Manual - Precision Abrasive Machinery
Contents
1. from each rod It first makes the Primary Length Cuts until the amount set at section 6 15 is satisfied then it makes the Secondary Cut Lengths from the Remainder of the rod until the Pusher Done Proximity Limit Switch is energized This Limit Switch is located on the front side right end of the PUSHER Table The Pusher Done Limit Donut Target has been factory set and should not be moved After energizing the Pusher Done Limit the PUSHER returns Home to receive the next rod At this time the Primary Length Accumulated Count is reset and this cycle may be repeated If only one cut length dimension per rod is desired the number of Primary Cuts set at section 6 15 may be set to a number greater than possibly obtainable from the Rod Length being cut or the Secondary Cut Length set as section 6 17 may be set the same as the Primary Cut Length section 6 13 The minimum amount that may b ntered here is 0 060 Inch and the maximum value is 12 75 Inch When the correct entry has been made press the UP Arrow Key and the following message will be displayed on the O 1 U screen 9 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 6 15 NUMBER OF PRI CUTS 999 6 16 While this message is displayed the desired number of Primary Cuts may be entered see section 6 14 for explanation When the correct entry has been made press the2. the Socket Head Set Screw on the Donut shaped target Then press F9 to Home axis Check for 1 Inch 1 4 Clearance distance 6 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 6 0 AUTO SETUP 6 1 After adjusting TOOL BED Home Zero and PUSHER Home and Homing Axis F9 several Data Entries must be reviewed befor attempting an Automatic Cycle 6 2 Press F2 to enter the Automatic Mode and the following message will be displayed on the O 1 U 6 3 SINGLE CUT F5 FULL AUTO F6 FA 6 4 While this message is displayed Single Cut Mode F5 or Full Automatic Mode F6 may be selected In Single Cut Mode the machine will pause after each cut until F1 is pressed to resume operation In Full Automatic Mode the machine will cycle continually until the TOOL BED is empty See Section 4 3 4 4 Refilling the TOOL BED The FA at the lower right of the display indicates that FullAuto Mode is selected If Single Cut Mode is desired press F5 and then FA will be replaced by SC on the display to indicate that Single Cut Mode is selected When changing from Single Cut Mode to Full Auto Mode while machine is paused after cut the machine will immediately resum operation when F6 is pressed When a selection of Single Cut or Full Auto has been made press the UP Arrow Key on the O 1 U and the following message will be displayed on the O 1 U
3. homes then press F3 to stop the Wheel Motor and then F6 to open the Clamps 9 15 Press F2 for Automatic Mode to access O 1 U screens 21 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 9 16 Access Screen 249 of O 1 U follow next line Press MODE key then 2 key 4 key 9 key then ENTER key The O I U will display the screen as follows 9 16a V TO WHEEL X XXXX 9 16b Enter the value calculated from section 9 13 By pressing LEFT arrow key numbers will then be flashing then enter number with Decimal point Check entered number if correct then press ENTER key if not press CLEAR key and reenter number 9 After returning to User Controlled Messages use the UP arrow to find the message as displayed below Then press F5 to reset 9 17a WHEEL WEAR COMP RESET F5 9 18 Press the DOWN arrow key once and the message screen as seen below will be displayed The value shown at the lower right of the display should be the same value as entered at screen 249 9 18a WHEEL WEAR COMP F5 F6 X XXXX 22 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 10 0 ACCESSTO PLC DATA USING THE O I U LO xc Many PLC Registers containing Timer settings Limits Motor Speeds Ect These Registers may be accessed and altered from the O I U This should only be attempted by qualified personnel with a thorough understanding of the PLC Program If it becomes nece
4. 5 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 5 0 ADJUSTING PUSHER HOME POSITION Sel After adjusting the TOOL BED for the New Rod Diameter Setup the PUSHER Home Switch Target split donut or torus shape must be adjusted for carbide rod length PE The PUSHER Home Switch Target is located on the front side left end of the Pusher Table on an adjustment slide rod As viewed from the operator position 5 3 Select Manual Mode F2 if needed Select PUSHER F7 three times to the PUSHER screen 5 4 For Shorter Rod Lengths that being a farther distance from the existing Split Donut target first Jog PUSHER Forward from the Split Donut Target to a place that leaves a extra 1 Inch clear distance between the PUSHER END PIECE and the end of the rod Then loosen the Socket Head Set Screw on the Donut shaped target and slide the Target up to the Left Hand Proximity Switch close enough to make the Prox Sw signal Then tighten the Socket Head Set Screw on the Donut shaped target Then press F9 to Home axis Check for 1 Inch 1 4 Clearance distance Deo For Longer Rod Lengths that being a lesser distance from the existing Split Donut target first move the Split Donut Target home ward to a place that leaves 1 Inch clear distance the difference between the PUSHER END PIECE and the end of the rod Then tighten
