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AC650 Manual PDF - Paw-Taw

1. Pairs 5 amp 6 only used with Proportional valves t C t DUTPUTS USE WITH 1834567 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 650 OUTPUTS m 1 e 3 4 5 6 7 8 9 10 1 19 13 14 15 16 17 18 19 20 21 22 23 24 2526 27 28 29 31 32 OOOOOOOOOOOOOOOO e dv lt SET 00 SIZE 18 345 SYSTEM INPUTS switches etc DIE FIG 6 gt OUTPUTS to lamps relays etc 7 9 F1 Fe CONTROL PANEL 4 5 6 4 Typical 1 OR 2 50 Cond Q T x 1 3 5 6 moe 7 EE F7 F8 Paw Taw John Services Inc 046 2046 Rothdrum ID 83858 208 687 1478 MUTIPLE AXIS SETWORKS TYPICAL SYSTEM SCHEMATIC e 51
2. AC650 COMMANDS Command Sequence Function or Action CLEAR Return system to Run mode ENTER Enter values previously typed in SPACE Scroll forward to next entry DELETE Scroll backward to previous entry 123 A Enter Species 1 Set Value Table 223 B Enter Species 2 Set Value Table 12 Enter Species 3 Set Value Table 52 gt P Enter Parameter Table 1 Displays Axis 1 Target and Actual Position 2 Displays Axis 2 Target and Actual Position 3 to 8 Displays data for Axis number entered Shortly after power up of the system the TransTerm 5 will display the following 1 15 95 SYSTEM At any time 5 terminal may be placed in or returned to the RUN MODE by de pressing the CLEAR key The display will show the following DEFINITION OF SYSTEM PARAMETERS COORDINATE SYSTEM l The AC650 servo control system measures movement of the cylinder in inches The coordinate system can be set up to place the zero reference at any point that is most useful The direction of Increasing Position can also be selected 2 The EXT TO ZERO IF 1 operating parameter establishes the direction of in creasing cylinder position When set to one 1 the zero position is near the ex tended end of the cylinder and position increases toward the retract end of the cyl inder 3 If EXT TO ZERO IF 1 is to any value exce
3. mA AC650MB cardrack Communications cable 2 486DX computer to multiple card rack system See E p je 1 _ al Sie E T m TH FEET Paw Taw John Services Inc X Chapter 1 Introduction 1 30 00 5 3 Transterm 5 handheld terminal to single card rack E E ze E ES s BARRA els 0 se Paw Taw John Services Inc X Chapter 1 Introduction 1 30 00 6 CHAPTER 2 SYSTEM INSTALLATION SERVO SYSTEM COMPONENTS Servo control systems are made up of numerous components generally procured from several vendors The specific servo system components are generally somewhat standard but the source for each component can vary as established by the system designer The following items will be delivered in one or more boxes for servo control systems de s
4. C jt jt t t Tt 00000000000000000000000000000000 L 00000000000000000000000000000000 1 1 1 Install jumper cable between GSC 2 of rack 1 and GSC 1 of rack 2 using following cabling diagram COMMUNICATIONS CABLE INTERCONNECT GSC2 RED BLK WHT BLK PAIR GRN BLK SHIELD ARE CONNECTED TO EARTH GROUND NOTE Usually a three pair shielded cable is used for this jumper INITIAL SERVO SYSTEM SETUP WARNING INSURE ALL LOCAL LOCKOUT PROCEDURES ARE FOLLOWED VOLTAGE TESTS AND WIRING CHECKS Eod m TET FREE ITH Le EEEEEEEEEDEEERE E DUDIEEEEEEEEEEEE Refer to figure above for the tests and checks tha
5. 1 ecc jAXIS 1 AXIS 2 AXIS 3 AXIS 4 AXIS 5 AXIS 6 quad T BEIDE ddp 1 21 24 42 OFFSET SAW 1 OFFSET SAW 2 CHANGED TO CHANGED TO OFFSET SAW 4 CHANGED TO PReCieS SEG Cys sea 7217 7 ee Je _ NEW PARAMETERS Recent upgrades and improvements to the AC650 have increased servo controller s performance and flexibility Several new parameters are involved with the changes Re fer to the following during system setup or changes XXXXX INPOS WINDOW This parameter adjusts the on target window for a set position Example ifthe target is 14 000 and the Tempo feedback position is 14 060 and the INPOS WINDOW 00 100 then the cylinder is considered to be JN position XX NULL ENABLE IF 12 By entering the value of 12 in this location the AC650 card will correct for Servo Valve null errors XXX JOG INCR XXX Jog increment allows setting the Jog speed RUN SCREEN Set size for Saw 1 Species selected Set size for Saw 2 Picker saw following XX lt X7 997 TEMPO SCALE XX XXX ZERO OFFSET ADJ XX ACCEL XX DECEL XX XXX DECEL MIN POS XX MAX VEL 1 to 99 X zEXT TO ZERO IF 1 XX XXX MIN LIMIT XX XXX MAX LIMIT XX XXX SYSTEM MAX LIMIT XX XXX RETRACT MIN LMT for Bury Valve XX XXX MIN DIST BETWEEN SAWS Used so saw guides don t touch XX XXX KERF XX XXX INPO
6. 400mA 5 AC700 power requirements are as follows 5VDC 100mA 15 100mA 15 100mA If a 5 regulator is used on this board 15 amp requirement goes to 500mA 6 MTS I Temposonics power requirements are as follows 15VDC 100mA ISVDC 75 12VDC 4 50mA 7 MTS II Temposonics power requirements are as follows 12VDC to ISVDC 140mA 8 MTS LP Temposonics power requirements are as follows 15VDC to 24VDC 10 100mA 9 MTS LH Temposonics power requirements are as follows 13 5 to 26 4 VDC 100mA ELECTRICAL INSTALLATION The electrical installation of servo system is also governed by NEC regulations Spe cific attention must be paid to conduit fill rations based on the type of wire used Care should also be given to system and enclosure grounding Some additional electrical in stallation suggestions are l 2 AC wire to power terminals in System Control Enclosure should be 16 gauge minimum Input AC is 120 VAC and should be protected with a 15A breaker at the electrical distribution panel AC wire runs and DC wire runs should be put in separate rigid conduits Color codes for AC are a AC Hot Black THHN or equivalent b AC Neutral White THHN or equivalent c Ground Green THHN or equivalent Power supplies used in Paw Taw John Services Inc systems are isolated linear supplies and therefore no Iso
7. The user may fabricate or procure system components that must interface to Paw Taw John Services Inc Setworks Systems To assure correct interface and take advantage of extensive design experience Suggested Design Drawings will be provided often prior to system delivery Examples may include 10 Suggested Operator Panel Layout Drawing NOTES 144 14 SET 00 512 12 345 Rae F8 A GND 15V 15 5 104 12 120 32C 144 140 SERVO SERVO PS1 TEMPO GATE 5VDC TEMPO GATE GND 15VDC 15VDC GND 9 GND 6 PIN 10 GND CONNECTOR 1 1SVDC Lo 12 15VDC 5 OF DIPSWITCH 650 AUTO NULL 700 AC 910 PIN CONNECTOR SERVO 0 CONNECTOR Paw Taw John Services Inc ACGSOLAYOUT Rothdrum ID 83858 208 687 1478 650 LAYDUT n TYPICAL SYSTEM SCHEMATIC PS1 5VDC TEMPO SERVO to ELECTRICAL SERVICE GND CABLE TABLE PANEL 15 xl ES 15VDC 15VDC onhatton elden PR TECTED CIRCUIT 15VDC Poir 1 Red Yellow Poir 1 Black Black Poir 2 Red White Pair Black Black Pair Red Red NEUT PS2 Poir Black Black 120 VAC Pair Red Green Pair Black Black I e4VDC B Pair Red Brown OO A teave Pair 5 Black
8. low are situations that may cause a system failure and the corrective actions Situation When the hydraulics are turned off and the valves are not nulled the hy draulic cylinders will drift from target position When hydraulics is turned on again the Auto Null function will already have drive present to correct the position If the valve is out of null greater than a small amount the cylinder will move slowly or violently in one direction until the auto null can get control and keep the target and actual positions equal If the cylinder has a short stroke the rod of the cylinder can fully retract or fully extend before the auto null can correct the error This action may cause the cylinder to remain in this state Also servo drive to the valve will generally be off at this time Corrective Action Ifthis problem occurs the user can turn off and on the power to the set system This will cause the AC650 cards to reset the target of the Temposonics feed back position A set target value can be entered at this time and the cylinder rod will move and lock on to the target position Operation can then proceed If the above problem persists the servo valve must be nulled mechanically Refer to Servo Valve General information WHEN AUTO NULL IS NOT USED When driving a servo valve without the Auto Null enabled the servo drive out from the AC650 card will act differently but still effectively The offset adjustment capability of the AC650 card w
9. Black RETURN Pair Red Blue RETURN RETURN Pair Black Black OO Poirs 5 amp 6 only used with Proportionol volves to RECIRCULATION and VALVE INTERFACE 6 Pair Shielded TEMPO TEMPD SERVO de 190 GROUND 15VDC 24V RET SET 1 LMP SET 2 LMP SET 3 LMP SET 4 LMP 5 6 7 SERVO SERVO O STATUS O 15VDC e4VDC SET 1 PB SET 2 PB SET 3 PB SET 4 PB SET 5 PB SET 6 PB SET 7 PB O RCV DATA O TRX DATA 2 KEYPAD SET 5 LMP SET 6 LMP SET 7 LMP 0000000000000000 0000000000000000 260 24C 22C 20C 186 16C 14C 120 10C BC 6 46 2 5VDC GRDUND SET 00 SIZE 18 345 SYSTEM UK T il to OPERATOR 718 9 J F1 JLF CONTROL PANEL 1 ily sx Typical 20 Cond gt 5 6 1 4 5 v Xf el 7 L3 em FS F rz re Filename Paw Taw John Services Inc ows 1 ows Rathdrum ID 83858 208 687 1478 Drawn By JT SINGLE AXIS SETWORKS Date TYPICAL SYSTEM SCHEMATIC to RECIRCULATION ELECTRICAL SERVICE PANEL ISAMP TEMPO SERVO and VALVE INTERFACE PROTECTED CIRCUIT CABLE TABLE 6 Pair Shielded Manh
10. Care should be taken if the value of R18 must changed A qualified electronic technician should be used to perform the change or the AC650 card s may be returned to Paw Taw John Services Inc Install all AC650 cards in their correct positions with the Master in the left most position Note The card connectors are keyed to prevent incorrect orientation TransTerm 5 TT5 Keyboard SETUP Install the keypad cable between TransTerm 5 and KEYPAD jack on face of the left most AC650 card master position When power is applied the TransTerm 5 should beep three times The top line will display the AC650 firmware program name date and whether the AC650 card is a master or slave The bottom line will initialize for a moment and then display a card status message PRGMNAME 1 15 97 MASTER SYSTEM OK The AC650 card status messages have the following meanings Tempo Bad Temposonics transducer system has incorrect or no input to numbered card Bad Module numbered module not communicating or working System OK all cards are communicating and working Bad Null card drive to servo valve is unable to maintain null This message can occur during power up or if hydraulic system is not on Overtravel axis has reached software stroke limit A TransTerm 5 register check should be conducted next to make sure the TTS is set to properly communicate with AC650 cards It is necessary to switch to the setup mode by entering the follow
11. control system must conform to NEC standards ap plicable at time of installation because these enclosures contain electrical circuits There fore component and enclosure location and mounting must be in accordance with the voltages contained within each system component and other components in the immedi ate area It is advisable to mount enclosures on surfaces where vibration will be mini mized Proceed with mechanical installation using the following steps as a guide 1 Mount the System Control Panel in a cool dirt free environment However this enclosure has a NEMA 12 rating and may be mounted in more harsh environments if necessary 2 Mount the Operator Panel in an ergonomic way so the operator has unobstructed access to all controls for ease of operation 3 When AC700 Temposonics Recirculation Boxes are used to interface to Tem posonics probes they should be mounted to protect the connectors and box from mechanical damage Cabling should also be routed and protected from damage 4 Sometimes J boxes are used to terminate Temposonics probe and servo valve ca bles These boxes should be mounted so there is no interference with the machinery 5 Temposonicso probes mounted in hydraulic cylinders should be easily accessible and allow sufficient clearance to pull the entire probe out of the cylinder 6 blue cap end of Temposonics probes also should be protected from physical dam age If not the probe end ca
