin M8 Use a circular connector compliant at IEC61076 2 101 standards and crimp the shielded wire as indicated by the diagram below MNO0010 VERSION 1 0 DATE 2014 10 17 49 ELECTRICAL INSTALLATION STRAIGHT PRESS sma iL rasa 4 PIN CONNECTION FQ 0V PROXIMITY SIGNAL CONNECTOR Connect the proximity switch to the 24 VDC supply voltage ant to the servo drive connector X3 as indicated in the diagram below SERVO DRI
30. ESS sm LL iL rona H HARMONIC SUPPRESSION 41 HOME POSITION AND TRAVERSE STROKE SET UP 56 IDENTIFYING RESIDUAL DANGER AND HAZRDOUS AREAS 8 INPUT OUTPUT CHARTS IN STANDARD PRESS FIT OPERATION 38 INPUT POWER CONDITIONING 40 INTENDED USE 8 INTRODUCTION 6 MAINTENANCE 58 MANUFACTURER DECLARATION 13 MECHANICAL STRUCTURE 17 MOTOR CIRCUITS CONTACTOR 46 MOTOR CONNECTIONS 42 MOTOR POWER CONNECTIONS 43 MOTOR POWER CABLE SHIELDING 44 MOTOR FEEDBACK 46 MOTOR THERMAL PROTECTION 25 MOTOR THERMAL SWITCH CONNECTIONS 43 MOTOR WHIRES TERMINATOR 43 MOUNTING PAYLOAD 35 MULTIPLE PRESS FIT OPERATION 20 N NOMINAL LIFETIME 69 O ORDER CODE 73 P PACKAGING STORAGE AND TRANSPORT 14 PLANNING THE ELECTRICAL INSTALLATION 23 POWER DISCONNECT AND PROTECTION DEVICE 41 POWER SUPPLY FILTERS 41 PRECAUTIONS TO COOLING THE SERVO DRIVE 32 PRESS FIT MESUREMENT 19 PROTECTING AGAINST SHORT CIRCUIT IN THE SUPPLY CABLE OR DRIVE 24 PROTECTING THE CONTACTS OF RELAY OUTPUTS AND ATTENUATING INDUCTIVE LOADS 27 PUTTING IN OPERATION 55 R REPAIR 63 RISK ANALYSIS 7 REQUIRED TOOLS FOR MOUNT THE SERVO DRIVE 31 REVERSING THE FILTER 41 ROLLER BEARING LIFETIME 71 ROUTING THE CABLES 28 MN0010 VERSION 1 0 DATE 2014 10 17 11 STRAIGHT PRESS sma 5 SAFE TORQUE OFF STO 54 SAFETY INSTRUCTIONS 6 SAFETY INSTRUCTIONS FOR COMPANIY THAT USING THE SYSTEM 9 SAFETY INSTRUCTIONS FOR ELECTRICAL COMPONENTS INSTALLATION 10 SAFE
31. ESS FIT OPERATION position set 1 position set 2 position set 3 position set 0 approach introduction end fit 0 home position home position idle stroke introduction fitting to the target back stroke fast foward until slow forwad value fast backward workpiece for few millimetres force or position until home position to bear the correct workpiece alignment In this programming mode the functions of the individual position sets are determined by servo drive with APM Home position the ram return in home position and then stop Idle stroke end the ram approach workpiece Introduction stroke the ram insert slowly the workpiece Fitting to the target value the ram fit the workpiece to the target value and then stop 20 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS PRESS FIT MEASUREMENT sma EL iL rona The user s PLC only starts position set 0 The required speed reduction at the end of the blank stroke is performed by the APM servo drive without standstill and without additional control by the PLC The following record 2 3 introduction and fit are automatically started and managed by APM servo drive Only when the target fit value is reached the servo drive stops the analysis and the ram returning back after a dwell time programmable Now the user s PLC is ready to starts a new cycle In applications where the data analysis are saved on a remote PC through the Ethernet network the user s P
32. G GROUND s A A A A Motor terminal box termination for power brake and thermal switch PIN A C 1 2 3 4 OO OQ Ol Ole j j N A N A N A A V W U 2 ses 7 4 4 MOTOR CABLE SHIELDING N A N A N A N A 1 GND It is essential that the motor cable shield is correctly bonded to a functional earth typically the same earthed metal backplane on which the MicroFlex e150 is mounted The motor power output cable carries a high frequency high current waveform to the motor so the cable s shielding must be earthed to prevent the cable radiating electromagnetic contamination into the surrounding area Such contamination can cause spurious errors in unrelated parts of the installation such as low voltage communication cables To provide a low impedance path to earth and effective shielding the conductor must provide contact with a large proportion of the cable s circumference The following diagram shows two possible methods Exposing the cable shield 1 Make a single circular cut in the cable s outer sheath ensuring that the cable s braided shield is not damaged 2 Slide the section of outer sheath towards the end of the cable to expose an area of braided shield Carefully remove the excess sheath at the end of the cable MNO0010 VERSION 1 0 DATE 2014 10 17 45 mm casa ELECTRICAL INSTALLATION STRAIGHT PRESS
33. INSTALLATION MANUAL FOR STRAIGHT SERVO PRESS MODULES POWERED BY MICROFLEX E 150 sa c3 STRAIGHT PRESS m Foreword The specifications in this manual can change at any time without prior notification Auloma reserves the right to improve and to change the product for the purpose of technical progress without the obligation to inform persons and organizations as the result of such changes The data correspond to the current status at the time of printing Headquarter Auloma Holding S r l Via Mussolina 1074 40018 San Pietro in Casale BO ITALY Tel 39 051 818285 mail info auloma com Web www auloma com Production Site Auloma Holding S r l Via Mussolina 1074 40018 San Pietro in Casale BO ITALY Tel 39 051 818285 mail info auloma com Web www auloma com Nonwarranty clause We checked the contents of this publication for compliance with the associated hard and software We can however not exclude discrepancies and do therefore not accept any liability for the exact compliance The information in this publication is regularly checked necessary corrections will be part of the subsequent publications Additional information Our product on the Internet http www auloma com MNO0010 VERSION 1 0 DATE 2014 10 17 3 sm LL IL rona STRAIGHT PRESS 1 INTRODUCTION 6 1 1 TYPE SPECIFICATION PLATE 6 1 2 SAFETY INSTRUCTION 6 1 2 1
34. If you want to exploit the maximum possible lateral force at 100 you will have to reduce the duty cycle to 40 or you can only exploit 40 of the max possible lateral force if you want to operate at a 100 duty cycle 13 3 NOMINAL LIFETIME Nominal lifetime of ballscrew and rear screw bearing The lifetime depends strongly on the degree of power exploitation and on impermissible operating states occurring even if only for a short time The lifetime of the spinle depends strongly on the frequency and speed of motion especially in connection with lateral forces danger of heating as well as the amount of contamination Prerequisite eBearing and screw temperature between 20 C and 40 C eno affectation of the lubricant for example by external particles elubrication conform to the specifications ethe given values for thrust force speed and acceleration must be adhered to at any rate eno contact to mechanical end stops external or internal and no other abrupt loads eno lateral forces are being applied to the spindle rod eno short stroke stroke smaller than 5 x screw pitch eno vibration at standstill or at very low speed eno high exploitation of several power features at a time for example maximum speed or thrust force only under these circumstances the service life corresponds to the nominal lifetime Mean load calculation If the load on the ballscrew is varying the lifetime must be determined with the aid of the
35. L in rasa 4 3 SERVO DRIVE AMBIENT CONDITION DESCRIPTION MAXIMUM OPERATING TEMPERATURE 113 F SIORAGE TEMPERATURE RANGE 40 TO 85 C 40 TO 185 F MAXIMUM HUMIDITY 93 MAXIMUM INSTALLATION ALTITUDE 100 mt 3300 ft ABOVE m s l SHOCK 10G VIBRATION 1G 10 150 Hz SERVO DRIVE E152AO03EIOA NOT REQUIRED FORCED AIR COOLING BOWL VERICAL FROM BOTTOM TO THE TOP SERVO DRIVE E152A06EIOA 1 m s FORCED AIR COOLING BOWL VERICAL FROM BOTTOM TO THE TOP SERVO DRIVE E152A09EIOA 2 5 m s FORCED AIR COOLING BOWL VERICAL FROM BOTTOM TO THE TOP 4 4 PRECAUTIONS TO COOLING THE SERVO DRIVE ALL SERVO DRIVE The APM servo drive Microflex e 150 shall be mounted inside the electrical cabinet verticlly in its rear side the side opposite the front panel M5 bolts or screws should be used to mount the MicroFlex e150 Detailed description of the operations for install the servo drive will be descibed in the next chapters For effective cooling the MicroFlex e150 must be mounted upright on a smooth vertical metal surface The MicroFlex e150 is designed to operate in an ambient temperature of 0 C to 45 C 32 F to 113 F Output current must be derated between 45 C 113 F and the absolute maximum ambient temperature of 55 C 131 F Within the ambient temperature range The model code E152A03EIOA is designed to operate without any additional cooling methods The model code E152A06EIOA and E152A09EIOA is designed t
36. LC shall wait a signal of data saved on PC before start a new cycle home position PLC start Position set 1 Position set 2 Idle stroke Stop Pe V mm s IS IE 18 Fitting r3 l l l l l l l l Back stroke I Position set 0 Position set 3 Measurement La 2 2 MULTIPLE PRESS FIT OPERATION For more complex press operations or if breakpoints for the supply of material or tools are required an extended sequence of press fit programs is available The APM has the capability of 5 steps in sequence to provide operational profiles with breakpoint and inversion of the direction of travel Example program 1 press fit position set O position set 1 position set 2 position set 3 position set O approach introduction end fit 0 home position home position idle stroke introduction fitting to the target back stroke fast foward until slow forwad value fast backward workpiece for few millimetres force or position until tool change to bear the correct position workpiece alignment MNO0010 VERSION 1 0 DATE 2014 10 17 21 sm EL iL rona PRESS FIT MEASUREMENT STRAIGHT PRESS Example program 2 flaring of the wokpiece fit earlier position set 0 position set 4 position set 5 position set 0 0 tool