5. 30 PLCs User s Manual October 1997 GFK 1464 Table B 1 Continued DSM302 Error Codes Continued Error Number Hexadecimal Response Description Error Type Encoder Alarms CO Stop Fast Servo not ready when MCON command is on may be caused by E STOP input to amplifier Axis C1 Status Only Serial Encoder Battery Low Axis C2 Stop Normal Serial Encoder Battery Failed Axis C3 Stop Normal Servo Motor Over Temperatur Axis C4 Stop Fast Servo Motor Over Current Axis C5 Stop Fast Loss of Encoder Axis C6 Stop Fast Error in encoder pulse detection Axis C7 Stop Fast Encoder counter error Axis C8 Stop Fast Encoder LED is disconnected Axis C9 Stop Fast Encoder CRC checksum failure Axis CA Stop Fast Unsupported encoder linear or Type A Axis CB Stop Fast Unsupported encoder Type C Axis DSP Alarms D1 Stop Fast Over current Detected Axis D2 Stop Fast Loss of Analog Feedback Axis D3 Stop Fast Over Acceleration Detected Axis D4 Stop Fast Over Velocity Detected Axis D5 Status Only KpVelFix Too Large Axis D6 Status Only IntGainFix Too Large Axis D7 Status Only Alpha Calculation Overflow Axis D8 Status Only IntGain Calculation Overflow Axis D9 Status Only Kp Calculation Overflow Axis DA Stop Fast FPGA Error Detected Axis Special Purpose Errors
6. EO Status Only Custom Loop Type Mismatch Axis E2 Stop Fast DSP Interrupt failure Module Follower Errors F1 Status Only Follower Position Error Limit Encountered Axis F2 Status Only Follower Velocity Limit Condition Encountered Axis F3 Status Only Follower Ratio B value 0 Axis F4 Status Only Follower Ratio B value lt 0 Axis F5 Status Only Follower Ratio A B or B A gt 32 Axis Winder Errors F6 Status Only A B Change Not Allowed in Winder Mode With Follower Enabled Axis F7 Status Only Set Winder Position Immediate Command Out of Zone Axis F8 Status Only Zone Length Out of Range or Zone Length Change Exceeded 25 Axis F9 Status Only Zone Length Change Not Accepted Previous Change Still in Effect Axis Internal Errors FD Stop Fast System software error Axis FE Stop Fast Unrecognized encoder not supported Axis 29 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW GFK 1464 Appendix B Error Reporting B 7 LED Indicators There are seven LEDS on the DSM302 module which provide status indications These LEDS are described below STAT Normally ON FLASHES to provide an indication of operational errors Flashes slow four times second for Status Only errors Flashes fast eight times second for errors which cause the servo to stop ON When the LED is steady ON the DSM302 is functi
7. The minimum amount that may b ntered here is 0 01 and the maximum is 4 00 I P M When the correct entry has been made press the UP Arrow Key and the following message will be displayed on the O 1 U screen Note If Break Thru Speed at section 6 21 was set to NO disregard this message and skip to section 6 27 6 27 SENSOR TO WHEEL F5 F6 1 125 6 28 While this message is displayed the recognized distance from the Pusher Rod Edge Proximity Sensor to the left edge of the cutting wheel used for internal calculations may be adjusted This distance will only effect the first cut from each rod Due to various rod densities and mass size the location of the Proximity Sensor and its sensitivity setting the Proximity Sensor will not activate at the same setting for all diameters If the first cut from the rod is too short add the difference of being short to the Wheel to Sensor value by pressing F5 each press of F5 will add 0 0012 Inches Holding F5 will advance the value 1 increment per second for approx 5 seconds After holding F5 for approx 5 seconds the will advance the value 10 increments per second Then after holding F5 for approx 15 seconds the will advance the value 100 increments per second If the first cut form the rod is too long subtract the difference of being short to the Wheel to Sensor value by
8. UP Arrow Key and the following message will be displayed on the O 1 U screen 6 17 SECONDARY CUT LENGTH 3 500 IN 6 18 While this message is displayed the Secondary Cut Length may be entered see section 6 14 for explanation The minimum amount that may b ntered here is 0 060 Inch and maximum is 12 75 Inch When the correct entry has been made press the UP Arrow Key and the following message will be displayed on the O 1 U screen 6 19 MAJOR CUT SPEED 2 00 I P M 6 20 While this message is displayed the WHEEL HEAD Axis major cutting speed in inches per minute may be entered The minimum amount that may b ntered here is 0 01 I P M and the maximum is 4 00 I P M If the Break Thru Speed is set to NO the entire cut will be at this speed see section 6 21 for more detail on Break Thru Speed When the correct entry has been made press the UP Arrow Key and the following message will be displayed on the O 1 U screen 10 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 62 271 BREAK THRU SPD N YES F5 NO F6 6 22 While this message is displayed the Optional Break Thru cutting speed may be selected This machine is capable of using two different WHEEL HEAD Axis feed speeds during each cut If the Break Thru Speed Option is set to NO the Major Cut Speed entered at section 6 1
9. lst press OPEN 2nd press CLOSE 1 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW IT F7 AXIS SELECT TOOL BED WHEEL HEAD PUSHER This Key is active while in Manual Mode and is used to select the desired Axis to be jogged Upon entering the Manual Mode after Homing the machine or after clearing a fault condition the Tool Bed Axis is the default selection Each press of the F7 Key toggles the Axis Selection from TOOL BED gt WHEEL HEAD gt PUSHER gt TOOL BED 1 8 F8 JOG SPEED FAST SLOW This Key is active while in Manual Mode and is used to select the desired jog speed Upon entering the Manual Mode after Homing the machine or after clearing a fault condition Jog Slow is the default selection Each Press of F8 toggles the jog speed between Slow and Fast The current jog speed selection is shown at the lower left of the O 1 U Display screen 1 9 F9 SEND PUSHER amp WHEEL HEAD HOME This Key is only active while in Manual Mode and is used to return the Pusher and Wheel Head Axis to their Home Positions 1 9 TO HOME The TOOL BED AXIS After each machine Power Up the O 1 U will display a screen to Home Axis by pressing CLEAR or F9 After the Homing function the Tool Bed Axis will need to set to Home and Zero The Tool Bed Axis is set to Home and Zero by manually jogging the Tool Bed Axis to a proper distance
