CNC-210A Series H6681 User`s manual
Contents
1. IP5 A AUX I O alle FOOT SW STOP START RESET HOME SR CNTB 03B b b b 4 4 4 E a 3 1 3 1 3 1 RS 485 Operate Switches Home Sensor Turn Counter Connection Box 8 3 Wiring diagram for CNC 210AS 22 50 210 0 0 Oloo a 21515 lt 2 lt Beeee Beee Pulse Output perate Switches Home Sensor AUX I O COM CW CCW Vout A GIG 9 EARTH AC Input Winding Spindle DC24V 12W 2 6V 2A Motor Brake Guiding Traverse STEP Motor TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 14 8 4 Wiring diagram for CNC 210AE Drive STEP Motor in directly uu cuo 5 5 ITIS e 20 Rs N T 510 U VS2. POWER SW 1 TLP 503D DC 12V 10 2 Periodically maintain Please periodically clean up the controller inner accumulate dust and dopants Please periodically check the wire connection between controller and machine if have loose or bad contact The following parts must be maintained or changed periodically as list below If any part is found faulty it must be changed immediately even when it has not yet reached the end of its life which depends on the operating method and environmental condition For parts replacement please contact your sales representative No 1 WWrangspidesTumseomerCNTBGGBUSC 2yrs 2 Guiding taveses HOME SENSOR COOLING FAN DC 12V 6cm RELAY on the 210A DVR driver board it used to le 100 000 times switching the winding direction 5 Carbon BRUSH of the DC motor 1 year LES BR TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 18 10 3 Error message When a fault occurs during operation the DATA DISPLAY shows error massage stop winding and then RESET go back to the READY mode Err O The parameters or data in memory fault Err 1 SHIFT value sets exceed the Travel Limit Err 2 During winding the guiding traverse to exceed the Travel Limit Err
3. setting value half pitch or double pitch Eie eei EI LES BR iz TAILY AUTOMATION CO LTD
4. ii IQ JJ 214 be Ic DOC 021016 Mauro 5 ETT AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 2 1 INTRODUCTION CNC 210A is a series of COIL WINDING MACHINE CONTROLLER developed by TAILY AUTOMATION not only retains all the features of previous designs it also has a low noise level and is less sensitive to external power fluctuation Furthermore it also includes a RS 485 network interface making coil winding operation easier to manage CNC 210A also features an integrated design putting stepper motor driver DC motor speed controller brake and power supplier control circuits into one control box simultaneously achieving size reduction high performance and low cost CNC 210A Series offers CNC 210AS Standard Model and CNC 210AE External Connection Model depending on whether a close loop driver is provided for various applications MODEL Winding Spindle Guiding Traverse CNC 210AS Drive 0 5hp DC motor in directly Drive 2 phase 2A STEP motor in directly Drive 2 phases 2A STEP motor in directly External connect winding spindles Or external connect guiding traverse STEP CNC 210AE motor driver motor driver 2 MAIN FEATURES Single chip Microprocessor design has further higher performance and higher functions it also has less sensitive to external power fluctuation or to external electromagnetic interfer
5. C Select item of parameter during edit or to switch display mode during running Select guiding direction for each step during edit 41 Select winding direction for each step during edit MO To specify whether to suspend winding during the guiding traverse moving to the edges of the width SJ Select whether to have auto positioning function for each step xsl Select whether to have auto starting function for each step Reduce step number by one or reduce production counter by one During programming clear current data to zero 0 Copy the data of previous step into current step Write data into memory Switch display to shows between production counter and speed RPM ir Hold down this key for two seconds to reset production counter wo Switch between automatic and manual mode E J Switch the brake between lock and unlock during motor stop Skip current step and go to the next step Discard current step and go to the previous step At any time discontinues current operation and return to ready mode Pause during winding fT Restart during pause or pause during winding TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 4 3 3 Digital display STEP DISPLAY Show the current step number being wound or being programmed HHH the parameter being programmed During winding or ready mode show DATA DISPLAY