37. N 1 0 DATE 2014 10 17 43 sm LL iL rona ELECTRICAL INSTALLATION STRAIGHT PRESS 7 4 1 MOTOR POWER CONNECTIONS SERVO DRIVE CONNECTOR Connect motor earth ground to protective earth MOTOR on top of drive I V V V V Unshielded lengths should engths shou Optional motor be as short as circuit contactors possible 7 4 2 MOTOR HOLDING BRAKE AND THERMAL SWITCH CONNECTIONS Connect the motor s brake contacts via relay connected to a digital output on servo drive s connector X3 Connect the motor s thermal switch contacts normally closed to control a relay connected to a digital input on servo drive s connector X3 A typical circuit Both connections are shown in the following diagram MOTOR HOLDING User supply User supply V BRAKE GND s SERVO DRIVE ZN CONNECTOR lt l l l Relays 13 DOUT 1 A Y 0V 24V Separate custo mer supplied MOTOR THERMAL 24V DC supply SWITCH _ lt 7 4 3 MOTOR WHIRES TERMINATOR Motor whires are normally terminated using a Connector or Terminal Box See the digram and the schedule below to connect correctly the motor power wires to the servo drive 44 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS ELECTRICAL INSTALLATION sm LL iL rona Motor connector termination for power brake and thermal switch PIN WHIRE COLOR WHIRE NUMB GREEN WHITE NA
38. N N A Nominal tension Force continuos Weight Mass moments of inertia Kgm 2 Repeatability 0 01 Reversing play um N A Efficency 0 90 Minimum measured step mm N A Force linearity error on Max compression Force Gearbox ratio Rated Motor Torque 400 V Nm N A Max Overload Motor Torque Nm N A witout working load applied and at the same thermal steady state MN0010 VERSION 1 0 DATE 2014 10 17 67 SPECIFICATIONS STRAIGHT PRESS Description Unit Value Nominal input voltage V AC 115 or 230 Minimum input voltage V AC 105 Maximum input voltage V AC 250 Nominal input current maximum rated output current A N A Nominal DC bus voltage 2230 V AC input V 321 Frequency Hz 48 to 63 maximum rate of change 17 s Imbalance Max 3 nominal phase to phase input voltage Foundamental power factor 0 98 at nominal load Network type TN grounded systems Corner grounded TN and IT ungrounded system not allowed Short circuit current protection UL 508C The drive is suitable for use on a circuit capable of deli vering not more than 5000 A symmetrical amperes rms at 230 V maximum when protected by fuses Heat dissipation W 151 Minimum power cycle delay period S 65 Time for DC bus to discharge to 50 V
39. NING THE ELECTRICAL m INSTALLATION 3 6 STANDARD COMPLIANCE WITH 61800 3 Definitions EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality First environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Drive of category C2 drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the first environment Note A professional is a person or organization having necessary skills in installing and or starting up power drive systems including their EMC aspects Drive of category C3 drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment The servo press shall be used in industrial environmet and all applications in EMC first environment are excluded Category C3 The drive complies with the standard with the following provisions 1 The drive is equipped with a suitable EMC filter 2 The motor and control cables are selected as specified in this manual 3 The drive is installed according to
40. NO 5 08 E7 Picture 5 To facilitate the mounting operations of the servo press is possible use the centre in tolerance 17 to align the devi ce The flange interface is also provided by a hole in tolerance E8 for parallel pin to orient the servo press See Picture NO 5 Tighten the screws to fix the servo press with the properly torque To blocking in correct manner the cylinder tight the screws in clock sequence 12 6 2 8 11 5 3 9 Use screw made according the class resistance 12 9 See picture NO 6 MNO0010 VERSION 1 0 DATE 2014 10 17 35 SERVO PRESS MODULE STRAIGHT PRESS INSTALLATION sma LLL rasa Picture NO 6 5 1 2 SERVO PRESS HORIZONTAL MOUNTING The servo press is studied to be mounted in vertical position This features in any case don t limit the possibility to arrange the spindle in horizontal position by supports suited on its design In horizontal mounting position each mass mounted on the thrust ram generates a lateral force on the bearing Note the indications The spindle housing must be precisely aligned to the load direction of motion Use of a guiding system to stiffen the press ram Cheek on diagrams for maximum permissible lateral force without aditional guiding system on the ram 5 1 3 SERVO PRESS VERTICAL MOUNTING In vertical mounting position each force applied horizontally on the press ram represents a lateral force load Here applies logically the sam
41. ON sm rona 1 1 TYPE SPECIFICATION PLATE The exact designation of servo press is marked on the type specification sticker Product designation Model designation Serial number Year of manufactu ring PRODUCT C2114 MODEL 0300 100 BA SERIAL PRJ 14 03 12 001 01 en YEAR OF MANUFACTURING 2014 QR code for pro duct traceability C COUNTRY OF ORIGIN INDIA 1 2 SAFETY INSTRUCTION 1 2 1 GENERAL HAZARDS General Hazards on Non Compliance with the Safety Instructions This machine component has been designed in accordance with state of the art technical developments and is operationally reliable If it is not operated by qualified or at least trained personnel or if it is operated improperly or not in accordance with the operating instructions however the unit may bear the risk of hazards Electronic moving and rotating components can danger for life and limb of the operator or third persons cause material damage If the servo press is installed in a machine plant the safety requirements noted in the operating instructions for that machine must be combined with those described in this manual Minimum safety requirement Appropriate safety measures e g start with two hands protective grid etc are to be provided by the manufacturer of the ready for use machine or facility respectively and are to be installed into the control circuit according to the established risk category The safety ci
42. OSYS ERROR POSSIBLE CAUSES Jog mode functions however not Servo press not referenced automatic mode Program is not validated Setup values out the safety limits Sensor not plugged REMEDY Reference the servo press Edit paramenters allowable see the servo press specifications Check if the sensor s cable is well connected and plug in if is necessary No force sensor signal Check if the sensor s cable is damaged and substiture Sensor cable failure Force sensor failure Substitute the force sensor the force sensor loose the tare cooling the environment or the sensor by air conditioner or air gun The environment temperature exci ding the 40 C Calibration lost Execute a new calibration Calibration lost after heavy Substitue the force sensor overload the force sensor ever loose the tare Calibration lost by fatigue after se Substitue the force sensor veral cycles gt I U fm CD 66 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS SPECIFICATIONS sm EL iL rona The characteristics given in this chapter are not to be exceeded Please respect especially the maximum permissible speed which might be exceeded in combination with many drives Lead Screw Screw Diameter Stroke Max permissible speed mm s N A Max acceleration m s42 Nominal compression Force continuos Max compression Force istantaneous k
43. OTOR CIRCUITS CONTACTOR 46 4 6 BENEFITS OF THE SINUSUAL FILTER AT MOTOR EFFICENCY 46 4 7 MOTOR FEEDBACK 46 5 FORCE SENSOR CONNECTION 46 5 1 FORCE SENSOR POWER SUPPLY 46 5 2 FORCE SENSOR PIN ASSIGNMENT 47 5 3 FORCE SENSOR POWER SUPPLY CONNECTION 47 5 4 FORCE SENSOR ANALOG OUTPUT CONNECTION 48 5 5 FORCE SENSOR DIGITAL INPUT CONNECTION 48 7 DIGITAL INPUT OUTPUT COMMUNICATION CONNECTION 49 1 7 1 USER S PLC OUTPUT CONNECTION 50 1 1 2 USER S PLC INPUT CONNECTION 51 7 8 ETHERNET CONNECTION 52 7 8 1 SERVO DRIVE SET UP FOR ETHERNET CONNECTIONS 52 7 8 2 ETHERNET CONNECTORS AND ROUTING 53 8 SAFE TORQUE OFF STO 54 9 PUTTING IN OPERATION 55 9 1 ELECTRICAL INSTALLATION CHEEK LIST 55 9 2 SYSTEM CHEEKING BEFORE START 56 9 3 HOME POSITION AND TRAVERSE STROKE SET UP 56 10 MAINTENANCE 58 10 1 CLEANING 58 10 2 BEARING RELUBRICATION 58 10 3 ANTY TWIST GUIDE RELUBRICATION 59 10 4 BALL SCREW RELUBRICATION60 10 5 FORCE SENSOR CALIBRATION 62 11 REPAIR 63 12 TROUBLESHOOTING QUICK FAULT DIAGNOSYS 64 MNO0010 VERSION 1 0 DATE 2014 10 17 sma EL IL rona STRAIGHT PRESS 13 SPECIFICATIONS 66 13 1 GENERAL INFORMATIONS 68 13 2 ALLOWED LATERAL FORCE 68 13 3 NOMINAL LIFETIME 69 13 4 BALL SCREW LIFETIME 70 13 5 ROLLER BEARING LIFETIME 71 14 ORDER CODE 73 15 INDEX 75 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS INTRODUCTI