12. cylinder stops moving or just creeps When an adjustment is done to one side of the valve in one direction the opposite side must adjusted the same amount in the opposite direction It will be necessary to connect valve drive connector to the valve frequently so the cylinder doesn t extend or retract fully The Allen head screws must not be turned more than 180 degrees in either direction Step 5 After the cylinder stops moving connect box end wrench and tighten The cylinder might move again Correct with the Allen head screw until there is no movement and the locking nut is tight 15 Note When pressures are changed in a system servo valves generally will need null adjusted again Most servo valves when adjusted at the factory are nulled at 1000 psi If the pressures are increased the null will change thus the valve null will need further adjustment This completes the Servo Valve adjustment procedure 16 CHAPTER 6 RUNNING THE SETWORKS SYSTEM TURN ON Power up the setworks system in the following sequence 1 Turn ON power to Setworks 2 ON control power if used 3 Turn ON hydraulic power 4 Wait 30 seconds and proceed to operation OPERATING THE SETWORKS After allowing a half minute wait period the setworks is initialized and made ready to operate by pushing any one of the SET buttons The indicator lamp for that SET will flash while the system is moving to position When the target po
13. design drawings as assistance to the job Installation and fabrication drawings may be made available prior to system delivery ELECTRICAL DRAWINGS The electrical drawings provided in this tutorial are for general design and reference Other system specific electrical drawings and wiring lists will be included with the Installation and Operation Manual for the system Electrical drawings that may be included are Typical Single Axis System Schematic Typical Multiple Axis System Schematic Typical Multiple Axis AC650 I O Listing Typical Recirculation Interface Wiring Typical Multiple Axis Operator Panel Schematic MECHANICAL DRAWINGS Several mechanical drawings of specially fabricated components used in Servo Control System are provided These documents are included for reference purposes but may be of value should changes or additions be made to the system Examples may include 6 Typical Operator Control Panel Overlay Fabrication drawing 7 Typical Control System back panel layout drawing INSTALLATION DRAWINGS Installation drawings required for efficient and accurate construction of a setworks system at the user location are often provided prior to system delivery These drawings might cover such topics as conduit routing panel location or recommended component mounting Examples may include 8 Electrical Installation Drawing 9 AC700 Recirculation Enclosure Mounting SUGGESTED DESIGN DRAWINGS
14. enclosure should be drilled for attachment of con duits during installation Temposonice Probe A linear transducer mounted inside the center of each cylinder used to measure position A magnet that moves with the piston reflects an internal square wave generated at the probe head The reflected wave is processed and provides accu racy to 0 001 inches Recirculation Box The recirculation box contains a circuit card AC700 that distributes the servo drive and Temposonics signals for a single axis system may have one or more recirculation boxes The card controls the number of recirculations that the position signal will make in the Temposonicse probe The more recircula tions the greater the resolution The AC700 also sets the probe operating fre quency and triggering signal Please refer to recirculation box manuals for setup and operation information Operator Control Panel The Operator Control Panel is the main user system operating and control inter face This panel is typically custom designed and constructed to suit the require ments of the servo system An assortment of Set control lighted push button switches and other switches or joysticks for jog and cut control allow the operator to control the system This panel is connected to the System Control Enclosure via a multi conductor cable TransTerm 5 Terminal The keypad terminal is used to display system status and adjust operating parame ters axis offsets jog fu
15. enough to allow this but in the case of an electronic failure or servo valve failure the cylinder will move at a very slow speed This prevents damage to saws and machinery and personal injury The accumulator dump valve is also activated when system control power and the hydraulic power unit is turned on On many hydraulic systems an accumulator is used to provide extra pressure in case oil flow decreases as a cylinder is stroked The accumulator is usually charged to 2 3 system pressure This charged device needs to be discharged when the hydraulic is removed from the system This is accomplished by the accumulator dump valve Should questions arise call Paw Taw John Services Inc Phone No 208 687 1478 e mail pawtaw pawtaw com CHAPTER 8 MTSe Temposonicse PROBE REPLACEMENT Proper Temposonics probe removal and installation procedures are very important to minimize downtime and prevent further system damage This chapter covers the recommended steps for replacement of probes used with hydraulic cylinders A 1 3 4 deep socket capable of fitting over the probe end cap or a 1 3 4 open end wrench and an Allen wrench set hex wrench will be required Channel Lock pliers and large Crescent wrenches should be avoided as they can slip and are very difficult to attach to the probe Some cylinders have probe guards attached to the end of the cylinder to prevent probe damage Other cylinders have the probe cap and cable completely
16. equivalent product s by form fit and function return shipping prepaid for any product s returned shipping prepaid to Seller s facility and found to contain a liable defect within the warrantee period Paw Taw John Services Inc shall accept liability only if the product s 1 erected tested and operated in a manner approved by or in accordance with instructions provided by seller 2 have not been subjected to electrical or mechanical misuse or abuse or accident 3 have been used for the purpose for which the goods were designed 4 have not been altered or repaired by persons other than seller in any respect which in the judgment of seller affects the condition or operation of the product s This warranty constitutes Paw Taw John Services Inc entire and only warranty There are no other warranties expressed or implied in law or in fact including implied warranties of fitness and merchantability Paw Taw John Services Inc will not be liable for compensatory or incidental damages caused by defects and will not be responsible for costs or repairs done by others Returned goods must be carefully packed preferably using the original shipping carton and packaging material Product s should be returned prepaid to Paw Taw John Services Inc 18125 N Ramsey Road Rathdrum ID 83858 208 687 1478 System item sold Buyer authorized agent signature company name and date of acknowledgment of Product Warran
17. is mounted at a specified distance and measures the actual physical movement The results are plugged into the formula to calculate a new value for TEMPO SCALE Difference in Physical Move Tempo Scale Difference in Display Value Move 7 997 Stroke of cylinder gt 1 Select a fixed reference point that the cylinder moves to or from This will be 0 000 B for the formula shown below Example the front head of a cylinder face of a carriage knee or table end Mark this point accurately with a piece of electrical tape or other precision means 2 Using the TransTerm 5 or computer record the position displayed Temposonics feedback position for that axis This will be D in the formula below 3 Using the set size table enter even value for a set input For example 1 equals 4 000 4 Now enter the set The cylinder will move approximately 4 000 5 Using the TransTerm 5 computer record new position displayed posonics feedback position for that axis This will be C in the formula 6 Using dial calipers measure from the reference point in Step 1 to the current cyl inder position This will be A in the formula below 7 Do the computations as follows A 4 026 B 0 000 Tempo Scale 8 049 C 18 982 D 14 928 7 997 8 049 would be the new TEMPO SCALE value that is entered in the PARAMETERS mode Repe
18. of saws This value 15 entered in thousandths and is used by the program in computing multiple saw cut targets Offset Saw 1 etc OFFSET SAW 1 are entries used by the program for multiple saw offsets For example if the user offsets Saw 1 left or right Saw 2 and 3 move the same direction and amount of offset Furthermore if the user offsets Saw 2 Saw 3 will move the same direction and amount This feature permits the user to adjust the offsets for all saws from the master AC650 card Saw 1 SETTING SYSTEM PARAMETERS The parameter mode is used to set up dynamics of servo loop Temposonics cali bration starting offset values of the machine and other selected functions To enter this mode do the following l 2 10 Depress CLEAR 52 and P keys in sequence Display will show the following To sequence through the parameter mode depress SPACE To sequence the dis play in reverse depress DELETE The cursor will be present at the beginning of the values that can be changed To enter a new value key in the new number on the keypad Then press the lt ENTER gt key to send the new number to sys tem The following are sample parameters that appear when sequencing through the parameters mode starting at the GAIN XX GAIN 1 TO 64 XX XXX TEMPO SCALE XX XXX ZERO OFFSET ADJ XX ACCEL 1 TO 50 XX DECEL 1 TO 64 XX XXX DECEL MIN POS VEL 1 TO 99
19. 0 INPUTS OUTPUTS 24V 24V SAW SET 1 LAMP Blu Blk Wht SAW SET 2 LAMP Blk Red Grn SAW SET 3 LAMP Wht Red Grn 4 5 24 Blk 24 RET Wht SAW SET 1 PB Red SAW SET 2 PB Grn SAW SET 3 PB Blu SAW SET 4 PB Wht Blk SAW SET 5 SAW SET 6 PB Grn Blk SPECIE 2 SELECT SW Org Blk ENABLE SAWS Blu Blk JOG LEFT BANK Blk Wht JOG RIGHT RIGHT Red Wht SAW 3 SET 1 PB Grn Wht SAW 3 SET PB Blu Wht SAW 3 SET PB Blk Red SAW 3 SET PB Wht Red SAW 3 SET PB Org Red SAW 3 SET PB 2 3 3 SAW SET LAMP Red Blk Grn SAW SET LAMP Grn Blk Org SAW 6 LAMP Org Blk Grn SAW SET COMPLETE Blu Wht Org OUTPUT TOGGLE Blk Wht Org 00000000000 WHY 99999999999 o 9 Wht Red Blu BIk Wht Grn Wht Blk Grn Red Wht Grn Grn Wht Blu Org Red Grn Blu Red Grn BIK Wht Blu Wht Blk Blu Red Wht Blu Blu Red SAW SET PB Red Grn SAW SET PB Org Grn SAW SET PB Blk Wht Red SAW SET PB C WW WD Grn BIk Wht JOG SAW 3 LEFT Org Blk Wht JOG SAW 3 RIGHT 650 CARD 4 650 CARD 650 CARD 2 650 CARD 1 a A lt O 40 C lt a lt O e 40 C lt a lt O e 40 C lt c lt O e 40 C lt AC650 DIP SWITCH SETTINGS Program used is EDG2S97B HEX SWITCH 1 e 3 4 CARD 1 OPEN OPEN CLO