6. I Beeee perate Switches Home Sensor Turn Counter CN3 4 CN5 CN6 lt 92 v AUX I O Pulse Output STEP Motor CN8 Winding Driver 28 SEW gt 0210 E 6 o Olle AC Output EARTH AC Input Winding Spindle DC24V 12W 2 2A Brake Guiding Traverse MAX 400W Motor STEP Motor External connect STEP Motor driver zl Oooo amp O e 2 9 9 Blo r 515 EH Oooo Beeee Pulse Output perate Switches Home Sensor AUX I O STEP Motor B Winding Spindle DC24V 12W 2PhaseSTEP Motor AC Output EARTH AC Input Motor Brake Guiding Traverse MAX 400W TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s man
7. t f 1 t f f f 1 ej Eae 3 Moving speed The guiding traverse moving speed 0 represents high speed 1 represents low speed 2 Moving The travel increment of the guiding traverse 1 represents 0 01mm 4 mm per revolution 2 represent 0 02mm 8 mm per revolution 4 represent 0 04mm 16 mm per revolution 3 Counting mode Select the counting mode of the winding spindle shaft 0 represents with zero point and using absolute counting mode 1 represents without zero point and using relative counting mode Edge slow Slow down the winding speed before the guiding traverse reach to the two edges of the width 0 represents not slow down 1 represents to slow down 5 Braking model Select the braking mode of the winding spindle 0 represents single brake mode 1 represents double brake mode e Counting unit Select 0 1 or 1 turns as your count unit 0 represents 0 1 0 0 to 9999 9 turns 1 represents 1 0 to 99999 turns Guiding traverse unit Select the basic unit of guiding traverse 0 represents mm 1 represents inch must using lead screw in imperial Operation model Select operation mode for the START switch 0 represents ON OFF mode 1 represents Trigger mode Thef key on the front panel always as the Trigger mode TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 10 7 2 Station number 2 1 oet the station number of the wi
8. 3 During winding the guiding traverses reach to the Home sensor Err 5 RS 485 communication error Err p Password error key in 4 numbers password before edit 10 4 To abort seeks the original position At boot and reset procedures if because of unknown reason however engender the winding shaft and guiding traverse can t find out the original position and make the controller can t get into ready mode can key to abort seeks the original position make controller get into ready mode 10 5 Troubleshooting This section provides information to guide the user in understanding different fault condition and their general troubleshooting procedures and with their possible solutions Do not connect or disconnect wires and connectors while power is applied to the controller Make sure that the leads and connectors are connected correctly before doing the troubleshooting procedures Do not remove welded parts on the PC board without appropriate tools Fault Description Correctives Action Power ON but the display Check AC power input shows nothing Check the LED lamp TLP 503D power supply if not lit replace TLP 503D Replace 210A CPU 2 Power but the display shows confusion massage Replace 210A CPU Power ON but winding Press sto make the controller get into READY mode spindle didn t rotate cannot stop rotation And Check the winding L S setting valu
9. During programming in combination with LED shows the current number of turns or show the guiding traverse shafts position H H H H A COUNTER DISPLAY Shows production counter or RPM 3 4 Status indicators OY oO OO READY SLOW MOVE O S LAN FINISH RPM QTY SHIFT WIDTH PITCH TURNS S SLOW E SLOW H S L S FUN Lit means in READY mode flash means PAUSE mode Not lit means winding or programming in progress Lit means winding in progress not lit means not in progress During winding lit means low speed winding not lit means high speed winding Lit means guiding traverse is fixing the starting position for winding or is returning to the home position Lit means winding operation is over speed guiding traverse and winding spindle shaft are out of synchronization Lit means currently are communicating with network Will lit when reaching the preset production counter display count Lit means the counter display shows RPM Lit means the counter display shows production counter 5 Winding parameters definitions Start position of the guiding traverse Setting range 0 00 999 99 Guiding region of the guiding traverse Setting range 0 999 99 mm Diameter of the copper wire Setting range 0 9 999mm Total number of turns to be wound Setting range 0 0 9999 9 or 0 99999 turns Number of turns to be wound at low