44. SOR CALIBRATION Calibrate sensors at regular intervals and perform a counter measurement with a separate reference sensor In addition the press force is measured with an additional force sensor and compared with the internal system measured value In case of unacceptably high deviation the sensor must be replaced The servo press is supplied calibrated with a test of calibration To calibrate the force sensor see the procedure in the APM process monitoring software user manual MN0010 VERSION 1 0 DATE 2014 10 17 63 _ REPAIR STRAIGHT PRESS 11 REPAIR In the event of a damage or a mechanical defect the entire unit must be returned for repair Auloma see page 2 The repair must be made by trained Auloma personnel User Conversions and Changes are Not Permitted The servo press NUST NOT be changed in its design or in terms of safety without our approval Any change as defined here made by the user excludes any liability on our part 64 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS TROUBLESHOOTING ERROR POSSIBLE CAUSES REMEDY Servo drive not start Ethernet network busy or Find the causes of network traffic Interrupted jam to the hosted PC or the net connection Hosted PC with full memory back up the data and delete to empty the PC memory Servo drive error Wrong activation see the ABB documentation of the servo controller Press ram not in home position Home proximity switch failure Sub
45. TY INSTRUCTIONS FOR OPERATING PERSONELL 9 SAFETY LABELS 18 SCHEMATIC DIAGRAM USING APM SERVO DRIVE MICROFLEX e 150 36 SCOPE OF DELIVERY 16 SELECTING POWER CABLES 25 SELECTING THE SUPPLY DESCONNETTING DEVICE 23 SERVO DRIVE AMBIENT CONDITION 32 SERVO DRIVE FIXING HOLES TEMPLATE AND MOUNTING 33 SERVO DRIVE MECHANICAL INSTALLATION 31 SERVO DRIVE REQUIREMENTS FOR INSTALLATION SITE 31 SERVO DRIVE SET UP FOR ETHERNET CONNECTIONS 52 SERVO DRIVE THERMAL OVERLOAD PROTECTION 24 SERVO PRESS MODULE INSTALLATION 34 SERVO PRESS FLANGE MOUNTING 34 SERVO PRESS HORIZONTAL MOUNTING 35 SERVO PRESS MODULE MOUNTING 34 SERVO PRESS VERTICAL MOUNTING 35 SPECIFICATIONS 66 STANDARD PRESS FIT OPERATION 19 SYSTEM CHEEKING BEFORE START 56 T THERMAL OVERLOAD AND SHORTCIRCUIT PROTECTION 24 TRADE MARKS 18 TROUBLESHOOTING QUICK FAULT DIAGNOSYS 64 TYPE SPECIFICATION PALTE 6 U USER S PLC INPUT CONNECTION 51 USER S PLC OUTPUT CONNECTION 50 W WARRANTY CONDITIONS 15 WORKING SAFELY 9 78 DATE 2014 10 17 MNO0010 VERSION 1 0
46. VATION AND SIGNAL STRAIGHT PRESS 6 3 INPUT OUTPUT CHARTS IN STANDARD PRESS FIT OPERATION LLI Y lt m T 55 X A A LLI Y LLI o 6 o 6 gt 2 5 Ss uj 2 z a 0 v E T E D lt lt lt z 2 lt lt z O D lt D x 5 9 z o eo E G O9 cr g 09 6 QO gt QO S I 5 1 d O ul I5 1 2 1 Q lt v O lt Zo LL gt X gt z lt X gt z gt O o TT I o lt L E A lt I x u O A A 0 LNdLNO sdAlWNd OA H3S LAdNI 3Al HG OAYSS LAdNI Old 39 DATE 2014 10 17 MNO0010 VERSION 1 0 ELECTRICAL INSTALLATION STRAIGHT PRESS sma iL rasa The work described in this chapter may only be carried out by a qualified electrician Follow the instructions in chapter entitled Safety Ignoring the safety instructions can cause injury or death Make sure that the drive is disconnected from the input power during installation If the drive is already connected to the input power wait for 5 minutes after disconnecting the input power See the requirements in Electrical power network specification on page 26 Use a fixed connection to the AC power line 7 1 CHEEKING THE INSULATION OF THE ASSEMBLY Servo Drive Every drive has been tested for insu
47. VE CONNECTOR 400 V 2 3 4 5 6 T 8 9 PROVIMITY 1 RED 24 V 4 BLACK SIGNAL DIN1 3 BLUE 0 V 7 7 DIGITAL INPUT OUTPUT COMMUNICATION CONNECTION The software APM installed in the servo drive use the Input Output network to execute the operations The digital Input Output are used to exchange signals among the servo drive and the user s PLC and among the servo drive and the servo press Follow the next instruction to connect correctly the digital Input Output signals DO NOT wrong the connection of Digital Input and Output gateway A wrong connection means a wrong software execution and could cause of mechanical damages and health injuries Warning Before start the use of servo press it is necessary verify the digital Input Output connection Set the device in Jog mode and cheek if all digital Input and Output corre spond at its purposes 50 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS ELECTRICAL INSTALLATION sm LL iL rona 7 7 1 USER S PLC OUTPUT CONNECTION The Microflex e 150 sero drive has a built in PLC connected as a slave to the user s PLC Master See the dia gram page 36 The communication between master and slave occur through the digital Input Output signals The signal output provided by user s PLC shall be minimum of 12 VDC until a maximum of 28 VDC and the connection occur through a shielded wire The master s operations commanded by a digital outpu
48. arate trays Avoid long parallel runs of motor cables with other cables to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Where control cables must cross power cables make sure that they are arranged at an angle as near to 90 degrees as possible The cable trays must have good electrical bonding to each other and to the grounding electrodes Aluminium tray systems can be used to improve local equalizing of potential A diagram of the cable routing is shown below POWER CABLE min 300 mm 12 inches MOTOR CABLE min 500 mm 20 inches FORCE SENSOR CABLE MNO0010 VERSION 1 0 DATE 2014 10 17 29 PLANNING THE ELECTRICAL STRAIGHT PRESS sm Lic rasa Separate control cable ducts Route 24 V and 230 V cables in separate ducts unless the 24 V cable is insulated for 230 V or insulated with an insulation sleeving for 230 V 24 V 230 V 24 V 230 V YES NO Tipical installation example Installation cabinet star point a Drive earth wire must be at least 10 mm 7 AWG MicraFlex 2150 on the same metal pane Connect AC power cable shield to metal panel using power wires should be as short as conductive shield possible typically less than 0 3 m 1 ft earth ground clamps Longer wires must be shielded as shown Qn painted panels CAUTION expose bare metal PE 30 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS PLAN
49. ause of crush cut fingers and the collision with tool introduced in the hole can be cause of mechanical da Warning mages socket cap plug 1 y pic NO 11 3th Step Unscrew and remove the socket set screw NO 2 in the ball screw flange Use an hex magnetic key See picture NO 12 4th Step Mount the extension AT000003 in the ball screw flange Tighten the extension in threaded hole See picture NO 13 MN0010 VERSION 1 0 DATE 2014 10 17 61 sm LL iL rana MAINTENANCE STRAIGHT PRESS E set screw NO 2 P a PF NO 12 gt pic NO 13 5th Step Pump 1 of grease Bechem High Lub LFB 2000 Multipurpose EP thrugh the nipples mounted in ball screw flange 6th Step Remove the extension from the ball screw flange 7th Step Tighten the socket set screw on the ball screw flange to close the lubrication hole 8th Step Run the spindle approximately at a speed of 10mm s to move out the rod for a stroke minimum of 4 time the lead of the ball screw 9th Step Return the spindle at home position 10th Step Repeat the steps 8 for 4 cycle to distribute the grase in the nut circuits 11th Step Tighten the socket cap plug NO 1 as soon as the grease filling operation is finish 62 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS MAINTENANCE sm LL iL rona 10 5 SEN
50. e as with the horizontal mounting position Do mount the servo press so that all forces apply in the direction where the servo press can bear the entire lateral force load See Picture NO 7 Picture NO 7 5 1 4 MOUNTING PAYLOAD Connect the payload always to the end of the ram so that occurring lateral forces are minimized If the payload is separately guided even minimal deviations between this guiding system and the spindle length axis can generate high lateral forces and reduce the service life of the servo press considerably To avoid this problem is necessary mount a device with 3 degrees of freedom between the thrust ram and the guiding system such as flexible join coupling or spherical eye bolt 36 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS ACTIVATION AND SIGNAL 6 1 SCHEMATIC DIAGRAM USING APM SERVO DRIVE MICROFLEX e 150 MASTER DIGITAL OUTPUT DIGITAL INPUT a gt O TIOME o lt lt 12 15 gt iz la 2 o 10 o Orr lu gt 9 a gt lt 5 5 o o izlo o 9 5 lt lt gt Z o 2 2 O a a liz lt LLI I DIGITAL Q OUTPUT E a O s AM 5 5 z u x x 5 gt 3 9 TT lt lt 2 2 5 le gt 2 5 2 e 5 le gt gt 1 5 19
51. e up to 100 m 328 ft long Two varieties of CAT5e cable are available straight or crossed Straight cables have the TX pins of the connector at one end of the cable wired to the TX pins of the RJ45 connector at the other end of the cable Crossover cables have the TX pins of the connector at one end of the cable wired to the RX pins of the RJ45 connector at the other end of the cable Recommended cables are listed in Ethernet cables below Crossover or straight cables can be used Many Ethernet devices including hubs and ABB e150 products incorporate Auto MDIX switching technology which automatically compensates for the wiring of straight cables The cables are standard CAT5e shielded twisted pair S UTP crossover Ethernet cables x a NRI NUN The MicroFlex e150 Ethernet interface is galvanically isolated from the rest of the MicroFlex e150 circuitry by magnetic isolation modules incorporated in each of the Ethernet connectors This provides protection up to 1 5 kV The connector cable screen is connected directly to the chassis earth of the MicroFlex e150 The EtherCAT interface supports the 100Base TX 100 Mbit s speed Use dedicate ducts container to routing the Ethernet cables 54 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS SAFE TORQUE OFF STO sm LL iL rona The Microflex e 150 own the STO function that disables the control voltage of t
