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DLC-R Feed-to-Length Control With SOT Supplement

1. 19 A Waiting Press 1 1A A C Stop Active 1B A Start Active 1C A Resume Active 20 JoglnputActive 22 A P Stop Active 23 A Part Stop Minor Errors 40 DLC SYSTEM ERROR Code MNROO0 ssssssssssssssssssesssrereeenn 41 Zero Feedlength Entered 43 Zero Feedrate Entered 44 Drive Is Not Enabled 46 Axis 1 Has Not Reached Position 48 Stop Due To Interrupt Input DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostic codes on the IDS 8 16 8 16 Diagnostics and Troubleshooting 8 23 DLC R Feed To Length Control User s Manual 8 24 Diagnostics and Troubleshooting 49 4C 4D 4E 53 Feed Angle Is Missing 8 17 Change in Fdlgth Exceeds Limit 8 17 Feedlength Exceeds Maximum 8 17 Feedlength Less Than Minimum 8 17 Auto Mode Exit Required 8 18 Soft Faults 60 61 62 63 64 65 66 67 68 69 6A eB eD 6E 7D 7E 73 74 76 77 78 DLC SYSTEM ERROR Code SFT00 8 10 Serial Com Port Disconnection 8 10 Serial Com Port Overrun Error 8 10 Serial Com Port Framing Error 8 11 Serial Com Por
2. nn 7 8 7 8 Axis Jogging In Manual Mode 7 9 7 9 Automatic Operation MM 7 9 Chapter 8 Diagnostics and Troubleshooting 8 1 8 1 Digital Servo Drive Normal Operating Diagnostics r 8 1 8 2 Status Diagnostic Display Alphabetical Index 8 2 8 3 Diagnostic RTE EE E Le 8 4 Lee IMDB UEM IIR Mc CD 8 4 Soft AU e E 8 5 MIRO ee 8 5 EE e E 8 6 8 4 Hard Fault Messages 8 6 8 5 Soft Fault Messages EEN 8 10 8 6 Minor Error Messages A 8 15 9 7 System Status M6ssages E 8 18 General Messages A 8 18 Automatic Mode Messages A 8 19 Manual Mode Messages aa 8 21 Set up Mode Mee geg e e mU Rd d te a ttam ua e ated 8 22 8 8 SOT Status Diagnostic Codes Index 8 23 8 9 IDS Status Diagnostic Codes Index nter nnne nennen nnne nnn 8 25 Appendix A Display Map A 1 Appendix B Blank Parameter Worksheets B 1 BAL BEG R Cramer Eeselen 2 B 1 B 1 2 DEC RH B1 Parameter Seti tr REFERT ETE RIF REFERO FER ERN REEF EFT EHE REX RR FERE tede sien it ia B 2 B 1 9 DEC R CO Parameter Set oerte ENNEN B 3 Appendix C Schematics C 1 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Contents V DLC R Feed to Length Control User s Manual Appendix D Installation Drawings E Index Figures Figure 1 1 DKS DLC R Feed To Length Positioning Control System Figure 1 2 Block Diagram Figure 1 3 Optional Thumbwheel Switch amp Alphanumeric Display Modules Figure 1 4 SOT Station Operator Terminal
3. WALSAS 31VNIQMOOD SNIAO1104 3HL ONISN Q3nNILNOO z 3MV S3NIT OVA OZL 3SVHd SIONIS OWA OZI 3NI OVA OCC MJTIOMINOO 12VdWOO Y11910 S x GNS l13NIBVO DLC R Feed To Length Control User s Manual DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 C 2 Schematics DLC R Feed To Length Control User s Manual OLD RAMAN MYT LHOWAdOD 3ON3N343M 03SV3T38 MO Q3id02 38 OL LON ATNO 3SN nien HO4 LNANNSOG SIHL CALIGIHONd SLNINGSY WA 2333NI9N3 A8 G3SA38 AB a3xo3H2 304 NOISIA3H SC 1190 6 WI 16 11 90 003 Yad 3538 6 Si 7 ZNUNVWO vw 8 402 1aaHs SIN JWS M3BWDN Lued N38WhN 003 3NVN alva NoLLdiios3a ava nen O3NI A1HuiBHuu i 9911 38 YIANNN 9NMV3O EE gaz NOILO3 OQQN 3 218 NO OM3LNI Sxa S31v1S3 NVW440H JN WON HIOUuxau Q3Q33N LON SI AlddNS H3MOd OGQAS SHL GSSN LON SI SOV4SYSLNI SGI IVNOlLdO JHL 4l Q3Q33N LON SI X Z AV I3M 3HL ASN LON SI 3OVJdM3lNI LOS vNOlLdO 3HL A AQV3M IVNIAM3L F 4dF 4sz z lal qols
4. Accessing Working Part with Wild Card Characters Any batching data may be sent or received to or from the working part by using wild card characters Examples B F 1 cr 1lf equests Feed 1 data for the working part d B C 001234Shh lt cr gt lt 1f gt sends a part quantity of 1234 to the working part Using Working Part and Wild Card The working part and wild card are useful for reducing communication program logic since only one set of strings needs to be sent for all information It is also useful when accessing data by Part ID rather than Part block number DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 29 DLC R Feed To Length Control User s Manual INDRAMA Parameter Request Note The C Parameter Text response will be 32 characters long K_C003 Example Access data by Part ID without knowing Part Block _B_P_NPart 001 hh lt cr gt lt lf gt Change working part to ID Part 001 B C cr 1lf Request part info for Part 001 B CO1 001234 000001 1 OO1 hh cr 1f DLC response B F 1 cr 1lf Request Feed 1 info for Part 001 B F0114012 345 67 8 OO01 hh cr 1lf DLC response d B W N222 2222Shh lt cr gt lt lf gt Store a jump to Part ID 222 2222 froPart 001 There are two types of parameter requests and responses The extended parameter format string includes the digits exactly as they appear on the DLC display wi
5. Axis 1 Drive Stalled Indicates the position feedback is not being controlled within the tolerance of the position command The DLC uses a mathematical model of the system to calculate the expected position error lag Drive Stalled occurs when the motor is moving too far behind the expected lag The Monitoring Window Parameter A112 must be set to a value that is greater than the deviation in position error caused by normal mechanical and electrical characteristics see Chapter 5 for parameter description The following items should be checked 1 There is a velocity command but no axis motion check for a disconnected encoder cable and for a faulty encoder feedback cable DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 7 DLC R Feed To Length Control User s Manual INDRARMA 8 8 Diagnostics and Troubleshooting 2 Max RPM in Parameter A102 Drive Max RPM is not the correct entry for the motor being used 3 Acceleration rate is too high correct in Parameter A106 4 Position Gain is too high for system inertia correct in Parameter A109 5 Drive Enable RF signal from DLC is not reaching the drive check cable connections Axis 1 Drive Runaway Indicates the position feedback is not being controlled within the tolerance of the position command The DLC uses a mathematical model of the system to calculate the expected position error lag Drive Runaway occurs when the motor is movi
6. This input is typically wired to a normally open push button switch on the user control panel Resume Cycle Connector Function High X17 pin 5 Input Used to resume the automatic cycle after a soft fault or minor error is cleared refer to section 3 3 8 momentary Causes the automatic cycle to resume from its point of interruption This input is typically wired to a normally open momentary push button switch on the user control panel Feed Angle Connector Function High Low X17 pin 6 Input Controls the DLC feed cycle See Normal Operation Signals Indicates that material can be fed safely When this signal goes high in Automatic Mode it initiates the next feed cycle Indicates that material cannot be fed In a metal forming application a low signal indicates the press ram is into or too close to the material to allow feeding In a metal forming application after the press leaves the material on its upstroke a switch or sensor is activated See Figure 3 8 Feed Angle Switch Layout This switch provides a high signal to the DLC during the rotation angles that the ram is clear of the material and it is permissible to feed DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 17 DLC R Feed To Length Control User s Manual INDRAMA If Feed Angle goes low during a feed the DLC issues the Press Immediate Stop output in an effort to
7. 81 Parameters Lost Clear to Cont 82 Axis 1 Drive Runaway 84 DLC SYSTEM ERROR Code PL001 85 DLC SYSTEM ERROR Code FXPM0001 86 Parameters Lost Select P Mode 87 DLC SYSTEM ERROR Code UPRGO1 88 EMERGENCY STOP EMERGENCY STOP 89 Axis 1 Amplifier Hardware Fault 8B Axis 1 Motor Has Overheated BC Axis 1 Drive Stalled 8E DLC SYSTEM ERROR Code FLPM0003 90 Measuring Wheel Encoder Fault 92 Invalid Drive Configuration 93 Drive Watch Dog Error 94 DPR Not Readable 96 Drive Error Press the CR Key 97 Invalid Drive Software Serial Interface Errors There are two types of interface errors transmission errors and format errors Transmission Errors Transmission errors are cycle stop soft faults since they indicate that the serial cable or port is faulty code 62 Serial Com Port Overrun Error Overrun occurs when the baud rate of the host is greater than the baud rate of the DLC Itis also issued when the DLC has missed data due to a faulty cable or port 4 38 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual code 63 Serial Com Port Framing Error This error occurs when the baud rate of the DLC is greater than the baud rate of the host or if the start and stop bit parameters are not the same at both ends of the communication line It is also issued when the DLC has missed data due to a faulty cable
8. Count 000001 Feed 1 Cnt 001 Current Part Information Display This is a real time display that shows most current information for the current part part currently executing or selected to execute next The part block and part ID number will change as each part executes in the batch program The part quantity and count show the quantity of the current part to execute and the number executed The count mode can be selected in parameter to count up or count down The current feed number changes with each feed The current feed count increments or decrements depending on the count mode selected The current feed length and feed rate display on the Feed Length page Row C DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Controls and Indicators 2 15 DLC R Feed To Length Control User s Manual INDRARMA 2 16 Controls and Indicators If the part is programmed to execute continuously FREERUN will display in place of quantity and count will always increment If the part is linked to use more than six feeds quantity is replaced by or Linking Part until feeds execute to the page which includes the quantity for the part Then the quantity displays and INFO changes to LINK on this display In addition to displaying real time part information the selection of the starting part number and micro adjustment of the current part count are done from this page Use the arrow keys to move the cursor in the data fields Type over the par
9. e If B102 is set to 03 the Batching option is selected with Auto Indexing disabled This will disable the selection of a batch by using the Part ID Number With this feature enabled a unique Part ID Number is no longer required With this interface option enabled entry of new batch data is easier if entering new Part ID Numbers Refer to the Batching operational description in Chapter 4 for further information Parameter B103 Auxiliary Feed Length Note The value stored in this Aux Feed Length parameter is usable only in B103 1234 56 Automatic Mode Units Input Units with feed direction sign Decimal Places See Parameter A100 figure shown A100 02 Input Value Limit none This parameter specifies an auxiliary secondary feed length The Auxiliary Feed Length is triggered by an external signal from a device such as a PLC a counter buffer selector switch or another type of control device See Chapter 3 Upon energizing this external signal the feed length originally stored in the DLC by the DLC keypad the IDS or from a host via the serial interface port is ignored and the value stored in this parameter is used For example the Auxiliary Feed Length could be used with a Feed to Shear operation or to feed damaged material off the end of the roll or any other operation which requires a secondary feed length If auxiliary lengths are requested during Batching they will be produced but not counted in the batch No
10. Control voltage and main power are present DC bus voltage is present The drive is ready to be enabled If the DLC Control Card has an error the drive is typically displaying this diagnostic Check the CTA display to determine the DLC error detected then consult the Diagnostic Display Categories section for a description of the error and how to correct the problem CODE Drive State Af 102 Drive Enabled The drive has powered up properly and the DLC Control Card has enabled the servo system The DLC Servo System can now be operated in Automatic Set Up or Manual mode DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 1 DLC R Feed To Length Control User s Manual 8 2 Status Diagnostic Display Alphabetical Index 8 2 Diagnostics and Troubleshooting INDRAMA This section is an alphabetical index listing of the DLC diagnostic message displays It provides a quick reference for locating and identifying displays in question Following sections describe the meaning and recommended action for each display Note that when using the SOT or other host the diagnostics may be requested through the serial interface port in full text format or as a corresponding diagnostic number The following index lists the displays in alphabetical order A similar index in section 8 7 of this chapter correlates the displays in order of the numeric diagnostic code equivalents When using the IDS its two digit d
11. DLC 12 RS 485 Mode DLC 13 RS 485 Mode DLC 14 RS 485 Mode DLC 15 RS 485 Mode mm Do D gt OO OO O Q Q N I DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 15 DLC R Feed To Length Control User s Manual INDRAMA 4 16 Function Description Special Features These characters are format characters which tell the DLC the information to be uploaded or downloaded Information Type Format Information X Status messages feed length feed rate etc B Batching information K Parameters S Action Request jog step etc U_ Upload Request message tables XD BD KD UD With only will send diagnostic code at the end of the string before the checksum These characters are identifiers which are specific to each format They may include decimal digits alphabetic characters or spaces Identifiers are described in the section pertaining to each format This is the data to be sent The length of this string depends upon the information requested When downloading or requesting action _ or _ the data section must end with a checksum if checksum is enabled A character indicates the start of a 2 digit ASCII checksum A checksum isn t needed with a command Each transmission must end with a carriage return followed by a linefeed CR ASCII OD hex LF 0A hex Note that spaces aren t required or sent between the end of data and the checksum Any characters between
12. Example B C100001234 001000 1 OO01 hh cr 1f bbbqqqqqq bbb Block number Part Block 10 qqqqqq part quantity Most data can be echoed as is from the DLC and back including the parameters which are always 12 characters long when unformatted and 32 characters including text when formatted All data that isn t needed in the send string is discarded by the DLC 4 3 Measuring Wheel This feature can be used when slippage of the feed rolls or stretch of material causes inaccurate feed lengths A measuring wheel which rides on the surface of the material can be used with the DLC to correct any deviation in length that may occur between the feed rolls and the point at which the material is measured The DLC offers three different methods for position correction using a measuring wheel When Measuring Wheel is selected by input or enabled in parameter B112 to be active without the input every feed in automatic and setup mode will be length compensated The dynamic position correction mode continuously measures the difference between the motor encoder and MW encoder Correction to the feed length is made throughout the entire feed Position is maintained by the motor encoder The second method uses the MW encoder to measure the feed but when the feed angle transitions to a low signal position is maintained by the motor encoder The third method is for the MW encoder to measure the feed and maintain position continuously All th
13. Figure 1 5 Standard Configuration Of DKS With DLC Control Card and DEA 4 I O card Figure 2 1 CTA Display Keypad Module Figure 2 2 Map of CTA Control Panel Display Pages Figure 3 1 Use of Feed Interrupt Input Figure 3 2 Generation of Feed Angle Signal Figure 3 3 Continuous Mode Press Before Feed Figure 3 4 Continuous Mode Feed Before Press Figure 3 5 Intermittent Mode Press Before Feed Figure 3 6 Intermittent Mode Feed Before Press Figure 3 7 X17 Input Output Connector Showing Input Pin Designations Figure 3 8 Feed Angle Switch Layout Figure 3 9 X17 Input Output Connector Showing Output Pin Designations Figure 4 1 DLC X31 Connector Figure 4 2 Signal Level Requirements Figure 4 3 RS 232 Serial Cable Configurations Figure 4 4 Data Format Table 5 1 Typical Decimal Placement Table 5 2 Decimal Placement Figure 5 1 Profile without Jerk Limiting Figure 5 2 Profile with Jerk Limiting Figure 5 3 In Position Threshold Figure 5 4 PBF Batch Complete 0 end with press cycle Figure 5 5 PBF Batch Complete 1 end with feed cycle Figure 7 1 Example Input Diagram Figure A 1 DLC Display Map Figure D 1 CTA4 Keyboard and Cabinet Cutout Dimensions Figure D 2 IDS Outline Drawing Figure D 3 Vorne Display Dimensions and Connections Figure D 4 Vorne Display DIP Switch Configuration Figure D 5 Station Operator Terminal SOT 02 for Rollfeed NIDA IZ D 1 E 1 VI Contents DOK DIAX02 DLC1 1 DR1 02VR
14. If A108 not 0 A107 must be equal to A106 If A107 0 Default is A1072A106 Decimal Places A100 1 figure shown A100 02 When Constant Acceleration is selected this parameter specifies the constant deceleration rate used to ramp down from peak velocity to zero velocity The deceleration rate is not required to equal the acceleration rate When Jerk Limiting trapezoidal Acceleration is selected the value stored in Parameter A106 or zero must be stored in this parameter so A107 A106 The deceleration rate is required to equal the acceleration rate You select the shape of the acceleration profile in Parameter A108 refer to the section Parameter A108 Maximum Allowable Jerk Note It is absolutely necessary to balance the Position Gain and the Maximum Deceleration Rate in order to avoid position overshoot Parameter A108 Maximum Allowable Jerk 5 10 Parameters Maximum Jerk A108 0000123 4 If A108 0 constant acceleration rate is selected If A108 is not 0 Units Input units per second Decimal places A100 1 figure shown A100 02 Low Limit 60 x A106 A104 High Limit 99999999 This parameter selects the shape of the acceleration profile If A108 is set to zero Constant Acceleration Rate is selected If A108 is not set to zero the jerk rate is selected Jerk is defined as the rate of acceleration change The DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DS SA DLC R Feed To Length Control User
15. Input Value Limit XX 00 01 02 03 This parameter selects the method of entering the Feed Length and Feed Rate in the DLC Viewing of the DLC Feed Length Feed Rate display is performed differently with each option selected They are described in Chapter 2 Controls and Indicators The following possible input values for B102 are further explained below 00 Standard DLC 01 Standard DLC with IDS option 02 Enable Batching Operation O3 Enable Batching without Part ID number Auto Indexing e f B102 is set to 00 the standard DLC is selected Feed Rate and Feed Length are entered directly through the DLC keypad or through a host terminal via the serial interface port DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 IRNIDRADIZAL DLC R Feed To Length Control User s Manual e If B102 is set to 01 the IDS option is selected Feed Length and Feed Rate are entered through the IDS thumb wheel switches The serial interface port is automatically configured for the IDS and is not available for a separate host terminal input Note 02 and 03 are the only If B102 is set to 02 the Batching option is selected The Feed selections that allow the use of the Length and Feed Rate are entered for different parts in the batching batching function program The part or parts to execute with preprogrammed feed lengths feed rate etc are selected through the DLC keypad or through a host terminal via the serial interface port
16. Software and Hardware Version Request X 08 The DLC will respond with a copy of the information that appears on the Version Number screen on the LCD X 08 3 DLCO1 1 l DLC1 1 DR1 02V06_ hh lt cr gt lt 1f gt DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 19 DLC R Feed To Length Control User s Manual INDRAMA Note one extra space than X 19 Strokes Min and Time Used Request X 09 The first four digits of the data string will be the current Strokes Min value The next two digits following a space will be the percent of feed angle used see Time Optimization document X 09 0123 Ap hh cr 1f System Inputs Request in Hexadecimal X 10 The DLC will respond with the hex values of inputs 1 15 The Least significant rightmost bit corresponds to input 1 X 10 00006064 hh cr 1f increasing input 8 System Outputs Request in Hexadecimal X 11 The DLC will respond with the hex values of outputs 1 16 The Least significant rightmost bit corresponds to output 1 X 11 00000D81 hh cr 1f increasing output Total Piece count and Total Length Request X 12 The first eight digits of the data string will be the total number of pieces The next 12 characters following a space will show the total amount of material X 12 00001234 40123456 789 hh cr 1f Diagnostic Text Request X 14 cc cc diagnostic code This is a req