10. back to fill the Tool Bed with carbide rods After this has been established the Tool Bed Axis will auto return to its Home position after the Tool Bed has reached its End Limit Switch SEO F10 SPARE FUNCTION KEY kd F11 STOP BEFORE NEW ROD This Key is only active during an Automatic Cycle Pressing F11 during an automatic cycle will cause the machine to Cycle Stop before loading a new rod Shut Down Auto Cycle and STOP the Wheel Head and Coolant motor Press Fl to start a new cycle 2 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW w12 F12 STOP AFTER CUT This Key is only active during an Automatic Cycle Pressing F12 during an automatic cycle will cause the machine to pause upon completion of the current cut Press F1 to resume normal operation 2 0 OTHER OPERATOR CONTROLS 2 1 EMERGENCY STOP When this button is pressed in all machine functions are stopped the clamp will lock close and E STOP FAULT will be shown on the O 1 U display PAR JOG FORWARD This Pushbutton is only active in Manual Mode and is used to jog the currently selected axis displayed by the O I U in the direction opposite of its Home Position If the Pusher Axis is selected the Clamp must be in the open position before this Pushbutton will be active If the Wheel Head Axis is selected the Clamp must be
11. in the closed position before this Pushbutton will be active 23 JOG REVERSE This Pushbutton is only active in Manual Mode and is used to jog the currently selected axis displayed by the O I U in the direction of its Home Position Jog Reverse is not active beyond the Home Position Limit 2 4 INCYCLE This Pilot Light is only active in Automatic Mode and will be illuminated during and automatic cycle If Single Cut Mode is selected or F12 STOP AFTER CUT was pressed this Light will go off upon completion of the current cut 245 CYCLE DONE FAULT FLASHING This Pilot Light flashes during a Fault condition or illuminates upon completion of the current cut if Single Cut Mode is selected or F12 STOP AFTER CUT was press 3 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 3 0 INITIAL MACHINE POWERUP Fed Pulled out the Emergency Stop and connect and turn on the Air Supply Next turn on the Disconnect Switch Then the following O I U message will be displayed 34 2 POWER UP FAULT CLEAR RESET 323 Press the CLEAR Key on the O 1 U to clear this fault and the following message will be displayed on the O 1 U 3 4 HOME REQ D PRESS CLEAR 325 This message is to alert the operator that the Pusher and Wheel Head Axis must be sent to their Home positions While this message is displayed pressing the CLEAR or F9 Key on the O 1 U will send the Pu
12. screen 6 5 FRONT NIP NO YES F5 NO F6 6 6 While this message is displayed the operator may choose whether or not to make a trim cut on the front of each Rod FRONT NIP If Front Nip is desired press F5 and NO at the upper right of the display will be replaced by YES to indicate the Front Nip is selected Press F6 if NO Front Nip is desired When this selection has been made press the UP Arrow Key and the following message will be displayed on the 0 1 U screen 7 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 6 7 NIP AMOUNT 0 062 IN 6 8 While this message is displayed the length of the Front Nip may be entered The bottom line of this message indicates the current Front Nip length in Inches To change this amount enter the desired amount using the Numeric keys on the O 1 U keypad When changing data entries the value displayed on the 0O 1 U will flash If a mistake is made during number entry just press the CLEAR Key and the previous value will be displayed then reenter the desired value When the desired value is flashing press the ENTER Key The displayed value will stop flashing and will show the new entry When making entries that are less than 1 000 press 0 Zero then a decimal point then the remaining decimal number The minimum N amount that may b ntered here is 0 062 Inches When the correct numb
13. 9 will be used during the full cut If the Break Thru Speed option is set to YES the cut will start at the Major Cut Speed and then change to the Break Thru Speed entered at section 6 25 when it reaches the percent of the rod diameter entered at section 6 23 and finish the cut If the Optional Break Thru Speed is desired press F5 and the N shown at the upper right of the display will change to a Y indicating that Break Thru Speed is selected If no Break Thru Speed is desired press F6 and an N will appear at the upper right of the display indicating that no Break Thru Speed is selected When the correct entry has been made press the UP Arrow Key and the following message will be displayed on the O 1 U screen 6 23 START BREAK THRU SPEED AT 75 6 24 While this message is displayed the percent of the rod diameter to travel before changing to the Break Thru Speed may be entered Then minimum amount that may b ntered here is 75 and the maximum is 95 When the correct entry has been made press the UP Arrow Key and the following message will be displayed on the O 1 U screen Note If Break Thru Speed at section 6 21 was set to NO disregard this message and skip to section 6 27 11 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 62 25 BREAK THRU SPEED 0 01 I P M 6 26 While this message is displayed the WHEEL HEAD Axis break thru cutting speed may be entered in Inches Per Minute