52. ed instead of circuit breakers Circuit breakers should only be used when absolutely necessary UL compliance can only be achieved when using the recommended fuses The use of circuit breakers does not guarantee UL compliance and provides protection for the wiring only not the MicroFlex e150 Your local ABB representative can help you in selecting the breaker type when the supply network characteristics are known 3 2 3 MOTOR THERMAL PROTECTION According to regulations the motor is protected against thermal overload and the current is switched off when overload is detected The drive is configured to include a motor temperature input that protects the motor and switches off the current when necessary 3 2 4 BRAKE OUTPUT SHORT CIRCUIT PROTECTION The brake resistor output is fully short circuit proof according to EN 61800 5 1 3 3 SELECTING THE POWER CABLES General Rules Dimension the input power and motor cables according to local regulations The input power cables must be able to carry the corresponding load currents The cable must be rated for at least 70 C US 75 C 167 F maximum permissible temperature of the conductor in continuous use The conductivity of the PE conductor must be equal to that of the phase conductor same cross sectional area 600 V AC cable is accepted for up to 500 V AC Apply the EMC requirements A four conductor system is allowed for input cabling but a shielded symmetrical cable is recomm
53. ended Compared to a four conductor system the use of a symmetrical shielded cable reduces electromagnetic emission of the whole drive system bearing currents and wear To dimensioning the imput power cables see the electrical power network specification for the servo drive 26 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS PLANNING THE ELECTRICAL INSTALLATION sm EL ic rasa ELECTRICAL POWER NETWORK SPECIFICATION FREQUENCY IMBALANCE FUNDAMENTAL POWER FACTOR NETWORK TYPE Short circuit current protection UL 508C AC INPUT 38 150 OR 250 48 to 63 Hz maximum rate of change 17 5 Max 3 of nominal phase to phase input voltage 0 98 at nominal load TN grounded systems Corner grounded TN and IT ungrounded systems not allowed ALL SERVO DRIVE The drive is suitable for use on a circuit capable of delivering not more than 5000 A symmetrical amperes rms at 230 V maximum when protected by fuses SERVO DRIVE E152A03EIOA NOMINAL INPUT CURRENT MAXIMUM RATED OUTPUT CURRENT SERVO DRIVE E152A06EIOA NOMINAL INPUT CURRENT MAXIMUM RATED OUTPUT CURRENT SERVO DRIVE E152A09EIOA NOMINAL INPUT CURRENT MAXIMUM RATED OUTPUT CURRENT 3 3 1 ALTERNATIVE POWER CABLE TYPES oymmetrical shielded cable three phase conductors and a concentric or otherwise constructed PE conductor and a shield Check with local state country electrical codes for allowance See below
54. ervo drive is connected to hosted to download the analysis data each cle it is important consider that the servo pres can run a new cycle ONLY when the PC has confirmed that the previous data are saved and it is ready to save the new ones The timing for save the data on PC and the relative confirmaton to the servo drive depends by the PC capability and by the Ethernet network performances Ethernet port E2 is fixed in EtherCAT mode so port E1 must be used for other Ethernet connections Cheek that the port E1 set up is switched to standard Ethernet mode to know that see the front panel in SW1 and veify the switch NO 4 that must be in ON posi tion The DIP switches allow special settings to be selected on power up Changing the switch positions after power up has no effect NOTE The switch NO 4 is switched in ON when the white index on the switch is turn on the right side DIP Switch SW1 MN0010 VERSION 1 0 DATE 2014 10 17 53 ELECTRICAL INSTALLATION STRAIGHT PRESS sma iL rasa 7 8 2 ETHERNET CONNECTORS AND ROUTING To connect the MicroFlex e150 to other devices through the Ethernet network use CAT5e Ethernet cables either S UTP unshielded screened foiled twisted pairs or preferably S FTP fully shielded screened foiled twisted pairs To ensure CE compliance Ethernet cables longer than 3 m should be S FTP cables bonded to the metal backplane at both ends using conductive clamps Cables can b
55. evices to break the load circuit before the opening of the main contacts of the disconnector EN 60947 3 a circuit breaker suitable for isolation in accordance with EN 60947 2 Other Regions The disconnecting device must conform to the applicable safety regulations 24 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS PLANNING THE ELECTRICAL INSTALLATION sm EL ic rasa 3 1 2 EMERGENCY STOP DEVICE For safety reasons install emergency stop devices at each operator control station and at other operating stations where emergency stop might be needed The emergency stop shall be connected to the servo drive and cut off the power immediatelly Note Exist the possibility to set up the Microflex e 150 with the Safety Torqe Off STO function activated for brief maitenance operations For more info see the chapter 8 3 2 THERMAL OVERLOAD AND SHORT CIRCUIT PROTECTION 3 2 1 SERVO DRIVE THERMAL OVERLOAD PROTECTION The servo drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive No additional thermal protection devices are needed 3 2 2 PROTECTING AGAINST SHORT CIRCUIT IN THE SUPPLY CABLE OR DRIVE Protect the supply cable with fuses or circuit breakers The fuses protect the input cable in short circuit situations restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive
56. for LT0313 MicroFlex e150 drives MicroFlex e150 wall chart LT0296 Baldor brishless servo motor MN1240 You can find all manuals and other product documents in PDF format on the Internet See section Document library on the Internet web site www abbmotion com The installation must always be completed according to applicable local laws and regulations Auloma does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by Auloma and ABB are not followed the drive might experience problems that are not covered by the warranty The installation methods described in this chapter will improve the reliability of the system reduce troubleshooting time and optimize the EMC electromagnetic compatibility behavior of the control system 3 1 1 SELECTING THE SUPPLY DISCONNETTING DEVICE Install a hand operated supply disconnecting device disconnecting means between the AC power source and the drive The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work European Union To meet the European Union Machinery Directive according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types switch disconnector of utilization category AC 23B EN 60947 3 a disconnector having an auxiliary contact that in all cases causes switching d
57. he power semiconductors of the drive output stage which prevents the inverter generating the voltage required to rotate the motor By using this function short time operations like cleaning and or maintenance work on non electrical parts of the machinery can be performed without switching off the power supply to the drive The drive supports the Safe Torque Off STO function according to standards IEC 61800 5 2 EN 61508 2010 EN ISO 13849 1 and IEC 62061 2005 The STO funtion is provided as optional and can be implemented only by skilled personnel trained by our technical course or by our official system partner Contact Auloma Headquarter to know our official system partners enable to implement the STO function info auloma com In case in the servo drive Microflex e 150 is enabled the STO function it is important know that STO DOES NOT disconnect the voltage of the main and auxiliary circuits from the drive Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply If the drive was Warning connected to the input power wait for 5 minutes after disconnecting the input power MN0010 VERSION 1 0 DATE 2014 10 17 55 sma LL rasa PUTTING IN OPERATION STRAIGHT PRESS 9 1 ELECTRICAL INSTALLATION CHEEK LIST Check the mechanical and electrical installation of the drive before start up Go through the checklist together with anot