10. s manual 16 9 2 Adjustments for CNC 210AE Speed Mode selection To select the speed signal output mode for winding driver Selected by JP1 1 V out mode Represents the speed signal with DC 0 10v output 2 model Represents the speed signal with HI LOW lever output Hi speed with HI lever low speed with LOW lever V out adjust 1 Set the winding parameter H S L S in 99 and to change the DISPLAY shows RPM Then press key to start winding 2 Rotate V out potentiometer to make the winding speed RPM as you want Then to stop winding 3 This function only worked in Vout mode CN2 AC POWER 100 120V TF808C1 AC 220 240V TF808C2 o c oM Ldf CD o amp elTe CD lt S gt jw TAILY OO AUTO 210A EXD ID XXXXXX Eie eei EI LES BR zin iz TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 17 10 MAINTAIN AND TROUBLESHOOTING 10 1 Internal wiring diagram 210A CPU CN4 210A CPU CN2 2 CI 1 25 21 5 25 210A CPU CN3 210A DVR 210A EXD 210 KBD 210A CPU anng
11. two edges of the width work with E SLOWJ turns After the guiding traverse veered then restore to hi speed winding Refer to the section 7 1 edge slow mode Automatically circularly mode If une key set to on it means Automatically circularly mode in this mode when finish a step of winding it will automatically get into next step and start winding without press key work with keys 5 5 How to set winding turns accurately Preset method Set the E SLOWLJto zero first and then set the TURNS to the desired number Set proper parameters according to copper wire bobbin tension etc then Start winding When finished obtain the actual number of turns and calculate the number of overshot turns Go into programming mode and subtract the number of the overshot turns from the TURNS to obtain the required setting This method has a higher throughput however the resulting stopping location may not be precise High Low speed method This method uses a combination of 5 L S and E SLOWJ to achieve the desired number of turns L S should not be too high The number E SLOW turns must be adequate to allow the spindle shaft to slow down to low speed before reaching the total number of turns This can result in precise stopping location Double brake method As the winding turns of the winding shaft reach the numbers of the E SLOWI brake for a short
12. c noise Do not block the intake exhaust ports of the controller Otherwise a fault may occur Make sure that the power source supplies the correct voltage and is capable of supplying the required current to the controllers Do not connect or disconnect wires and connectors while power is applied to the controller Make sure the machine and controllers are properly grounded Make sure that the leads and connectors are connected correctly Normally operate under 10 C 40 C environment over 40 C should perform under good ventilation avoid heating 8 1 Accessories and options 2104 2 RS 485Connecionbk 210A CN3 Operate switches connection cable O 210A CN4 Home sensor connection cabe 210A CN5 Counting sensor connection cable 210A CN6 Aux I O signal connection cable HOME SR Home sensor Counting disc Push button switch Push button switch 1 Foot switch RUN STOP Foot switch Power cord AC Power cord Optional not use in this model TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 8 2 Wiring diagram for CN2 CN6 Beeee 79 EH Oooo Beeee Beeee Pulse Output perate Switches Home Sensor Turn Counter AUX I O CN7 UUUUUUUUUU CN3
13. e of START controller cannot get into STEPO ready mode Replace turns counter CNTB 03B Replace 210A CPU Power but guiding 94 make the controller get into READY mode traverse didnt move or cannot stop moving And Replace HOME SENSOR controller cannot get into Replace 210A DVR ready mode Replace 210A CPU BE CNC 210A Series H6681 User s manual 19 Fault Description Correctives Action NO Key in four numbers password before edit if the password has been set before Replace 210 KBD Replace 210A CPU Display shows Err 0 Replace 210A CPU then reset and get into READY mode Display shows Check winding parameters SHIFT and O WIDTH setting value b Check configurations TRAVEL LIMIT setting value Err 1 Err 2 then reset and get into READY mode Display shows Err 3 Check winding parameters SHIFT and WIDTHL setting then reset and get into value READY mode Replace HOME SENSOR Display shows Err 5 Check wire connection of RS 485 connection box moses Brake failure Check wire connections of brake 10 Replace brake Replace 210A DVR Winding spindle can Check configurations Winding spindle control mode 11 not switching winding selection setting value direction Replace 210A CPU Counting failure Replace turns counter Replace 210A CPU Guiding traverse moves Check Configurations Moving