14. HEA The Coolant Valve turn 7 14 Cutting Wheel has cu The WHEEL HEA Thru option was selected then t thru the Rod ARBI DE ROI s ON Major Cut Speed for and then diameter 0 050 In Tels Then the WHEEL HEA to a position 0 250 In the percent and the Coolant Valve turns Off 7 16 outlined at section 7 13 The WHEEL HEA 7 17 Cut Next the Clamps open F12 D CUT OFF SAW D Axis advances rapid until rod O is 0 050 D D Axis advances at the Major Cut Speed until the f the Break Diameter 0 50 In the WHEEL HEAD Axis tage of the Rod Diameter advances at the section 6 23 the Break Thru Speed finishes the remainder of the direction D Axis moves rapidly in the hom pause at this point until Fl is pressed 7 18 Primary Cut Length or Secondary Cut Length The Pusher advances rapidly the distance of Wh the PUSHER If beyond the position outlined at section 7 13 D Axis then moves rapidly forward to the position If Single Cut was selected or Stop After was pressed after the cycle was started the Cycle will eel Width Done End Limit Switch is activated during this move the PUSHER and WHEEL HEA Tak The Clamps close and 7 20 interrupted by an Emergency St The machine repeats st to Cycle Stop before loading a new rod the Cool tep
15. Only Set Position while Program Selected error Axis 51 Status Only Set Position Data overrang rror Axis 52 Status Only Servo Axis 1 2 Set Position while not In Zone error Aux Axis 3 Set Position while ENC3 Velocity gt 128 error Axis 53 Status Only Attempt to initialize position before digital encoder passes reference point Axis 54 Status Only Digital encoder position invalid must use Find Home or Set Position Axis End of Travel and Count Limit Errors 56 Status Only Commanded Position gt Positive End of Travel or High Count Limit Axis 57 Status Only Commanded Position lt Negative End of Travel or Low Count Limit Axis 58 Status Only Absolute Position Position offset gt Positive End of Travel or High Count Limit Axis 59 Status Only Absolute Position Position offset lt Negative End of travel or Low Count Limit Axis Drive Disable Errors 5B Stop Normal Drive Disabled while Moving Axis 5C Stop Normal Drive Disabled while Program Active Axis Software Errors 5F Status Only Software Error Call GE Fanuc Field Service Axis Program and Subroutine Errors 60 Status Only Absolute Encoder Rotary Position Computation error Axis 61 Stop Normal Subroutine not in list Axis 62 Stop Normal Call Error subroutine already active Axis 63 Stop Normal Subroutine End command found in Program Axis 64 Stop Normal Program End command found in Su
16. Precision Abrasive Machinery Inc 14200 W COMMERCE RD P O BOX 43 DALEVILLE INDIANA 47334 765 378 3315 FAX 765 378 3316 11 04 97 AUTOMATIC CARBIDE ROD CUT OFF SAW 1 0 FUNCTION KEYS 1 1 F1 CYCLE START This Key is only active while in automatic mode It is used to start the automatic cycle and resume cycle while in single cut mode or after using F12 STOP AFTER CUT 1 2 F2 MODE SELECT AUTO MANUAL After clearing any fault conditions machine will be in MANUAL MODE In this mode each axis may be jogged and all machine functions may be performed Pressing F2 will switch the machine to AUTOMATIC MODE In this mode data entries may be made and Auto Cycle may be started Pressing F2 again will change the machine back to Manual Mode Bes F3 WHEEL MOTOR START STOP This Key is only active while in Manual Mode and is used to Start and Stop the Wheel Motor lst press ON 2nd press OFF 1 4 F4 COOLANT OFF ON This Key is only active while in Manual Mode and is used to toggle the Coolant Valve ON and OFF lst press ON 2nd press OFF cas F5 LOADER EXTEND RETRACT Air Cylinder Equipped Models Only This Key is only active in Manual Mode and is used to Extend and Retract the Loader Rod Cylinder lst press ON 2nd press OFF 1 6 F6 CLAMP OFF ON This Key is only active while in Manual Mode and is used top Open and Close the Clamp
17. RESS CLEAR 8 34 To clear this fault press the clear Key and then check for errors in the Setup Entries speeds lengths other 20 of 24 9 1 Target AUTOMATIC CARBIDE ROD CUT OFF SAW 9 0 ADJUSTING PUSHER VEE CENTER TO WHEEL DISTANCE The Recognized Distance from the Pusher Vee Block Center to the outside diameter of the wheel when WHEEL HEAD Axis is at Home position is used to calculate all WHEEL HEAD Axis moves If this Distance is altered by changing the Home Proximity switch to Home t relationship the Recognized Distance used by the PLC must be adjust Block ted using the following steps Remove the splash guards around the wheel Select Manual Mode and press F9 to home PUSHER and WHEEL HEAD Clamp a known diameter rod in the cutting area of the Vee Press F3 to start the Wheel Motor Press F7 three times to select the WHEEL HEAD Axis SEE 9 9 Press F8 to select FAST jog speed SEE 9 9 Press Jog Forward Pushbutton until the Wheel is within 1 2 of the Tool in the Vee Block MAN WHEEL HEAD MAN WHEEL HEAD SLOW XX XXXX FAST XX XXXX Press F8 to select SLOW jog speed SEE 9 9 Carefully Jog Forward until the Wheel dusts the tool Record the WHEEL HEAD position shown at the lower right of the display Add 1 2 of the tool diameter to the display value Press F9 to home the WHEEL HEAD Axis After the WHEEL HEAD