58. her person Only qualified electricians are allowed to carry out the work described below Follow the complete safety instructions related in this manual Ignoring the safety instructions can cause injury or death Open the main disconnector of the drive and lock it to open position Measure to ensure that the drive is not powered Check that There is an adequately sized protective earth ground conductor between the drive and the metal mounting surface There is an adequately sized protective earth ground conductor between the motor and the drive All protective earth ground conductors have been connected to the appropriate terminals and the terminals have been tightened pull conductors to check The supply voltage matches the nominal input voltage of the drive Check the type designation label The input power cable has been connected to appropriate terminals the phase order is correct and the terminals have been tightened pull conductors to check Appropriate supply fuses and disconnector have been installed The motor cable has been connected to appropriate terminals the phase order is correct and the terminals have been tightened pull conductors to check The brake resistor cable if present has been connected to appropriate terminals and the terminals have been tightened pull conductors to check The motor cable and brake resistor cable if present has been routed away from other cables No power fact
59. inductive proximity switches external the servo press The servo press stroke limited by an inductive proximity switch IS NOT a safety control Caution Set up for brushless equipped with absolute encoder Set the speed motor at 2 on nominal speed and cheek the direction of the ram according the motor rotation Rotate the motor slowly to insert the ram inside the press until will be against the mechanical stop As soon as the ram is against the mechanical stop shut off the motor Invert the rotation sense of the motor and estract the ram for the quantity of stroke enough for your application Save this position in your system as home Repeat the same operation in the opposite side to know the maximum extension of the ram Run slowly at the 2 of nominal speed the motor for all traerse stroke MN0010 VERSION 1 0 DATE 2014 10 17 57 sm LL L rona PUTTING IN OPERATION STRAIGHT PRESS DO NOT use the mechanical stop as home position and for end strohe Frequently colli sion of the ram onto the mechanical stop at operative speed could be cause of mechani cal rupture and healt injuries Warning Set up for brushless equipped with incremental encoder or resolver oet the speed motor at 2 on nominal speed and cheek the direction of the ram according the motor rotation Rotate the motor slowly to insert the ram inside the press until will be against the mechanical stop As soon as the ram is against the mechanical stop shut off the m
60. lation between the main circuit and the chassis at the factory If further high potential hipot testing is performed use only DC voltages as AC voltage hipot tests could damage the drive It is recommended to seek advice from your ABB sales representative before performing hipot tests Input power cable Check the insulation of the input power cable according to local regulations before connecting to the drive Motor and motor cable Check the insulation of the motor and motor cable as follows Check that the motor cable is connected to the motor and disconnected from the drive output terminals U V and W Measure the insulation resistance between each phase conductor and the Protective Earth conductor using a measuring voltage of 500 V DC The insulation resistance of the motor must exceed 100 Mohm reference value at 25 C or 77 F Moisture inside the motor casing reduces the insulation resistance If moisture is suspected dry the motor and repeat the measurement 7 2 CONNECTING THE SERVO DRIVE POWER CABLE Connect earth ground SERVO DRIVE Route L1 L2 L3 and Circuit breaker to protective CONNECTOR earth ground together or fuses AC filter earth on top of drive in conduit or cable AC SUPPLY LINE 11 LINE L2 wa LINE 13 acm Isolating switch Incoming safety earth ground PE To earth ground outer shield use 360 clamps connected to enclosure backplane MicroFlex e15
61. manent magnet motor drives Ignoring the instructions can cause physical injury or death or damage to the equipment Do not work on the drive when the permanent magnet motor is rotating Also when the supply power is switched off and the inverter is stopped a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live Warning Before installation and maintenance work on the drive execute the follow procedures Stop the motor Ensure that there is no voltage on the drive power terminals according to step 1 or 2 or if possible according to the both of the following steps 1 Disconnect the motor from the drive with a safety switch or by other means Measure that there is no voltage present on the drive input L1 L2 L3 motor output U V W or brake terminals R1 R2 Ensure that the motor cannot rotate during work Make sure that no other system like heavy tool is able to rotate the motor directly or through any mechanical connection Measure that there is no voltage present on the drive input L1 L2 L3 output U V W or brake regeneration terminals R1 R2 Ground the drive output terminals temporarily by connecting them together as well as to the PE Servo drive and motor general safety Ignoring the following instructions can cause physical injury or death or damage to the equipment The drive is not field repairable Never attempt to repai
62. mean load The mean load is determined as follows in the event of cascaded load changes 1 3 E D Deis demi F n t 1 1 where Fm mean load N F varying load N n varying rotation peed rpm t time ratio s n mean rotationel speed To calculate the mean load is necessary know the spindle s mass and the payload generated by tool holder tools workpiece and others Spindle s mass costanly stress the ball screw Ask to Auloma to know the spindle mass 70 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS Mean rotational speed calculation 13 4 BALL SCREW LIFETIME SPECIFICATIONS sm EL IL rona Calculation of ball screw life in number of revolutions Ball screw specifications D hi ee n t na DOR reete t Ca L 10 Fm fw where L Fatigue life total number of revolution rev Fm mean load N fw load factor Ca Basic Dynamic rate load N Cheek in your data sheet and ask to Auloma the data to calculate the ball screw life The RAM of the servo press is developed to travel at a nominal speed max of 250 mm s The load factor to consider when the speed not exceed 250 mm s is the follow fw 1 0 1 2 Calculation of ball screw life as total operating time Lt 60 n where Lt Fatigue life total operating time hr n mean rotationel speed MNO0010 VERSION 1 0 DATE 2014 10 17 71
63. mended circuit breakers are thermal magnetic devices 1 or 3 phase as required with characteristics suitable for heavy inductive loads C type trip characteristic Circuit breaker or fuses are not supplied see pag 24 and 25 for racco mended fuses For CE compliance see pag 30 From supply Circuit breaker From supply Fuse L1 L1 L1 N L1 L3 LN L3 L3 L3 Circuit breaker and fuse three phase Metal conduit or shielded cable should be used Connect conduits so the use of a line reactor or RC device does not interrupt EMI RFI shielding Using 2 phases of a 3 phase supply Power can be derived by connecting two phases of an appropriate three phase supply L1 and L2 for example When supplying AC power in this way the voltage between the two phases must not exceed the rated input voltage of the MicroFlex e150 A two pole breaker must be used to isolate both lines Fuses must be fitted in both lines 42 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS ELECTRICAL INSTALLATION sm LL iL rona 7 3 24V CONTROL CIRCUIT SUPPLY A 24 V DC supply must be provided to power the controlling electronics This is useful for safety reasons where AC power is removed from the power stage but the controlling electronics must remain powered to retain position and I O information A separate fused 24 V supply should be provided for the MicroFlex e150 If other devices are powered from the same 24 V supply a filter part FI0014
64. mperature of 0 C or below Please provide The packaging material is inflammable if it is disposed of improperly by burning lethal fumes may develop The packaging material must be kept and reused in the case of a return shipment Improper or faulty packaging may lead to transport damages The servo press must be stored evenly and without any mechanical load Transport Make sure to transport the servo press always in a safe manner and with the aid of suitable lifting equipment Means of transport see chapter 1 4 1 Disposal We recommend to dispose of the respective materials in accordance with the respectively valid environmental laws The following table states the materials suitable for recycling and the materials which have to be disposed of separately Material option Suitable for recycling Disposal Metal Yes No Plastic Yes No Grease Yes No 1 4 1 SPECIAL NOTE ON TRANSPORT MN0010 VERSION 1 0 Special notes on transport Use only transport equipment with sufficient lifting capacity When using ropes make certain they are not twisted or knotted If you are using more than one rope all the ropes should be equally taut Never step under overhead loads danger of being injured Moving parts must always be secured against slipping or moving Required minimum load bearing capacity of the means of transport 700 Kg This value a safety factor of S 8 is taken into consideration DATE