14. e s key After that the STEP number will automatically increase by one to continue set the SHIFT for next step When the STEP number is larger then the END STEP the STEP number will restore to the START STEP and the indicator light will change from SHIFT tol WIDTH to specifying the width for each STEP Repeat the same procedure using numerical keys and the key all winding parameters for each STEP can thus programmed after that press key again to go back to ready mode The following functions are also available To select guiding direction forward or reverse select winding direction clockwise or counter clockwise To specify whether to suspend winding when the guiding traverse moves to the two edges of the width select whether guiding traverse move to the starting position automatically or upon manual pressing of the key MeO Select whether to have auto starting function for each step Clear the setting value Er Copy the content of the previous step to the current step Go back to the previous step To scroll through different parameters Each time when change the parameters and selections s key must pressed to effect the change TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 6 4 3 Guiding traverse shaft introduce setting During set thel SHIFTI I WIDTH guiding trave
15. ence Memory use FLASH ROM capacity capable storing up to 1000 steps winding data 9 winding parameters and 5 options can be independently assigned for each step Off power memory retention without battery Winding speed can be specified using the front panel keypad resulting in easy programming of multi step multi speed settings Guiding traverse shaft stepper motor with a constant current driver offering fast wire guiding speeds Guiding traverse shaft offering 10 steps moving speed selection Offering RS 485 interface for PC linking and data transfer Software be update through the personal computer Power input AC100V 120V 220V 240V 600VA max TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 3 3 FRONT PANEL DESCRIPTION E MOWE E SHIFT Ea TURNS E H 5 E RUN 0 5 Ei WIDTH BIS SLOW 5 5 ELAN ENPITCH BESLOW FUN STAR 588688 3E 200E cani in E RFM FINISH UTO 4 3 DIR HOME EDGE 3 1 Power switch Power supplier equipped controls the AC power to the controller 3 2 Key pads 0 9 10 key for entering numerical values I Enter into EDIT mode Specify target production quantity EMT Specify starting step in memory Specify ending step in memory
16. from the START STEP to the END STEP the counter will automatically increase by one Preset production counter In READY mode press 2 key once and key in desired values seeesifollowed by the Jkey During winding when the production counter reaches the preset value the FINISH led will lit Setting range 0 99999 Decrease production counter During READY or PAUSE mode press the key and hold down for two seconds the piece counter will decrease by one Reset production counter In any time holding down key for two seconds it will set the piece counter to zero TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 9 7 CONFIGURATION SETTING CNC 210A is a multi purpose design to meet various requirements additional settings are configured to provide flexibility for additional applications In the READY mode press the following keys combination as section 7 1 7 10 the DATA DISPLAY will show corresponding setting value If no change is necessary press the s key get back to READY mode Or 55 to get into change mode then the parameter be changed by pressing the numerical key followed by the s key 7 1 Winding mode 0 In this function the STEP display and the DATA display will shows eight digits representing eight winding mode selections respectively Press numerical keys as below to set each digit
17. ire guiding will follow the wire direction to proceed two wire diameters and regress one wire diameters cyclically until the step of winding ends This mode especially suits the inductor winding Non wire guiding sometimes the winding device be used to winding adhesive tapes or copper foil When the wire guiding is not needed PITCH may be adjusted to zero and the wire guiding won t be move 5 3 Start switch operation mode ON OFF mode Press down start switch to start winding and release start switch to stop winding immediately Trigger mode Press and release start switch once to start winding press and release start switch again to stop winding 5 4 Running mode Continual mode TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 7 Before it begins winding of the step set as 999 99 then the starting position the width the wire guiding direction and the winding direction won t be re read The values are not changed that is the wire guiding will continue guiding wires on the same position The width and left right margins are the same as the ones of the previous section Both the wire guiding and winding directions are not changed either This mode especially suits to winding which have the multiple drawing tops in the same sets of coils Edges slow mode The winding speed will slow down before the guiding traverse reach to the