18. broutine Axis 65 Stop Normal Sync subroutine encountered by non sync program Axis Program Execution Errors 71 Status Only Too many programs requested in same PLC sweep Module 72 Status Only Request Program 0 10 with multi axis program active Module 73 Status Only Request two programs on same sweep with program active Module 74 Status Only Request two programs for same axis lower number program executed Module 75 Status Only Empty or Invalid Program requested Module 76 Status Only AQ Move Command Position Out of Range Axis 27 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW GFK 1464 Appendix B Error Reporting B 5 Table B 1 Continued DSM302 Error Codes Error Number Hexadecimal Response Description Error Type Program Execution Conditions Errors 80 Status Only Execute Program while Home Cycle active Axis 81 Status Only Execute Program while Jog Axis 82 Status Only Execute Program while Move at Velocity Axis 83 Status Only Execute Program while Force Digital Servo Velocity Axis 84 Status Only Execute Program while Program Selected Axis 85 Status Only Execute Program while Abort All Moves bit set Axis 86 Status Only Execute Program while Position Valid not set Axis 87 Status Only Ex
19. ecute Program while Drive Enabled not set Axis 88 Status Only Execute Program with active Error Stop Axis Enabled off Axis Program Synchronous Block Errors 8C Status Only Sync Block Error during CMOVE Axis 8D Status Only Sync Block Error during Jump Axis EEPROM Errors 90 Status Only Flash EEPROM memory programming failure Module Hardware Limit Switch Errors AO Stop Fast Limit Switch error Axis Al Stop Fast Limit Switch error Axis Hardware Errors A8 Stop Fast Out of Sync error Axis A9 Stop Fast Encoder Loss of Quadrature or Linear Feedback Loss of Signal error Axis Digital Servo Alarms BO Stop Normal Main DC power supply overvoltage Axis B1 Stop Normal Control power undervoltage Axis B2 Stop Normal Dynamic brake failure Axis B3 Stop Normal Main DC power supply undervoltage Axis B4 Stop Normal CNV Overload Axis B5 Stop Normal Cooling fan failure Axis B6 Stop Normal Over current Axis B7 Stop Normal Regenerative discharge energy error resistor thermal switch open Axis B9 Stop Normal Control power undervoltage Axis BA Stop Normal Error detected by IPM circuit Axis BB Stop Normal Main DC power supply undervoltage Axis BD Stop Normal Cooling fan failure Axis BE Stop Normal Over current Axis 28 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW B 6 Motion Mate DSM302 for Series 90
20. er has been made press the UP Arrow Key and the following message will be displayed on the O 1 U screen Note If Front Nip was set to NO disregard this message and skip to the next Screen Use the UP Arrow Key 6 9 ENTER WHEEL WIDTH 0 040 6 10 While this message is displayed the Wheel Width may be entered If a different width wheel is installed be sure to change the value This message is also useful to adjust second and consecutive cut lengths if second cut from rod is too short add that amount to the Wheel Width factor When the correct entry has been made press the UP Arrow Key and the following message will be displayed on the 0 1 U screen 8 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 62 11 ENTER ROD DIA 0 0630 IN 6 12 While this message is displayed the Rod Diameter may be entered The bottom line of this message indicates the current Rod Diameter setting in Inches Measure the Rod Diameter and enter the amount here The minimum amount that may b ntered here is 0 0630 In and the maximum is 1 0625 In When the correct entry has been made press the UP Arrow Key and the following message will be displayed on the O 1 U screen 6 13 PRIMARY CUT LENGTH 2 500 IN 6 14 While this message is displayed the Primary Cut Length may be entered This machine is capable of cutting two different cut lengths
21. he Pusher Home Limit reviewing all data entries AUTOMATIC CARBI DE ROD CUT OFF SAW 7 0 AUTOMATIC CYCLE SEQUENCE Donut Target and an Automatic Cycle may be executed The Following sequenc takes place he ed The Machine must be in Automatic Mode While in Automatic Mode the Operator will have control of the O I U displays using the UP or DOWN Arrow Keys Ter After the first Bed of rods is cut or the first bed of rods is interrupted the Operator must place the a rod of the next batch onto the Pusher VEE before Cycle Start 7 4 The Operator presses F1 cycle start Tep The Cycle On light Illuminates and the Wheel and Coolant Motor starts 7 6 The Clamps Open 7 7 After first rod is cut the TOOL BED then Indexes the next rod onto the PUSHER VEE Teg Sensor detects the end of the rod the machine shuts down and the NO ROD FOUND fault The PUSHER advances slowly until the Rod End Prox If the sensor noes not detect a rod within 7 seconds screen is displayed Ee distance of the If Front Nip was selected the PUSHER moves the rod the 1 Wheel Width Sensor to Wh Nip Amount 7 10 If Front Nip was NOT selected the PUSHER moves the rod the distance of the Sensor to Wheel Wheel Width Primary Cut Length 15 of 24 AUTOMAT Beane The Clamps close Pee from Cutting Wheel The WHEEL
22. he current status of the DSM302 module ON When the LED is steady ON the DSM302 is functioning properly Normally 30 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW this LED should always be ON the DSM302 is not functioning Thi OFF When the LE result of a D is OFF s is the hardware or software malfunction which will not allow the module to power up CFG This LED is ON when a valid module configuration has b from Store TO EEPROM operation EN1 When this EN2 When this EN3 When this 3 is active EN4 When this 4 is active LE LE LE LEI D D D the PLC Flashes slow function Flashes fast is is is is four eight ON the ON the ON the ON the times second during the Motion t times second during the Write servo drive for Servo Axis 1 is servo drive for Servo Axis 2 is Force Analog Output command for Force Analog Output command for 31 of 24 n received Program User RAM enabled enabled Aux Axis Aux Axis