65. n this manual Ignoring the safety instructions can cause injury or death Mechanic installation of all system components Please observe the correct assignment of the individual components according to the system configuration Exchanging of components may cause failures Connect the hosted PC with APM installed to the Microflex e 150 System power ON Verify and adjust all settings in the APM system menu Verify the digital control inputs and signal outputs in APM the service menu Function test of the press and triggering in the jog mode according to the function plan Reference the spindle positions according to the instruction manual for the servo controller i e determine the home position Reference the spindle positions according to the instruction manual for the servo controller i e determine the home position In APM menu Setup recording of characteristic and determination of setpoint values see APM manual In APM menu Setup define the servo press working parameters Use the Jog mode to determinate the cha racteristic parameters Function test of the press in the automatic mode 9 3 HOME POSITION AND TRAVERSE STROKE SET UP The servo press can accept motor brushless controlled with all kind of encoder For enco der that need of a reference signal to recognize the hope position it is possible use the M8 seat for mounting inductive proximity switches This DO NOT exclude the possibility of mounting additional
66. o operate with additional cooling methods require a forced air flow passing vertically from the bottom to the top of the MicroFlex e150 case to allow full rated current at 45 C 113 F Failure to meet cooling air flow requirements will result in reduced product lifetime and or drive overtemperature trips It is recommended to check periodically the operation of the cooling equipment 4 4 1 EFFECTS OF MOUNTIG SURFACE AND PROXIMITY BETWEEN SEVERAL SERVO DRIVE The proximity of the MicroFlex e150 to other components could affect cooling efficiency If the MicroFlex e150 is mounted beside another MicroFlex e150 or other obstruction there should be a minimum space of 15 mm 0 6 in tomaintain effective cooling If the MicroFlex e150 is mounted above or below another MicroFlex e150 or other obstruction there should be a minimum space of 90 mm 3 5 in to maintain effective cooling Remember that a MicroFlex e150 will be receiving air that has been already heated if it is mounted above another MicroFlex e150 or heat source Multiple MicroFlex e150 units mounted above each other should be aligned not offset to promote air flow across the heat sinks It is recommended to allow approximately 60 mm 2 4 in at the front to accommodate wiring and connectors See the Picture NO 4 MNO0010 VERSION 1 0 DATE 2014 10 17 33 FORCED AIR FLOW SERVO DRIVE MECHANICAL STRAIGHT PRESS in ana METAL BACKPLANE O I 15 mm E
67. or compensation capacitors have been connected to the motor cable All low voltage control cables have been correctly connected If a drive bypass connection will be used for induction motors The direct on line contactor of the motor and the drive output contactor are either mechanically or electrically interlocked cannot be closed simultaneously There are no foreign objects or dust inside the drive Drive and motor connection box covers are in place Verify that all wiring conforms to applicable codes The motor and the driven equipment are ready for start up Disconnect the load from the motor until instructed to apply a load If this is not possible disconnect the motor wires at connector X1 Check no physical damage is present Check all instruments have been properly calibrated 56 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS PUTTING IN OPERATION sm LL iL rona 9 2 SYSTEM CHEEKING BEFORE START After the complete cheek of electrical intallation the system must controlled with power on The system has been examined and pre configured at the factory Only the machine specific parameters e g tolerance windows position specifications etc must be accomplished Before start the complete press set up Take the maximum care and cheek the operation commands and execute the zero set up Only qualified operators are allowed to carry out the work described below Follow the complete safety instructions related i
68. or less max 5 248 Nominal output phase current Arms N A Peak output phase current for 3 s Arms N A Nominal output 230 V 38 VA 2390 Output voltage line line V DC bus 320 V Vms 0 230 Output frequency Hz 0 2000 Output dv dt kV us 2 at drive phase phase 11 at drive phase ground 19 at motor using 20 m cable 18 at motor using 20 m cable phase ground Nominal switching frequency kHz 8 0 Minimum motor inductance mH 1 Efficency gt 95 Protection Class IP 20 68 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS SPECIFICATIONS sm EL iL rona Description Unit Value Nominal input voltage V DC 24 Minimum input voltage V DC 20 Maximum input voltage V DC 30 Maximum ripple 10 Typical input current not powering feedback device A 0 5 0 6 Typical input current powering feedback device A 0 6 0 8 Maximum continuous current 24 V DC A 1 Power on surge current typical 24 V DC 100 ms A 4 13 1 GENERAL INFORMATIONS Temperature range without derating C 0 25 Installation altitude m 1000 Servo Press Protection class IP 54 13 2 ALLOWED LATERAL FORCE Contact us to know the maximum lateral force of your device Info auloma com MN0010 VERSION 1 0 DATE 2014 10 17 69 sm LL iL rona SPECIFICATIONS STRAIGHT PRESS Lateral forces may reduce the lifetime of the spindle
69. or similar operations If an M Contactor is installed the MicroFlex e150 must be disabled at least 20 ms before the M Contactor is opened If the M Contactor is opened while the MicroFlex e150 is supplying voltage and current to the motor the MicroFlex e150 can be damaged Incorrect installation or failure of the M Contactor its wiring result in damage to the Caution MicroFlex e150 7 4 6 BENEFITS OF THE SINUSUAL FILTER AT MOTOR EFFICENCY A sinusoidal filter is used to provide a better quality waveform to the motor reducing motor noise temperature and mechanical stress It will reduce or eliminate harmful dV dt values voltage rise over time and voltage doubling effects which can damage motor insulation This effect occurs most noticeably when using very long motor cables for example 30 5 m 100 ft or more ABB and Baldor servo motors intended to be used with drives are designed to withstand the effects of large dV dt and overvoltage effects However if very long motor cables are unavoidable and are causing problems then a sinusoidal filter can be beneficial 7 4 7 MOTOR FEEDBACK The servo press mount a brushless motor controlled by an incremental encoder with halls The device is provided by a ready made cable The cable has a 16 pin connector to be connected to the motor and the opposite edge has a DA 15 subminiature connector to be connected to the servo drive in the connector X8 Follow the next consideration
70. otor Cut the current from the press to working in safety Remove the treaded plug from the press s lateral plate to screw the proximity switch until will be stopped against the anti twist device mounted on the ram inside the press see Picture NO 8 The anti twist is made in bronze phosphorous alloy Cheek in the proximity data sheet the suggested distance to detect this kind of material by the proximity switch Re lease backward the proximity switch for the distance suggested from the manufacturer Connect the proximity whire and turn on the voltage to powering the system If the posi tion of the proximity is correct the anti twist ram is detected by the proximity switch Invert the rotation sense of the motor and estract the ram for the minimum quantity of stroke enough for enabling the proxinity switch and stop the motor Invert again the motor ro tation and run backward until the proximity switch is enable and stop immediately the mo tor Set this position as home position of your encoder Invert the rotation sense of the motor and estract forward the ram slowly at the 2 of nominal speed Run for entire tra verse stroke until the ram will be against the mechanical stroke to know the maximum extension of the ram Set the maximum traverese stroke to avoid collision against the ma chanical stop DO NOT use the mechanical stop as home position and for end stroke Frequently colli sion of the ram onto the mechanical stop at operative speed could
71. peration throughout the torque range provided by the drive Improper operation or programming of the drive can cause violent motion of the motor and driven equipment Be certain that unexpected motor movement will not cause injury to personnel or damage to equipment Do not activate automatic fault reset functions if dangerous situations can occur When activated these functions will reset the drive and resume operation after a fault Do not control the motor with an AC contactor or disconnecting device disconnecting means use instead external commands I O or fieldbus If a drive enable signal is already present when power is applied to the MicroFlex e150 the motor could begin to move immediately The metal heat sink on the left side of the MicroFlex e150 can become very hot during normal operation MEDICAL DEVICE PACEMAKER DANGER Magnetic and electromagnetic fields in the vicinity of current carrying conductors and industrial motors can result in a serious health hazard to persons with cardiac pacemakers internal cardiac defibrillators neurostimulators metal implants cochlear implants hearing aids and other medical devices To avoid risk stay away from the area surrounding a motor and its current carrying conductors A brake resistor can generate enough heat to ignite combustible materials To avoid fire hazard keep all combustible materials and flammable vapors away from brake resistors DO NOT install the servo press in ex