20. 0 movement O extend cyl to decr pos if 1 00000 min target allowed 00000 max target allowed 00 value to be changed Depress the lt Down gt arrow key on the keyboard until the highlight is on the Gain parameter Enter 06 at the value to be changed line by depressing the keyboard lt 0 gt and lt 6 gt keys Depress lt ENTER gt The value 06 will appear to the left of the Gain parameter line Continue the procedure for the next value by following Step 17 above and enter the following parameters 7997 temp scale factor typ 7995 13000 zero adjust 25 accel 1 TO 99 99 is fast 25 decel 1 TO 99 99 is fast 00 100 below this pos no decel used 30 per cent max vel fwd 30 per cent max vel rev O extend cyl to decrease pos if 1 Scales the Temposonics for a linear movement The stroke of the cylinder 1 is entered here Example for a 44 stroke the number entered is 45000 Used in conjunction with gain Sets the front ramp to the servo valve Used in conjunction with gain Sets the rear ramp to the servo valve This value is disables the decel before the postioner arrives at the target This value sets the speed of the positioner going forward This value sets the speed of the positioner going reverse Input enables user to flop the Temposonics reading from reading 0 at the extended position or 0 at retracted position 00150 min target allowed Sets the minimum position the u
21. 60 to the position of the saw enter 060 Depress ENTER Subse quently each time the ENTER key is depressed the saw will move 060 4 To subtract 060 from the position of the saw depress S1 F7 The minus sign appears before the offset entry area Enter 060 and depress the ENTER button Again each time the ENTER key is depressed the saw will move back 060 5 To change the sign back to a positive value depress S2 F7 The plus sign will reappear before the offset entry area 6 When the offset for saw on has been set to the desired value press the CLEAR key to exit the OFFSET CALIBRATION mode 7 Repeat steps 1 through 6 for saws 2 3 etc Begin each procedure by pressing the CLEAR key followed by the saw number Then press S1 and DELETE keys to enter the offset entry mode 8 Remember to press the CLEAR key to return to the Run mode 12 AUTO NULL FUNCTION The Auto Null function of the AC650 card is used to correct minor null problems when a system is using a servo valve On the AC650 card a dip switch 15 used to establish an address for a card and to enable the Auto Null function By switching dip switch 4 to the on position the AC650 servo controller will keep the actual position and target positions within 001 This servo action will work as long as the servo valve doesn t require more than 1096 of full drive to keep cylinder on target Due to action of the Auto Null function some common problems can occur Listed be
22. AC650 SERVO CONTROLLED SETWORKS SYSTEMS TUTORIAL amp TECHNICAL REFERENCE Paw Taw John Services Inc R Phone 208 687 1478 e mail pawtaw pawtaw com FAX 208 687 4148 0 SERVO CONTROLLED SETWORKS SYSTEMS Table of Contents CHAPTER 1 INTRODUCTION ABOUT THIS TUTORIAL amp TECHNICAL REFERENCE ABOUT Paw Taw John Services Inc ABOUT SERVO CONTROLLERS Paw Taw John Services Inc SERVO CONTROL SYSTEMS TYPICAL SYSTEM COMPONENTS CONFIGURATION OPTIONS CHAPTER 2 SYSTEM INSTALLATION SERVO SYSTEM COMPONENTS GENERAL INSTALLATION NOTES MECHANICAL INSTALLATION ELECTRICAL SPECIFICATIONS ELECTRICAL INSTALLATION ELECTRICAL INSTALLATION CHECKLIST CHAPTER 3 INITIAL SERVO SYSTEM SETUP HARDWARE CHECKOUT INITIAL SERVO SYSTEM SETUP VOLTAGE TESTS AND WIRING CHECKS AC650 CARD ADDRESS SETUP AC650 CARD SERVO OUTPUT SETUP TransTerm 5 TT5 KEYPAD SETUP CHAPTER 4 SERVO LOOP DYNAMICS SETUP SERVO LOOP DYNAMICS SETUP OFFSET CALIBRATION PROCEDURE AC650 FACE PLATE INDICATIONS AC650 SERVO LOOP SETUP USING 486DX MONITOR SCREEN CHAPTER 5 SYSTEM OPERATION TransTerm 5 TERMINAL OPERATION DEFINITION OF SYSTEM PARAMETERS SETTING THE SAW OFFSET REFERENCES TO ZERO SYSTEM RESPONSE SETTING TEMP SCALE ALTERNATIVE TEMPO SCALE FORMULA SETTING SYSTEM PARAMETERS ENTERING SPECIES SET SIZES OFFSET CALIBRATION PROCEDURE AUTO NULL FUNCTION SERVO VALVE GENERAL INFORMATION Paw Taw John Services Inc AC650 Table of Con
23. AC650 card DIP Switches AC650 DIP Switch Positions AXIS Switch 1 Switch 2 Switch 3 OFF OFF OFF ON OFF OFF OFF N OFF N ON ON Example for single axis systems address switches 1 2 and 3 are off NOTE Axis 115 always the MASTER DIP position number 4 is the auto null enable When ON the AC650 card supplies correct servo drive current to counter any out of null conditions the valve might have In this mode the target position and the actual position on the terminal should be within 0 001 AC650 cards have been pre programmed and tested at the factory AC650 CARD SERVO OUTPUT SETUP The AC650 servo drive output range may require adjustment depending on the type of servo proportional valve being used Refer to the servo valve manufacture s specifications to determine the amount of servo drive current required The AC650 is shipped from Paw Taw John Services Inc factory preset to 30mA A 50K ohm resistor is installed in position R18 Refer to the drawing and table below should it be necessary to change servo output current Note Each AC650 card must be matched to it s own servo valve AC650 cards installed in this system have been pre programmed for proportional valves 330 ohm resistors have also been added across the AC650 Cage Servo Output terminals AC650 Servo Ouput Current Adjustment Servo Valve R18 Resistor Current Required Value 50K ohm 82K ohm 100K ohm 180K ohm
24. CIE DHD 2 00 SUC HOSEA Seer NOTE All switch holes are 875 SUGGESTED OPERATOR PANEL OVERLAY LAYOUT
25. INC of the claims breach and such notice must be given within thirty 30 days after discovery thereof 7 INSTALLATION REPAIR TESTING TRAINING OF EQUIPMENT Buyer agrees that all hands on installation and repair work will be done by competent personnel and that PAW TAW JOHN SERVICES INC personnel will only perform a supervisory service for the installation and or repair and or testing and or training for the computerized industrial control system 8 SYSTEM SOLD BUYER Company name address date and owner acting agent signature SELLER owner acting agent signature date PAW TAW JOHN SERVICES INC PAW TAW JOHN SERVICES INC 18125 N RAMSEY ROAD RATHDRUM IDAHO 83858 208 687 1478 SERVICE AGREEMENT 1 SCOPE This service agreement is good for a 2 year period The agreement starts at the beginning of the issuing date of the Purchase Order At the end of this time frame can enter into an extension of the service agreement for one a 1 year period This extension must be requested within thirty 30 days of expiration of the service agreement requested in writing by the authorized agent for the Canadian Company and only for the equipment sold 2 SYSTEM TO BE SERVICED Henceforth referred to as computerized industrial control system 3 SERVICES RENDERED PAW TAW JOHN SERVICES INC agrees to visit the computerized industrial equipment site once a
26. RATION TransTerm 5 TERMINAL OPERATION The TransTerm 5 is a complete dummy terminal capable of all functions used on stan dard personal computer systems The 5 may be powered using an external 12VDC power unit or powered via its data cable from the AC650 Typically AC650 cards pro vide 12 to 15 volts through their 6 pin keypad jacks The 5 terminal has two shift buttons labeled S1 and S2 S1 is Red and when first de pressed activates all red characters on the keypad An example would be if a function requires to be entered first press 51 which activates the Red characters then press the A key to send the command The 52 key activates the all Blue characters on the key board To enter a requires first pressing the S2 key to activate Blue characters and then the P key to send the command 9 D E 7 8 9 NS S2 4 6 NE fes EHE x EL deis It is a good practice to press the CLEAR key before beginning a command sequence to assure the TransTerm 5 is not already in the middle of a command sequence Single character or word commands in Black on the keyboard are direct entry commands in that they may be entered at anytime after the CLEAR key has been pressed Refer to the ta ble below for valid AC650 commands entered from the 5 terminal
27. S WINDOW XX XXX XX XXX XX XXX XX XXX X NULL ENABLE IF 12 zJOG INCR XXX zOFFSET SAW 1 zOFFSET SAW 2 zOFFSET SAW 3 zOFFSET SAW 4 This value is also used for PICKER offset zSPECIES SEL 1 to 4 Selects up to 4 set value groups OFFSET OPERATION Offsets for saw 1 2 amp 3 are additive or subtractive CHAPTER 7 TROUBLESHOOTING INITIAL SYSTEM TROUBLESHOOTING Discussed below are some common problems sometimes encountered after installation of a new system TROUBLE When the hydraulics are applied the cylinder extends or retracts to the maximum The ACTUAL POS Display value is jittery The cylinder is hunting when it arrives at target The cylinder overshoots or under shoots the target When power applied to the system the AC650 doesn t respond consist ently to commands The board sizes get thicker orthinner as the cylinder extends or retracts The board sizes vary out of tolerance When a set button is depressed the enable cylinder doesn t move SOLUTION Check the TransTerm parameter EXT TO ZERO value If okay switch the SERVO and SERVO cable pair Swap the TEMPO and TEMPO cable wire pairs GAIN value is too high Lower the value Adjust the ACCEL or DECEL value to correct Also check adjust the GAIN Verify the 150 ohm resistors are installed on the cardrack Refer to Initial System Setup Step 6 Check TMP ADJUST value for linearity of cylinder strok
28. SED CARD CLUSED OPEN OPEN CLDSED OPEN OFF f Filename Sheet Df REV CARD 3 OPEN CLUSED OPEN CLOSED CLOSED DN Paw Taw John Services Inc Dwe 3 pwe s 101 tA dq estes 66250478 TYPICAL MULTIPLE AXIS Date 04 10 97 650 CAGE 1 0 LISTING PROPORTIONAL VALVE 24VDC RETURN VALVE A PROPORTIONAL TEMPO INTERFACE RECIRCULATION e coc UTPU TU Ut CONTROLLER ec PROBE Ci 59000 lt 1 15 1 INTRGT LONG OBOS SHLD RTRN LU PULSE 00000000 GATE 8 MISI ofog GATE 9999664 PRN 12V 19 tte o7 g 00000000 17 1 Blk amp Shld Red Green Blue SYSTEM CONTROL ENCLOSURE 120191 CONDITION NORMAL OPERATION 5VDC LOW TEMPO SERVO Manhattan Belden M39150 9874 Poir 1 Red Yellow Poir 1 Black Black Pair Red White ABSOLUTE Pair Black Black CONTROLS Pair Red Red INC Poir Block Black MADE IN U S A REPLACES 1120 ird MOD 4 AC700 REV 2 INT EXT Black Black SER PROBE LENGTH EE Poir Red Brown DATE RECIRCULATIUNS Poir Black Black Filename Sheet Of REV Pair 4 6 nee Blue Configure AC700 Recirc card for Probe typ
29. X EXT TO ZERO IF 1 XX XXX MIN LIMIT XX XXX MAX LIMIT XX XXX SYSTEM MAX LMT XX XXX MIN DIST BETWEEN XX XXX KERF XX XXX OFFSET SAW 1 Refer to the previous section DEFINITION OF SYSTEM PARAMETERS for explanation of terms and values New entries should be recorded on a paper for future reference Located at the end of chapter six is a parameter worksheet Press the CLEAR key to exit the PARAMETER mode ENTERING SPECIES SET SIZES The SPECIES SET SIZES mode is used to set up board sizes To enter this mode fol low the procedure below 1 Depress buttons CLEAR S1 2 To sequence through SPECIES SET SIZES mode depress SPACE 5 quence the display in reverse depress DELETE The following is an example of size displays seen when scrolling through XX XXX SET 1 XX XXX SET 2 XX XXX SET 3 XX XXX SET 4 3 The cursor will be present at beginning of values that can be changed enter a new value key in the new number on the keypad Then press the ENTER key to send the new number to the system 4 Press the CLEAR key to exit the SPECIES SET SIZES mode OFFSET CALIBRATION PROCEDURE 1 Enter Saw 1 Offset Adjust mode by depressing CLEAR 17 keys 11 2 To adjust Saw 1 Offset depress 51 DELETE and display will show following 3 To add 0