23. he rods do not pile up 4 2 Next for New Rod Diameter Setup jog Tool Bed Rod Pusher Plate BACKWARD or FORWARD to desired position to fill with carbide rods Then important jog Tool Bed Rod Pusher Plate FORWARD until a rod falls into the Pusher Vee This will Zero the Tool Bed so it will increment the other rods into the Vee DO NOT REMOVE THIS ROD 4 2a Tool Bed Sequence Information The Tool Bed Sequence is designed NOT TO INDEX the First Rod from its Home Zero Position The TOOL BED will advance rod to rod until it reaches its End Limit and then it will return to it defined Home Zero Position The machine will then attempt to push the first rod of the next batch that is not present and then the machine will time out because of no rods and a Fault message will appear The Tool Bed Rod Pusher Plate will still be at Home Zero Position A message on the O 1 U screen will request to clear the fault message and then HOME Axis Follow the Commands 4 3 Refilling the TOOL BED same diameter from setup After the machine has run out of rods the TOOL BED is at prior Home Zero and Homing is done refill the TOOL BED with carbide rods and then simply place a rod in the Pusher Vee Then press F1 to start a new run 4 4 Refilling the TOOL BED with a new rod diameter See 4 1
24. itch The distance from the Proximity Switch to the wheel was established as 3 500 by carefully pushing a 1 8 diameter rod up to the sensor to find where the signal led activates This is a static measurement to provide a starting distance The proximity switch sensing distance is proportional to the mass of the target carbide rod diameter A trial run of different rod diameters was done to find the mean sensing distance for each diameter shown below The Distance Chart below may change from Machine to Machine because of the mechanical position of the Proximity Switch and the Amplifier Gain Adjustment Stock Measured Sensor Difference Mean Dia diameter 1 8 Ref from Ref Distance 1 16 O OTAN 32500 0 045 3 455 1 8 0 141 3510 0 0 008 3 492 1 4 0255 S500 0 003 3 497 SIA 0 394 3 51010 0 008 3 492 cy 0 526 S2500 0 020 3 480 3 4 0 769 301010 O 055 3 445 1 13 033 3500 0 100 3 400 Test Run 6 23 97 Greg Maynard EET 24 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW Appendix B Servo Axis Error Codes Section Response Methods 1 Status Only Errors Set the Module Error Present I bit and Module Status Code or Axis Error Code SAI word but do not affect motion Note Unless otherwise noted any command which causes a Status Only Error is ignored 2 Stop Normal Errors Perform an internal abort of any c
25. le this message is displayed will return the recognized distance from the Pusher VEE Center to Wheel O D of the WHEEL HEAD Axis and the WHEEL HEAD Axis Over Travel Limit back to their Original settings Reset may be confirmed by checking the value displayed at section 6 29 Press the UP Arrow Key and the following message will be displayed on the O 1 U screen 6 33 CYCLE START F1 CYCLE STOP F12 6 34 This is a read only message that marks the end of the data entry messages and reminds the Operator that F1 is Cycle Start and F12 is Stop after each cut Pressing the UP Arrow Key will return the O 1 U display to the message shown at section 6 3 13 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW Note Pressing F11 during an automatic cycle will cause the machine to Cycle Stop before loading a new rod Shut Down Auto Cycle and STOP the Wheel Head and Coolant motor See section 1 11 6 35 Notes to Auto Setup 6 35a The Machine will be in Automatic Mode when any of the messages at section 6 3 to 6 33 are displayed on the O 1 U screen F1 Cycle Start may be initiated while any of these massages are displayed 6 35b Changes made to data entries during an Automatic Cycle will not take effect until the next use of that entry 6 35c Using the DOWN Arrow Key will scroll thru the O I U messages in reverse order 14 of 24 7 1 After adjusting t
26. oning properly Normally this LED should always be ON OFF When the LED is OFF the DSM302 is not functioning This is the result of a hardware or software malfunction which will not allow the module to power up Flashing When the LED is FLASHING an error condition is being signaled Constant CFG LED ON The LED flashes slow four times second for Status Only errors and fast eight times second for errors which cause the servo to stop The operational error code will be placed in one of the first four SAI status words and the Module Error Present I status bit will be ON Constant CFG LED Flashing If the STAT and CFG LEDs both flash together at a constant rate the DSM302 module is in boot mode waiting for a new firmware download If the STAT and CFG LEDs both flash alternately at a constant rate the DSM302 firmware has detected a software watchdog timeout due to a hardware or software malfunction Irregular CFG LED OFF If this occurs immediately at power up then a hardware or software malfunction has been detected The module will blink the STAT LED to display two error numbers separated by a brief delay The numbers are determined by counting the blinks in both sequences Record the numbers and contact GE Fanuc for information on correcting the problem OK The OK LED indicates t