72. plosive or flammable area Ignoring the following instructions can cause physical injury Warning The motor and the attached mechanical parts reach faster temperature over 100 C DO NOT touch the motor without protective glove capable to resist at this kind of temperature Do not touch the motor after use until it has had sufficient time to cool Severe burns may result from touching the motor after use DO NOT use water or other liquid to dumping the temperature MNO0010 VERSION 1 0 DATE 2014 10 17 13 INTRODUCTION sma LL IL rona 1 3 MANUFACTURER S DECLARATION Declaration of Incorporation for partly completed machinery The declaration is provided in the user manual of specific servo press STRAIGHT PRESS 14 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS INTRODUCTION 1 4 PACKAGING STORAGE TRANSPORT First Cheek Check the packaging for damages packaging material for return deliveries appropriate worker protection e g protective gloves Caution Storage Ensure that the consignment does correspond to your order Check the product for damages Do never use a device which seems damaged Read the installation manual carefully before installing or commissioning the device Packaging material sm LL iL rona Remove the packaging Do not discard the packaging it is strongly recommended to use the original Depending on the storage location metal surfaces may have a te
73. r a malfunctioning drive contact your local AULOMA representative or Authorized Service Center for replacement Make sure that dust from drilling does not enter the drive during the installation Electrically conductive dust inside the drive can cause damage or lead to malfunction Drives shall be installed inside an electrical cabinet that provides environmental control and protection Installation information for the drive is provided in this manual Motors and controlling devices that connect to the drive should have specifications compatible with the drive Avoid locating the drive immediately above or beside heat generating equipment directly below water or steam pipes or in the vicinity of corrosive substances or vapors metal particles and dust Ensure sufficient cooling Failure to meet cooling air flow requirements will result in reduced product lifetime and or drive overtemperature trips The metal heat sink on the left side of the MicroFlex e150 can become very hot during normal operation 12 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS INTRODUCTION sm Li rona Safe start up and operation These safety instruction are intended for all who plan to start up or operate the servo drive and the servo press Ignoring the following instructions can cause physical injury or death or damage to the equipment Before adjusting the drive and putting it into service make sure that the servo press is suitable for o
74. rcuit must be activated during usage of the servo press Emergency stop switches are to be connected according to the safety and coupling instructions of the servo controller according to EN 4918 Cat 1 or more restrictive specifications The applicable guidelines standards and regulations for the prevention of industrial accidents have to be complied with Non compliance can lead to serious personal and material damages The system must not be deployed in explosive facility areas MNO0010 VERSION 1 0 DATE 2014 10 17 sm EL iL rona INTRODUCTION STRAIGHT PRESS The equipment of the servo press with safety components brakes speed monitor control safety switching device and their integration into the safety concept will then be determined on the basis of the requested hazard analysis An operation of the units with bridged safety protection devices is strictly forbidden Provided that due to technical reasons operators occasionally or permanently have to work in the danger area the equipment of the machine must to be provided with a safety concept that is adjusted to this kind of operation It has to be observed that for servo press without brake the tool weight does not exceed the limits defined by Aulo ma Holding For acceptable weights please refer the instruction manual 1 2 2 RISK ANALYSIS The press ram traverse is provided by a ball screw that transform the motor rotation in a linear movement The ball scre
75. roFlex e150 has permanently connected power factor correction capacitors an input AC line reactor or an isolation transformer must be connected between the power factor correction capacitors and the MicroFlex e150 to limit the maximum symmetrical short circuit current to 5000 A If the feeder or branch circuit that provides power to the MicroFlex e150 has power factor correction capacitors that are switched on line and off line the capacitors must not be switched while the drive is connected to the AC power line If the capacitors are switched on line while the drive is still connected to the AC power line additional protection is required A Transient Voltage Surge Suppressor TVSS of the proper rating must be installed between the AC line reactor or isolation transformer and the AC input to the MicroFlex e150 7 2 2 1 SUPPLY INPUT POWER FROM A VARIAC VARIABLE TRANSORMER When AC power is supplied from a variac the MicroFlex e150 s pre charge circuit might not operate correctly To ensure that the pre charge circuitry operates correctly increase the variac voltage to the desired level and then power cycle the 24 V DC control circuit supply This will restart the pre charge circuit and allow it to operate correclly MN0010 VERSION 1 0 DATE 2014 10 17 41 sm LL IL rona ELECTRICAL INSTALLATION STRAIGHT PRESS 7 2 3 POWER SUPPLY FILTERS To comply with EC directive 2004 108 EC an AC power filter of the appropriate type mu
76. s when wiring the motor feedback The servo drive inputs are not isolated The feedback device wiring must be separated from power wiring Where feedback device wiring runs parallel to power cables they must be separated by at least 76 mm 3 in Feedback device wiring must cross power wires at right angles only To prevent contact with other conductors or earths grounds unearthed ungrounded ends of shields must often be insulated The overall cable shield screen must be connected to the metallic shell of the D type connector Connector X8 includes a Sense pin which is used to detect the voltage drop on long cable runs This allows the MicroFlex 150 to increase the encoder supply voltage on pin 12 to maintain a 5 V supply at the encoder 400 mA max 7 5 FORCE SENSOR CONNECTION The force sensor is equipped with a 6 meter long six wire connection cable and the calibration is effectuated on this cable length If during the installation will be necessary reduce the force sensor s cable lenght will be necessa ry calibrate the force sensor because the impedance of the cable is reduced 7 5 1 FORCE SENSOR POWER SUPPLY Connect the force sensor to a power supply stabilized with the capability to provide a tension of 24 VDC MNO0010 VERSION 1 0 DATE 2014 10 17 47 sm LL iL rona ELECTRICAL INSTALLATION STRAIGHT PRESS 7 5 2 FORCE SENSOR PIN ASSIGNMENT pewemmmm LEN DIGITAL INPUT IN1 ZERO
77. st be connected This can be supplied by ABB and will ensure that the MicroFlex e150 complies with the CE specifications for which it has been tested Ideally one filter should be provided for each MicroFlex e150 filters should not be shared between drives or other equipment 7 2 3 1 HARMONIC SUPPRESSION When operating the 3 A MicroFlex e150 part E152A03 on a single phase AC supply a 13 mH 4 A rms 10 peak line reactor is required to ensure compliance with EN 61000 3 2 class A limits when the total equipment supply load is less than 1 kW 7 2 3 2 REVERSING THE FILTER When using ABB filters FI0015A00 or FI0015A02 they must be reversed to ensure that the MicroFlex e150 complies with the CE specifications for which it has been tested The AC power supply should be connected to the filter terminals marked as the outputs with the MicroFlex e150 connected to the filter terminals marked as the inputs Alternative filters or protection devices must be connected as specified by the manufacturer Warning 7 2 4 POWER DISCONNECT AND PROTECTION DEVICE A power disconnect should be installed between the input power supply and the MicroFlex e150 for a fail safe method to disconnect power The MicroFlex e150 will remain in a powered condition until all input power is removed from the drive and the internal bus voltage has depleted The MicroFlex e150 must have a suitable input power protection device installed preferably a fuse Recom