30. ame sequence as and in place of the wire stubs on the terminal blocks Tighten screws securely Pairs 5 amp 6 must be wire nutted to Black and Orange wires inside enclosure In the System Control Cabinet cut strip and connect the wires of pairs 1 and 2 in the same sequence as and in place of the wire stubs on the terminal blocks at AXIS 3 on the top edge of the AC650 enclosure Connect Pairs 3 through 6 to the power terminal blocks at the right side of the cabinet Tighten all screws se curely At each AC700 location 3 connect the Temposonics probe plug into the lower jack at the right side of the enclosure At each AC700 location 3 install a jumper cable supplied between the AC700 upper jack at the right side of the enclosure and the Servo Valve This completes all low voltage DC wiring Clean wiring scraps from each enclosure and dress wires cables for appearance and safety Installation of the primary 120VAC must follow all safety regulations and precautions Pull a 214 GA Black White and Green wire from the electrical service panel to the System Control Cabinet In the System cabinet strip and connect the Black wire to the AC IN terminal Strip and connect the White wire to the N terminal Strip and connect the Green wire to the GND terminal In the electrical service panel strip and connect the Black wire to a 15Amp cir cuit breaker St
31. are program stored in a 28 pin memory IC The card has another memory device for storing set and servo dynamics parameters stroke limits and trans ducer interfacing information Both of these devices are non volatile so their data is not lost if power is removed The main I O connector opposite of the face of the card is an Euro style 32 pin dual read out This provides the card with flexibility to mount in single or multiple cardrack con figurations A complete custom Paw Taw John Services Inc servo control system is built from one or more AC650 controllers Servo systems also typically in clude power supplies wire and cable terminating blocks suitable enclosures and custom operator panels Paw Taw John Services Inc Chapter 1 Introduction 1 30 00 3 TYPICAL SYSTEM COMPONENTS A typical servo system from Paw Taw John Services Inc will be constructed from one or more of the components below l System Control Enclosure The servo control enclosure contains a cardrack used for support and interconnec tion to one or more AC650 Servo Controller Cards power supplies necessary to operate the controller cards and other system components AC power switch and fuses and suitable terminal blocks for connecting external component wiring of these parts are housed in NEMA 12 enclosure designed for wall mount Care is taken in design to provide wire ducting so that primary AC and secondary DC may be kept separated The
32. at Steps 1 through 7 above until the actual movement of the cylinder and the displayed move from the TransTerm 5 are equal The TEMPO SCALE values are preset during AC650 testing at Paw Taw John Ser vices Inc based on probe length as shown in the table below FACTORY SET TEMPO SCALE VALUES NOTE Values assume 4 Recirculations Probe Stroke IN Factory Set Tempo Scale 4 10 12 18 24 36 Note Individual machine parameters may require adjustment to the TEMPO SCALE ALTERNATIVE TEMPO SCALE FORMULA SETTING TEMPO SCALE As stated previously all Temposonics amp probes have differing gradient values due to min ute mechanical misalignments The AC650 Servo Control Card has a compensation factor called TEMPO SCALE found in the PARAMETERS menu which 15 used to ensure cylinder the stroke 15 linear and accurate Use the following formula to compute the TEMPO SCALE Do the computations as follows 2048 Gradient X 28 322 Tempo Scale Ignore us extension Ignore MHz extension Example 2048 8 041198 8 042 8 9926 28 322 Always round LSD to next higher value 8 042 would be the new TEMPO SCALE value that is entered in the PARAMETERS mode TEMPO SCALE VALUES WHEN USING OTHER RECIRCULATIONS If recirculation values are required other than 4 the Tempo Scale values must be changed accordingly The following table shows this TEMPO SCALE RECIRCULATION VALUES NOTE Values determined by 4 Rec
33. attan Belden M39150 9874 TYPICAL CONNECTION One cable for each axis used GND Pair 1 Red Yellow AXIS Pair 1 Black Black AXIS 1 NEUT Pair Red White 120 Pair Black Black Pair Red Red Pair Black Black Red Green Pair Black Black Poir Block Block Poir Lf 150 Ohm 150 Ohm Red Blue Black Black P SC AXIS 2 AXS3 AXIS 4 GSC e M id 00000 OOOO 0000 OOOO 00009 ARAR AR algls lglalalale Pow Tow John Services Inc Pow Tow John Services Inc OO 5VDC 5VDC 5VDC 5VDC PSI 15VDC 5VDC 10 GND 15VDC 15VDC 15VDC 15VDC GND 15VDC 15 15VDC 15VDC GND GND GND PS2 GND GND 24VDC LT 24VDC RETURN 24V DC 24VDC RETURN RETURN RETURN RETURN SERVO SERVO SERVO SERVO SERVO SERVO status status status O RCV DATA RCV DATA RCV DATA DATA DATA DATA KEYPAD KEYPAD d KEYPAD Poir 6
34. aw John Services Inc setworks systems employ several standard compo nents but are semi custom designs to best fit the user s application Therefore some components and installation requirements may differ from system to system This instal lation chapter is designed as a guide to get the system installed and running quickly safely and accurately Installation should be conducted and supervised by knowledgeable and experienced electricians Some judgment and interpretation may be required beyond the individual step by step procedures presented in this manual Paw Taw John Services Inc supplies all components specified in the system quo tation Most installations will require additional materials such as conduit wire circuit breakers etc These items must be provided by the user or installer to complete the in stallation task Paw Taw John Services Inc also provides drawings and wire lists etc that are specific to the system being installed Where possible installation drawings will be shipped before the system to permit rough in or location planning Additional and useful sample drawings are located at the end of this manual If questions or problems arise with the installation please call Paw Taw John Ser vices Inc at 208 687 1478 Assistance is available over the phone Paw Taw John Services Inc also provides system design services under contract MECHANICAL INSTALLATION Mechanical installation of the servo
35. ax limit parameters is set to high By depressing Clear 1 through 8 the appropriate servo controller will show the overtravel indication Enter the Parameter mode for that module and correct one of the parameter limits stated above If using an AC700 tempo interface card check the LED indications If POWER LED out check power on board Fix power problem If RUN LED out replace probe Follow AC700 operation manual for repair Push button lamp blinks Axis has not reached target position Verify target and actual position are within 050 Check mechanical or objects preventing the completion of the set TRANSTERM 5 TROUBLESHOOTING The TransTerm 5 is a complete terminal capable of all functions encountered on a normal personal computer system The unit can be powered using a 12 volt external power unit or powered can be applied to the D 25 connector The AC650 is usually jumpered to supply this voltage through the 6 pin telephone jack Listed below are troubles that are sometimes encountered and solutions TROUBLE SOLUTIONS Unit displays erroneous characters Check the terminal for proper configuration Unit displays cursor in upper left Check the connections between the terminal corner of display only and the AC650 With power applied the terminal The terminal is I O bounded Try another doesn t display a cursor or characters AC650 board or replace the terminal or doesn t beep three times when pow
36. deceleration which are necessary to produce smooth starts and stops without objectionable jerks or overshooting Note It is necessary to follow any data entry or change in parameter value by pressing the ENTER key Refer to the Servo Output curve for the following discussion a Cylinder movement begins with the servo output signal from the AC650 card controlling the servo valve by supplying an operating current The Acceleration ACCEL parameter sets the rate at which cylinder speed in creases This is demonstrated by the rising part of the curve The Accel eration parameter can be set to any value between 1 and 50 The higher the value the faster the acceleration and the quicker the cylinder will jerk to full speed b When the maximum desired operating cylinder operating speed is less than the cylinder maximum Maximum Velocity MAX VEL may be set to prevent an over speed condition The Maximum Velocity may be set at any number from 0 to 99 which is demonstrated by the flat part of the curve c At some point prior to reaching the new target it will be necessary to slow the cylinder to a stop gradually This is done in two stages as shown on the following edge of the curve The first stage called Deceleration DECEL is used to reduce speed quickly The second stage called Gain GAIN provides a more gentle speed reduction making an easy to stop without overshooting the target d DECEL may have a value between 1 and 50 The hig
37. e This procedure should minimize the oil loss 4 If the cylinder rod is extended half way or fully difficulty will be encountered trying to insert the probe tip into a hole about the size of a dime at the end of the rod 5 Maneuver the probe tip into the hole at the end of the rod 6 Once the hole in the rod has been found the probe can be screwed in 7 Avoidance of damage to the probe cable if applicable while screwing in the probe is extremely important 8 Tighten the probe securely with the appropriate wrench used during removal 9 Clean and reconnect cable to probe Connect probe cable to J box and secure adequately if cable is attached to probe 10 Reinstall guard or protective probe and cable cover Note this step may be required prior to reconnecting cable 11 Power may now be re applied to the Setworks system 12 Verify the probe is working with Setworks system electronics 13 Turn on hydraulics power 14 Verify no leaks are present at the installation site 15 Proceed with operation of the machine 16 If problems are still present consult Troubleshooting chapter of the manual for other possible solutions 9 1 AND INSTALLATION Changes to system hardware or requirements for additional software functions may make it nec essary to change the Program Integrated Circuit IC which operates the AC650 While this may happen seldom or ne
38. e Check linkage for security and proper ratios Check the cylinder mounting for security and the clevis for integrity Check that Set Enable in put is on If set function is not used the input must be jumpered to 24VDC Refer to system drawing OPERATIONAL SYSTEM TROUBLESHOOTING These are common problems encountered after the system has been operating TROUBLE Cylinder moves slower and slower Cylinder stops moving Cylinder will not move AC650 drive LED on Cylinder will not move AC650 drive LED off Transterm 5 display shows Bad Module Transterm 5 display shows Tempo Bad Troubleshoot Transterm 5 display shows Overtravel Temposonics Bad indication SOLUTION Check AC650 drive LEDs for ON If ON use external drive box to check for movement of cyl If no movement check filter for blockage or replace Also check hydraulic unit for 1500 psi or greater Check wiring to servo valve Replace servo valve Check that Set enable inputs are working Does the Transterm 5 display show an Overtravel Bad module Temposonics Bad indication Repair problem Replace the AC650 card associated with the number displayed with the Bad Module indication Check the corresponding Tempo Bad indication with the AC650 card The Tempo lamp should be on constantly the Temposonics loop A program software limit has been reached One of the AC650 min max parameter limits or system m