18. ize the controller to which the current data is being sending Refer to the section 7 2 station numbers Wiring diagram as below 210 5 210 5 210 5 een ele sie eee ie eats RS 485 RS 485 RS 485 CONNECTION BOX CONNECTION BOX CONNECTION BOX STATION PREVIOUS STATION o COOMUNICATION CABLE 6P4C COOMUNICATION 6 r NNA TERMINATOR RESISTOR 47 1000hm In READY mode press following keys combination its will sent each setting data to target station cor o 00 99 sends configuration setting data to the specify station er fever 1 00 99 Sends winding parameters to the specify station een for 2 9 Sends password to the specify station lt will send the winding data from the START STEP until to the END STEP when sent the winding parameters from one station to another oo es Represents target station number If the target station number specify as 00 all the stations on the same network will receive the data is being sent TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 12 8 INSTALLATION AND WIRING controllers should be operated in an environment that is protected from moisture corrosive gases or liquid and free from airborne dust metallic particles and magneti
19. le shaft and guiding traverse are in synchronization The controller uses this value to calculate with wire PITCH of current step and then to limited maximum winding speed of current step Setting range 0 99999 Set 0 means no limit speed 7 7 Brake holding time s To set the hold times for brake Setting range 0 1 9 9 sec 7 8 Guiding traverse moving speed 5 7 The speed at which the guiding traverse moving to the starting position and returning to the home position Setting range 0 9 7 9 Winding spindle output mode selection set to 1 for CNC 210AS and CNC 210AE or occur a fault 7 10 Acceleration times 9 Set the accelerate times for the winding spindle Setting range 00 99 00 means shortest acceleration times 1 99 means longest acceleration times T ms 0 0 H S 1 5 XT 10 TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 11 7 11 Reset all configuration e J In READY mode press 0 it will reset all the configuration data and replace by initial data Be cautious in use this function 7 12 Data transmit The CNC 210AS has a RS 485 serial communication interface can be used to send the winding data to the others station Up to 32 stations can be operated on the same network In this function set station numbers to the controllers to recogn
20. nding machine controller This number is used to identify the station when using RS 485 communication function Up to 32 stations can be operated on the same network Setting range 01 99 7 3 Passworde This password is used to protect the setting data in memory After you set this password you cannot change any winding parameter and configuration data in normal sequence You have to key in four numbers of password before press 55 keys If the password has been passed once you can change any data in normal sequence until you turn off the power or press You must to remember the password you cannot change any data Setting range 0000 9999 Set 0000 means no password 7 4 Travel limit e set the maximum travel distance of guiding traverse During winding when the guiding traverse reaches this position the motor stop winding immediately and the DATA DISPLAY shows error massage then RESET and go back to the READY mode Setting range 000 00 999 99 999 99 Means no limit 7 5 Fixed 2 To set how often must be correct the guiding traverse location Each time when finish this number of product pieces the guiding traverse will moves to the home position to correct the location before moving to starting position Setting range 00 99 Set 00 means not to do this function 7 6 Limited winding speed s This value is to limited winding speed and make sure the winding spind