27. or Axis 3B Status Only Move at Velocity while Home Cycle active error Axis 3C Status Only Move at Velocity whil Jog error Axis 3D Status Only Move at Velocity while Abort All Moves bit is set error Axis 3E Status Only Move at Velocity Data greater than 8 388 607 user units sec Axis 3F Status Only Move at Velocity Data greater than 1 million cts sec error Axis 26 of 24 B 4 Motion Mate DSM302 for Series 90 30 PLCs User s Manual AUTOMAT C CARBI DE ROI Table B 1 Continued DSM302 Error Codes Error Number Hexadecimal Response Description Error Type Jog Errors D CUT OFF SAW October 1997 GFK 1464 40 Status Only Jog while Find Home error Axis 41 Status Only Jog while Move at Velocity error Axis 42 Status Only Jog while Force Digital Servo Velocity error Axis 43 Status Only Jog while Program Selected and not Feedholding error Axis Force Digital Servo Velocity Errors 47 Status Only Force Digital Servo Velocity while Jog error Axis 48 Status Only Force Digital Servo Velocity while Move at Velocity error Axis 49 Status Only Force Digital Servo Velocity while Program Selected error Axis 4A Status Only Force Digital Servo Velocity while Follower Enabled error Axis Set Position Errors 50 Status
28. pressing F6 each press of F6 will add 0 0012 Inches F6 has the same progressiv ffect when held down Press the UP Arrow Key and the following message will be displayed on the O 1 U screen Note An Addendum will be supplied to illustrate how to calculate the ROD END PROXIMITY SENSOR with an example spread sheet chart 12 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 6 29 WHEEL WEAR COMP F5 F6 1 1250 6 30 While this message is displayed the Wheel Wear may be compensated The value shown at the lower right of the display represents the distance from the PUSHER VEE Center to the outside diameter of the Cutting Wheel when the WHEEL HEAD Axis is at its home position Each press of F5 will add 0 001 Inches to this distance and to the HEEL HEAD Axis Software Over Travel Limit Each press for F6 will subtract 0 001 Inches Press the UP Arrow Key and the following message will be displayed on the O 1 U screen Note Be sure to reset Wheel Wear Comp when installing a new Wheel see section 6 31 6 31 WHEEL WEAR COMP RESET F5 6 32 While this message is displayed the Wheel Wear Compensation may be reset Be sure to reset Wheel Wear Comp when installing new Wheels or if the recognized distance from the Pusher VEE Center to Wheel O D of the WHEEL HEAD Axis when at Home position is altered see section 9 0 Pressing F5 whi
29. s 7 1 Lani 4 D Axis are sent Home and the sequence starts over al step 7 6 Valve turns On thru 7 19 unless it is Shut the Wheel Head and Coolant mot COY 16 of 24 Down Auto top or a Fault Condition or Pressing F11 Cycle and STOP AUTOMATIC CARBIDE ROD CUT OFF SAW pared If Emergency Stop is used during a Automatic Cycle the next cycle must be started at step 7 2 8 0 FAULTS Bal When a Fault condition occurs the Automatic Cycle is terminated and all machine functions are stopped and the Clamps close The Cycle Done Fault Flashing light will illuminate and flash and the Fault will be displayed on the 0O I U screen Upon clearing the fault condition the machine will be placed in the Manual Mode 8 2 If the Emergency Stop is depressed the following message will be displayed By5 3 E STOP FAULT 8 4 To clear this Fault pull out the Emergency Stop Pushbutton seers Upon initial power up or after a momentary power loss the following message will be displayed 8 6 POWER UP FAULT CLEAR RESET 8 7 To clear this fault press the CLEAR Key on the O I U 8 8 In the event of a Wheel Motor Overload the following message will be displayed 8 9 WHEEL MOTOR OR COOLANT MOTOR OVERLOAD FAULT OVERLOAD FAULT 8 10 To clear this fault allow the Wheel Motor or Coolant Motor Overload Relay to cool down and then press the Rese
30. sher and Wheel Head Axis to their Home positions If this screen changes and appears again then the Tool Bed Axis may need to be set to Home and Zero See Section 1 9A on page 2 3 6 After Homing the Pusher and Wheel Head Axis the following message will be displayed on the O 1 U en MANUAL TOOL BED SLOW 0 0000 3 48 This message should be considered as four separate sections MANUAL at the upper left of the display is to alert the operator that the machine is in the MANUAL MODE TOOLBED at the upper right of the display indicated that the Tool Bed is the currently selected Axis pressing F7 would replace TOOL BED with WHEEL HEAD and then PUSHER SLOW at the lower left of the display indicated that a slow jog speed selected pressing F8 would replace SLOW with FAST The 0 0000 X XXXX Resolution at the lower right of the display represents the current position relative to Home of the selected Axis in Inches Home 0 0000 4 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 4 0 ADJUSTING TOOL BED POSITION 4 1 The TOOL BED Home and Zero position for New Rod Diameter Setup is adjusted by Jogging the Tool Bed Rod Pusher Plate FORWARD or BACKWARD Then place enough Carbide Rods on the Tool Bed so that the rods will not pyramid when being pushed forward Check this by jogging the Tool Bed Slow Forward enough distance to observe that t
31. ssary to view or alter these parameters use the following steps 10 2 The machine must be in the Automatic Mode for the Operator to have control of the messages by using the UP or DOWN arrow keys These are the Normal User Controlled Messages 10 3 To access other O 1 U Screens press the MODE key on the O 1 U 10 4 Enter the Number of the screen that you wish to access one number at a time slowly slow update time between PLC amp OIU and then press the ENTER key tsa When the desired Screen is displayed you may alter the Information using the numeric keypad on the O 1 U If and incorrect Number is entered press the CLEAR key and the previous number will restore itself When the correct Number is entered press the ENTER key to accept the new value 10 6 To return to the User Controlled Messages press the UP key Alternate method press the MODE key then enter 0 from numeric keypad and then press the ENTER key Note See the HORNER ELECTRIC Operator Interface Unit Manual for more details on the O I U 23 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW Precision Abrasive Machinery Inc Addendum 14200 W COMMERCE RD P O BOX 43 DALEVILLE INDIANA 47334 765 378 3315 FAX 765 378 3316 6 29 97 AUTOMATIC CARBIDE ROD CUT OFF SAW Tool End Sensor to Wheel Calculations Proximity Sw