17. The Parameter Mode Select overrides any other mode selection input Selecting Parameter Mode while either Automatic or Set up Mode is already selected does not cause an error When Parameter Mode is de selected the DLC returns to the previously selected mode Automatic Set up or Manual default when no other modes are selected Automatic Mode Select Connector X17 pin 2 Function Input Selects Automatic Mode High Automatic Mode selected Parameter Mode can override selection Emergency Stop Connector X17 pin3 Function Input Commands Motor Drive to immediate stop High Allows the DLC to operate Low The motor drive is commanded immediately to zero velocity Drive reaches zero speed in the minimum time possible given the inertia and maximum torque available The DLC issues an Emergency Stop diagnostic message WARNING This signal must be used to ensure safety Conditions which warrant pressing the E Stop include e Any condition posing an immediate danger to personnel e Ajamin the machinery or any other condition that poses an immediate harm to the system equipment 3 16 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA Cycle Start Connector Function High DLC R Feed To Length Control User s Manual X17 pin 4 Input Starts automatic feed cycle momentary Starts the automatic feed cycle when the DLC is in the Automatic Mode
18. 8 22 15 S Fd Incomplete Set up Mode feed inc 8 22 16 S Release Jog Set up Mode feed done 8 22 17 DLC PARAMETER MODE 8 18 18 DLC Input Active see display for type Minor Errors 40 Zero Feedlength Entered 8 15 41 Zero Feedrate Cntered 8 16 42 Feedlength Less Than Minimum 8 17 43 Feedlength Exceeds Maximum 8 17 44 Change in Fdlgth Exceeds Limit 8 17 45 Drive Is Not Enabled 8 16 47 Axis 1 Has Not Reached Position 8 16 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 25 DLC R Feed To Length Control User s Manual 8 26 Diagnostics and Troubleshooting 49 Stop Due To Interrupt Input 8 16 50 X Feed Angle Is Missing 8 17 57 Auto Mode Exit Required 8 18 Soft Faults 60 Feed Angle Lost During Feedl 8 11 61 Movement While Feed Angle Low 8 12 62 Press Cycle Without Feed 8 12 63 Press Timeout Has Expired 8 12 64 Invalid Mode Selection 8 12 65 Aux Feedlength is Zero 8 13 66 Ger Up Mode Cycle Incomplete 8 13 70 Para Invalid Select P Mode 8 14 71 Battery is Low Replace it Soon 8 14 75 Motor Overtemp Warning 8 15 76 Amp Overtemp Warning 8 1
19. If Jog Step is set ON from DLC control panel display the DLC feeds material at the jog velocity until the jog input goes low jog button released or the step length set in Parameter B108 has been reached The Jog inputs are not functional in Parameter or Automatic Modes The effect of these inputs in Set up Mode is described in the following section Set up Mode is normally used to jog the material through the feeder for set up in progressive die applications A progressive die application has multiple stations A series of feeds and press strokes moves the material through multiple stations in a single die to produce a finished part It is often necessary to manually thread the leading edge of the material through the die to set up the operation In order to avoid damaging expensive dies during set up in most cases it is critical to cycle the press only after a full feed has been made for each progression The press must be cycled before the feed for the next progression can occur The DLC Set up Mode ensures this sequence It allows the user to set up his feeder by running several progressive feeds using the jog inputs and manually cycling the press after each feed When Set up Mode is selected the jog inputs function differently than in Manual Mode As in Manual Mode a high on the Jog Forward input causes the axis to feed forward at the parameter specified jog velocity However unlike Manual Mode no matter how long the Jog
20. Input Value Limits from 00000100 to 10000000 regardless of decimal pos Decimal Places A100 1 figure shown A100 02 The Feed Constant is the ratio of material movement per motor revolution The feed roll diameter and the gear ratio are two of the values needed to determine the Feed Constant value The DLC uses this constant value in several mathematical computations in order to command axis motion This parameter defines the Input Units IU used in other parameters Use the formula below to obtain the feed constant value required for your application Enter the feed roll diameter in the Input Unit value that you want to use inches millimeters etc feed roll diameter x x Feed Constant gear ratio Parameter A102 Drive Max RPM Drive Max RPM A102 01500 This parameter defines the Maximum RPM of the motor This value is found on the motor nameplate DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 7 DLC R Feed To Length Control User s Manual INDRARMA Parameter A103 Not Used Not Used A103 Disabled Parameter A104 Maximum Feed Rate Max Feedrate A104 0123456 7 Input Unit Input Units IU Unit of Measurement per minute Input Value Minimum 00000100 regardless of decimal point Input Value Maximum Max RPM A102 x Feed Constant A101 Decimal Places A100 1 figure shown A100 02 This parameter defines the maximum feed rate at which material can be fed and is expressed in uni
21. Jog Step mode is enabled in Manual Mode only The DLC feeds material at jog velocity until the jog input goes low jog button released or until the step length has been reached Once the step length is nearing completion the motor s will be ramped down to zero velocity and a 1 5 second delay occurs to provide time to release the jog button After the delay another feed will start if the jog button has not been released Ifthe jog button is released before the step feed has completed the DLC will complete the parameter set feed length Any time the motor is ramped down to zero velocity the Feed Complete output will go high If the step mode ON OFF is toggled while the motors are in motion the motors will be ramped down and Jog Input Active will be displayed Row B Refer to the Display Map in Figure 2 2 Map of CTA Control Panel Display Pages Pressing the down arrow key from any of the displays on the top row changes to the Axis Position Displays This is the home display set of the second row Row B of displays Use the left or right arrow keys to scroll through the input output status and total piece count displays on this row Use the CR key to toggle between certain pages as described below The Position Display shows either axis lag or distance moved The Distance Moved Display shows the distance moved by the axis during each feed the actual position read from the encoder Axis Position Dist 00123 456 Axis Pos
22. Used to indicate Automatic feed cycle operation Indicates Automatic feed cycle operation is in progress Indicates a Cycle Stop a fualt error condition is present or the Feed Interrupt signal is not present is low This signal is issued high only in Automatic Mode after Cycle Start It remains in this state until the Cycle Stop is activated or a fault or error is detected Feed In Progress Indicator Connector Function High Low X17 pin 25 Output Used for feed progress status Indicates feeding is in progress or the feed axis is not in position as specified in Parameter A110 Indicates feeding has stopped as a result of reaching position or a fault error exists which has stopped the feed This signal is operational in Automatic Set up or Manual Modes Typically this output is wired to an indicator light on the user control panel DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 27 DLC R Feed To Length Control User s Manual INDRAMA Axis 1 In Position Indicator Connector X17 pin 26 Function Output Used to indicate axis 1 is in position High Indicates the axis is in position within the In Position Threshold set in Parameter A110 Low Indicates the axis is not in position not within the In Position Threshold Typically this output is wired to an indicator light on the user control panel Press Immediate Stop Connector X17
23. already at the starting point reverse feed is not possible This input is typically wired to a normally open push button switch on the user control panel Auxiliary Feed Length Select Measuring Wheel Enable Note See Chapter 5 Parameters for more information on Parameter B112 Connector X17 pin 11 Function Input Used to enable disable Auxiliary Feed Length or Measuring Wheel MW operation depending on the selected setting of Parameter B112 High Enables the selected option Low Disables the selected option The Auxiliary Feed Length option can only be selected in Automatic Mode When this option is selected the primary feed length value is ignored and the DLC operates using the feed length value entered in Parameter B103 This option allows selection of a feed length different from that used in normal operation It can be used to feed scrap material from the end of the roll to easily change to a second operation that requires a different feed length etc The Measuring Wheel MW feature is used to base the feed length on the measuring wheel encoder rather than the axis position servo encoder If this input is toggled during an Automatic Mode cycle MW 3 20 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual length compensation won t be enabled or disabled The state of the input is only read at Cycle Start or Re
24. and section where each signal is individually described then describe the general function of the signals These signal descriptions apply to the DLC R except where specifically noted Later sections in this chapter describe the I O connections signals individually as required by the machine builder and for troubleshooting Figure 3 7 X17 Input Output Connector Showing Input Pin Designations illustrates the X17 I O connector and the signal designation for each pin Operating Mode Selection 3 2 Functional Description Standard Features Input Signal Descriptions See Page 3 15 e Parameter Mode Select e Automatic Mode Select e Setup Mode Select Output Signal Descriptions See Page 3 23 e Manual Mode Indicator e Automatic Mode Indicator e Parameter Mode Indicator e Setup Mode Indicator The DLC will always be in one of four operating modes Parameter Mode Automatic Mode Set up Mode Manual Mode Allows entry verification of the parameters required to set the control for the specific requirements of the application Either continuous or intermittent feeding operations occur automatically cycles Used to set up for the automatic material feed Especially useful in a metalforming system with progressive dies Default mode when none of the above are selected Used to jog the material forward or reverse through the system DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA Safety Inte
25. and vice versa Signal ground connection must be common on both devices This often requires a Null Modem cable It connects pin 3 of one end to pin 2 on the other end Consult the manufacturers information for the serial card in your computer for its specific pin configuration DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 13 DLC R Feed To Length Control User s Manual INDRAMA Data Format To achieve proper communications configure the communication parameters to match between your computer and the DLC Figure 4 4 Data Format illustrates the data format Refer to Chapter 5 for specific parameter entry options and procedures Note that when you set the interface option Parameter B102 for the IDS the port is automatically configured 2400 8 1 00 to work with the IDS board Configuration data in the Serial Port Parameters B118 B119 are then ignored When the Interface Option Parameter B119 is set for the SOT the proper entry in Serial Port Operation Parameter B119 is 1920 8 1 00 LOGICAL 1 LOGICAL oO START BIT DATA BITS PARITY BIT STOP BITS WORD Figure 4 4 Data Format Message Format This section describes the message format required for the RS 232 Interface A message is divided into six sections as illustrated below and described on the next page x 300 012 345 67 8 8E lt cr gt lt 1f gt l l l l l l l l l l l l 1 2 3 ais us 5 EE Legend cr
26. enter the Part ID number the next block to jump to the part quantity and the Early Warning count for each part Within the page use the right and left arrow keys to move the cursor through the data fields The cursor will wrap from row to row within the page Other than home position pressing the up or down arrow keys causes the cursor to move to the first position of the next or preceding row in the display Type over data to change Press the STORE key to save any changes saves all data as currently displayed and return the cursor to home position Press DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual the CR key before pressing STORE to clear any changes to data reverts to data previously saved and return the cursor to home position Press the keysto scroll through batch main programming pages and enter information for each part numbers 01 to 99 Press the CR key to toggle between the Batch Main Programming page and the Batch Feed Programming Display page for each part Part O1 11111111 Feed 1 Cnt 001 Length Rate 012 345 67 8 Batch Feed Programming Display There can be up to six Batch Feed Programming pages associated with each Batch Main Programming page From these pages enter data for up to six feeds per part including feed quantity length and rate Press the keys to scroll through feed programming pages with the cursor next to Feed in the disp
27. or power cycle the servo drive If this error reoccurs contact Indramat Service for further assistance 8 5 Soft Fault Messages 8 10 Diagnostics and Troubleshooting This section provides a list of soft fault diagnostic messages and an explanation of the potential cause s DLC System Error Code SFTOO An internal system fault has occurred in the DLC The following soft fault system errors can occur code SFT00 2UPRGO2 FLPM0001 FLPMO002 NOTE For any DLC system error display call Indramat home office Advise them of the error code number displayed Serial Com Port Disconnection This indicates the IDS is not properly connected to the RS 232 port of the DLC when the IDS is selected for the Interface Option in Parameter B102 Check the cable connection of the IDS to the DLC front panel connector The time for disconnect detection is automatically set to 2 seconds when IDS is enabled Serial Com Port Overrun Error This indicates the baud rate of the host is greater than the baud rate of the DLC via the RS 232 485 communications port Check and verify settings are same Also issued if DLC has missed data due to a faulty cable or port Chapter 4 describes the serial port communication settings and error diagnostics DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual Serial Com Port Framing Error This occurs when the baud rate of the DLC is greater than the ba
28. pin 27 Function Output Used to immediately stop the press High The normal state during operation Wire so this signal must be high for the press to operate Low Immediately stops the press stroke NOTE Due to various factors such as inertia and press stroke speed the ram will not be able to stop instantaneously However if wired as described in this section the DLC will attempt to stop the press ram as soon as mechanically possible if an Emergency Stop or other various faults occur This signal goes low at the occurrence of the following faults refer to Chapter 8 for fault descriptions All Hard Faults Soft Faults Feed Angle Lost During Feed Movement While Feed Angle Low Press Cycle Without Feed Zero 96 Feedrate Programmed Press Timeout has Expired Minor Error Feed Angle is Missing 3 28 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual This output signal is wired to the machine builder s press engagement clutch brake retaining circuitry Upon receiving a Cycle Stop signal the press engagement clutch brake retaining circuit is designed to retain clutch engagement until the press returns to the Top Dead Center position However with the Press Immediate Stop signal wired to the clutch retaining circuit when this signal goes low the press attempts to stop the ram regardless of where it may be in the press stroke WA
29. 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual B111 B Press Before Feed Batch Complete This digit specifies whether the last feed in a single part or sequence of parts is performed when Press Before Feed Operation is selected in the Press Interface Parameter It does not apply to Feed Before Press operation The following shows examples of press feed cycle conditions HD Initial Jog Stroke Feed Stroke Figure 5 4 PBF Batch Complete 0 end with press cycle 4 d Initial Jog Stroke Feed Stroke Feed Figure 5 5 PBF Batch Complete 1 end with feed cycle If PBF Batch Complete is set to 0 the batching program will end with a press cycle The end of a program is indicated on the DLC display with the A Part Stop status message This option assumes that the first feed of the part executed at cycle start has been jogged into the machine The feed count is incremented with each press stroke resulting in the jogged in material being counted as one feed The press operator is responsible for jogging the material over the die to avoid a double hit of the press The DLC will not inhibit a cycle start if the material is not jogged in If PBF Batch Complete is set to 1 the part program will end with a feed The feed it ends with at a Part Stop state is the next feed to be executed For example if another part is jumped to and the part stop input is activated the first feed of the next pa
30. 082 2 u10001 2 HL9N31 XV S8 SY EST ALIHM 91 M3dwnr vc xo NMOHBH 791 80S EENS BER SHlvd GSLSIML LOG BEES 3SM3A3M SOF 90S NMOUG QMVMMO4 SOr LN SHU S06 31049 3WnS3H N33N5 LOS 40S 5 LVS 31049 X1 X3 9 QGu xu XL xXy v X1 X8 06 SG 1933S 300W dn 13S QNO S QNS m 193138 Q13HS quis ama IQON 2uvwWolnv ZL00 S l 10S TK dOlS FIOAD LEX 8OLO3NNOO ay EE PPW 21d Zx MOLO3NNOO v00 SMI 39vd 33S 318vo S1ndlno L1X NOLLO3NNOO YX MHOLO3NNOO v30 SyxG OL a DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 C 6 Schematics DLC R Feed To Length Control User s Manual DLR SN MYI LHONAdOD 3ON3Mid3H Q35V3TdM MO Ou 38 OL LON A1NO ISN N3NOISQO NOJ IN3AnOOQ SIHL CALIGIHONd SINIud3N 48 dasiay NAQMddY M33NION3 304 NOISA3H A8 Qq3 03H9 SC L190 6 Wo 16 11 90 003 Hd Oe 3 AB TNUNNO vy 8 409 l33HS SIN FOS XIANNN Loved XIANNN 70703 3NVN ava NOLLdlsi0S30 A38 3AVN O3NI L1HuBuuuli EEF YO4 HUN AN 33000N3 110SN02 Z 9911 38 MJ8WNnN INMYYA NOILO3 QQNW s AvSOVIO ONIMIM M3dOMNd Q3sn LON Zug 10 0 SMI 318vO LYWYYONI IHL NO NMOHS LON S3MIM 3018 ONY 1310 3HL L 310N NOOM3LNI 210 s a TI 831V183 NV A4JOH AJVIWV HCGNI HIOUHX3
31. 1 Use of Feed Interrupt Input Material is fed through a leveler or straightener into a looping pit with an optical sensor in the pit tied to the feed interrupt line If the material pulls too tight Feed Interrupt goes low and the feed cycle is interrupted As soon as an adequate amount of material is fed into the looping pit the signal returns high and the feed cycle immediately resumes Warning If the automatic cycle is interrupted by a low on the Feed Interrupt ine all feed motion is suspended Once this signal is restored high the feed cycle will immediately resume Personnel should use extreme caution when entering the work area if the feed has stopped as a result of this signal Normally a Feed Interrupt is of short duration so it only stops the feed momentarily it does not stop the press ram operation Should the feed remain interrupted too long the Feed Angle input from the press will drop before the feed cycle is completed and the system will be halted with a diagnostic error message displayed Press Permissive Interface Note that the following description refers to the operation of a press and press feeder These descriptions are equally valid for a feed system with other types of processing station such as a seal shear station or a thermoforming station Input Signal Descriptions See Page 3 15 e Feed Angle e Press Continuous Intermittent Select DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Descriptio