21. period first After the winding shaft stops continue winding at low speed Therefore the numbers of the slow speed may be reduced and the efficiency of winding may be increased Refer to the section 7 1 braking mode TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 8 6 WINDING EXECUTION 6 1 To start winding After set up all data items press key the winding process begins in accordance with the set up content Press key to pause winding During winding press 1 0 key the winding speed can be switch between high speed and low speed The following key functions are available during PAUSE mode Give up the numbers of the winding turns regress step Finish current step and proceed to next step Continue winding Give up winding and go back to the READY mode 6 2 Change the display mode During winding or during PAUSE mode the DATA DISPLAY can be change the display mode between turns or guiding traverse position 6 3 Winding speed RPM display Pressing key will cause the PIECE COUNT DISPLAY to display the spindle shaft RPM without interrupting the counting Pressing again will change the PIECE COUNT DISPLAY back to displaying the piece count 6 4 Production counter management Upon turning on the power the counter display will show the production counter During wining each time the winding process goes
22. rse travel limit can use numeric keypad to set location data or can also use ev to leading the guiding traverse shaft location 4 4 Clear all winding parameter In the READY mode press e s clear all the winding parameter in the memory cautious in using this function or all the data will be lost 5 WINDING METHOD DESCRIPTION Prior to winding the general winding principles are explained below so the operators can have a better understanding of the performance of the controller and make better use of it 5 1 Turns counting mode Absolute counting mode Winding spindle shaft is capable of fixed point stopping Upon each restart the turn count will reset only the integer portion of the turn s to zero with the decimal unchanged For example for a previous number of 100 3 turns when restarting the next step winding the counting will start with 0 3 to avoid accumulation of spindle shaft free play error from consecutive windings This counting method may cause insufficient winding by one turn Therefore when starting from 0 9 the spindle will turn to the 0 0 before it starts counting Relative counting mode This counting method zeros the counter upon each restart therefore it is easy to understand and will not cause insufficient winding 5 2 Special Wire guiding mode Interlace wire guiding If theL WIDTH of the step is zero the wire guiding becomes interlace mode When it begins winding the w
23. speed when start winding Setting range 0 999 9 turns Number of turns to be done at low speed prior to stopping Setting range O 999 9 turns High winding speed Setting range from 099 Low winding speed Setting range from 0 25 Winding complete output signal setting Eie eei EI LES BR jl TAILY AUTOMATION CO LTD E CNC 210A Series H6681 User s manual 5 4 PROGRAMMING WINGING PARAMETER 4 1 MEMORY RANGE SELECTION CNC 210A contains 1000 memory step by defining the region users can effectively manage the memory Various winding parameter can be stored in different regions and can be retrieved instantaneously After specifying the regions programming and winding can be done in those regions all un selected regions will retain their original contents and unmodified When setting the STEP number the Ending step number must be larger than the Starting step number or the winding operation will not start Specifying starting step In ready mode 5 999 to selected Setting range 0 999 Specifying ending step In ready mode press 55 o se to selected Setting range 0 999 4 2 Programming winding parameter In READY mode the programming mode the STEP DISPLAY shows START STEP the parameter indicator SHIFTUlit the DATA DISPLAY shows SHIFT setting value the SHIFT can be changed by pressing the numerical keys followed by th
24. ual 15 9 ADJUSTMENT 9 1 Adjustments for CNC 210AS CL Output current limit 1 Connect a DC Amperes meter between terminal and DC motor as below 2 In ready mode make the DC motor starting rotate and then press to holding the winding spindle 3 Rotate CL to set limited current show on Amperes meter 2A for 180v DC motor 4A for 90v DC motor The CL have been set by factory before delivery Only adjust it when change DC motor and replace 210A DVR driver board IRE Torque compensation 1 Set the winding parameter H S L S in 20 then change the DISPLAY shows RPM Then to start winding 2 Rotate IR potentiometer to make it in same speed during the winding spindle shaft in full load and unload Then press key to stop winding MAXU Maximum winding speed 1 Set the winding parameter H S L S in 99 and press key to change the DISPLAY shows RPM Then press key to start winding 2 Rotate MAX potentiometer to make the winding speed RPM as you want Then to stop winding DC MOTOR 10A AMPERE METER 0 CN2 POWER AC 100 120V TF808C1 AC 220 240V TF808C2 R33 XVN Yl 19 CO AUTO 210A DVRID XXXXXX O AUTOMATION CO LTD E CNC 210A Series H6681 User
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