39. e per manual Pair Black Black Rathdrum ID 83858 208 687 1478 mer bet u TYPICAL ELECTRICAL WIRING Date 04 29 97 RECIRCULATIUN INTERFACE FAULT TABLE TRANSDUCER FAULT SERVO VALVE i gO0o 0I 0I 4 4 CO CO PO PO 4 SPECIE GND SAW 2 SET 1 PB SAW 2 SET 1 LAMP SAW 1 SET 1 PB SAW 1 SET 1 LAMP 930 lf unJpuioy OU Uuor b MDd 2400 6 60 v0 86868 1 ipeAoaddy 8 1 89 802 8 13S TANVd 1 JILVN3HOS 19214 1 SPECIE SELECT AUTO S4 53 52 R1 i Qoo d 1 RAAAAA AE a dd e O O 8 B B PENA PN p gt WY 7 WY Ave vL F i REF NT X f WY YW WY NS ee S A A dee A 00 00 00 li a 5 Z m ic 15 17 20 00 Filename Sheet OF REV w DWG 6 dwg FABRICATION NOTES dosis Reverse engrave Black w White lettering OPERATOR CONTROL PANEL 2 Drill all switch holes 125 except two marked Engrave locating dot only ron By ST Approved OVELAY FABRICATION Drawn By JT Date 05 01 97 Date SUGGESTED OPERATOR PANEL LAYOUT SAW 1 SET 1 SET 2 SET 3 SET 4 SET 5 2 SPE
40. ect Proportional Valve cables supplied by Paw Taw John Services Inc between each AC700 and respective valve 10 Route AC input power from electrical supply panel 15A circuit breaker and the System Control Cabinet Connect this circuit to terminals provided in the upper left of the cabinet as shown on the system Schematic ELECTRICAL INSTALLATION CHECKLIST Please refer to the system Interconnect Wiring Drawing at the back of this manual for the following steps Paw Taw John Services has left cable stubs connected at all termination points as assistance for cable and color coding reference Should a wire come loose refer to the drawing for the correct connection Check off each step as completed Pull a Manhattan P N 13330 cable into conduit between Operator Control Panel and System Control Cabinet Cut strip and connect wires in the Operator Control Panel in the same sequence as and in place of the wire stubs on the terminal blocks Tighten screws se curely Cut strip and connect wires in the System Control Cabinet in the same sequence as and in place of the wire stubs on the terminal blocks at the bottom edge of the AC650 enclosure Tighten screws securely Pull a Manhattan P N 39150 or equivalent cable between the Machine end Line bar AC700 enclosure and the System control Cabinet for Axis 1 Cut strip and connect wires in the AC700 enclosure in the same se
41. enclosed Use the appropriate wrenches necessary to remove and reinstall the guards Some probe cables have connectors at the probe head and allow the user to disconnect the cable from the probe Others are hardwired to the probe end and have a connector at the system end of the probe cable Whether the probe is an MTS I amp or MTS or L Series care must be taken when disconnecting the probe cable REMOVAL OF PROBES WARNING OBSERVE ALL LOCAL LOCKOUT AND SAFETY PROCEDURES l Turn off Setworks system power and Control power to hydraulics Lock Out 2 Insure area around the probe is clean and free of dirt sawdust and any other foreign material 3 Survey the area in back of the cylinder to make sure there is sufficient room to withdraw the probe without encountering obstructions Some sawmill headrig carriages are installed with minimal clearance and probes may only be removed at certain places on the track 4 If possible the hydraulic cylinder should be moved to the fully retracted position This permits easier installation of the new probe 5 Remove all protective covers from the back of the probe and cable 6 Disconnect cable from probe and secure away from work area If cable is attached to probe remove any cable clamps and disconnect from the terminating J boxes 7 Place an oil drip pan underneath area where probe is to be removed 8 Insure personnel are not looking directly at the probe or are stand
42. ering up To check the terminal for proper configuration depress S2 S1 S2 Refer to TransTerm 5 operators manual Chapter 6 page 11 TransTerm 5 set up The shift registers are as follows SR1 00000000 SR2 00000010 SR3 00001001 SR4 00000000 OPERATING MODE 001 CONTRAST 007 UNIT ADDRESS 001 TOTAL COLUMNS 024 The DB25P cable is wired per table Check connector for broken wires other damage and repair as necessary TRANSTERM 5 CABLE WIRING Signal Color DTD green DTD red DRD black DRD yellow GRD blue 12VDC white DRO jump to RD DTR jump to CTS TROUBLESHOOTING HYDRAULIC CONTROL SYSTEMS TROUBLE SOLUTION Cylinders don t move Check the set enable is active Ensure the lock up valve is active Cylinder overshoots target Decrease gain values for cylinder Product sizes are incorrect Check computer stored sizes are correct Check the target and actual positions are within 050 Check mechanical linkage for cylinder No movement of mounts etc Cylinders move slowly Check velocity values for drive Check for plugged filter indications Check for minimum 1500 psi out of pump Verify Lock up valve is activated Cylinders don t move Check the cylinder for free movement HYDRAULIC CONTROL VALVE TROUBLESHOOTING FOR CONVENTIONAL CARRIAGES Most all conventional carriages using knees with a dogging system use some form of hydraulic valving for control of the hydraul
43. her medium are for use by Buyer only and will not be used or given to any other party for use 3 GOVERNING LAW The laws of the State of Idaho USA shall govern this Agreement except that its conflict of law rules shall not apply 4 DEFINITIONS as used herein 1 Product shall mean any hardware software services and documentation purchased from PAW TAW JOHN SERVICES INC For purposes of this Agreement the term sale or purchase will be understood to mean license whenever used in connection with such software or documentation 2 Computer Software shall mean computer or processor programs and computer data bases including software embedded in semiconductor chips and all other forms of software Computerized industrial control system will refer to item 8 5 LIABILITIES Buyer agrees to use system hardware and software in a safe manner using all safety precautions local lockout procedures and follow all local or ruling government authority procedures to prevent personal injury or equipment damage Buyer also agrees to free PAW TAW JOHN SERVICES INC of any responsibility from personal or equipment damage suits as a result of misuse or non compliance of safety procedures specified in tech manuals local or ruling government authority 6 NATURE OF BREACH PAW TAW JOHN SERVICES INC liability for breach of warranty under the terms set forth herein shall arise only after Buyer s notice to PAW TAW JOHN SERVICES
44. her the value the quicker more abrupt the approach to the target The transition from the Deceleration phase to the Gain phase is controlled by Minimum Deceleration Position MIN DECEL POS A number be tween 1 and 999 determines how far from the final target this happens A larger number makes the transition occur further from the target f GAIN controls the system response while jogging the cylinder in addition to holding the set point after leaving the Deceleration mode The value can be between 1 and 64 with 25 to 30 being most common A high value will give quicker system response but could cause cylinder oscilla tions A value that 15 too low will cause sluggish system response and large errors between actual and target position SERVO SYSTEM RESPONSE Servo Valve Output Percentage Servo Output 96 Cylinder Position inches Cylinder Position gt A A DN NYT ENN 4 e e e e e T N N N N Cylinder Operate Time seconds SETTING TEMPO SCALE All Temposonics probes have differing gradient values due to minute mechanical mis alignments The AC650 Servo Control Card has a compensation factor called TEMPO SCALE found in the PARAMETERS menu which is used to ensure cylinder the stroke is linear and accurate Use the following procedure and formula to compute the TEMPO SCALE The procedure involves using the servo system to move the cylinder The probe
45. ics to the hydraulic cylinders attached to the knees These valves when activated cause the knees to perform in certain ways A combination of software limits provided by a computerized control system and limit switches are commonly used Discussed below are elements of a typical system Three valves are usually used They are a lock up valve safety creep valve and an accumulator dump valve A lock up valve is usually activated when the hydraulic power unit is turned on For hydraulic oil to be present at the cylinders this valve is on It can be activated when the Start Stop of the hydraulic power unit is turned Also normally the Start Stop of the hydraulic power unit is in series after a control Emergency Stop button Also a series of limit switches mounted on the knees can enable this circuit allowing oil to be present at the cylinders If the computer looses control to the knees these limit switches deactivate causing the oil pressure to be removed from the knee cylinders The safety creep valve usually has a flow control after it to cut down the amount of oil to the knees This valve is activated when any movement of the cylinder is required The valve stays on while the movement takes place When the cylinder has completed its travel the valve is electrically shut off At this time the flow control is in the circuit allowing enough oil to the servo valves mounted on the cylinders to keep them active The flow control is adjusted open
46. igned using controllers from Paw Taw John Services Inc Please conduct an inventory upon receipt of the shipment to confirm all items are accounted for and are not damaged System Control Enclosure manufactured by Paw Taw John Services Inc to system designer s specifications TransTerm 5 keypad terminal manufactured by Computerwise Inc and pro vided with the system from Paw Taw John Services Inc Servo Operator Control Panel supplied by user or custom manufactured by Paw Taw John Services Inc to user requirements AC700 Recirculation Box s may be required depending on type of Temposon ics probes used in the system These may be manufactured by Paw Taw John Services Inc Paw Taw John Services Inc Installation and Operation Manual sys tem specific document generally shipped inside the system control enclosure Numerous other components will be used to make up the system but the items directly associated with the servo control function will include Control Valve s servo or proportional valves one per axis to be controlled part of hydraulic system Temposonics Probe s one per axis to be controlled as specified by system de signer manufactured by MTS Sensors and may be provided by Paw Taw John Services Inc Conduit and wire as specified by the system designer Hydraulic cylinders pumps piping and hoses specified by the system designer GENERAL INSTALLATION NOTES Paw T
47. ill correct for any out of null condition the servo valve might have To determine an out of null condition when using the Transterm 5 or computer system observe the following 1 On face of the AC650 cover plate one of the LED s for the servo drive output will be on The LED can be dimly or strongly lit 2 When viewing the target position and actual position of the axis the values will not match The system usually gives an in motion error when the target and the 13 actual position have a difference of greater than 050 Corrective Action Perform the null adjustment procedure NOTE Ifthere is a difference error between the target and actual position calibrating the position of the cylinder using the offset procedure will correct for this er ror This calibration will maintain the cylinder on target as long as the servo valve null is not changing SERVO VALVE GENERAL INFORMATION Servo valves have been an industry standard for the past several years when applied to cylinders Many different manufacturers types and sizes are still used today The fol lowing information will cover typical adjustment procedures for certain models and cau tions a user must observe when using a servo valve TYPICAL SERVO VALVE ADJUSTMENT PRODCEDURE WARNING OBSERVE ALL LOCAL SAFETY PROCEDURES REGARDING HYDRAULIC SYSTEMS The following procedures will cover both the Rexroth and Moog servo valves Other valves like the Vicker