32. 4 Input Output Card plugs into the U2 slot of the the Indramat Digital AC Servo Controller The Indramat Digital Controller being used mounts to the panel of a control cabinet electrical enclosure Installation procedures are described in Chapter 6 1 10 General Description DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual O Control UO Card Figure 1 5 Standard Configuration Of DKS With DLC Control Card and DEA 4 I O card The standard configuration for the DLC DEA 4 with DKS Digital Compact Controller is illustrated in Figure 1 5 Standard Configuration Of DKS With DLC Control Card and DEA 4 I O card The DLC with DEA 4 Input Output card has 15 system inputs and 16 system outputs The functional description of the I O signal connections is described in Chapter 3 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 General Description 1 11 DLC R Feed To Length Control User s Manual INDRARMA 1 5 Brief Operational Description The DLC servo amplifier servo power supply and servomotor are designed into a mechanical feed system which feeds some type of material into another processing station such as a punch press thermoforming station etc The machine builder or user enters data into the DLC parameters to specify the mechanical and operating characteristics of the system Based on this data plus the feed length and feed rate entered by the operator the DLC issues veloc
33. 4 X 00 Feed length and feed rate may be downloaded to the DLC The length can also be micro adjusted by a parameter defined value Axis 1 Feed length Feed rate Entry x 00 0123 45 67 8 hh cr 1f l l l l Checksum Axis 1 __ Feed rate l Feed length Feed length Micro Adjust If an M is sent to the DLC the feed length will be increased by the value stored in Parameter B107 A X 00 M Shh lt cr gt lt l1f gt If an M is sent to the DLC the feed length will be decreased by the value stored in Parameter B107 A X 00 M Shh lt cr gt lt l1f gt Reset Distance Moved X 02 The Distance Moved Display for both axes will be cleared when this string is received 4 X O2 hh cr 1f DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 23 DLC R Feed To Length Control User s Manual INDRARMA Reset Total Piece count X 03 The Total Piece count accumulator is cleared when this string is received 4 X OS3 hh cr 1lf Reset Total Length 4 X 04 The Total Length accumulator is cleared when this string is received X OA4 hh cr 1f Batching Information All batching information may be uploaded from the DLC and downloaded to the DLC Each identifier includes a letter to indicate the type of information and a part block number Feed data also includes a feed number A B FO11 Il Feed 1 Il Part block 01 Feed data The part block
34. 4 for additional information on the batching function 3 22 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DS SA DLC R Feed To Length Control User s Manual 3 4 Output Signal Descriptions This section describes the outputs from the DLC control system to external devices The connector and pin numbers of these signals are described in the following sections and shown in Figure 3 9 X17 Input Output Connector Showing Output Pin Designations Figure 3 9 X17 Input Output Connector Showing Output Pin Designations DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 23 DLC R Feed To Length Control User s Manual INDRARMA Manual Mode Indicator Connector X17 pin 16 Function Output Indicates that Manual Mode is active High Noother modes are selected The DLC defaults to Manual Mode This output signal is typically wired to an indicator light on the user control panel Automatic Mode Indicator Connector X17 pin 17 Function Output Indicates that Automatic Mode is active High Automatic Mode is selected This output signal is typically wired to an indicator light on the user control panel Parameter Mode Indicator Connector X17 pin 18 Function Output Indicates that Parameter Mode is active High Parameter Mode is selected This overrides any other mode selection This output signal is typically wired to an indicator
35. 8 10 Drive Diagnostic 8 9 Drive Error Press the CR Key 8 9 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DLC R Feed To Length Control User s Manual DLC Display Page Drive is not Enabled 8 16 Drive Watch Dog Error 8 9 Count Exceeds Part Quantity 8 14 EMERGENCY STOP I 8 7 Feed Angle Is Missing 8 17 Feed Angle Lost During Feed 8 11 Feedlength Exceeds Maximum 8 17 Feedlength Less Than Minimum 8 17 Initializing SYS 8 18 Invalid Drive Configuration 8 9 Invalid Drive Goftware 8 9 Invalid Mode Selection 8 12 Jog Input Active 2222 8 19 M Feed Forward 8 21 M Feed Reverse 8 21 M No Jog Command 8 21 M Wait Fd Angle 8 21 Measuring Wheel Encoder Fault 8 9 Motor Overtemp Warning 8 15 Movement WhileFeed Angle Low 8 12 Parameter Invalid Select P Mode 8 14 Parameter
36. Carriage return 1f Linefeed Space 4 14 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 UDP SA DLC R Feed To Length Control User s Manual 1 The first two characters in each message are a command which specifies the type of information requested First 1 Control String Character Transmission Type All data transmissions to the DLC must start with one of the following control characters to identify what type of transmission is to follow Command Request The DLC interprets this character received via the RxD channel as a Request for Information when followed by the proper requesting codes the DLC will transmit the desired data via the TxD channel This character signifies a block of Information to be Stored into memory The data that follows will be read into the proper memory location This character signifies a Control Command is to follow Second 2 Control String Character DLC Unit Identifier This character is only present if communicating in the RS 485 mode It is used to identify the DLC unit to receive the current message If communicating in RS 232 mode this character will be a space Hex 20 Space RS 232 Mode DLC 1 RS 485 Mode DLC 2 RS 485 Mode DLC 3 RS 485 Mode DLC 4 RS 485 Mode DLC 5 RS 485 Mode DLC 6 RS 485 Mode DLC 7 RS 485 Mode DLC 8 RS 485 Mode DLC 9 RS 485 Mode DLC 10 RS 485 Mode DLC 11 RS 485 Mode
37. DIESIBODZAGIZALI Signal Level Requirements Figure 4 2 Signal Level Requirements illustrates the signal level requirements for the different communication formats RS232 485 for the DLC To minimize signal degradation over long cable runs the serial device driver should provide the following levels RS 232 15 Vdc 15 m maximum run RS 485 5 Vdc 1000 m maximum run As EM 59 NOT ALLOWED BEE RS 232 dE ES RS 485 15 VDC 5 VDC Figure 4 2 Signal Level Requirements 4 12 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual Serial Cable Connection to Computer For RS 232 serial communications you should note that the connector on the serial card in your computer can vary in configuration Figure 4 3 RS 232 Serial Cable Configurations illustrates two common serial connections for interfacing from the RS 232 port of a computer to the DLC COMPUTER COMPUTER 9 pin 9 pin to 25 pin 9 pin to 9 pin D connector D connector Figure 4 3 RS 232 Serial Cable Configurations The DLC requires only three lines of the standard 9 pin connector for RS 232 communication Pin 3 is for Transmitted Data pin 2 for Received Data and pin 7 is the Data Signal Ground Typically pin 1 connects the cable shield to ground on one end only The transmit data connection from one device connects to the receive data of the other device
38. DR1 02VRS ANW1 AE P 06 97 DLC R Feed To Length Control User s Manual Serial Port Message X 14 xx U xx Minor Errors DLC SYSTEM ERROR Code MNROO Zero Feedlength Entered Zero Feedrate Entered Drive Is Not Enabled Axis 1 Has Not Reached Position Stop Due To Interrupt Input Feed Angle Is Missing Change in Fdlgth Exceeds Limit Feedlength Exceeds Maximum Feedlength Less Than Minimum Auto Mode Exit Required Soft Faults DLC SYSTEM ERROR Code SFTOO Serial Com Port Disconnection Serial Com Port Overrun Error Serial Com Port Framing Error Serial Com Port Parity Error Serial Com Port IDS Format Error Feed Angle Lost During Feed Serial Com Port RS485 Bus Error Movement While Feed Angle Low Press Timeout Has Expired Invalid Mode Selection Press Cycle Without Feed Zero Feedrate Programmed Set Up Mode Cycle Incomplete DLC SYSTEM ERROR Code UPRGO2 DLC SYSTEM ERROR Code FLPM0001 DLC SYSTEM ERROR Code FLPM0002 Aux Feedlength Is Zero Count Exceeds Part Quantity Battery is Low Replace it Soon Para Invalid Select P mode Batching Program was Lost Motor Overtemp Warning Amp Overtemp Warning or oro ox oo mm X6 An lt mm An Am mm An CU mm mn Am UNH An lt gt UU An lt gt Function Description Special Features 4 37 DLC R Feed To Length Control User s Manual INDRARMA Serial Diagnostic Serial Port Message X 14 xx U xx Code Hard Faults 80 DLC SYSTEM ERROR Code HRD00
39. Forward is maintained the axis will feed only the feed length entered on the DLC control panel then stop If Jog Forward is released before the feed is 3 12 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual complete the feed will again continue until feed length is complete when Jog Forward is pressed again The DLC will allow the press to be manually cycled only when the user selected feed length is complete See notes below Another feed will not be allowed until the press has cycled DLC sees Feed Angle drop then return Once this occurs the jogging process described above can be repeated after changing the feed length entry when required until the material has been threaded through all stations in the die Note that an error will be detected if Set up Mode is exited prior to completing the feed and cycling the press However selecting Set up Mode again clears the error and allows completion of the set up operation In Set up Mode if the Jog Reverse signal is high the axis feeds in reverse at the parameter specified jog velocity However Jog Reverse will only function if the feeder had previously been jogged forward and the reverse jog can only be as far back as the starting point of the feed If the feeder is already at the beginning of a feed length reverse feed in Set up Mode is not possible NOTES e The Set up Mode is
40. If you use this example for testing do not mechanically connect the servomotor to the actual load Refer to the drawings in the Appendixes D and E for additional mounting and connection information NOTE Do NOT apply power until all connections have been made 1 Install the TVD DDS Power Supply Digital AC Servo Drive or DKS Digital Compact AC Servo Drive per their respective support manuals 2 Connection the MDD motor power cable and high resolution feedback cable to the DDS or DKS per interconnect drawings in Appendix D or refer to the DDS or DKS support manuals 3 Connect the CTA Keypad Display to the DLC Connector X30 via ribbon cable Refer to the interconnect drawings in Appendix D 7 2 DEA A Input Connections The DEA 4 input connections used in this example are minimized for the sake of simplicity see Figure 7 1 Example Input Diagram Refer to the interconnect drawings in Appendix D for any additional details Connect the incoming side of each switch to a external 24 Vdc source 1 Connect a 2 position selector switch to provide a 24 Vdc signal to Pin 2 Automatic Mode input The second position is not wired 0 Vdc and is used for Manual Mode default mode Connect a key switch to provide 24 Vdc to Pin 1 Parameter Mode input DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Start Up 7 1 DLC R Feed To Length Control User s Manual INDRARMA 2 Connect a Normally Closed pushbutton switch to Pin 3 Emergency
41. Permit Press Timeout Permit Press Timeout is set from 1 to 99 minutes The DLC issues a soft fault Press Timeout Has Expired if the press hasn t cycled high to low Feed Angle transition in the specified time period during an automatic mode cycle After this fault is cleared a resume input is required to continue the cycle If this fault is not desired set the digits to 00 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 23 DLC R Feed To Length Control User s Manual INDRARMA Parameter B110 Not Used Not Used B110 Disabled Parameter B111 Batching Option 5 24 Parameters Batching Option B111 1 1 G 111 O A B CDE F A Count Mode 0 Up 1 Down B PBF Batch Complete 0 Do not end on feed 1 Endon feed C Must be set to 0 D Must be set to 0 E Must be set to 0 F Must be set to 0 If using this batching option the Interface Option Parameter B102 must be set for 02 or 03 Batching Otherwise the values in this parameter are ignored Note The following pages describe the entry options and procedures for this parameter Refer to Chapter 4 for detailed information on the batching function B111 A Count Mode This option allows the display of the number of parts created or parts remaining It applies to both the current part count and the feed count To count up from 1 to the selected quantity enter a 0 in this digit To count down from the quantity to 0 enter a 1 DOK DIAX02 DLC1 1 DR1
42. SSIOOV QOVdA3M V19 3Hl NO SA3 0313313s SNOLLdO NO c NOLLdO Wosuv 4 wwoa so g an 3HL ONISN SNION3d3Q J MO v OL MOT38 NO 3AOBV AVIdSIC IHL SS300V d I J33HM NIYNSYAN C QN3931 lt H3HM ONISNSVAN J33HM SNINASV SN Y ANE HI9N31 Q334 IN3MHOD OL Q319313S NOlldO NO ONIGNSd30 3 MO Q v OL oa d Y AV 1dS IG SUINN SHIONJI 0334 DUNN HIN Q334 x HLO9N3I 0334 SNOANVTTSOSIN LNSNYNO D ZE AW1dSIG NOILISOd SIXV OL AV 1dSIQ HOM Q334 ING3HHDO Ol _ E A ij LNNODAOAld _ z AW1dSId 5v1 WIS 91 1 SL ndino SL 1 SINANI KEE RV HISN31 WLol Ye nw lt AN MS SALVLS OL AW1dSIG NOlLISOd SIXV OL AV dei SNLVIS OL NYNLAY e e SLVIGAWWI NOs A3 MNY IB SS3Hd 1 TON JOW SS3ud S3ovd AVIdSIG ALINN gaS ANL AW1dSI0 SALVIS N33M13B8 319901 OL A3 X9 IHL ISN NIW S3wONIS SniviS 3AlIMQ Q319313S NOlLdO NO ONKIN3d3G 9 HO Q 9 OL d Controls and Indicators 2 5 Figure 2 2 Map of CTA Control Panel Display Pages DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DLC R Feed To Length Control User s Manual INDRARMA 2 6 Controls and Indicators Row A Refer to the Display Map in Figure 2 2 Map of CTA Control Panel Display Pages After system initialization the display shows the current operating condition
43. Total Piececount 000123 Total Piececount Display Press the CR key to toggle between Total Piececount Display and the Total Length Display Total Length 1234567 890 Total Length Display The total number of pieces and length of material run through the feeder are displayed on these Length and Piece Accumulator Displays These totals may be reset at any time The piece count is incremented when one full cycle of the press is completed in the Automatic mode or after each part is completed when batching mode is selected Normally 6 digits are displayed but up to 8 can be shown as they are needed The count is retained in memory at power down To reset the counter to zero 1 Press the CL key The count display is replaced by a prompt Total Piececount RESET DATA DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA Note The Total Length value is generated from the motor encoder and not from the Measuring Wheel function DLC R Feed To Length Control User s Manual 2 If you wish to reset the counter to zero press the STORE key to clear the count The added step of pressing the STORE key prevents the count from being reset inadvertently 3 If you do not wish to reset the counter to zero press any other key or leave the page This action will restore the original count The Total Length Display is accessed by pressing the CR key while in the Total Piececount display The length is accumulated in Automatic mode on
44. Upload _U__ 00 lt cr gt lt 1f gt Minor Error Block Upload 2U 40 lt cr gt lt 1f gt Soft Fault Block Upload 2U 60 cr 1f Hard Fault Block Upload _U__ 80 lt cr gt lt 1f gt The DLC will respond with a header block that has the identifier and the length of the block U 60 23SEFindicates that the soft fault table is being sent and that there are 23 decimal messages Each message in the block will start with a U and the message number and end with cr 1f The text string is 40 characters long and corresponds to the DLC s LCD but with spaces removed If the status table is requested the DLC will send a 40 character message that is more descriptive than that of the LCD The following is an abbreviated example of a response from the DLC when the hard fault table is requested U 80 10SEA U 80DLC SYSTEM ERROR Code HRDOO CD U 81Parameters Lost Clear to Cont SED U 82Axis 1 Drive Runaway 6A U 84DLC SYSTEM ERROR Code PL001 DA U 85DLC SYSTEM ERROR Code FXPM0001 6A U 86Parameters Lost Select P Mode 57 U 87DLC SYSTEM ERROR Code UPRGO1 85 U 88EMERGENCY STOP EMERGENCY STOP 60 U 89Axis 1 Amplifier Hardware Fault BE U 8BAxis 1 Motor Has Overheated C5 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 35 DLC R Feed To Length Control User s Manual Serial Diagnostic Codes NID ZZ This section lists the current status messages minor errors soft faults a
45. against the feed length limits DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 5 DLC R Feed To Length Control User s Manual INDRAMA Part Linking The DLC normally provides up to six feeds per part If a part requires more than six feeds up to 99 parts may be linked together to create one part with up to 594 feeds To link a part to another part enter a in the part quantity in the Main Page The characters will be displayed in place of the part quantity and Early Warning and the part will be linked with the next block The feeds programmed in the current block will be completed followed by those in the jumped to block The part quantity jump to block and early warning are defined in the last part block the last link in the chain To select a linked free run part set the part quantity to 999999 In the example below a linked part is entered in blocks 10 and 20 After the six feeds in block 10 are completed the six feeds in block 20 are executed Part block 20 is defined as the end of the part by entering a valid part quantity The linked part in blocks 10 and 20 with 12 feeds will execute 100 times then execution will continue at the next part in block 30 Linked Part Programming Example 12 feeds Main 10 10 Jump to Block 20 Quantity Early Warn Part Block 10 Main 20 20 Jump to Block 30 Quantity 000100 Early Warn 002 Part Bloc
46. and the press low feed angle causes the material to pull turning the feed rolls causing feedback to the DLC the DLC will issue a fault This parameter allows setting a tolerance that will allow the feed rolls to move some amount before causing the DLC to issue a fault This parameter should not affect the accuracy of the feed because it is used only after the feed is complete The in position feeding and feed complete signals all depend on the value in this parameter If all zeros are entered in this parameter the DLC uses the Position Tolerance A110 Parameter A114 Not Used 5 16 Parameters Not Used A114 Disabled DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual 5 6 Parameter Set B1 The following section describes the B1 set of parameters They are used to configure or structure the DLC to a particular environment or application Some of these parameters determine the language the display will use the units of measurement employed and options selected if any Entering the B1 Parameter Set To enter the B1 Parameter Set the DLC must first be in the Parameter Mode Upon selecting the Parameter Mode the DLC normally displays A100 the first parameter in the A1 set refer to Parameter A100 Feed Length Resolution Once in the Parameter Mode press the CR key on the CTA keypad to change between the A1 and B1 set of parameters from any parameter within any set Par
47. cycle See Press Permissive Interface page 3 5 for a description of handshaking using this and other DLC I O signals Connector X17 pin 13 Function Input Selects Set up Mode High Setup Mode selected Parameter Mode can override selection See Set up Mode page 3 12 for description of operation in this mode DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 21 DLC R Feed To Length Control User s Manual Cycle Stop Connector Function High Low INDRARMA X17 pin 14 Input Used to stop the automatic cycle Continuous Allows Automatic Mode operation Momentary Stops Automatic Mode cycling at the completion of the current cycle The ending point of the automatic cycle depends on the selection entered in Parameter B109 Press Before Feed or Feed Before Press See Press Permissive Interface page 3 5 This input is typically wired to a normally closed push button switch on the user control panel Part Stop Connector Function High Low X17 pin 15 Input Used to stop Automatic Mode cycling after completing the current part only functional when using the batching feature Indicates normal operation allows continued batching operation Loss of a high causes the DLC to stop automatically cycling after all feeds are complete for the current part executing This input is typically wired to a normally closed momentary switch Refer to Chapter