78. stitute the proximity switch Encoder failure Substitute the brushless motor join coupling failure Tight the join coupling screws or Substitute the join coupling a foreign body block the ram stroke Set servo press in jog and to free of the foreign body Press ram run slow than the target The environment temperature exci cooling the environment or the motor speed ding the 40 C by air conditioner or air gun Motor has less perfomances Substitute the motor join coupling failure Tight the join coupling screws or Substitute the join coupling gearbox failure Tight the gearbox screw that clamp the motor shaft power lost in press ram The environment temperature exci cooling the environment or the motor ding the 40 C by air conditioner or air gun Motor has less perfomances Substitute the motor join coupling failure Tight the join coupling screws or Substitute the join coupling servo drive overheated by a pre set the machine in stand by to cool vious overload down the servo drive gearbox failure Tight the gearbox screw that clamp the motor shaft Press ram does not operate any join coupling failure Tight the join coupling screws or more Substitute the join coupling gearbox failure Tight the gearbox screw that clamp the motor shaft Servo drive failure See the ABB documentation of the servo controller MNO0010 VERSION 1 0 DATE 2014 10 17 65 TROUBLESHOOTING s ic canas QUICK FAULT DIAGN
79. t cooling air flow requirements will result in reduced product lifetime and or drive overtemperature trips The maximum suggested operating altitude is 1000 m 3300 ft The MicroFlex e150 must be installed where the pollution degree according to EN 60664 shall not exceed 2 The atmosphere must not contain flammable gases or vapors There must not be abnormal levels of nuclear radiation or X rays The threaded holes in the top and bottom of the case are for cable clamps The holes are threaded for M4 bolts no longer than 11 mm 0 43 in The D type connectors on the front panel of the MicroFlex e150 are secured using two hexagonal jack screws sometimes known as screwlocks If a jack screw is removed accidentally or lost it must be replaced with 4 40 UNC jack screw with an external male threaded section no longer than 10 mm 0 4 in gt n REQUIRED TOOLS FOR MOUNT THE SERVO DRIVE A small slot screwdriver s with a blade width of 3 mm or less for connector X1 and 2 mm 1 10 in or less for connectors X3 and X4 A drill and M5 screws or bolts for mounting the MicroFlex e150 Wire stripper For UL installations use UL listed closed loop connectors that are of appropriate size for the wire gauge being used Connectors are to be installed using only the crimp tool specified by the manufacturer of the connector 32 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS SERVO DRIVE MECHANICAL INSTALLATION sm E
80. t least 1 Mohm that there is no voltage between the drive input phases L1 L2 and L3 and the ground Do not work on the control cables when power is applied to the drive or to the external control circuits Externally supplied control circuits can carry dangerous voltage even when the input power of the drive is switched off Do not make any insulation or voltage withstand tests on the drive All ELV extra low voltage circuits connected to the drive must be used within a zone of equipotential bonding i e within a zone where all simultaneously accessible conductive parts are electrically connected to prevent hazardous voltages appearing between them This is accomplished by proper factory grounding Even when the motor is stopped dangerous voltage is present at the power circuit terminals L1 L2 L3 U V W R1 R2 connector X1 If a motor is driven mechanically it can generate hazardous voltages that are conducted to its power terminals The enclosure must be earthed grounded to prevent possible shock hazard To prevent equipment damage be certain that the input power has correctly sized protective devices installed To prevent equipment damage be certain that input and output signals are powered and referenced correctly To ensure reliable performance of this equipment be certain that all signalsc to from the drive are shielded correctly Do not tin solder exposed wires Solder contracts over time and can cause loose connections
81. t to the slave are the follow Home position the press will move to zero position Cycle start the press start its working cycle Reset Press will be referenced and initialized Drive error will be resetted Program wait Press program will wait on a step Wait for input The program will be continue after this input is on Jog Press will jog downwards Press will upwards The user s PLC output Master shall be connectet to the Input connectors OPT1 and X3 located in the Microflex e 150 servo drive Slave as indicated in the diagram below SERVO DRIVE CONNECTOR SERVO DRIVE CONNECTOR USER S PLC MASTER 24VDC A 2 3 4 5 6 7 8 9 JOG PROGRAM WAIT RESET DIN7 DING DIN5 DIN7 2 3 4 5 6 7 8 9 DIN3 CYCLE START HOME POSITION PLC OUTPUT DIN0 SERVO DRIVE INPUT MN0010 VERSION 1 0 DATE 2014 10 17 51 ELECTRICAL INSTALLATION STRAIGHT PRESS sma LLL rasa 7 7 2 USER S PLC INPUT CONNECTION The Microflex e 150 sero drive has a built in PLC connected as a slave to the user s PLC Master See the dia gram page 36 The communication between master and slave occur through the digital Input Output signals The servo drive Slave provide to the user s PLC Master the follow digital output Press ready Press is referenced Motor is enabled and is ready to work Motor break Servo motor break Analisys OK
82. the grease in the Nipples NO 4 5 7 8 11 12 for a quantity of 10 cm3 for each nipples 2nd step Move the spindle at low speed 20 of nominal speed until the end of stroke and stop the spindle 3th step Pump the grease in the Nipples NO 6 7 10 for a quantity of 10 cm3 for each nipples 60 DATE 2014 10 17 MNO0010 VERSION 1 0 STRAIGHT PRESS MAINTENANCE sm Li rona 4th step Move the spindle forward and backward for 2 or 3 cycles and run at low speed 20 of nominal speed The grease will be spread on the sliding surfaces Pump the grease ONLY when the spindle s supply current is cut off The relubrication shall be effectuated only by skilled personnel 10 4 BALL SCREW RELUBRICATION The ball screw has to be greased at least every 1500 hours of working according to the maintenance plan To lu bricate the ball screw is raccomended the grease Bechem High Lub LFB 2000 Multipurpose EP DO NOT use different type of grease and DO NOT introduce different kind of grease and mix with the grase present in the device Procedure 1st Step Release and Remove the socket cap plug NO 1 See picture NO 11 2nd Step Set the speed of the spindle at 1mm s or less and allign the hole in the bronze anti twist to the hole of the socket cap plug See picture NO 12 DO NOT insert when the spindle is in movement the fingers or tools inside the free hole after the socket cap plug removal The spindle in movement could be c
83. the servo press may under no circumstances be collided during operation The internal end positions may only be collided by the spindle in setup mode and only for determining the end positions with low force of a few N torque limitation if possible below 10 and very slowly max 2 of the nominal speed Cable set composed by shield motor power cable shield encoder cable shield force sensor cable MN0010 VERSION 1 0 DATE 2014 10 17 17 sm EL iL rona INTRODUCTION STRAIGHT PRESS Servo press modules APM PC Tool Kit software for servo press set up compatible with all MS Windows PC from Vi sta operative system of later versions Depending on the purchase order components may be missing or additionally available 1 7 MECHANICAL STRUCTURE SCHEMATIC OF STRUCTURE Force sensor Encoder Force sensor Ball screw connector motor Motor Tool holder The Servo Press mainly consists of a housing with ram ball bearing spindle and servomotor as drive including a position encoder Installation can be done vertical or horizontal Assembly is performed at the machine rack either with hexagon socket screws or by flange mounting The ram edge is provided by threaded holes for tool holder 18 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS INTRODUCTION sm Li rona Mode of operation The motor drives the gearbox which is connected over the coupling to a ball screw spindle The ball screw is held
84. w nut own a preload that goes to reduce its efficency This effect added to the friction of the mechanism makes an opposite torque that avoid the effect of the back driving To Avoid dangerous effect of back driving on the ram will be important not exceed the admissible payload Cheek in the data sheet of your servo presses which is the maximum weight of the tool The risk estimation was be evaluated with the max payload applied on the ram Any payload over the admissible li mit further being cause of healt injuries for the operator and annul the follow risk analysis Note The max payload is the total weight that is possible attach to working in safety in tha ram in its axe direction but this doesn t means that is possible attach the maximum paylod declared The C2114 is supplied without tool holder to clamp the workpoiece Verify the payload capability of the tool holder or tools that will be mounted in the servo press ram Risk estimation Frequency of exposure Accidend probability Possible injuries Category 1 Minor injuries crushing of the hand and fingers Category 2 Major injuries loss of fingers severe crushing of the hand Category 3 Death Severe crushing of the head 8 DATE 2014 10 17 MN0010 VERSION 1 0 STRAIGHT PRESS INTRODUCTION sma EL iL rona Injuries Contermeasures None Type of malfunction Anti twist ram slide wear blocking after being damaged Bushing ram wear blocking after

ABB straight servo press installation manual

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