48. ing in front of the probe area It is possible for hydraulic systems using accumulators with dump valves or other devices used to release stored energy in the accumulator to be defective If so the probe and oil could shoot out from the cylinder and cause serious injury 9 Loosen probe from cylinder until the probe can be turned with bare hand using 1 3 4 socket wrench for probes without cables or a 1 3 4 open end wrench for probes with cables attached 10 Support the cable if required while unscrewing probe 11 Place a clean cloth around the base of the probe to limit the loss of hydraulic oil as the probe is removed and continue to unscrew the probe 12 Wrap the rod portion of the probe with the cloth and keep the cloth pushed against the hole while the probe is removed 13 Insert the rag in the hole as the probe is pulled from the hydraulic cylinder to prevent any additional oil from spilling 14 Wipe cables clean of any hydraulic oil that might have come in contact with them Hydraulic oil can cause deterioration of cable integrity 15 Proceed with probe replacement immediately INSTALLATION OF PROBES WARNING OBSERVE ALL LOCAL LOCKOUT AND SAFETY PROCEDURES l Verify the new probe is compatible with the old probe Insure the proper O ring is installed on the new probe 3 Carefully remove the cloth from the cylinder hole while inserting the new probe through the cloth and into the hol
49. ing keystrokes S2 blue key S1 red key and S2 blue key 10 The top line shows SR indicating setup register mode and two sequential counts from 1 to 8 to mark data bit positions The bottom line of the display shows which of the four registers SR1 SR4 is active the data for that register and the blinking cursor at the first new data entry position Each register contains 8 data bits that are either 1 or 0 This data determines how the TT5 will work It is necessary to have the registers filled with the exact sequence of 17 and 078 so the terminal can talk with the AC650 The bit sequence for register SR1 should be as follows SR1 00000000 If the data displayed does not match key in 00000000 Then press the ENTER key If the data displayed does match bit sequence just press the ENTER key to accept the data as displayed After the ENTER key is pressed in step 7 the display will automatically increment to the next register Repeat the procedure in step seven for all four registers confirming or changing the data bits to match the following SR2 00000010 OPERATING MODE 001 TOTAL COLUMNS 024 SR3 00001001 CONTRAST 004 SR4 00000000 UNIT ADDRESS 065 Hit the ENTER key after each register entry When all four registers are correct press the CLEAR key to exit the setup mode Please refer to TransTerm 5 Troubleshooting if no data is displayed Also refer to the TransTer
50. irculation value RECIRC NO Factory Set Tempo Scale multiply by 4 multiply by 2 1 2 4 8 000 8 divide by 2 16 divide by 4 Example 2 recirculations and the current value is 8 000 multiply the tempo scale fac tor by 2 The value for 2 recirculations will now be 16 000 MISCELLANEOUS PARAMETERS l 2 Note Remember it is necessary to follow any data entry or change in parameter value by pressing the ENTER key Temposonic Scaling Factor TEMPO SCALE used to adjust individual Tem posonics probes to a standard scale Minimum Limit MIN LIMIT sets the minimum allowed cylinder position This parameter should be set to prevent cylinder movement beyond mechanically safe positions Key in the value then press ENTER Maximum Limit MAX LIMIT sets the maximum allowed cylinder position Similar to Minimum Limit but in the opposite direction Follow same procedure Number of servos OF SERVOS is used to set the number of axis or servos in the system Track Limit TRACK LIMIT sets the maximum distance that the cylinder posi tion is allowed to deviate from the target The system will stop cylinder motion if this limit is exceeded Min Dist Between MINIMUM DISTANCE BETWEEN SAWS sets the minimum distances saws in edger systems can move to The system will stop cyl inder motion before this is reached This value prevents guide systems from crashing Kerf KERF is the thickness or cutting tooth
51. itioning carriage systems or any other linear position control may be implemented using one or more AC650 Servo Controller Cards in conjunction with Temposonice probes servo or proportional valves and some type of operator control While most systems are semi custom in design and function the operation of the AC650 Servo Controller Card remains constant Therefore understanding the AC650 becomes very important for system designers installers maintainers and operators The information included in this Technical Reference Tutorial is generic to most Paw Taw John Services Inc setworks systems and should be followed for installation setup and operation Information that is specific to a particular system such as me chanical and electrical drawings and schematics control location and operation and parts lists is provided in addition to this manual ABOUT Paw Taw John Services Inc Paw Taw John Services Inc is a designer and manufacturer of semi custom servo controller systems and associated components used in wood products and other manufacturing industries The company brings together individuals with decades of ex perience in systems and software design custom electrical and electronic systems manu facturing and technical sales with expertise in sawmill operation and automation Paw Taw John Services Inc specializes in systems that provide greater user flexibility lower maintenance increased productivity quicke
52. lation Transformers are required DC power wires used in the Paw Taw John Services Inc System Control Enclosures are wired to the following color code a 24 VDC Orange MTW 16 or 18 gauge b 15 VDC Yellow MTW 16 or 18 gauge 15 VDC Blue MTW 16 or 18 gauge d 5 VDC Red MTW 16 or 18 gauge e DC Ground Black MTW 16 or 18 gauge f Earth Ground Green MTW 16 or 18 gauge g 12 VDC Brown MTW 16 or 18 gauge h 12 VDC Violet MTW 16 or 18 gauge Proceed with electrical installation as follows l 2 3 Route 9 pair cable Manhattan E 95534 between Operator Panel and System Control Enclosure Connect a wire to each Input and Output of the AC650 cardrack following the wire colors of the stubs left on the terminals from the factory Wire the other end of the cable to the Operator Panel also following the wire col ors of the stubs left on the terminals from the factory Route each of the 6 6 Pair cables Manhattan M 39150 from the System Control Cabinet to each AC700 Recirculation Box NOTE Number each cable at each end for identification In the System Control Cabinet connect each cable to the AC650 Con nect Tempo Servo outputs and power supply terminals as shown on the System Schematic Connect the other end of each cable to the terminals of the AC700 as shown on the Temposonics Recirc Wiring drawing Connect the Temposonics Probe and servo valve connectors to the AC700 Conn
53. luminate when card is sending servo current to a valve The LED s will glow brighter as more current is applied to a valve Servo is one direction while Servo is the opposite direction The Status LED will remain on while the cylinder is within 050 of the target position If not moving or while the cylinder is moving the LED will flash The Tempo LED must remain on at all times No blinking or intermittent blinking is acceptable If so the Temposonics loop has a problem The RCV and TRX DATA lamps will blink most of the time in a random mode The Transterm 5 cable is connected at the KEYPAD area AC650 SERVO LOOP SETUP USING 486DX MONITOR SCREEN S to enter servo parameter mode Shown below is a typical monitor screen for AC650 parameter inputs These inputs are used to adjust the dynamics of the servo loop plus safety limits and Temposonics configuration Entering lt 8 gt calls up the display screen for the servo parameter mode LOG BREAKDOWN LEFT SAW RIGHT SAW I O ONLY TARGET X XXX 0 000 POS X XXX X XXX 0 000 STATUS ok ok ok setup0 13 setup1 20 set enable is OFF LEFT SAW servo parameters 41 8 0 1 scale mult typ 8378 7 adjust 17 18 19 00 accel 1 to 99 99 is fast 00 4 1 to 99 99 is fast offset 0000 below this pos no decel used 00 cent max vel towards 0 00 cent max vel away from
54. m 5 User s Manual included with the system for more detail on terminal setup To enter the Parameter Mode depress CLEAR 52 and P The top line will display PARAMETERS 11 By depressing SPACE key the bottom line will display the following XX GAIN 1 TO 25 XX XXX TEMPO SCALE XX XXX ZERO OFFSET ADJ XX ACCEL 1 TO 50 XX DECEL 1 TO 50 XX XXX DECEL MIN POS XX MAX VEL 1 TO 99 X EXT TO ZERO IF 1 XX XXX MIN LIMIT XX XXX MAX LIMIT XX XXX TRACK LMT XX XXX TRACK LEAD CHAPTER 4 SERVO WARNING WHEN USING HYDRAULICS USERS SHOULD BE CLEAR OF MOVING MACHINES AND ALL LOCAL SAFETY AND LOCK OUT PROCEDURES MUST BE FOLLOWED 1 Ensure Transterm 5 is connected to the Master AC651 servo card Each AC650 card in the system can have the same parameters loaded 2 To prevent any violent movement when the hydraulics is turned on enter the parameter mode Clear gt S2 gt P and enter the following 06 GAIN XX XXX ZERO OFFSET ADJ MAKE EQUAL TO CYLINDER STROKE LENGTH 25 ACCEL 25 DECEL 00 200 DECEL MIN POS 30 7 MAXVEL 30 7 MAXVEL DECREASE X 1 OR 0 FOR STROKE DIRECTION 00 500 LIMIT XX XXX MAX LIMIT ENTER MAXIMUM VALUE THAT CYLIN DERS WITHIN THE LIMITATIONS OF THE MACHINE 3 After Master AC650 servo card is loaded remove cable from phone jack and install in the next AC650 Repeat entering the above parameter values Perform this procedure fo
55. n be stepped on or hit with a foreign object causing irreparable damage 7 Temposonics probe should be mounted in an area free from moisture or wet saw dust Ifthis is not possible to keep the area clean some type of additional protection must be fabricated 8 Some systems may require additional J boxes for either AC or DC cabling and connec tions In this case refer to the System Conduit and Cabling Design Guide drawing in the drawing section of this manual for guidance in location and mounting 9 Some systems carriages may also require pantographs for cable interface Refer to mechanical drawing section of this manual for design guide drawings ELECTRICAL SPECIFICATIONS Electrical Specifications are as follows 1 System power requirements are 115 60 HZ breakered at 20 Amps 2 System DC power used are 5VDC 15VDC 5VDC 24VDC Amp requirements are figured per the number of discrete items used Power supplies are selected for twice the amount of current used and 12VDC are occasionally used 3 TransTerm 5 handheld computer terminal power requirements are as follows 12VDC or Vrms 2 wire Frequency 47 63 Hertz Current Max 500 milliamps 12 VDC power charger can be used if no power is used from computer system 4 AC650 power requirements are as follows 5VDC 400mA 15VDC 200mA With TransTerm 5 connected 15 700mA 15 100mA 24VDC