48. describes the user entered parameters required for the DLC to perform the motion control operation The user adapts the DLC to his machine and the mechanical characteristics of the application by entering values for various parameters This permits a standard control system to conform to different but similar applications Note The DLC requires that all parameters be correctly entered before operation is possible 5 1 Parameter Set Description The DLC includes the following sets of parameters Parameter Set A1 This parameter set includes the axis operating values for Automatic Manual and Set up Mode operation These parameters allow the user to configure the DLC for the motor and drive package that the DLC is controlling They also allow the user to set the various factors of the motion profile as required for the material and application These include the resolution of the feed acceleration and deceleration rates feed rates in different modes etc Parameter Set B1 This parameter set establishes the operating arrangement of the DLC It allows the user to configure the DLC for various options such as the language that shows on the display English German Spanish French or Italian selecting control interface options such as the IDS or SOT selecting and configuring other optional features like Batching Parameter Set CO This parameter set allows drive tuning through the DLC Drive parameters can be set using CTA keypad
49. feed length and one for feed rate may be placed anywhere in the string independent of the feed length resolution The PC or SOT may then echo the string format sent from the DLC Example strings with without decimals 4 X 00 012 345 67 8 hh cr 1lf Sending feed length and rate for standard interface decimal points included DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 17 DLC R Feed To Length Control User s Manual INDRARMA 4 X O00 012345 678 8E cr 1f Sending the same data without decimal points Data sent to the DLC R may be selectively stored within a string When data is replaced by star characters its current value is retained This allows the PC or SOT to change feed length without affecting feed rate for example Examples X OO 012 345 hh cr 1lf Feed length is changed but feed rate is not 4 B gon Ol hh cr 1f Jump to Part is the only information that is changed Each status request is described in the following pages Position Error Request X 00 If an axis is disabled stars will be sent in place of that axis DLC R Response X 00 0000 1000 S hh lt cr gt lt 1f gt Current Status Message Request X 01 also see X 25 The DLC will send the current status message as it appears on the LCD The 32 character message is in the current language and is centered for 16 characters x 01 Axis 1 Motor Has Overh
50. for your application B 1 1 DLC R A1 Parameter Set DLC1 1 DR1 02VRS A1 Parameter Set for Axis 1 FEEDLENGTH RES A100 _ _ 0 4 FEED CONSTANT INPUT UNITS REV BIS 0 0 La DRIVE MAX RMP A102 MAX FEEDRATE INPUT UNITS MINUTE A104 MAX FEEDRATE MAX RPM A102 X FEED CONSTANT A101 JOG FEEDRATE INPUT UNITS MINUTE A105 MAX ACCEL RATE INPUT UNITS SEC A106 MAX DECEL RATE INPUT UNITS SEC A107 MAXIMUM JERK A108 MAX JERK lower limit 60 X A1062 A104 POSITION GAIN A109 MIU IN POS THRESHOLD PUTO eee DIRECTION A111 Enc cmd MONITOR WINDOW A112 96 The recommended percentage for the Monitor Window is 10 096 LOW FA THRESHOLD A113 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Blank Parameter Worksheets B 1 DLC R Feed To Length Control User s Manual INDRARMA B 1 2 DLC R B1 Parameter Set DLC1 1 DR1 02VRS LANGUAGE B100 00 GERMAN _ 01 ENGLISH _ 02 FRENCH _ 03 SPANISH _ 04 ITALIAN DIMENSIONAL UNIT B101 IN FT MM CM M RAD DEG REV INTERFACE OPTION B102 00 STANDARD DLC _ 01 IDS BOARD _ 02 BATCH OPTION _ 03 BATCH OPTION w out AUTO INDEX AUX FEEDLENGTH B103 4 FEEDLENGTH MAX B104 FEEDLENGTH MIN B105 ____ _ FEED MAX CHANGE B106 o 4 25 FEED INCREMENT B107 L1 JOG STEP B108 ____ _ PRESS INTERFACE B109 SEC BATCHING OPTION B111 G 3 MEASURING WHEEL ENABLE BITA e MW FEED CONSTANT B116 Ll cec MW ENCODER zin p SERIAL INTERFACE B118 M S _ SERIAL OPERAT
51. is allowed only when the DLC is not in an Automatic Mode cycle With the desired part number showing on the page press the STORE key to select it as the starting part If the current part is entered as the starting part the batching program will be reset to the start of the current part by pressing the STORE key Micro adjustment of Current Part Count Move the cursor into the first digit of the current part count cccccc for an on line adjustment of this count Press the key to add a part to the count Press the key to subtract a part from the count 4 2 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRARMA DLC R Feed To Length Control User s Manual Real Time Part Information This page provides a real time display of the current part information while the DLC is cycling The displayed part block and Part ID will change as the current part changes begins executing the next part in the batch program The part quantity qqqqqq is displayed along with the current part count cccccc to show the quantity of parts to be produced and the current number of parts The current part count will be increased or decreased depending on the count mode selected in Parameter B111 count up or count down If a part is a free run described in next section FREERUN is displayed in the part quantity and the counter counts up regardless of the count mode A linked part is indicated with a differ
52. or port code 64 Serial Com Port Parity Error This error occurs when the parity type of the DLC doesn t match that of the host It also is issued during transmission if the parity check fails indicating a faulty serial cable code 67 Serial Com Port RSA85 Bus Error This error is issued when data is being sent and received at the same time when SOT operation is selected in Parameter B118 If the device communicating with the DLC is not a DR1 02VRS compatible SOT the Interface mode in B118 should be set to 1 If the DLC is talking to an SOT this error indicates a faulty cable or port code 61 Serial Com Port Disconnection This error is issued when the IDS decade switch is not communicating with the DLC when Parameter B102 is set to 01 The time for disconnect detection is automatically set to 2 seconds when IDS is enabled Serial Com Port IDS Format Error This error is issued only when the IDS interface option is selected and indicates a faulty serial port or cable Format Errors Every format error sent from the DLC includes a code number It is also sent in the currently selected language and in both upper and lower case Otherwise the text for the existing errors have not been changed since LRO1 2 005 1 The format error string has the following format E nn 16 char message hh cr 1f Format error code DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 3
53. other data transfer between the DLC and a host device such as a computer programmable controller the IDS Remote Display or SOT A remote thumbwheel switch assembly used for entering feed length and feed rate for operation displays status and fault codes A remote mounted vacuum florescent tube display requires the IDS option Station Operator Terminal Used for displaying diagnostics entering feed length feed rate etc It also contains Cycle Start Stop Jog Mode Micro adjust and other control pushbuttons DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DIO SA DLC R Feed To Length Control User s Manual Chapter 2 Controls and Indicators The DLC R uses the CTA keypad and display module which consists of a keypad with 20 pressure sensitive membrane type keys and a liquid crystal display LCD that has four lines of up to 16 alphanumeric characters each The display informs the operator of the operating status of the DLC system It displays all status and diagnostic messages It is used when entering or editing parameters batch programming or other operations from the DLC keypad The keypad contains all the keys used for data entry cursor movement clearing fault error messages entering feed length and feed rate data and storing entries LIQUID CRYSTAL DISPLAY 20 BUTTON KEYPAD Figure 2 1 CTA Display Keypad Module 2 1 Data Entry Keys This section describes the general function of each k
54. s Manual value stored in this parameter is used to ramp up the acceleration to the value stored in Parameter A106 Maximum Acceleration Rate When this value is set to the lowest level a triangular acceleration profile will result This profile produces the smoothest starts and stops but increases the time required to reach maximum acceleration To decrease acceleration time and maintain the smoothest profile the jerk should be increased By increasing jerk the acceleration profile will approach trapezoidal and acceleration time approaches that of constant acceleration Due to the earlier mechanical method of Jerk Limiting primarily cams some users may refer to Jerk Limiting as a Modified S Curve In applications where stretch or slip are a problem Jerk Limiting will improve performance The profiles shown in Figure 5 1 Profile without Jerk Limiting and Figure 5 2 Profile with Jerk Limiting illustrate the effect of Jerk Limiting The Velocity Profile in Figure 5 2 has much smoother S shaped ramps than the ones in Figure 5 1 The Acceleration Profile in Figure 5 1 is a near square while the profile in Figure 5 1 is a trapezoid shape The Jerk profile in Figure 5 2 is far less severe than the one in Figure 5 1 VELOCITY O lt D LJ _ Lu O O lt Figure 5 1 Profile without Jerk Limiting DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 11 DLC R Feed To Length Control User s Manual
55. sensitive to Press Before Feed PBF and Feed Before Press FBP Interface Modes e When using FBP the first action required is for the axis to be fed the commanded length The sequence is completed by the press being cycled manually e When using PBF the first action required is the press being cycled manually followed by the axis being fed the commanded length e The Permit Press output will be turned ON at the appropriate point in the cycle depending on the Press Interface Mode selected PBF or FBP e f batching is enabled Set up Mode can only use the current feed length For multiple feed lengths set up can be simulated by using Single Step Cycle Stop Cycle Start in Automatic Mode although this causes an automatic press cycle not manually cycled DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 13 DLC R Feed To Length Control User s Manual INDRARMA Fault Diagnostic Monitoring Input Signal Descriptions See Page 3 15 e Resume Cycle e Clear Output Signal Descriptions See Page 3 23 e System Fault Indicator The DLC includes extensive diagnostic monitoring circuitry detecting normal operating status operator errors errors in the control itself and machine faults There are several categories of faults as described in Chapter 8 In general once a fault is detected an error message is displayed on the DLC display and the feeder and press are halted either immedi
56. system parameters Appendix C Drawings and schematics of the DKS DLC Appendix D Installation drawings amp details for the DLC and options IDS Thumbwheel Switch Panel and Remote Display Module Appendix E Index Supplement User s Guide for the Station Operators Terminal SOT an optional operator interface terminal for the DLC 1 3 System Features 1 6 General Description Superior Performance and Ease of Operation The system offers press rates up to 1200 strokes per minute and feed resolution of 0 001 inch which minimizes scrap and lowers cost Note that maximum system performance depends on the mechanical characteristics of the user s system The user simply and easily operates the feed control system by entering feed rate and feed length using front panel controls Operating status messages appear on the display in English German French or Spanish as selected by parameter Other input and display options are described later in this section The DLC system includes features to make set up quick and easy eliminating time consuming mechanical set up or complex programming when changing parts System operation is described in detail in Chapter 3 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRARMA DLC R Feed To Length Control User s Manual Parameter adaptable to Multiple Machines The feeder manufacturer or the user easily adapts the DLC to the mechanical and electrical characteristics of an application by en
57. the end of data and the are ignored by the DLC so that longer strings may be sent for compatibility with other software DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA Status Request X DLC R Feed To Length Control User s Manual Information may be requested from the DLC with a status request command Status identifiers consist of a space a status number and a space The host should send the following string to request most status information X nn cr lf Note that there must be 2 spaces between X and nn unless XD is used Status No nn Information 00 Position error in input units min 001 iu 01 Diagnostic message 32 characters 02 System Information mode in cycle step 03 Distance moved in input units 04 Measuring Wheel Data 05 Feed length and feed rate Axis 1 07 Diagnostic code 2 characters 08 Hardware and Software version numbers 32 char 09 Press strokes per minute 10 Inputs 1 15 in hexadecimal LSbit input1 11 Outputs 1 16 in hexadecimal LSbit output 12 Total Piececount and Total Length 14 Diagnostic Text 15 DLC Inputs in Binary 16 at a time left to right 16 DLC Outputs in Binary 19 DLC Version Number 21 System Flags 22 Throughput in Units Minute 25 Current Status Message 28 Drive Status 29 DSM Firmware Version The DLC allows decimal points to be sent in feed length and feed rate strings for both standard interface and batching One decimal point for
58. the information on each screen Following sections in this manual further describe the information provided procedures to edit the screens data etc as required for a specific function To allow easier description each row of the map is labeled A B C etc In general use the up or down arrow keys to change to the home display screen of the proceeding or following row Use the left or right arrow keys to scroll through the displays on each row Screens that allow editing data have a cursor Use the right left arrow key to move the cursor in the data field and type over data to change Continue pressing the arrow key to change to the next display screen on the row Rows allow wrapping from the last screen on the row back to the first screen Certain displays on the same row have alternate pages such as Total Piece and Total Length Use the CR key to toggle between them Batching display screens require the CR key and the keys for scrolling Procedures are described below for each Screen The example displays shown in the following descriptions show the batching feature enabled by parameter If the feature is not enabled its respective display pages do not appear when scrolling through the screens Pressing the down arrow key from a screen on row C will scroll back to row A or to the first enabled option in row D E or F NOTES e The current DLC display provides four lines with 16 character spaces on each line However all scree
59. 2 Decimal Placement For example if 02 is entered as a value in Parameter A100 The Feed Length Limit The Acceleration Rate The Feed Constant 2 decimal places 1 decimal place 3 decimal places The following table summarizes the decimal places that result from the four possible values of Parameter A100 A100 Parameter Feed Length Max Jerk Feed Constant and Entry Value Parameters Accel Velocity In Pos Threshold a ae ee eee eee Wee Table 5 2 Decimal Placement The remainder of the parameters either do not use number values or have fixed decimal places The parameters that have fixed decimal places are A102 Drive Input Sensitivity A109 Position Gain A112 Monitor Window B109 Press Interface Minimum Cycle Time 5 6 Parameters DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual Note When A100 is changed the numerical digits in other parameters remain in place but the decimal point shifts As an example with A100 set to 03 and the value entered in A101 1 2345 if A100 is changed to 02 then A101 data becomes 12 345 If you change parameter A100 you then need to verify and change other parameters as required Note For simplicity and consistency all parameter display illustrations in this manual reflect the decimal placement when A100 is set to 02 Parameter A101 Feed Constant Feed Constant A101 01234 567 Units Input units per motor revolution
60. 3 8L TVOIdA1 dng 1X3 250 OG Lt I o dols AON3OH3W3 K y Ald YIMO RS dns doa OVA vVv9 A OQA S OZ ve v9 Add H3MOd 20 dns OVA OZL 3 swz 3 syz N 430 sny M 430 snv NO Ni iO dols dols NO Nia to MJTIOHINOO 19VdNOO TWLISIG szad Schematics C 3 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DLN DR SN DLC R Feed To Length Control User s Manual Wei HOIMAdOO 3ON3N343N O3SV3138 MO OC 38 OL LON AND 3SN NANOLSND YO4 IN3AT2OQ SIHL C3LISIHONd SNCH WAQHddY AB 0353Y 333NI9N3 AB Q3 03HD M04 NOISIA3M GC 190 6 16 11 90 003 Mad ISAY 3 o1 Ag 16 Gl Z3NLMVN O NA VM 8 40 133HS SIN FOS M38W N lNVd M38WAnN 0 03 ava NOlLdlN2S3Q AM alva Hd OGN AiHuHBuuul EE Fl Le 9911 38 SOEN 9NM YO TI S31V1S3 Menn NOILO3NNOO3INI QQNW 3 210 s a A Ava ove ts NMONB Qaid ldWOO Wva4SONd HALVE BEE Q3131d4WOO LYVd G33 Nag ONINNVM ATVI LNVd 034 734 z x 300N dn 13S AMLIQOMIO dOLS 3LVIO3AMWI Ia lt S3301lng SS33d OL H R
61. 5 01 Monitoring Circuit for Velocity Loop 0 OFF 1 ON DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 31 DLC R Feed To Length Control User s Manual INDRARMA Parameter C006 Not Used Parameter Not Used C006 Disabled Parameter C007 Not Used Parameter Not Used C007 Disabled Parameter C008 Error Reaction Error Reaction C008 02 02 Error Reaction 0 The drive switches itself to rotational speed control and defaults to a RPM setpoint of 0 The brake engages after maximum 400 msec and it disengages after another 100 msec DDS Error report to the power supply package reaction DDS Error report to the internal power supply Failure of power system protection 1 Same as error reaction 0 but no error report to the power supply package reaction or to the power supply 2 The drive disengages immediately If there is a brake it engages immediately No error reaction no package reaction The drive switches itself to rotational speed control and defaults to a RPM setpoint of 0 Parameter C009 Current Loop Proportional Gain Current Loop P Gain C009 000120 00 000 Not used must be set to 000 120 00 Volts Amp 000008 00 000127 47 5 32 Parameters DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual Parameter C010 Velocity Loop Proportional Gain Velocity Loop P_Gain C010 00800 000 Not used m
62. 5 Hard Faults 80 EMERGENCY STOP 8 7 81 Axis 1 Drive Runaway l 8 8 83 Axis 1 Drive Stalled 8 7 85 Axis 1 Amplifier Hardware Fault 8 8 89 Measuring Wheel Encoder Fault 8 9 90 Parameters Lost Select P Mode 8 7 92 Invalid Drive Configuration 8 9 93 Drive Watch Dog Error 8 9 94 DPR Not Readable 8 10 96 Drive Error Press the CR Key 8 9 97 Invalid Drive Software 8 9 99 Communications or System Error INDRARMA See DLC Display DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DLC R Feed To Length Control User s Manual Refer to Chapter 2 section 2 2 for a description of how to use this map to scroll through the display screens on the DLC control panel display CTA Appendix A Display Map DESDE 2 SN SMACO L43801 1010 A NOISHJ3A 3HVM1dOS NOJ ANYA C AV IdSIO SNINAVHS0Hd NIVW 66 10 HOLVE 9 1 50334 HOlve M3BNON M9018 LYVd JHL JN ONY LN3AGNONI OL GVdASM VLO JHL NO AJJ ONY 3HL ISN E C NOILdO ONIHOLVE AV1dSIG NOILVIASQJNI Luvd LNJHNDO MOMBHV 1H9lM SO 1431 3HL ONISN Luna YO 1431 JHL OL AV IdSIO JHL SS3OOVv Y QVdA3M VLO JHL NO SA3 A C S E 4 OVdA3M V
63. 5 9 A106 Maximum Acceleration Rate 5 9 A107 Maximum Deceleration Rate 5 10 A108 Maximum Allowable Jerk 5 10 A109 Position Gain 5 12 A110 In Position Threshold 5 13 A111 Direction of Operation 5 14 A112 Monitoring Window for Drive Diagnostics 5 15 A113 Low Feed Angle Threshold 5 16 A114 Not Used 5 16 Axis Position Display Screens Distance Moved Display on DLC R 2 8 B B1 53 Entering 5 17 B100 B101 B102 B103 B104 B105 B106 B107 B108 B109 B110 B111 B112 B113 B114 B115 B116 B117 B118 Language 5 17 Dimensional Units 5 18 Interface Option 5 18 Auxiliary Feed Length 5 19 Feed Length Maximum Limit 5 20 Feed Length Minimum Limit 5 20 Feed Length Maximum Change During Cycle 5 21 Feed Length Micro Adjust Increment 5 21 Jog Step Parameter 5 22 Press Interface Mode 5 22 Not Used 5 24 Batching Option 5 24 Measuring Wheel Selection 5 26 Not Used 5 26 Not Used 5 26 Not Used 5 27 Measuring Wheel Feed Constant 5 27 Measuring Wheel Encoder 5 27 Serial Interface 5 27 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Index E 1 INDRARMA DLC R Feed to Length Control User s Manual E 2 Index B119 Serial Port Operation 5 28 B120 Not Used 5 29 B121 Not Used 5 29 B122 Slug Width Compensation 5 29 Batching4 1 Automatic Mode 4 7 Current Part Information Display 4 2 Default Batch Program Values 4 9 Entry and Status Displays 4 2 Feed Programming Display 4 5 Interf