32. t Button on the Overload Relay 17 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 8 11 In the event of a Clamp Solenoid or Clamp Air Pressure failure the following message will be displayed 8 12 CLAMP PRESSURE FAULT 8 13 To clear this fault check the Clamp Solenoid Valve the Clamp Air Pressure Switch and then correct the problem 8 14 During the Automatic Cycle while the Rod Pusher is retracting if the Rod Edge Proximity Sensor is activated the following message will be displayed 8 15 ROD EDGE SENSOR FAULT 8 16 To clear this fault remove obstruction from Proximity Sensor If this does not clear the fault then check proximity sensor Gain adjustment or replace Proximity Sensor and or amplifier 8 17 In the event of a Pusher Forward End Limit fault the following message will be displayed 8 18 PUSHER FWD LIMIT PRESS CLEAR 8 19 To clear this fault press the CLEAR Key on the O I U and the message at section 3 4 will be displayed Press CLEAR again and the PUSHER and WHEEL HEAD will go Home 8 20 In the event of a Pusher Reverse End Limit fault the following message will be displayed 8 21 PUSHER REV LIMIT PRESS CLEAR 18 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 8 22 To clear this fault press the CLEAR Key on the O I U and the message at section 3 7 will be displayed Press and hold the Jog Forward Pushb
33. urrent motion using current Jog Acceleration and Jog Acceleration Mode LINEAR or S CURVE The Drive Enabled and Axis Enabled I bits are turned OFF after the configured Drive Disable Delay 3 Stop Fast Errors Instantly abort all motion by setting the servo velocity command to zero The Drive Enabled and Axis Enabled I bits are turned OFF after the configured Drive Disable Delay 25 of 24 AUTOMAT C CARBI GFK 1464 Appendix B Error Reporting B 3 Table B 1 DSM302 Error Codes Error Number DE ROI D CUT OFF SAW Hexadecimal Response Description Error Type 00 None No Error All Configuration Errors 02 Status Only Scaled data too big maximum value in range used Axis 03 Status Only Home Position gt Positive EOT Positive EOT used Axis 04 Status Only Home Position lt Negative EOT Negative EOT used Axis Configuration Parameter Errors 10 Status Only Position Loop Time Constant too large Immediate command ignored Axis 11 Status Only Position Loop Time Constant too small Immediate command ignored Axis 12 Status Only Position Loop Time Constant computation overflow reduced to non overflow value Axis IE Status Only Immediate command Jog Velocity out of range command ignored Axis 1F Stat
34. us Only Immediate command Jog Acceleration out of range command ignored Axis Program Errors 20 Status Only Program Acceleration overrange defaults to 16 7 million cts sec sec Axis 21 Status Only Program Acceleration too small defaulted to 32 cts sec sec Axis 22 Status Only Scaled Velocity greater than 1 million cts sec 1 million cts sec is used Axis 23 Status Only Program Velocity is zero defaulted to 1 count sec used Axis 24 Stop Normal Program Position too large Axis 25 Stop Normal Unconditional Jump Destination not found Axis 26 Stop Normal Jump Mask error Axis 27 Stop Normal Wait Mask error Axis 28 Stop Normal Parameter Position too large Axis 29 Status Only Dwell time greater than 60 seconds 5 seconds used Axis Position Increment Errors 2C Status Only Position Increment Overrang rror increment ignored Axis Find Home Errors 30 Status Only Find Home while Drive Not Enabled error Axis 31 Status Only Find Home while Program Selected error Axis 32 Status Only Find Home while Force Digital Servo Velocity error Axis 33 Status Only Find Home while Jog error Axis 34 Status Only Find Home while Move at Velocity error Axis 36 Status Only Find Home while Abort bit set error Axis Move at Velocity Errors 39 Status Only Move at Velocity while Drive Not Enabled error Axis 3A Status Only Move at Velocity while Program Selected err
35. utton until the message at section 3 4 is displayed Press the CLEAR Key and the PUSHER and WHEEL HEAD will go Home 8 23 While the Pusher is moving the rod or No rod to the Rod Edge Sensor and exceeds the time limit the following message will be displayed 8 24 NO ROD FOUND PRESS CLEAR 8 25 To clear this fault press the CLEAR Key and the message at section 3 4 will be displayed Press the CLEAR Key again and the PUSHER and WHEEL HEAD will go Home 8 26 This machine has a software programmed Wheel Head Axis Over Travel Limit If this limit is exceeded the following message will be displayed 8 27 WHEELHEAD OVERTR OR TABLE OVERTRAVEL PRESS CLEAR PRESS CLEAR 8 28 To clear this fault press the CLEAR Key and the message at section 3 4 will be displayed Press the CLEAR Key again and the PUSHER and WHEEL HEAD will go Home 8 29 In the event that the Carbide Rod becomes jammed while being pushed the following message will be displayed 8 30 TOOL JAM FAULT PRESS CLEAR 19 of 24 AUTOMATIC CARBIDE ROD CUT OFF SAW 8 31 Before clearing the Tool Jam Fault first check the for a problem with the PUSHER or Carbide Rod then press the CLEAR Key and the message at 3 4 will be displayed Press the CLEAR Key again and the PUSHER and WHEEL HEAD will go Home 8 32 When an error occurs in the Axis Drive the following message will be displayed 8 33 ILLEGAL MOVE P
Download Pdf Manuals
Related Search