56. nctions and troubleshooting Refer to the System Opera tion section of this manual for specific operating details The TransTerm 5 terminal connects directly to the AC650 cards inside the System Control Enclo sure Servo Proportional Valves Servo Valves and in some systems proportional valves control the flow of hy draulic pressure to the hydraulic cylinders One valve will be associated with each Paw Taw John Services Inc Chapter 1 Introduction 1 30 00 4 axis The Servo Valves controlled from servo output of AC650 cards lo cated in the System Control Enclosure Refer to the system installation section of this manual for adjustments to the AC650 that may be required by any specific valve type Personal Computer based System PC s are used with high performance machine applications These systems use all of the above items with the exception of the TransTerm 5 but are controlled through the use of a high speed serial interface These systems are used on opti mizers carriages multiple axis quads and other specialized machines When personal computer is used the TransTerm 5 is not CONFIGURATION OPTIONS 486DX computer to AC650MB card rack 486DX computer ay ay ay P
57. ocedure for alignment of the cylinders to the machine OFFSET CALIBRATION PROCEDURE To adjust the OFFSET Calibrate the set system to the sizes to be cut use the following steps l Depress CLEAR 1 2 The TRANSTERM 5 displays following 01 P XX XXX S XX I XX O XX OK 3 Depress S1 DELETE The display shows the following 4 add 060 to the position of the saw enter 060 Depress ENTER Subsequently each time the ENTER key is depressed the saw will move 060 5 To subtract 060 from the position of the saw depress S1 F7 The minus sign appears before the offset entry area Enter 060 and depress the ENTER button Again each time the ENTER key is depressed the saw will move back 060 6 To change the sign back to a positive value depress S2 F7 The plus sign will reappear before the offset entry area Vs Press the CLEAR key to exit the OFFSET CALIBRATION mode NOTE When product is processed check for users desired accuracy Due to machine inaccuracies some fine adjustments will be needed Follow the procedures stated above This completes the Servo Loop adjustments AC650 FACE PLATE INDICATIONS The indicators on faceplate of AC651 servo card provide valuable information about status of the module The following is a brief explanation of each indicator 1 The Servo and LED s il
58. perator switches limit switches or photo eyes and eight outputs can be used to drive lamps relays or alarms Paw Taw John Services Inc X Chapter 1 Introduction 1 30 00 2 lla The specific operating characteristics and personality of the AC650 are a function of the firmware programming that directs the microcontroller contained within This program is created special to meet each system s specific operating requirements The AC650 servo controller high speed serial communications port may be connected to a terminal or computer via a telephone style modular jack for system setups and calibra tion data tracking and certain operating program modifications Presently the Com puterwise TransTerm 5 terminal is used This feature allows the user on site setup changes or accommodates for mechanical component wear or replacements One final serial communications port allows several AC650s to intercommunicate mak ing possible multiple controller systems that can work in harmony In this manner one command from a control console might permit separate and different actions from two or more controllers simultaneously The AC650 has 8 inputs and 8 outputs that can operate between 5vdc to 30vdc A 4 position dip switch located on the component side of the circuit board provides the ad dressing necessary in multiple card configurations and for special functions The AC650 operates from a Firmw
59. pt one the zero value will be at the retract end of the cylinder and position will increase toward the extended end of the cylinder Note Temposonics probes are physically 4 5 to 5 0 longer than actual operating length Please refer to the drawing for discussions below 4 The ZERO ADJUST is used to place the coordinate system zero reference where it will be most useful for the system It can be set to any value between 0 and 65 5 If the zero reference is best at extended end of cylinder EXT TO ZERO IF 1 1 a value of the probe length plus 3 will place the zero reference near the extended end of the cylinder tip end of the probe 6 Example 12 probe would need a value of 15 000 to place the coordinate system zero reference near the extended end A higher value will move the zero reference beyond the end while a lower value will move the zero reference toward the retract end 7 If the zero reference is best at the retracted end of the cylinder EXT TO ZERO IF 1 0 ZERO OFFSET ADJUST value of 12 000 will place the zero reference near the retracted end of the cylinder base of the probe Values greater than 12 000 will move the zero reference off the base end of the probe while a ZERO OFFSET ADJUST value less than 12 000 will move the zero reference toward the extended end of the cylinder 8 EXT TO ZERO IF 1 and ZERO ADJUST are both set for each axis used in a mul
60. quence as and in place of the wire stubs on the terminal blocks Tighten screws securely Pairs 5 amp 6 must be wire nutted to Black and Orange wires inside enclosure In the System Control Cabinet cut strip and connect the wires of pairs 1 and 2 in the same sequence as and in place of the wire stubs on the terminal blocks at AXIS 1 on the top edge of the AC650 enclosure Connect Pairs 3 through 6 to the power terminal blocks at the right side of the cabinet Tighten all screws se curely Pull a Manhattan P N 39150 or equivalent cable between the Operator end Line bar AC700 enclosure and the System control Cabinet for Axis 2 Cut strip and connect wires in the AC700 enclosure in the same sequence as and in place of the wire stubs on the terminal blocks Tighten screws securely Pairs 5 amp 6 must be wire nutted to Black and Orange wires inside enclosure In the System Control Cabinet cut strip and connect the wires of pairs 1 and 2 in the same sequence as and in place of the wire stubs on the terminal blocks at AXIS 2 on the top edge of the AC650 enclosure Connect Pairs 3 through 6 to the power terminal blocks at the right side of the cabinet Tighten all screws se curely Pull a Manhattan P N 39150 or equivalent cable between the Saw AC700 en closure and the System control Cabinet for Axis 3 Cut strip and connect wires in the AC700 enclosure in s
61. r all AC650 servo cards used CAUTION WHEN HYDRAULICS ARE TURNED ON CYLINDERS MIGHT MOVE ERRATICALLY UNTIL AIR IS BLED FROM THE CYLINDERS PERSONNEL MUST REMAIN CLEAR OF THE MACHINE 4 Turn on the hydraulics and enter a position value from the set panel 10 11 12 13 14 Exercise the cylinders by changing sets on set panel until they move smoothly User is bleeding air from the cylinders With the Transterm 5 cable installed in the master AC650 phone jack depress Clear gt 1 and note the position and the position Increase the gain value in the parameter mode by 5 and enter a change in the set value from the set panel Observe the cylinder reaction and note the and P readings The readings should be within 004 of each other Continue increasing the gain value until the cylinder becomes erratic or enters a condition called hunting The cylinder s oscillate When the hunting condition is reached decrease the gain value until the oscillation stop While making set changes from the set panel adjust the ACCEL and DECEL values until the desired response 15 obtained Increase the MAX VEL INC values until the desired speed is obtained Repeat 1 through 11 for axis 2 and so on Minor adjustments might be needed for each axis after all cylinders are adjusted Using the parameter value entries stated above adjust accordingly Proceed to the Offset Calibration Pr
62. r pay back and higher yield Our systems are in use worldwide by companies wanting more intelligence with their controllers Paw Taw John Services Inc systems are easier to setup modify and use in eve ryday operation than most other programmable controllers No special programming lan guage must be learned and all programming may be done from a keypad terminal provided with the system Our systems also interface with most popular position and limit sensors directly or via economical interface boxes we can supply with systems Paw Taw John Services Inc can also control most all popular servo and propor tional valves directly This offers a significant reduction in equipment suppliers required to construct your servo system Paw Taw John Services Inc X Chapter 1 Introduction 1 30 00 1 ABOUT SERVO CONTROLLERS A servo control system when applied to positioning is an electro mechanical system that knows where it is at all times and provides for external data input whether from sensors computers or humans to act upon or produce a response to the input Most often in in dustrial applications the servo system 1s used to control linear motion such as positioning of a saw or movement of knees on carriages Each isolated linear motion is referred to as an axis Paw Taw John Services Inc systems are used to control one or more axes Several of the axes may be interactive in multi axis systems such as moving multiple saw
63. rip and connect the White wire to a Neutral terminal Strip and connect the Green wire to an electrical equipment ground terminal Setworks wiring is now complete CHAPTER 3 AC650 INITIAL SERVO SYSTEM SETUP HARDWARE CHECKOUT WARNING INSURE ALL LOCAL LOCKOUT PROCEDURES ARE FOLLOWED AC650 CARD RACK CONFIGURATION _ 00000000000000000000000000000000 550 00000000000000000000000000000000 Refer to figure above for the following check l Ensure 4 Master jumpers wires are installed near card 1 connector 2 Install if not present NOTE In multiple card rack configurations the second rack has 4 jumpers installed in the Slave locations MULTIPLE AC650 CARD RACK CONFIGURATION Refer to drawing below oo REEE ERER ETEEET Ekl 4 on 4 OS
64. s and Atchley valves will adjust in the same way as the Moog To mechanically null a servo valve follow this procedure Refer to figure 1 MOOG SERVO VALVE Step 1 Turn hydraulics on Step 2 Using a box end wrench sized for the locking nut loosen the locking nut Step 3 Insert an Allen wrench into the hex head screw Step 4 Remove the connector from the valve When the connector is off the cylinder will drift in one direction Adjust the valve until the cylinder stops moving or just creeps It will be necessary to connect the valve drive connector to the valve frequently so the cylinder doesn t extend or retract fully The Allen head screw must not be turned more than 90 degrees in either direction Step 5 After the cylinder stops moving connect box end wrench and tighten The cylinder might move again Correct with the Allen head screw until there is no movement and the locking nut is tight 14 Figure 1 REXROTH SERVO VALVE CAUTION THE TOP SET SCREWS AND NUTS OF THE VALVE MUST NOT BE ADJUSTED IF SO THE VALVE WILL NOT NULL AND MUST BE SENT IN FOR REPAIR Step 1 Turn hydraulics on Step 2 Using a metric Allen wrench loosen the locking plate on either side of the main body of the valve Step 3 Insert a metric Allen wrench into the center hex head screw Step 4 Remove the connector from the valve When the connector is off the cylinder will drift in one direction Adjust both sides of the valve until the