64. 8 SOT Status Diagnostic Codes Index When using the SOT or other host the diagnostics may be requested through the RS 232 485 serial port in expanded text format or as a corresponding diagnostic code number refer to Serial Interface in Chapter 4 The index at the beginning of this chapter lists the DLC displays in alphabetical order The following index correlates the DLC displays in order of the numeric diagnostic code equivalents are listed in the next section SOT Code Display Page System Messages 01 M No Jog Command 02 M Feed Forward 03 A No Cycle Start 04 A OycleStop 05 A Feeding sess 06 A Wait Fd Angle 07 A Cycle Delay 09 S Feed Forward 1 OA S Fd Incomplete OB S Wait Fd Angle OC S Waiting Press OD S Start of Feed OE PARAMETER MODE 12 S Release Jog 14 M Wait Fd Angle 15 A Resume Req d 16 S Feed Reverse 17 M Feed Reverse 18 Initializing Sys
65. 9 DLC R Feed To Length Control User s Manual INDRARMA Format errors are issued only over the serial interface and do not cause a DLC fault An E followed by a two digit error code followed by a 16 character string is sent from the DLC Each message starts with a different error code number for error detection by the host as shown in the following list List of Format Errors With Codes E_00_Format_Error_ E 01 Identifier Error E 02 4 Out Of Bounds E 03 Checksum Error E 04 String Invalid E 05 Batch Disabled E 06 K Xnnn Invalid xnnn replaced by para number E 07 Para Not Allowed E OE Flp Err 0001 E OF Part Not Found E 11 Not Implemented E 12 DLC Input High Each format error is individually described on the following pages E 00 Format Error hh lt Cr gt lt Lf gt This error is sent when the format characters chars 3 and 4 are invalid It is also a generic error that is issued when a message isn t being received properly due to improper handshaking or no carriage return or linefeed E 01 Identifier Error hh lt Cr gt lt Lf gt This error is issued when an identifier character e g the lowercase c in B c01 is invalid E 02 i Out Of Bounds hh Cr Lf This error is sent when the number in the identifier is greater than the maximum number of batches status messages or parameters E 03 Checksum Error J hh Cr Lf This error occurs when the checksum computed by the DLC d
66. Ag G3SA33 qe AB NMvHa DEIER SZ L19016 WO rg 093 Yd SN 3 ve sty ZANNO 8 40 133HS SUN S1VOS H38WnN lMVd YIANNN 70073 SAWN Alva NOLLdINOS30 A38 ava INYN GAN 401 HLONST XVW alr VLO 9911 38 M38A N ONY d aU woe HIN XV Nib VIO L NOILO3NNOO83LNI IvWVUaNi 310N OOW 3 210 S a H LOUWHX3H MJA L1NOHJd li p 3MIM Q3H a d 9m aNnouo Pl OL 3MIM l N3389 MOTI3A sum G3H N Q i STAD S l Flava YAYAN OX YOLOANNOO Sd DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 OID RAMAN DLC R Feed To Length Control User s Manual MYT LHORAGOD 3ON323433 03SV3138 YO Q3ldO 38 Ol LON A INO ISN Y3NOLSNO YOA IN3AT200 SIHL GALIIHONd SLNIAd RY KEIER M33NION3 A8 Q3 103H2 A8 NMYSO A8 Q3SIA3N N04 NOISIA3N SE W2 i5 1i 90 073 wad OSN zi fo 8 409 133HS SIN Ziel YIWAN l vd N38N N 003 IWYN Alva NOlLdhu9S30 alva aNWN ONI LHYWHYOUI 9911 48 SNO BRI VR 1 S31V183 NVN430H SI NOLLOSNNOOYSLNI IvWVUani OOW 3 o10 S d H LOtiX Siti vuOG dO ALMIGWdVO LNSYYND WAWIXVN v SvH 1ndInO LOS HOVE CI 310N M3dWnr auis e CH
67. B113 Disabled Parameter B114 Not Used Not Used B114 Disabled 5 26 Parameters DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual Parameter B115 Not Used Not Used B115 Disabled Parameter B116 Measuring Wheel Feed Constant M W Feed Const B116 0012 3456 Units Input units per measure wheel revolution Input Value Limits from 00000100 to 10000000 regardless of decimal pos Decimal Places A100 1 figure shown A100 02 This parameter scales input units to measure wheel revolutions Refer to Parameter B112 Measuring Wheel MW Selection and Parameter B1 17 for additional entries required for use of the measuring wheel Parameter B117 Measuring Wheel Encoder M W Encoder B117 L 1250 D 0 L Measuring wheel encoder lines revolution from data plate on encoder Units Encoder Lines per Revolution Input Value Limits from 0100 to 5000 D Measuring wheel encoder direction 0 Direction as wired 1 Reverse direction as a convenience in place of reversing the wiring for direction Parameter B118 Serial Interface Serial Interface B118 M 1 S 00 00 A B C A Serial Interface Mode 0 Serial port off 1 RS 232 full duplex communication with PC or other external host device 2 Communication with a single SOT via RS 232 485 half duplex 3 Operation with Indramat SOT via RS 485 Bus half duplex station 01 through 15 DOK DIAX02 DLC1 1 DR1 02VR
68. C1 1 DR1 02VRS ANW1 AE P 06 97 8 18 Diagnostics and Troubleshooting DES SA DLC R Feed To Length Control User s Manual Jog Input Active This indicates the Jog Forward or the Jog Reverse input X17 pin 9 amp 10 is high when entering the Manual or Set up Mode Inputs should be wired into normally open momentary push button switches input signal drops when button released Also if toggled between Step Mode and Jog Mode while the motors are in motion the motors will ramp down and this message will be displayed 1 Check both Jog buttons for proper operation 2 Check Jog switch wiring Automatic Mode Messages The following status messages are displayed in Automatic Mode A No Cycle Start This message indicates the system is ready and waiting for a momentary Cycle Start input This message appears only after the DLC is powered up and initialized or upon entry into Automatic Mode A Cycle Stop This indicates the CYCLE STOP button was pressed to cause the DLC to stop automatic cycling at the completion of the current cycle A Feeding Indicates the axis is feeding This may display if the Position Threshold parameter setting is too small A Wait Fd Angle Indicates the DLC is waiting for the Feed Angle input to go high This signal indicates when the press ram is away from the material and the DLC can safely feed DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 19 DLC R Feed To L
69. C1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 25 DLC R Feed To Length Control User s Manual INDRARMA At start of a linked part no count found BA 13 12 hh cr 1lf Start of linked part Current part block During a linked part BA 14 12 15 hh cr 1lf End of linked part where count and jump are found _Start of linked part _Current Part block Look Up Part Block Given Part ID B NO123ABCD cr 1f Part ID The DLC will look up the part ID it receives and send back the corresponding block number If a block number that matches the ID is not found the DLC will send back stars in place of the part number Note that the active part working part and jump to part downloads may also be accessed by part ID B N0O123ABCD O1 hh cr 1f Part block number Part ID requested Working Part Number BP The DLC sends the current working part number used for wild card part access When wild card characters are used the information from this part is sent or received BP 01 hh lt cr gt lt 1f gt Current working part block number Current Part Number by Part ID B AN cr 1lf DLC Response B A N0O1234567 hh cr 1lf Current part number The DLC will respond with the current part number Note that the B A request is used for current part block and linking information Working Part Number by Part ID B PN cr 1lf 4 26 Function Descri
70. Chapter 5 Parameters Chapter 6 Installation Chapter 7 Start up DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Describes the DLC control and the features which make it well suited for motion control Describes and illustrates various options Lists specifications Describes the CTA keypad and displays interfaced with the DLC control card Describes all pre defined input and output signals and the various interfacing and operating modes of the DLC This information is necessary for interfacing the DLC to the machine builder s equipment control panel design and troubleshooting Provides same type of information as Chapter 3 for enhanced features which include Batching multi format RS 232 485 interface Measuring Wheel and Single Step using Start and Stop Inputs Describes all user entered parameters required to adapt the DLC to the mechanical and electrical characteristics of each application Describes procedures for installing a DLC control system Provides an example of a DLC start up General Description 1 5 DLC R Feed To Length Control User s Manual INDRAMA Chapter 8 Diagnostics amp Describes the DLC s self diagnostic Troubleshooting system lists and explains all diagnostic messages and describes troubleshooting procedures Appendices Appendix A Display Map DLC display screens which appear on the CTA control panel Appendix B Blank parameter record forms for use in documenting your
71. DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual All parameter entries must be reentered and or Stored again regardless of the parameter values shown in the DLC display If when the data on the display is correct for the parameter press the STORE key to store save the data to memory Repeat this process for each parameter NOTE Maintain a current log of parameter settings for your system see Appendix C for an entry form Parameters Lost Select P Mode Indicates the parameters were lost when the DLC was powered up in the Automatic Manual or Set up Mode It is also displayed after installing new firmware Select Parameter Mode and re enter parameter values Check the memory back up battery condition if parameters were previously entered Note that after the Battery is Low fault first displays the battery needs to be replaced within two weeks All parameter entries must be reentered and or stored again regardless of the parameter values shown in the DLC display If when the data on the display is correct for the parameter press the STORE key to store the data to memory Repeat this process for each parameter NOTE Maintain a current log of parameter settings for your system see Appendix C for an entry form EMERGENCY STOP EMERGENCY STOP This indicates the E Stop chain is broken X17 Pin 3 Check the E Stop chain to determine the reason for the Emergency Stop condition
72. E P 06 97 INDRAMA DLC R Feed To Length Control User s Manual 8 9 IDS Status Diagnostic Codes Index When using the IDS the diagnostics appear on the two digit display in a corresponding diagnostic code number The index at the beginning of this chapter lists the displays in alphabetical order The following index correlates the DLC displays in order of the numeric diagnostic code equivalent display on the IDS IDS Code Display Page System Messages 00 Initializing Sys 8 18 01 M No Jog Command 8 21 02 M Feed Jog Forward 8 21 S Feed Forward 8 22 03 M Feed Jog Reverse 8 21 S Feed Reverse snsnssnnnnnnnnnnn nenna 8 22 04 A No Cycle Start 8 19 05 S Waiting Press Waiting for Press 8 22 A Waiting Press scce 8 20 06 M Wait Fd Angle Waiting Feed Angle 8 21 S Wait Fd Angle 8 22 A Wait Fd Angle 8 19 07 A Feeding sesss 8 19 08 A Cycle Delay 8 20 09 A Cycle Stop 8 19 10 A Resume Required 8 20 14 S Start of Feed Set up Mode Feegq
73. EECH NOLLISOd NI if SIXV EE SS3H50Md NI 0334 NEIEN 31042 NI X30334 NY9 ANd JA09 0334 A89 T24 1daNYY3LNI 0334 Linv4 WALSAS Bt MOTTAA J3IBVIIVAV AW 31949 13101 300W HL Nd 200 ouvwWolnv A85 1HM 3QON IVnNVN NYO AND Jg WON H LOUWHX3W cn SHO S 2040 vv OQAD ze dasn 10N YOLVOIONI I ALFIdWOD WYNIOHd HOLVE SOLVOIONI OC ALAIdNOS 1HVd HOLVOIGNI SC ONINVM ATI lHvd SOLVOIONI 8Z 3Q0ON dn 13S LZ dOlS 31VIO3AW SS3 d SO1V2IONI 9Z NOlLISOd NI L SIXV 3OLVOIONI GZ SS3H90Hd NI 0334 SOLVOIONI Z 31049 NI X30334 MOLVOIONI Z 31dJ1dWOO 0334 SOLVOIQONI ZZ Lang 1334 SNOLVOIONI IZ LINYA W3lSAS OZ SS3 d L d WOLVOIQNI 61 318v IIVAV INU 31049 YOLVOIGNI 81 300N YALINYYYd SO1VOIONI L 3QON ou vWolnv MO1VOIONI 91 3QON Termen z sinaino Nid IX HOIO3NNOO 0 FAE SYE GANNILNOD v 001 NOlLdO 10S 304 S 39vd 33S JO Alrllavdvo LN3WNDO WNWIXYN v 3 VH SLNdLNO v3a IHL MOT 3NV CH ONY 818 SIOndNI N3HM 3Q0N l11nv430 IHL SI 3qON WANVN 3dvl MO HLIM Q3ddv3M Al3ivsvd3s 38 OTNOHS SIYM Q3snNn AO SONI S31nH334 SQ YVAN 13NIBVO 3QISNI O31V201 38 GINOHS HOLIMS NO12313S YALSaWVaVd Zr SMa OQAvC OQAvZ 9E dOlS 1MVd dOlS 31049 300W dn 13s 1NOO 1NI SS3Nd JI8vN3 T33HM N
74. EX YOLOANNOD Q4vo8 sal 3 9700 Sai 318vO s Ass Da DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 C 8 Schematics DLC R Feed To Length Control User s Manual DLR SN MYT Luna Z it CASVITSY YO OdidOO 38 OL LON ATNO ISN M3AOIShO HOF LNINNODO SIHL GALIBIHOMd SINPdzH A8 Q35 34 WwAQHddv M33NIDN3 N04 NOISA3H A8 Q3 93H9 S2 1190 6 Wo 16 11 90 003 Mad OSSIAN 3 16 SI Z3NILHVN A8 NWO 8 408 133HS S UN divos M3BADN lavd M3BWDN 70703 INYN ava NOLLdlsi2S30 A38 ava E DANI 1HuHUnLI EENET 9911 38 M38W N NMYYO NOILOJ aan 4 010 NOS AYIM N33M9 VO ZL 831 NI EE JI S31V1S3 NV33OH JN Weg ON H IOUxiu HLIM GNNOYD L3NIBVO OL Q3193NNOO YO 3dAL SNIONnOMO 3NV SIVNINYXIL 93 Z ERD QNhON9 LI3NIBVO Q Q Q O OOOO O YVAN ONnONO 1l3NI8VO 31v9O 1 L SALON Schematics C 9 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual Appendix D Installation Drawings CAUTION Drawings in this appendix
75. INDRAMA DLC R Feed To Length Control User s Manual Bipolar Velocity Limit is 3000 RPM then when the motor is operating at 1500 RPM 5 Volts will be outputted Position the cursor to the right of the Velocity Data Scaling and type in the desired velocity per 10 Volts Typically the value entered here is the same value entered in the Bipolar Velocity Limit Value Press lt ESC gt to return to the Parameter Menu The Absolute Encoder Parameters are automatically set by the amplifier When power is applied the amplifier read the type of motor connected and sets the Absolute Encoder Parameters based on a single or multi turn feedback Press the number 3 Error Reaction Their are three types of Error Reaction to select The Error Reaction selected determines how the amplifier will react when a shutdown error occurs Typically 0 is selected as the Error Reaction Press lt ESC gt to return to the Parameter Menu The Torque Limits are currently not available Press the number 5 Gain Parameters The Gain Parameters allow the user to adjust the velocity current loop gains of the amplifier To set the amplifier motor combination to standard values position the cursor to Reset To Standard Parameters and press the Enter key The following question will be displayed Are You Sure Yes gt Y Press the Y key on your computer to reset to standard parameters Press lt ESC gt to return to the Parameter Menu The amplifier
76. INDRARMA VELOCITY Es O E lt D ul za ul O O lt Figure 5 2 Profile with Jerk Limiting Parameter A109 Position Gain 5 1 2 Parameters Position Gain A109 01 23 Input Units Input Units per minute per 0 001 input units IU in inches inches per minute per mil 001 inch IU in meters meters per minute per millimeter 001 m Decimal Places 2 not affected by A100 setting Input Value Limits 00 01 to 10 00 This parameter specifies the position gain of the closed loop positioning control The proper setting of position loop gain is essential for optimum performance of the drive system Position Gain is expressed in terms of commanded velocity per 001 units of position or following error The position control commands a given velocity units minute per each thousandth unit of position error detected by the control DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual Position Gain is represented by the expression Kv Use the formulas below to determine Kv US Customary International Metric in min m min Kv KV 0 001 in 0 001 m The higher the gain the smaller the position error Position Gain is tuned to achieve the desired performance of the system Gain should not be so high as to cause system overshoot or oscillation Note A position loop gain set too low will result in sluggish operation Too high a se
77. ION B119 SLUG WIDTH COMPENSATION B122 B 2 Blank Parameter Worksheets DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual B 1 3 DLC R CO Parameter Set DLC1 1 DR1 02VRS ANALOG OUTPUT 1 C000 O OQOurrent command _ 1 RPM command 2 RPM actual value from feedback S9 Position Actual value from feedback 4 Motor encoder Sinusoidal feedback ___5 Motor encoder Cosinusoidal feedback ANALOG OUTPUT 2 C001 _ 0 Current command _ 1 RPM command _ 2 RPM actual value from feedback 9 Position Actual value from feedback 4 Motor encoder Sinusoidal feedback ___5 Motor encoder Cosinusoidal feedback OVERLOAD FACTOR C002 POSITION DATA C003 Degrees 10V VELOCITY DATA C004 RPM 10V VELOCITY LOOP C005 0 Monitoring Circuit OFF 1 Monitoring Circuit ON ERROR REACTION C008 Oc The drive switches itself to rotational speed control and defaults to a RPM setpoint of 0 1 Same as error reaction 0 but no error report to the power supply 2 The drive disengages immediately CURRENT LOOP GAIN C009 Volts Amp VELOCITY LOOP GAIN C010 mAsec rad VELOCITY LOOP TIME C011 X msec SMOOTHING TIME C012 us DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Blank Parameter Worksheets B 3 DLC R Feed To Length Control User s Manual INDRAMA Appendix C Schematics CAUTION Drawings in this appendix are included for illustrative purposes only and are subject to change w
78. IYASYIN is H1SN31 Q334 xnv Den 90r s QuvMuo3 90 s s ldOHH3lNI d334 FIONV 0334 J049 3Ans38 s 1NVIS 31040 s dOlS AON39M3A3 300N ouvwolnv 3QON NaildAvHvd s e 4 SLNdNI Nid LIX YOLOSANNOO vv3a u 310N vel Cl eL 1al yor 18L SLOVLNOD lOMINOO SSdNd mg 1Hw NY9 1HM o dOlS 31945 TAA LHM is xo NUB lNd SNONNILNOD SS3Hd L ANGLLIAS3INI SS3Hd 18 1H JI8vN3 T33HM NIYNSYIN L xo D I HL9N31 Q334 ASvITXov H15N31 a334 Sai ln o 3SH3A34 90r Q35 1HM o QuvM3NOd 90 NH8 ANO D avi MOSN3S NuB TA G3SN LON 21 YadWAr Gov Lem 1NI 0334 fr8 034 HOLIMS WYO SS3Hd fr18 N85 a FTOAD 3Wns3s 18 734 o l vis 3149 G38 N3S xoo 8az EI olny 9 dni3s Tenue v 8 189 ZlO SMI Java SCH H ng NANY L DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 C 4 Schematics DLC R Feed To Length Control User s Manual DLR SN MYT LHORAdOD 3ONdH2 3M EWEN MO Q3id09 38 Ol 1ON ANO 3SN M3AOISn2 NO4 IN3ND2OQ SIHL O3LlBlHOWd SLNINGSY KSE M33NISN3 Schematics C 5 AB
79. If the button was not pressed check for a malfunction of the normally open push button or a wiring error to the input DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual A P Stop Active Displayed if the Part Stop input is low active at cycle start when batching is enabled Itis also displayed when single stepping in batching pressing Part Stop and Cycle Start together will cause the DLC to step one complete part at a time A Part Stop Displayed when the Part Stop input has gone high and the DLC stopped the cycle after the current part was complete or when the Batching program last part executes is complete Manual Mode Messages The following status messages are displayed in Manual Mode M No Jog Cmd Indicates that neither the Jog Forward nor the Jog Reverse inputs are high in Manual Mode M Feed Forward Indicates the axis is feeding in the forward direction Jog Forward active in z D 5 c gp lt o D M Feed Reverse Indicates the axis is feeding in the reverse direction Jog Reverse active in z D 2 c m lt o D M Wait Fd Angle Indicates that the Feed Angle input X 17 Pin 6 is low The DLC will not allow the axis to jog until the feed angle is available indicating that the press ram is clear of the material DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 2 1 DLC R Feed To Leng
80. LO AHL NO SAA 03193138 SNOlLdO NO mousy 4 wo sO f dn SHL ONISN S 1595 We OL NOILdO MOT38 HO JAOSV AVTdSIG 3HL SS3OOv p T4SHM SONINNSV SAN Y LNVLSNOO 334 AV ldSIQ C SNLVLS QN3931 lt H3HM SNISASVAN H3HM NIYNSYIN H lt AW1dSIG H15N31 Q334 1N338309 OL q3193138 NOlLdO NO ONION3d3Q d NO Q V OL a D Y AV 1dSIG SLIATI SHIONGI 0334 3lva HLON3 0333 HL NAI 0334 SnO3NVTT3OSIN LNANYNO e AN IdSIO NOILISOd SIXV OL AW1dSIO HLON31 Q334 IN3MMhO Ol em er 1 1Nn00303ld T a ANS SVT VEDI 91 1 SLAdLNO St b SLNANI iS PED u HISN31 WLOL 3ONVISIG Ave SNLYLS OL AW1dSIG NOLLISOd SIXV OL Avi SNLVIS OL NYNLAY e e 3LVIQ3ANI NOd A3 NIE SSdNd TR SOON SSaud S3ovd AVIdSIO JILIN N334138 349901 OL ABM A7 IHL ISN oe SSS IS AY EH Shiv Snivis IX N N y Q319313S NOlLHO NO 9NION3d3Q 9 HO Q d OL Display Map A 1 Figure A 1 DLC Display Map DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual Appendix B Blank Parameter Worksheets The following pages include blank Indramat parameter worksheets Make copies of the sheets that are applicable to your system Use these sheets to record the parameter settings entered
81. Limit Value stored in Parameter B104 maximum limit This parameter sets the minimum feed length limit that the DLC will accept from the DLC keypad or the optional IDS SOT or a host terminal via the RS 232 485 port If this parameter is set to all zeros 0000 00 there is no software minimum limit on feed length If the value entered in Parameter B105 is greater than the maximum feed length value stored in Parameter B104 the DLC issues an invalid parameter entry message B105 Is Invalid when the Store key is pressed Reenter the parameter data for B105 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual If the value entered in Parameter B105 is equal to the value stored in Parameter B104 only one programmed feed length is permitted in each direction Should the feed length entered be less than the minimum limit set in this parameter the diagnostic message Feedlength Less Than minimum will appear in the display Reenter a feed length within value limits Parameter B106 Feed Length Maximum Change During Cycle Feed Max Change B106 1234 56 Units Input Units Decimal Places See Parameter A100 figure shown A100 02 Limits None This parameter limits the amount the programmed feed length can change during an Automatic Mode cycle Should the difference in the old and the newly entered feed length be greater than the maximum limit set in this parameter the diagno