65. s simultaneously while still permitting individual saw adjustment A typical servo control system might consist of a hydraulic cylinder used to move a saw A servo valve under the control of the servo controller directs the hydraulic fluid power Some type of position sensor attached to the saw would provide positional data to the controller To make the system usable an operator console might permit the selection of several cut lengths In a real time example the operator could choose a 10 cut width by pressing the 10 but ton on the console This requests the servo controller to move the saw to the 10 posi tion The controller sends a signal to the servo valve to move the hydraulic cylinder in the correct direction Information returned to the controller from the saw position sensor is compared with the operator requested position and movement of the cylinder continues until the saw position reaches 10 At that position the controller removes the signal from the servo valve and the saw stops Paw Taw John Services Inc SERVO CONTROL SYSTEMS Paw Taw John Services Inc servo controllers are semi custom systems designed and assembled from a group of standard components The heart of the system is an AC650 servo control module The AC650 is designed to accept positional information from many industry standard sensors It will output the appropriate control for most in dustry standard servo valves Eight inputs are provided for sensing o
66. ser wants the postioner to move to 12000 max target allowed Sets the maximum position the user wants the postioner to move to within the limits of the stroke of the positioner 20 Depress the keyboard lt Esc gt key The screen returns to the Servo screen 2 Using the lt Down gt arrow key on the keyboard depress it until the highlight bar is on Right Saw 22 Depress lt S gt on the keyboard The screen now changes to the following LOG BREAKDOWN LEFT SAW RIGHT SAW I O ONLY TARGET X XXX 0 000 POS X XXX X XXX 0 000 STATUS ok ok ok setup0 13 setup1 20 set enable is OFF RIGHT SAW servo parameters 00 gain typ 4 to 8 0 tempo scale mult typ 8378 7 adjust 00 accel 1 to 99 99 is fast 00 4 1 to 99 99 is fast offset 0000 below this pos no decel used 00 cent max vel towards 0 00 per cent max vel away from 0 movement 0 to decr pos if 1 00000 min target allowed 00000 max target allowed 00 value to be changed 23 Repeat steps 17 20 24 Depress lt ESC gt key on the keyboard twice This will return you to the MENU screen Depress the keyboard lt R gt key The screen is now in the Run mode The status line shows the Left and Right saws as in motion 25 This completes the initial setup for the AC650 cards For any assistance please call Paw Taw John Services Inc at 208 687 1478 CHAPTER 5 SYSTEM OPE
67. sition is reached the lamp will light continuously The system is now ready to operate Pressing any one of the four SET buttons will move the saw to that set position Actuat ing the DOUBLE switch will double the position for each set and light the DOUBLE lamp Actuating the SPECIE SELECT switch will shift to the second of group of four SET values Pressing any one of the four CANT buttons will move the saw to that cant position Ac tuating the SPECIE SELECT switch will shift to the second of group of four CANT values CANT values are not affected by the DOUBLE function SYSTEM POWER DOWN Power down the setworks system in the following sequence 1 OFF hydraulic power 2 OFF control power if used 3 Turn OFF power to Setworks The system is now completely shut down ACESO PARAMETERS I M mt _______ AXIS 2 AXIS 3 AXIS 4 AXIS 5 AXIS 6 oO Al OF rm rm i gt 2 gt z 5 5 Z O Z 2 m m Ol a a aia 9 A9 gt m 5 9 zlo erlo ezlo zlo mio o o o m Sal Sle S zz 4 rim x J gt 0 gt gt gt a gt gt O gt 2121 Z Z cl z 2 gt m 2 3 OIIO Oj m m 2 m S m m m 2 m o 2 3 5 5 o o 35 0 d 2 a p 7 z o xo o z 1 KER 1 1
68. t follow Note All systems use AC650 servo cards System configurations may vary as applications demand All system employ AC650 servo cards in one of the following configurations Size Cards Configuration Small 1 Single card holder Medium 2 4 One AC650 card cage Large 5up 2 or more AC650 card cages Regardless of the system size or configuration the following steps must be conducted 1 Unplug all AC650 cards from cardrack before applying power 2 Apply AC power to system and verify correct DC voltages are present at power terminals on the AC650 cardrack s per the table below AC650 Cardrack Voltages Terminals Voltage From To Minimum Maximum 5VDC GND 4 9VDC 5 2VDC 15VDC GND 14 9VDC 15 2VDC 15VDC GND 14 9VDC 15 2VDC 24VDC 24V RET 5VDC Input Output Supply Voltage Turn off AC power Verify MTS Temposonics TEMPO and TEMPO connections are correct per the System Schematic drawing Verify SERVO and SERVO lines are present at the correct terminals per the System Schematic drawing Verify that 150 ohm terminating resistors are installed between REC REC and XMT XMT terminal pairs of the GSC 1 and GSC 2 terminal blocks Note When using single AC650 cardrack a 150 ohm terminating resistor is installed between terminals 6A and 8A AC650 CARD ADDRESS SETUP Referring to the AC650 drawing and the Dip Switch Table below adjust the card address DIP switch positions on each
69. tents 59 N Se We 15 17 18 19 20 23 25 26 28 07 22 03 CHAPTER 6 RUNNING THE SETWORKS SYSTEM SYSTEM TURN ON OPERATING THE SETWORKS SYSTEM POWER DOWN AC650 PARAMETERS DOCUMENTATION SHEET AC650 NEW PARAMETERS CHAPTER 7 TROUBLESHOOTING INITIAL SYSTEM TROUBLESHOOTING OPERATIONAL SYSTEM TROUBLESHOOTING TransTerm 5 TT5 Keypad TROUBLESHOOTING HYDRAULIC CONTROL SYSTEM TROUBLESHOOTING HYDRAULIC CONTROL VALVE TROUBLESHOOTING FOR CONVENTIONAL CARRIAGES CHAPTER 8 MTS TEMPOSONICS PROBE REPLACEMENT REMOVAL OF PROBES INSTALLATION OF PROBES CHAPTER 9 IC REMOVAL PROGRAM IC REMOVAL AND INSTALLATION CHAPTER 10 PRODUCT INFORMATION PRODUCT WARRANTY SALE AGREEMENT TERMS AND CONDITIONS SERVICE AGREEMENT CHAPTER 11 DRAWINGS ELECTRICAL DRAWINGS MECHANICAL DRAWINGS INSTALLATION DRAWINGS NOTES BLANK PAGE FOR NOTES GENERAL SCHEMATICS amp DRAWINGS AC650 LAYOUT VOLT TEST DWG 1 TO DWG 10 Paw Taw John Services Inc AC650 Table of Contents 49 49 49 50 51 53 54 55 56 57 58 59 61 63 65 67 69 69 70 71 07 22 03 CHAPTER 1 INTRODUCTION ABOUT THIS TUTORIAL amp TECHNICAL REFERENCE Paw Taw John Services Inc provides this Technical Reference Tutorial as an instructional aid for system design installation and operation of AC650 Servo Control ler Card based setworks systems Single or multiple axis systems for saw and or linebar pos
70. tiple axis system SETTING THE SAW OFFSET REFERENCES TO ZERO Each saw has an OFFSET REFERENCE that must be set to zero as part of the system setup procedure after the coordinate system parameters have been set This is done by entering the Parameter set mode and scrolling to OFFSET SAW 1 Use the following steps to zero each saw offset reference 1 Depress S1 P 2 Scroll to OFFSET SAW 1 mode by pressing the SPACE or DELETE keys to sequence forward or backward 3 Type in 00 000 and press lt ENTER gt to set the Offset Reference to zero 4 Repeat this procedure for axis OFFSET SAW 2 through the last saw by scroll ing forward with the SPACE key and entering 00 000 and pressing lt ENTER gt for each offset reference 5 Press the CLEAR key to exit parameter mode NOTE AFTER THESE VALUES HAVE BEEN ENTERED NO FURTHER CHANGES TO THESE OFFSET REFERENCES ARE REQUIRED UNLESS THE ZERO OFFSET ADJUST IS CHANGED SYSTEM RESPONSE The ability of the system to respond smoothly and quickly to a target position change is set using the ACCELERATION MAXIMUM VELOCITY DECELERATION MINIMUM DECELERATION and GAIN operating pa rameters An example of cylinder action is demonstrated in the following graph where a target position change was made from 1 to 11 by a cylinder with a travel rate of 5 per second The graph on the next page illustrates the effects of acceleration and
71. ty Seller authorized agent signature and date Paw Taw John Services Inc PAW TAW JOHN SERVICES INC 18125 N RAMSEY ROAD RATHDRUM IDAHO 83858 208 687 1478 SALE AGREEMENT TERMS AND CONDITIONS 1 General Any order resulting from a Quotation shall not constitute a contract until such order has been accepted either in writing or payment by terms Such acceptance is conditioned upon Buyer s acceptance of the express terms and conditions set forth in quotes invoices or attached contracts The order of precedence of all terms and conditions in the agreement are those designated 1 in body of a contract 2 in body of a quotation and 3 those herein PAW TAW JOHN SERVICES INC rejects the inclusion of any different or additional terms proposed by Buyer in any order resulting from the Quotation and if such different or additional terms are so included in such order Buyer agrees that a binding contract of sale will result including only the terms stated herein unless PAW TAW JOHN SERVICES INC agrees in writing to accept such different or additional terms By accepting PAW TAW JOHN SERVICES INC quotes proposals or any other PAW TAW JOHN SERVICES INC document marked as PAW TAW JOHN SERVICES INC Proprietary or Confidential Recipient Buyer agrees to the terms of item 2 below 2 PROPRIETARY DATA RIGHTS PAW TAW JOHN SERVICES INC and Buyer agree that all technical manuals computer software and any ot
72. ver we are including procedures for this change IC REMOVAL PROCEDURE l Using a small screw driver insert under bottom of Program IC between the IC and socket and lift up area 2 shown below Lift approximately 1 8 2 Position small screw driver at area 1 shown below between IC and socket and lift up 1 8 3 Continue between areas 1 and 2 shown below lifting IC further from socket until it comes completely out NOTE This procedure prevents the pins on the program IC from getting bent INSTALLATION 1 Check new Program IC to be installed has all pins straight both vertically and hori zontally 2 Orient IC matching indent on one end to indent on IC socket Refer to area 1 of the below drawing 3 Align the pins of IC to socket 4 With one finger push the IC into the socket GENTLY CAUTION If the pins don t align up properly they can be bent during installation 1 32 For further assistance call Paw Taw John Services Inc at 208 687 1478 10 PAW TAW JOHN SERVICES INC 18125 N RAMSEY ROAD RATHDRUM IDAHO 83858 208 687 1478 PRODUCT WARRANTY Paw Taw John Services Inc Seller warrants product s of it s manufacture to be free of defects in material and workmanship for a period of 90 days from date of shipment from Seller s facility Seller s only obligation under this warranty is to furnish an
73. year PAW TAW JOHN SERVICES INC personnel will supervise testing and or repair of all firmware software and software upgrades of the computerized industrial control system 4 PROGRAM CHANGES Program changes will be considered as service repairs and must be checked by PAW TAW JOHN SERVICES INC personnel 5 SERVICE FEES Fee s to be determined at time of request and in writing sent by FAX or mail 6 SEVERABILITY The terms of this agreement can be terminated at anytime Termination of this agreement must be submitted in writing to PAW TAW JOHN SERVICES 7 at the address displayed at the top of this document Acknowledgment of Service Agreement BUYER Company name address and owner acting agent signature SELLER PAW TAW JOHN SERVICES INC 7 CHAPTER 11 SYSTEM DRAWINGS The number and type of drawings provided with a system varies widely and is based on the particular servo system Small systems may only include a couple simple electrical drawings schematics and or cabling Mid sized systems may also include several mechanical drawings of specially fabricated components Large systems such as carriage control systems may also include electrical and mechanical installation drawings necessary during the planning and rough in stages of installation In cases where the user is fabricating or supplying components to the system Paw Taw John Services Inc will provide recommended

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