82. OV from left to right n 0 Outputs 1 16 X 16 O 0010000100100000 hh cr 1f Outputs 1 16 n increasing output i DLC Version Number X 19 The DLC will send the hardware and software version number This is the same as DLC R status X 08 except that there is not a space between the X 19 and the start of the string This corresponds exactly to the X 19 request in the DLC DA firmware X 19 DLCO1 1 DLC1 1 DR1 02V06 hh cr 1f l l Software version I Hardware version System Flags X 21 The DLC sends back 8 flags that are set depending on the condition they represent Currently only the first flag is used to indicate press cycle mode X 21 10000000 hh cr 1f __0 press intermittent l press continuous The other 7 flags are set to 0 and are reserved for future use Throughput in Units Min X 22 The DLC will send the throughput measured in the last automatic mode cycle Throughput Feed length Strokes min This data is always available from the DLC DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 2 1 DLC R Feed To Length Control User s Manual INDRARMA X 22 0001234 hh cr 1f Current Status Message in 40 character format X 25 The DLC will send the current status in a 40 character format This expanded format status request is a revision of X 01 where the status is returned with the message centered in a 16 character 32 charact
83. P Parameter Set Descriptions A1 5 1 B1 5 1 co 5 1 Parameter Set A1 5 5 Parameter Set B1 5 17 Parameter Set C 5 30 Parameters Entering 5 3 Set Descriptions 5 1 Unit of Measurement Input Unit 5 5 PBF Batch Complete 0 end with press cycle 5 25 PBF Batch Complete 1 end with feed cycle 5 25 Press Before Feed Batch Complete 5 25 Press Continuous Operation 3 7 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Index E 5 DLC R Feed to Length Control User s Manual INDRARMA Press Input Signal Descriptions Continuous INTERMITTENT Select 3 21 Press Intermittent Operation 3 10 Press Permissive Interface R 3 5 RS 232 422 485 Serial Interface Operation 4 9 Action Requests 4 32 Batching Information Batching Input 4 27 4 24 Batching Input Working Part and Wild Card 4 29 Batching Requests Block Uploads 4 35 Checksum 4 34 Connector Wiring X6 Data Format 4 14 Diagnostic Codes 4 36 Message Format 4 14 Parameter Input 4 31 Parameter Request Polling Request 4 33 4 24 4 30 RS 232 and RS 422 Flow Control 4 34 Serial Cable Connection to Computer 4 13 Serial Interface Errors Signal Level Requirements 4 38 4 12 SOT ScreenManagerTM Notes 4 41 Status Input 4 23 Status Request X S Safety Interlocks 3 3 Setup Mode 3 12 Signal Definitions 3 1 4 17 Single Step Using Start and Stop Inputs 4 43 SOT Status Diagnostic Codes Index 8 23 Specifications 1 12 Start Up Automatic Operat
84. Parameter C006 Not Used A 5 32 Parameter C007 Not Used rn 5 32 Parameter C008 Error Reaction a 5 32 Parameter C009 Current Loop Proportional Gain a 5 32 Parameter C010 Velocity Loop Proportional Gan 5 33 Parameter C011 Velocity Loop Integral Reaction Time 5 33 Parameter C012 Smoothing Time Constant 5 33 Parameter C100 Set Standard Drive Tuning Parameters Over CTA 5 34 Chapter 6 Installation 6 1 G TT die Ree 6 1 6 2 POWO ege T PEURE REDI PP PU pP E E E pne ees 6 2 6 3 Cable ROUTING EE 6 2 6 4 Transtormer Heat DISSIDatiOn uuu d RR EREY E RRRERRRRERR E ERRXRRRERERRRIERNRRXR RR XMRPKRA EENS 6 2 E e VE le e EE 6 2 EE Ee EE 6 3 IV Contents DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed to Length Control User s Manual 6 7 DEG DEA 4 Connectors genae ee gage da ke ere va gag sue ESA 6 3 Chapter 7 Start Up 7 1 enke enee 7 1 T2 DEA Input GCOFTmnectlolnsz ostio tnt hf dedit dt tnde dada tede daa de eio 7 1 7 3 DEA 4 Ouput Connections r 7 2 E POWOE UD R S a qu dau ua NS ku ua aR Susa e o ni M M dunes e 7 3 7 5 Digital AC Servo Amplifier Parameter Ent 7 4 Changing The Display Language nennen snnt nnns nnns snnt ga sasaqa 7 4 E e UU Meo MAREM RC pase 7 4 Setting The Drive s Parameters To Operate With The DLC Control Card nenea 7 5 7 7 Parameter Entry
85. Press the arrow keys to display the main feed length feed rate page home display of this row Simply pressing the or key on the keyboard adds or subtracts the increment to or from the previously programmed feed length and automatically stores the new value The micro adjust feature works from this display page for both the standard DLC and batching interface options and on the Batch Feed Programming display row G and other pages as noted e A key will add the value entered in Parameter B107 to the programmed feed length and store the new value If the Feed Length Maximum Limit B104 or the Maximum Change B106 are exceeded a minor error is issued A key will subtract the value entered in Parameter B107 from the programmed feed length and store the new DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Controls and Indicators 2 13 DLC R Feed To Length Control User s Manual INDRARMA 2 14 Controls and Indicators value Ifthe Feed Length Minimum Limit B105 or the Maximum Change B106 are exceeded or the change results in a zero feed length a minor error is issued Micro adjust will not cause the digits to roll over past 000000 to 999999 or a change in feed direction past 000000 to negative e f one ofthe limits is exceeded Maximum Limit Minimum Limit Maximum Change the respective error occurs The error may be cleared while the Batch Feed Programming page displays by entering a correct feed length and pressi
86. RATURE FEED ANGLE FEED INTERRUPT 24VDC 24VDC OVDC OVDC ZA Power up Figure 7 1 Example Input Diagram The system can now be powered up All voltages should be checked by a qualified electrician to ensure proper signals and connections The digital servo drive being used has two 7 segment LED s H1 which displays the current operating status of the drive If all connections are correct the H1 status will be bb If the diagnostic is not bb consult the drive s manual for information on how to correct the problem The CTA display should also display no errors Consult Chapter 8 Diagnostics And Troubleshooting for more information on how to correct the problem The DLC Digital Servo System is ready for drive amp system parameters to be installed DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Start Up 7 3 DLC R Feed To Length Control User s Manual INDRAMA 7 5 Digital AC Servo Amplifier Parameter Entry The Indramat Digital AC Servo Drive contains an RS232 interface Connector X2 This interface gives you information regarding the status of the drive and allows you to read and adjust all the drive s system parameters The RS232 interface provides screens and menus which are accessible via a VT100 terminal or a PC computer with a VT 100 emulator e g Procomm Windows 3 1 etc The communication settings are as follows Baud rate 9600 Parity None Data Bits 8 S
87. RNING The Press Immediate Stop signal must be incorporated into the safety logic circuitry of the machine Note that safety design of the system is the responsibility of the machine tool builder Set up Mode Indicator Connector X17 pin 28 Function Output Indicates the Set up Mode is active High Indicates the Set up Mode is selected This output signal is typically wired to an indicator light on the user control panel Part Early Warning Indicator Connector X17 pin 29 Function Output Used in batching to indicate when this part run is nearing completion High Indicates the batch has the user specified number of this part or less remaining to be executed Low Indicates the part count has not reached the user specified number of parts remaining or the entry is set to 0 disabling the output When using the batching function the user enters this Early Warning number on a page of the DLC display See Chapter 2 Display Screens The output turns ON when the parts remaining count reaches this number It remains ON as the remaining parts are completed It turns OFF when the next part begins to execute Refer to Chapter 4 for further information on the batching feature DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 29 DLC R Feed To Length Control User s Manual INDRAMA Part Complete Indicator Connector X17 pin 30 Function Output Used in batching to i
88. Request To Send and CTS Clear To Send lines on the RS 232 cable to provide flow control When the host lowers the CTS line transmission from the DLC will be interrupted until the CTS is raised The DLC will lower the RTS when an interruption in transmission from the host is necessary If the host does not support hardware handshake the RTS CTS lines are not connected or the use of RTS CTS is inconsistent with the DLC select software handshaking only no hardware handshake XON XOFF and RTS CTS are provided to keep the DLC s buffers from overflowing and should be used the same way by the host software The communicating device should employ some other type of internal flow control e g sending one message at a time to prevent the ports from 4 34 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 NID RADIAL Block Uploads DLC R Feed To Length Control User s Manual reaching a handshake state When a Block Upload is requested the DLC will send a block consisting of a header and several messages The header will contain the identifier and the number of messages that will be sent Currently the Block Upload feature allows each of the Status Minor Soft and Hard tables in the current language to be uploaded A table listing the current status error and fault messages is included as the next section Serial Diagnostic Codes A checksum is not required in the request string Status Message Block
89. S ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual Chapter 1 General Description The DLC is a single axis positioning control card which plugs into the Indramat Digital AC Servo Drives such as the DKS Digital Compact Servo Drive or DDS Digital AC Servo Drive products The DKS is a self contained power supply and digital servo drive The DDS is a digital servo drive which operates with the TVD AC Power Supply The DLC requires a DEA 4 Input Output card to provide the system inputs and outputs to operate the Digital AC Servo System The DLC plugs into the U1 slot and the DEA 4 plugs into the U2 slot of the Indramat Digital Servo Drives The DLC controls and Indramat maintenance free MDD Digital AC Servo Motor to drive feed rolls or some other positioning device This is a closed loop feedback system which provides precise control of speed and position at all times The DLC DEA 4 installed in the Indramat DKS Digital Compact AC Servo Drive is illustrated in Figure 1 1 DKS DLC H Feed To Length Positioning Control System The DLC servo system is used for material positioning applications It controls the feeding of metal foil film and similar materials through a shear punch press bagmaking machine thermoforming machine or similar production machine Complete interconnect cable sets are also available from Indramat The components are chosen to best fit the specific application Figure 1 2 Block Diagram is a bl
90. S ANW1 AE P 06 97 Parameters 5 2 7 DLC R Feed To Length Control User s Manual INDRAMA B Station number If M 1 All stored data is acknowledged with Y lt cr gt lt lf gt if S 10 If M 2 2 S values are ignored If M 3 Enter the Station number of the DLC on the RS 485 bus assign a different number for each DLC on the bus 01 through 15 C Not Used Select the mode of communication required to interface the DLC control to a host device Also select the communication requirements from Parameter B119 Serial Port Operation Refer to Chapter 4 for additional information on the RS 232 485 Interface operation and communication requirements Parameter B119 Serial Port Operation 5 28 Parameters Serial Operation B119 1920 8 1 00 A B C DE A Baud Rate 19200 enter 1920 9600 4800 2400 1200 0600 or 0300 B of Data Bits 8 7 C of Stop Bits 1 1 5 enter 3 or 2 D Parity 0 none 1 odd 2 even E Flow Control Checksum 0 Software XON XOFF Handshake with Checksum 1 Software and Hardware RTS CTS Handshake with Checksum 2 Software Handshaking with no Checksum 3 Software and Hardware Handshake with no Checksum Enter the data required for proper transmission between the DLC and a host device Select the mode of communication in Parameter B118 Refer to Chapter 4 for additional information on the RS 232 485 Interface operation and communication requirements When interfaced to the SOT the value
91. Stop of the DEA 4 connector X17 3 Connect a Normally Open momentary pushbutton to Pin 4 Cycle Start of the DEA 4 connector X17 4 Connect a Normally Closed momentary pushbutton to Pin 14 Cycle Stop of the DEA 4 connector X17 5 Connect a Normally Open momentary pushbutton to Pin 9 Jog Forward of the DEA 4 connector X17 6 Connect a Normally Open momentary pushbutton to Pin 10 Jog Reverse of the DEA 4 connector X17 7 Connect a Normally Open momentary pushbutton to Pin 8 Clear of the DEA 4 connector X17 8 Connect the 24 Vdc external power supply to pins 34 and 35 0 Vdc and pins 36 and 37 24 Vdc of the DEA 4 connector X17 7 3 DEA A Ouput Connections 7 2 Start Up For the purpose of a sample start up the connections for the DEA 4 outputs are not necessary The ends of the unused wires in the cable should be wrapped in electrical tape to prevent any damage to the outputs Refer to the interconnect drawings in Appendix D for properly interfacing the DEA 4 system outputs with the machine DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRARMA DLC R Feed To Length Control User s Manual CONNECTOR X3 PARAMETER MODE SELECT MANUAL SETUP AUTO O AUTOMATIC MODE SELECT 00X EMERGENCY STOP CYCLE START RESUME CYCLE AXIS 1 AMPLIFIER READY CLEAR JOG FORWARD JOG REVERSE SETUP MODE SELECT CYCLE STOP AXIS 1 MOTOR OVERTEMPE
92. ace Option Parameter 4 8 Main Programming Display Page 4 3 Part Linking 4 6 Selecting The Batch Option 4 1 Setup Mode 4 8 C CO 5 30 C000 Analog Output Channel 1 5 30 C001 Analog Output Channel 2 5 30 C002 Overload Factor 5 31 C003 Position Data Scaling at Analog Outputs AK1 and AK2 5 31 C004 Velocity Data Scaling at Analog Outputs AK1 and AK2 5 31 C005 Velocity Loop Monitoring 5 31 C006 Not Used 5 32 C007 Not Used 5 32 C008 Error Reaction 5 32 C009 Current Loop Proportional Gain 5 32 C010 Velocity Loop Proportional Gain 5 33 C011 Velocity Loop Integral Reaction Time5 33 C012 Smoothing Time Constant 5 33 C100 Set Standard Drive Tuning Parameters Over CTA Controls And Indicators 2 1 Data Entry Keys 2 1 Count Mode 5 24 D Diagnostic Display Categories 8 4 Hard Fault 8 4 Minor Errors 8 5 Soft Fault 8 5 Status Messages 8 6 Diagnostics Hard Fault Messages Axis 18 7 8 8 Axis 1 Amplifier 8 8 DLC R System Error 8 6 5 34 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRARMA DLC R Feed to Length Control User s Manual EMERGENCY STOP 8 7 Parameters Lost 8 6 8 7 Minor Error Messages 8 15 Axis 1 Amplifier Is Not Ready Axis 1 Has Not Reached Position Change in Fdlgth Exceeds Limit DLC R System Error Code MNR00 Feed Angle Is Missing 8 17 Feedlength Exceeds Maximum Feedlength Less Than Minimum Stop Due To Interrupt Input Zero Feedrate Entered 8 16 Zero Feedlength Ente
93. acter display on the DLC control panel The software in the SOT provides Help screens to assist the operator in using the SOT and for entering information correctly The SOT is pre programmed with appropriate screens for DLC R type applications The SOT can also be programmed using Indramat s ScreenManager when further customized screens are desired This command line editor software package runs on a DOS based computer This program can be used to customize write information and prompt lines for the operator that will appear on the SOT display When downloaded to the SOT these lines cannot be changed from the SOT keypad but data can be entered in response to the prompts The SOT keypad includes click contact keys for entering changing data in the DLC as well as several inputs normally provided on the user s control panel by the machine builder These include the mode selection axis jog forward reverse and cycle start stop resume The SOT connects to the serial communications port of the DLC and can be mounted up to 1000 meters away with an RS 485 cable An SOT User s Guide is provided at the end of this manual as a supplement DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 General Description 1 9 DLC R Feed To Length Control User s Manual INDRARMA Figure 1 4 SOT Station Operator Terminal 1 4 Standard Configuration Of DKS With DLC Control Card DEA 4 Input Output Card The DLC Control Card plugs into the U1 slot and the DEA
94. ameter B100 Language is the first B1 parameter that appears in the DLC display B100 Note The user may exit the Parameter Mode from any parameter set at any time The DLC returns to the selected operating mode Manual Automatic or Set up The following sections describe each of the B1 parameters in detail Parameter B100 Language Language B100 01 Input Value Limit 00 01 02 03 or 04 All displayed text messages appear in the language selected The language choices are as follows 00 German 01 English 02 French 03 Spanish 04 Italian DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 17 DLC R Feed To Length Control User s Manual INDRAMA Parameter B101 Dimensional Units Dimensional Unit B101 in Use this parameter only as a memory aid electronic note pad for the user The operator s selection of input units has no effect on the computation or operation of the DLC The selected dimensional unit displays with data on the SOT display Use the left or right arrow keys to scroll through the selection of dimensional units available Press the STORE key when the desired selection displays The following is a list of abbreviations which will display for available dimensional units in inches ft feet mm millimeters cm centimeters m meters deg degrees rad radians rev motor revolutions Parameter B102 Interface Option 5 18 Parameters Interface Option B102 XX
95. ameters To Operate With The DLC Control Card 1 Press the number 6 Motor amp Drive Data This will display the current amplifier motor combination Look under the Motor Parameters and make a note of the Maximum Velocity Of Motor RPM Press ESC to return to the Parameter Menu 2 Press the number 1 Operation Mode Scaling The Operation Mode allows the user to configure the following amplifier parameters Analog Outputs Bipolar Velocity Limit Value Overload Factor Analog Output Position Data Scaling Analog Output Velocity Data Scaling Analog Outputs The Indramat Digital AC Servo Drive has two analog outputs AK1 Connector X3 pin 1 referenced to OVm pin 2 and AK2 Connector X3 pin 3 referenced to OVm pin 4 These outputs can be configured to output following items Velocity Command Value Velocity Feedback Value DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Start Up 7 5 DLC R Feed To Length Control User s Manual INDRARMA 7 6 Start Up Position Feedback Value Motor Encoder Sine Motor Encoder Cosine Current Command Value Press the up or down arrow keys to position the cursor on the proper channel Then press the left or right arrow keys to select the desired output Continue pressing until the desired output is selected Bipolar Velocity Limit Value The Bipolar Velocity Limit Value sets the motor s maximum velocity limit in the forward or reverse direction Position the cursor to the ri
96. and press automatically stop If necessary the ram can be inched back the press speed can be reduced and press feed operation can be resumed without loss of material or damage to the tool or die An indicator informs the operator when the speed can be increased without causing this problem and when the speed is set so high that it may cause the problem Both fault and normal status messages are displayed on the DLC control panel or host device via the serial port in the user selected language Thus the operator is informed of the current operating status of the system and is alerted to any condition that causes a fault This helps the operator quickly locate and correct problems The DLC processor models and predicts the motion profile and continuously compares it with the actual response of the servo drive thereby detecting irregularities in drive conditions such as drive runaway or stalled conditions Parameters allow the user to set the magnitude of certain variations as required for the application before a deviation error is considered a fault condition Diagnostics are described in detail in Chapter 8 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 General Description 1 7 DLC R Feed To Length Control User s Manual INDRAMA Jerk Limited Acceleration Parameters allow the user to generate a jerk limited S shaped acceleration profile which increases machine life and allows handling difficult slippery compliant or delicate m
97. anual No cursor appears on this display for the DLC R However micro adjust described later in this section is allowed Additional Information Pages on Row C From the DLC feed length feed rate display you can view additional information pages These show settings made in different parameters You cannot edit the parameter values from these pages They are for information only Press the left or right arrow key from the feed length feed rate display until the desired Parameter Information page displays The following summarizes the lines of information on these displays Refer to Chapter 5 for further information on parameter entries Aux Fd 010 000 Jog Step 000 500 Fd Incr 000 050 Slug Cmp 000 650 Parameter Information Display Auxiliary Feed Length is a secondary feed length entered in Parameter B103 Use an external switch to trigger the DLC to use this feed length instead of the standard one entered Jog Step setting is entered in Parameter B108 This function is enabled disabled from a display on Row A In Manual Mode pressing a jog key will cause the DLC to feed the length entered in the parameter then stop if the function is enabled as further described under Row A Feed Length micro adjust Increment is set in Parameter B107 It allows you to fine tune micro adjust the programmed feed length by adding or subtracting the value entered in the parameter To use this micro adjust feature e
98. aoa 1 BACK VIEW Se 3 11 16 x r SIDE VIEW REMOTE DISPLAY CONNECTIONS 120 VAC D C GROUND N 5V OUT Q RESET SERIAL IN SERIAL IN O SERIAL OUT SERIAL OUT m N C gt di N O O EARTH GROUND w w 12 VAC DIDIN OPEN m m N CLOSED m m COMMON 6 PIN CONNECTOR 8 PIN CONNECTOR Figure D 3 Vorne Display Dimensions and Connections D 4 installation Drawings DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual ADDRESS Dp SS DIP SWITCHES 8 7 MSD ADDRESSING MUST BE SET TO 01 oo CR OFF ON FEED OFF ON BAUD RATE 7 8 DATA BITS PARITY STOP BITS LINE TERMINATOR LINE TERMINATOR LINE 2400 BAUD 8 DATA BITS 1 STOP BIT CR ON LINE TERMINATOR LINE FEED OFF LINE TERMINATOR Figure D 4 Vorne Display DIP Switch Configuration DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Installation Drawings D 5 DLC R Feed To Length Control User s Manual INDRARMA Figure D 5 Station Operator Terminal SOT 02 for Rollfeed D 6 installation Drawings DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA E Index DLC R Feed to Length Control User s Manual A A1 5 5 A100 Feed Length Resolution 5 5 A101 Feed Constant 5 7 A102 Drive Max RPM 5 7 A103 Not Used 5 8 A104 Maximum Feed Rate 5 8 A105 Jog Feed Rate
99. ardware and Software Support enne nnns nennen nnns nnne nnn ns 1 4 152 ek dee HUET ET EE 1 5 Eet EE EENS 1 6 1 4 Standard Configuration Of DKS With DLC Control Card DEA 4 Input Output Card 1 10 1 5 Brief Operational Description 1 12 1 6 9p6cIfICatiOliS EE 1 12 dal isis esso DEED C cc Rc RS MC M 1 13 luet 1 13 Interface Options ra snnt nnn ness sns 1 14 Chapter 2 Controls and Indicators 2 1 2 Data ENY EE 2 1 RRE ER 2 3 Chapter 3 Functional Description Standard Features 3 1 3 1 Signal Definitions oi eedem Codename repere me C pd ne m Peri ess 3 1 3 2 Interface Descriptions eene nens nnn nnn Y au aN UM Y K Na NA nsns 3 1 n e Bee EE Le EE 3 2 eaae cx ccc 3 3 Normal Operation Gonals ennt n snnt nnn nennen ss nnn nennen 3 4 Press Permissive Interface A 3 5 Joggingslnpulsssvodeeto edes tek cte eb bbc cts tet bdo taber ttt doter 3 12 SOL UM OCS eMe m 3 12 Fault Diagnostic Monitoring 3 14 3 3 Input Signal Descriptions A 3 15 Parameter Mode SeleGt ebd d BREL GRE dete ERO RORRREGERERERERERERERERERERERERR RR EEEa Aaaa 3 16 Automatic Mode E 3 16 Emergency Stops iioi cete mbi PAM Em D EIN IUDA athe 3 16 GV CIOS SISTi EE MENS Dx Ot TM ERN ME MEM D Up M Ufa 3 17 Ela To MEET 3 17 Feed nie EE 3 17 Feed INGS le EE 3 18 Glosa yayayku yaya IRR ucc EM 3 19 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Contents DLC R Feed to Length Control User s Man
100. are checks the parameter input value limits when you press the STORE key If you have entered a value higher or lower than DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 3 DLC R Feed To Length Control User s Manual INDRARMA 5 4 Parameters the limits of the parameter a diagnostic message appears in the display after you press the STORE key The parameter description and number remain on the display In place of the data the message Is Invalid appears Feed Length Res A100 Is Invalid Press the CL key to clear the fault status message The display returns to the normal parameter entry display Enter correct values for the parameter within limits and press STORE 2 The DLC checks the parameters each time power is applied to the unit It also does secondary calculations based on entered parameter data when you switch out of Parameter Mode In either case if required parameter s data is missing or incorrectly entered the DLC detects the error and displays the Parameter Is Invalid diagnostic message Parameter A105 Is Invalid Switch back into Parameter Mode The first invalid parameter automatically displays Enter the data correctly and press STORE for each parameter that appears as invalid To advance or scroll forward through the parameter set press the up arrow key on the DLC keypad Each time you press the key the parameters on the display advance from the first to last Use the down arrow key to scr
101. are included for illustrative purposes only and are subject to change without notice DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Installation Drawings D 1 DESIDOER2 SN DLC R Feed To Length Control User s Manual WWG SS3NDIOIHL JOVAYNS ONILNOOINW XVN LNA LND ONILNAOW v 0 eze v su ogv 4 O61 A V SVO py xou z o Bro 9v via z0 1z6 v SZL i cv9 S Z6 1 BZ SBL Lance ere gie v LOL WN 1108 QNnOHS Ss 8Z 4 SL cet SZL 9 2 0 re 9 808y9z ud v129 95Q0 318v29 MOBI ZS628Z wd 200 X04 MJAOO SSV IObGd 100 3Hd 9d00 V NI ONUNDON HO4 Q3Hinb3H S IVIH3I VN ANO 390N3M333H 04 HONI uu NI NMOHS 38V SNOISN3AIG Thy 310N ZGOc9Zz wd CLMMOVE NON N L YO YLO LGOCOZ ud LIT49V8 asi rO vgl o H WEEN pp 0Z oc9 s evi Figure D 1 CTA4 Keyboard and Cabinet Cutout Dimensions DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 D 2 installation Drawings INIDRADIZAL DLC R Feed To Length Control User s Manual Figure D 2 IDS Outline Drawing DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Installation Drawings D 3 DLC R Feed To Length Control User s Manual INDRARMA REMOTE DISPLAY DIMENSIONS TA 6 13 16 O
102. art Quantity Sending a zero in the part quantity will zero the current part count Sending a plus in the first digit of the quantity will select a linked part as it does on the display DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 27 DLC R Feed To Length Control User s Manual INDRARMA If M or M are sent in the part count micro adjust flag the count will be increased or decreased by 1 If the flag is any other character or is omitted the count will stay the same An echo of information received from the DLC will not affect the current count Axis 1 feed length feed rate and feed quantity B F0214012 345 67 8 O10 hh cr 1f Feed quantity end of part Axis 1 feed rate Axis 1 feed length with feed direction sign Selected feed number 1 6 Data may be sent with or without decimal points The feed length may also be micro adjusted up or down using the flags M and M B FO021M tShh lt cr gt lt 1lf gt Positive feed length micro adjust B FO21M hh cr 1lf Negative feed length micro adjust Change Starting Part Number 4 B SOL Change by part block number 4 B AN111 1111 I Change by part ID number send N and Part ID _B_AM 4 B AM Micro adjust starting part block number B AOO When not cycling reset program to the start of the current part The starting part can be selected by block number
103. ately or after the cycle is complete depending on the type of fault The fault recovery procedure is to first troubleshoot and remedy the problem Then press the Clear key or external Clear input to clear the DLC fault status and diagnostic message on the display For a Soft Fault or Minor Error a momentary high on the Resume Cycle input will continue Automatic Mode cycling For a Hard Fault the system must be restarted Diagnostics and fault troubleshooting procedures are described in Chapter 8 3 14 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual 3 3 Input Signal Descriptions This section describes the Inputs to the DLC control from external sources The connector and pin numbers of these signals are described in the following sections and shown in Figure 3 7 X17 Input Output Connector Showing Input Pin Designations Each section indicates the connector and pin number the general function of the input signal and the results when the signal level is in the active state high and or low Figure 3 7 X17 Input Output Connector Showing Input Pin Designations DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 15 DLC R Feed To Length Control User s Manual INDRARMA Parameter Mode Select Connector X17 pin 1 Function Input Selects Parameter Mode High Parameter Mode selected
104. aterials at increased production rates Independent Accel Decel Ramps Parameters allow different acceleration and deceleration rates for linear profiles This allows the user to most effectively accommodate differing material characteristics such as stretching susceptibility in various applications Batching The user can program the control for the sequence required to make different parts Then through simple keyboard entry select the quantity of one or several different parts to be made automatically The program allows multiple feed lengths for each part It also allows branching from one part program to another to make different parts and looping to continuously make the same part Up to 99 parts and 594 feeds can be entered and stored in the battery protected memory of the DLC RS 232 485 Serial Interface A multi format serial interface allows communication with a programmable logic control a Indramat IDS or SOT a personal computer or other host device Every function and more that can be entered with the keypad and displayed on the LCD can be communicated between the DLC and host device at rates of up to 19200 Baud Optional Thumbwheel Switch Panel And Alphanumeric Display An optional thumbwheel switch module IDS and an optional alphanumeric display illustrated in Figure 1 3 Optional Thumbwheel Switch amp Alphanumeric Display Modules are available for the DLC The IDS connects to the serial port of the DLC The re
105. ation of the motor s Lag is computed as follows Lag Velocity KV x 1000 MAX LAG A102 max RPM 1000 x A109 Allowed Deviation from computed Lag A112 x MAX LAG Notes 1 If A112 is too small a normal feed will cause Drive Runaway or Drive Stalled 2 For quicker error detection A112 may be entered as less than 10 as long as the condition noted above does not occur 3 A112 may be made larger than the suggested value if desired An upper limit of 2096 is placed on the parameter 4 Ifthe position tolerance is set to a high value larger than allowed deviation from max lag the DLC may not be able to distinguish stalled from runaway although a hard fault will still be issued See Chapter 8 for description of fault diagnostics DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 15 DLC R Feed To Length Control User s Manual INDRAMA Parameter A113 Low Feed Angle Threshold Low FA Threshold A113 00 0100 The DLC can use this parameter while the feed angle is low to determine if the material is in position It uses Parameter A110 In Position Threshold when the feed angle is high If the position error is greater than this value material slipped out of position while the feed angle is low the soft fault Movement While Feed Angle Low is issued Typically the machine builder will cause the feed rolls to open during the actual press operation then close to feed material If the rolls are closed
106. automatic cycle is ended the Permit Press output is dropped The machine builder typically employs a press clutch engagement retaining circuit that retains clutch engagement until the press ram reaches Top Dead Center and is stopped The timing for stopping the press depends on whether Press Before Feed or Feed Before Press is selected See Figure 3 3 Continuous Mode Press Before Feed and Figure 3 4 Continuous Mode Feed Before Press for timing details The Press Immediate Stop output is also dropped low when Feed Angle is lost during a feed or various faults are detected If this signal from the DLC is wired to the press it should attempt to stop as soon as mechanically possible DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual Figure 3 3 Continuous Mode Press Before Feed Figure 3 4 Continuous Mode Feed Before Press DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 9 DLC R Feed To Length Control User s Manual INDRARMA Press Intermittent Operation Conditions Automatic Mode input high Press Continuous Intermittent input low 1 Cycle Start input goes high 2 The DLC issues the Permit Press output to initiate engagement of the press clutch on a per cycle basis The Permit Press signal is dropped when the Feed Angle goes low The system typically operates as described below Refer to Figure 3 5 Intermittent Mode Press Be
107. avoid processing an incorrectly fed length The soft fault diagnostic message Feed Angle Lost During Feed is issued This fault typically indicates that the press cycle is too fast It does not allow sufficient time for the feed cycle to complete before the ram is too close to the material to allow feeding If the material slips out of the position window set in Parameter A113 as the Low FA Threshold after while the Feed Angle is low the soft fault diagnostic message Movement While FA is Low is issued This input is typically wired to a limit switch or sensor on the press See Figure 3 8 Feed Angle Switch Layout Figure 3 8 Feed Angle Switch Layout Feed Interrupt Connector Function High Low 3 18 Functional Description Standard Features X17 pin 7 Input Used to interrupt the feed cycle Indicates normal operation If not using this function this signal line must remain high for the DLC to operate Loss of a high signal interrupts the feed cycle feed decelerates The DLC displays a Stop Due to Interrupt Input diagnostic message and turns on the Feed Interrupt Indicator output Once the signal is restored the feed cycle resumes automatically in Automatic Mode In Manual or Set up Modes jogging is interrupted When restored jogging will resume if commanded DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA Clear Jog Forward DLC R Feed To Length Control User s Manual This input is typ
108. both operating personnel and the machine builder It explains how to interface install set up and operate the Indramat DLC Positioning Control with DR software Hardware and Software Support This manual describes the DLC1 1 hardware used with software version DR1 02VRS Indramat provides assistance for any problems you may encounter with this system Your first source of information should be this manual To report a problem or request assistance call Indramat at 847 645 3600 between 9 00 AM and 5 00 PM Central time Ask for a Service Engineer You may also write or FAX to the following Rexroth Indramat Attn Service Engineering 5150 Prairie Stone Parkway Hoffman Estates IL 60192 FAX Number 847 645 6201 1 4 General Description DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA 1 2 How To Use This Manual DLC R Feed To Length Control User s Manual The manual is organized such that Chapters 1 and 2 describe the DLC control and its operation These chapters plus Chapter 8 on diagnostics will be sufficient for most operating personnel Chapters 3 8 provide functional description installation set up parameter entry and diagnostic and troubleshooting information required by the machine builder and set up personnel Chapter 1 General Description Chapter 2 Controls amp Indicators Chapter 3 Functional Description of Standard Features Chapter 4 Functional Description of Special Features
109. cr 1lf ncstation number if B118 2 or 3 single SOT or SOT on RS 485 bus This message is an acknowledgment of correctly stored data when the Serial Interface Mode Parameter B118 is 2 or 3 or 1 or if acknowledgment is enabled SOT ScreenManager Notes The SOT is preprogrammed using Indramat ScreenManager This software package runs on any PC computer using MS DOS This program was used to write the information and prompt lines that appear on the SOT display The command lines are downloaded to the SOT From the SOT keyboard data can be entered in response to these command line prompts The SOT for the DLC R is preprogrammed with prompts for its general application Use this program if desired to further customize the screen for a specific application DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 4 1 DLC R Feed To Length Control User s Manual INDRARMA This section provides a short note about an easy access to the batching data over the serial port The working part can be used for easy access to all Batching data while conserving SOT memory Alternately the Part Blocks may be treated as program blocks For example instead of Part Block 10 the Block in the Screen manager can be set up in the command file as Block 100 To facilitate this the DLC ignores the character after the Part block Also each feed can be accessed as a program block Part 10 feed 1 can be called Block 101
110. ct 1 Turn OFF the Auxiliary Feed Length selection input 2 Press Clear and enter the Parameter mode 3 Enter the desired Auxiliary Feed Length in Parameter B103 4 Verify that the Parameter B112 MW Selection is not enabled to use the Auxiliary Feed Input DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 13 DLC R Feed To Length Control User s Manual INDRARMA 8 14 Diagnostics and Troubleshooting Count Exceeds Part Quantity This cycle stop soft fault is issued if the part quantity entered is less than the current part count To correct this error clear the current count by entering a zero in the part quantity then press the clear key or input Battery is Low Replace it Soon Indicates the RAM Backup Battery is low Fault will not be issued if an Automatic Mode cycle is in progress or if an axis is feeding After clearing the fault it will be issued every 60 minutes as a reminder To prevent loss of parameters and batch programming replace the battery within two weeks of when the fault is first issued Turn power OFF to the DLC remove the Memory and Battery Module and replace the 3 5 volt Lithium battery Before disconnecting the old battery connect the new battery to the second connector other side of battery NOTE If the battery voltage gets too low all RAM data parameters feed length and rate batch programming will be lost and needs to be re entered after replacing the batte
111. d OFF during DLC operation with R C networks AC or diodes DC Correct grounding is essential for trouble free operation The ground connection must be made by observing strictly the branching conditions shown in the wiring diagram 6 4 Transformer Heat Dissipation The incoming 3 Phase power must be ground reference Use an isolation transformer with a Y secondary if this cannot be confirmed If a transformer is needed for operation exercise caution on its location Do not install the transformer in the same cabinet as the modules unless a sufficient method of cooling is applied 6 5 Hardware Installation 6 2 Installation See Appendix E for mounting hole dimensions and location of the CTA keypad and display module the cut out dimensions for the remote keypad keypad gasket and mounting holes and cut out dimensions for the optional IDS The mounting dimensions and cabinet cut out data for the TVD DDS or DKS are located in the units respective support manuals DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual The method of mounting the MDD Digital AC servomotor is dependent upon the application Additional information and a drawing package for the MDD servomotor is available on request from Indramat 6 6 Electrical Installation There are many variations of wiring techniques used to connect the DEA 4 System I O Card to the machine builder s equipment The Interconnect Dra
112. d Set up Modes The jog feed rate is typically a much slower speed than the maximum feed rate It is recommended to start with a Jog Feed Rate at 10 of the Maximum Feed Rate A104 Adjust higher or lower as desired for the application Example Jog Feed Rate Maximum Feed Rate A104 x 10 Parameter A106 Maximum Acceleration Rate Accel Rate A106 0123456 7 Input Unit Input Units per second Input Value Minimum 00000100 regardless of decimal point Input Value Maximum 99999999 regardless of decimal point Decimal Places A100 1 figure shown A100 02 When Constant Acceleration is selected A108 0 this parameter specifies the constant acceleration rate used to reach peak velocity When Jerk Limiting trapezoidal Acceleration is selected A108 not 0 acceleration is ramped up to the value specified in A106 and then ramped down to zero until peak velocity is reached You select the shape of the acceleration profile in Parameter A108 refer to the section Parameter A108 Maximum Allowable Jerk Note It is absolutely necessary to balance the Position Gain and the Maximum Acceleration Rate in order to avoid position overshoot DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 9 DLC R Feed To Length Control User s Manual INDRARMA Parameter A107 Maximum Deceleration Rate Max Decel Rate A107 0000012 3 Input Units Input Units per second Input Value Limits If A108 0 Limits are the same as A106
113. d only during an Automatic Mode cycle The maximum change window is based upon the first programmed feed length after a Cycle Start or Resume A new Maximum Change limit will be accepted on the next cycle after it is changed and STORED The limit may be disabled by entering a zero 0 in the parameter Feedlength Exceeds Maximum The feed length Maximum Limit is set in Parameter B104 This error is immediately displayed if the programmed feed length exceeds this limit while not in an Automatic Mode cycle While an Automatic Mode cycle is in progress the programmed feed length is checked only when a feed is about to begin change not recognized until start of next cycle This prevents a feed from being interrupted by an erroneous feed length entry during the current cycle An erroneous entry will cause the error to display and turn off the Permit Press output Change length to within limits and press Resume Cycle to continue Feedlength Less Than Minimum The feed length Minimum Limit is set in Parameter B105 This error is immediately displayed if the programmed feed length is less than this limit while not in an Automatic Mode cycle While an Automatic Mode cycle is in progress the programmed feed length is checked only when a feed is about DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 17 DLC R Feed To Length Control User s Manual INDRARMA to begin change not recognized until start of next c
114. e The displayed Part Block Number and Part ID are being programmed by entries on this page Feed Number f The feeds are executed in order from 1 to 6 within each part Data fields for feeds 1 to 6 can be accessed sequentially by pressing the and keys or access a feed directly by typing over the number Feed Quantity xxx The feed quantity is the number of times the feed will be executed before starting the next feed or the next part If a is entered here the part is completed after the previous feed For example if only two feeds are desired for a Part a must be entered in the feed quantity of Feed 3 The display will show in the feed quantity for the end of the part A in the feed quantity is not allowed in Feed 1 since each part must have at least one feed An entry of 000 is not allowed in any feed quantity Feed Length mll Ill and Feed Rate rr r A unique feed length rate and direction can be selected for each feed The feed length can be micro adjusted by pressing or while in the first digit position indicated by m A minor error is issued immediately if feed length limits are exceeded set in parameter while the DLC is not in an automatic mode cycle The display changes to the status page first display on the DLC display map The current feed page is automatically displayed when you scroll to the batch main programming page During a cycle only the current feed is checked
115. e of a soft fault the following occurs If feeding the axis decelerates to a stop the DLC commands zero velocity axis decelerates at the rate set in parameter for deceleration Outputs remain in the last state they were in high or low at the moment of fault detection Position value of the axis is maintained by the DLC remembers position within feed The appropriate fault diagnostic message is issued displays To clear a soft fault Determine and correct the fault causing condition Initiate the Clear input or the CL key to clear the fault status and diagnostic message If in Auto Mode and A Resume Req d is displayed press Resume Cycle to continue automatic operation Some faults are issued after the DLC stops the cycle Minor Errors are messages which indicate that a condition required to continue has not been met Upon the detection of a Minor Error the following occurs If feeding the axis decelerates to a stop the DLC commands zero velocity axis decelerates at the rate set in parameter for deceleration Outputs remain in the last state they were in high or low at moment of error detection Position value of the axis is maintained by the DLC remembers position within feed DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 5 DLC R Feed To Length Control User s Manual INDRARMA Status Messages e The appropriate error diagnostic message is issued displays A Mino
116. e of two continuous modes Press Before Feed or Feed Before Press Figure 3 3 Continuous Mode Press Before Feed and Figure 3 4 Continuous Mode Feed Before Press are timing charts which illustrate these operations DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 7 DLC R Feed To Length Control User s Manual INDRAMA 3 3 8 Functional Description Standard Features When the Feed Angle input from the user interface goes high the DLC commands the servos to operate feeding material to the length and at the feed rate specified by the operator During the cycle the DLC issues various outputs which are normally wired to indicators on the user s control panel Feed In Progress output is issued while the feed is occurring Feed Complete output is issued when the feed is complete and the axis is within the position threshold Axis 1 In Position output is issued once the axis has arrived within the parameter specified in position threshold window If Feed Angle is lost during a feed the DLC decelerates the feeder to a stop and issues a diagnostic message This typically indicates that the press cycle is too fast It does not allow sufficient time for a complete feed to occur between when the ram leaves the material on its upstroke Feed Angle goes high feed begins and when the ram approaches the material on its downstroke Feed Angle drops low is lost If Feed Angle is lost or the
117. eated hh cr 1lf line 2 of display line 1 of display System Information Request X 02 The DLC will respond with a code that corresponds to the current mode and other operating information X 02 mx hh cr 1lf m Current mode 0 manual 12 automatic 2 parameter 4 18 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 NID ZZ DLC R Feed To Length Control User s Manual 3 2 setup X Other information 0 Step jog off not in cycle 1 Step jog enabled in manual mode In cycle in automatic mode Distance Moved Request X 03 If an axis is disabled stars will be sent in place of that axis DLC R Response X 03 1400123 456 k x x k S hh cr lf Measuring Wheel Data Request X 04 If measuring wheel is not enabled by parameter an error message will be sent X 04 xys_ mmm mmm_ aaa aaa hh lt cr gt lt lr gt x Selected axis for M W compensation 1 for DLC R y Free for future use always zero S status 0 M W compensation off 1 2 M W compensation on in auto mode amp input high mmm mmm Actual position of Measuring Wheel aaa aaa Actual position of corrected Axis Current Feed length Request for Axis 1 X 05 X 05 4012 345 67 8 hh cr 1lf If B100 00 always includes a sign Diagnostic Code Request X 07 The DLC will respond with the current diagnostic code see diagnostic code section X 07 8B hh cr 1lf
118. ed in Parameter B112 The Measuring Wheel Select input must be high to enable Length Compensation in Automatic Mode or parameter B112 has an option to enable it without an input DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual The Measuring Wheel position page shows the current position of the measuring wheel and the Axis being used for Length Compensation The STORE key will freeze the display for two seconds Axis 1 001 234 M Wheel 001 240 M W Position Display The M W position display is active in all modes regardless of the M W Select input so that deviation can always be checked Pressing the right or left arrow key will cause display of the axis and measuring wheel feed constants as set by parameter These are useful when fine tuning the system Editing of parameters is allowed only in Parameter Mode A101 0001 0000 B116 0001 0020 M W Parameter Display Refer to Chapter 4 and to the Parameters B112 B116 and B117 in Chapter 5 for further information on the Measuring Wheel feature Row F Refer to the Display Map in Figure 2 2 Map of CTA Control Panel Display Pages Press the down arrow key from any page in Row C to see the Batch Current Part Information Display if Batching option is selected This section overviews the display pages used in batching Refer to Chapter 4 for additional information on batch programming options INFO_01 11111111 Qty 000100
119. ed into the batching pages Pressing Cycle Start If the DLC has just been powered up or a new starting part has been entered execution begins at the starting part entered in the Batch Part Information Page or selected through the Binary BCD inputs If the cycle has been stopped during part execution by a Cycle Stop Part Stop or a Fault the program will be continued with its current part feed and count values until a Jump to Block 00 is encountered as programmed to end the current batching program Part Execution Sequence The current feed count is incremented upon each high to low transition of the feed angle signal The feed number is incremented when the target feed quantity is reached The DLC checks if the current feed number is 6 or the new feed has a stop on feed programmed If either condition is met the current part count is incremented and the feed number is reset to 1 If it is a linked part with more than six feeds the part continues with the feeds in the next block programmed as jump to DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 7 DLC R Feed To Length Control User s Manual INDRARMA If the part quantity is reached and a Jump to Block is programmed execution starts at the part block jumped to and the feed number is reset to 1 If the part quantity is reached and a stop at end of part is programmed by entering a 00 jump the cycle is stopped and the status
120. eed number and count will be the same regardless of which part is selected If a B COO is requested and the part is a linked part the counts defined in the end block will be sent B CO1 000123 000012 2 O12 hh cr 1f l l_Current feed count l Current feed number l Current part count Part quantity Axis 1 feed length feed rate and feed quantity B FO31l lt cr gt lt lf gt e g for Part 03 Feed 1 The feed number must be sent after the part identifier and the DLC sends the sign of the feed length after the feed number without a space between them The feed length and feed rate are sent from the DLC with the decimal points in the proper positions The target count for the selected feed are sent after the length and rate B F0314001 234 56 7 O12 hh cr 1lf II l Feed quantity N Axis 1 Feed rate Axis 1 Feed length Axis 1 Feed direction Current Part Block and Program Status B A cr lf When part linking is performed program status is also included in the string sent from the DLC If a linked part is being executed the starting block of the linked part is sent When the end of the part is found its corresponding part block is sent The status Linking Program and Link on the DLC display can be decoded from this string as well as the location of the current part counter DLC Response when part is not linked Normal response BA 12 hh cr lf Current part block DOK DIAX02 DL
121. engineerin g mannesmann Rexroth DLC R Feed to Length Control With SOT Supplement User s Manual DOK DIAX02 DLC1 1 DR1 ANW1 AE P K 274578 E Indramat Title Kind of documentation Docu type Internal filing remarks Purpose of this document Course of modifications Copyright Validity Published by DLC R Feed to Length Control with SOT Supplement User s Manual DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P IAE 68003 REV B 06 97 This document is written for both operating personnel and the machine builder It explains how to interface install set up and operate the Indramat DLC Positioning Control with DR software IAE 68003 REV A Firmware DRO1 1 01 0 03 94 Initial Release DOK DIAX02 DLC1 1 DR1 02VRS ANWH AE P 06 97 INDRAMAT 1997 Copying this document and giving it to others and the use or communication of the contents thereof without express authority are forbidden Offenders are liable for the payment of damages All rights are reserved in the event of the grant of a patent or the registration of a utility model or design DIN 34 1 All rights are reserved with respect to the content of this documentation and the availability of the product INDRAMAT e 5150 Prairie Stone Parkway e Hoffman Estates IL 60192 e Tel 847 645 3600 e FAX 847 645 6201 INIDRADIZAL DLC R Feed to Length Control User s Manual Contents Chapter 1 General Description 1 1 USR tore TD TIERE 1 4 H
122. ength Control User s Manual INDRAMA 8 20 Diagnostics and Troubleshooting A Cycle Delay Indicates the cycle is complete and the DLC is currently waiting for the Minimum Cycle Time delay set in Parameter B109 for Press Intermittent mode of operation to expire before starting the next automatic feed cycle A Resume Req d Displayed after clearing a fault to indicate a Resume Cycle input is required Pressing the Resume button causes the DLC to continue the automatic feeding cycle from where the axis stopped A Waiting Press Indicates the DLC is waiting for the press to continue its stroke cycle until the Feed Angle input is available indicating it is safe to feed material A C Stop Active Displayed if the Cycle Stop input is low active while in Automatic Mode but not cycling This message also displays when single stepping during batching pressing Cycle Stop and Cycle Start together causes the DLC to step one feed and press stroke at a time If the Cycle Stop button was not pressed as described for either case above check the push button switch connectors and wiring for an electrical open A Start Active Displayed if the Cycle Start input was high upon entering Automatic Mode This message could indicate the Cycle Start input is wired incorrectly or the Normally Open push button is not functioning properly A Resume Active Displayed if the Resume Cycle input was high upon entering Automatic Mode
123. ent display See Part Linking page 4 6 The current feed data is displayed in the bottom row The current feed number f changes with each change in feed The current feed count xxx is shown and counts up or down according to the count mode parameter The current feed length and rate are displayed in the Feed Length Page as described in Chapter 2 Controls and Indicators Batch Main Programming Display Page Batching programs are entered in the Batch Main Programming Page Data fields for a part may be accessed by typing either the Part Block or Part ID number The Batch Main Programming Page allows branching free run or single part operation A part quantity is entered to set the number of times the part is executed An Early Warning count is provided to turn ON an output when a part is near completion If more than six feed lengths are desired part blocks may be linked together to add up to six feeds per linked block You can create a single part with up to 594 different feed lengths and one part quantity Main nn iiiiiiii Jump to Block pp Quantity qqqqqq Early Warn eee Batch Main Programming Page Part Block Number nn This number from 01 through 99 is associated with feed and gagging data for a part The display of part block and its data can be changed by typing over with another part number The information on the display will be updated as the keys are pressed The part number may also be incremented or decreme
124. er string format The text is sent in the currently selected language Response format X 25 cc 40 character message hh cr 1f cc Current status code Examples X 25 8BAxis 1 Motor Has Overheated hh cr 1f X 25 O1M No Jog Command hh cr 1f Current Drive Status Message Request X 28 The DLC will send the current Drive Status Message as it appears on the CTAA display The 32 charater message is in the current language and is centered for 16 character lines Response format X 28 32 character message hh cr 1f Examples X 28 Drive Enabled hh cr 1f DSM Version Number X 29 The DLC will send the firmware version of the drive s DSM module Examples X 29 DSM2 1 C11 03V02 hh cr lf 4 22 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual Status Input Status Input Requests are used to download values to the DLC or to reset counters and accumulators Batching information may not be accessed by these requests but have their own set of identifiers see following sections for batching information requests and input information Status No nn Input Request 00 Feed length and feed rate Axis 1 when batching not enabled 02 Reset Distance Moved display 03 Reset Total Piece count 04 Reset Total Length Feed length rate Input when Batching not enabled
125. erial port Action requests to the DLC include Step Mode ON and Step Mode OFF commands All action requests must include a checksum if enabled Step Mode On Request S 01 hh lt cr gt lt 1 f gt This string will put the DLC into Step Jog Mode for manual mode jogging Step Mode Off Request S OO0 hh cr 1f This string will turn off the Step mode and cause the DLC to jog normally i e as long as the jog inputs are high Step Mode Toggle Request S 02 hh lt cr gt lt 1 f gt This string will toggle the DLC from jog step ON to jog step OFF and vice versa Operating Mode Requests The operating mode of the DLC may be changed through the serial port if the set up and automatic mode inputs are low Otherwise the DLC will issue a serial port error The parallel system inputs take precedence over the serial input strings once they are toggled from high to low Parameter mode can only be selected by DLC input Select Manual Mode S O3 hh lt cr gt lt 1f gt Select Automatic Mode S 04 hh lt cr gt lt 1 f gt 4 32 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DIESIBOD ZZ Polling Request DLC R Feed To Length Control User s Manual Select Set up Mode S O5 hh cr lf Press Cycle Mode Toggle Request S O7 hh lt cr gt lt 1f gt The Press Cycle Mode is toggled between Press Intermittent and Press Continuous if the corresponding DLC input is low The notes for
126. ets which show the organization of each parameter and provide spaces to list each entry 5 4 Unit of Measurement Input Unit The Unit of Measurement also referred to as Input Unit IU is the type of measurement category selected that best suits the application Categories include inches feet millimeters degrees etc Parameter B101 displays the dimensional input unit category currently selected This parameter is designed only as a memory aid for the user The settings in this parameter will in no way affect the computation or operation of the DLC All calculations are based on the feed length resolution A100 The unit of measurement is typically determined by the number of decimal places of resolution required for the application as described in the section Parameter A100 Feed Length Resolution 5 5 Parameter Set A1 The following sections describe the parameters in set A1 required for the DLC to command motion Each parameter description includes an illustration of the DLC display and the formula required to obtain the parameter value where applicable For easy reference this section describes each parameter in numerical order A1 set then the B1 set Parameter A100 Feed Length Resolution Feed Length Res A100 02 Input value limits between 01 and 04 This parameter controls the decimal point placement for most of the parameters shown in the DLC display The number of decimal places determines the level of resolu
127. ey on the CTA keypad Their use is further described throughout the manual for specific functions DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Controls and Indicators 2 1 DLC R Feed To Length Control User s Manual CL CR amp 7 0 9 lt gt 3 2 2 controls and Indicators INDRARMA Clear Use to clear the a displayed fault message if the fault can be cleared It also clears parameter entry errors See Store key for additional uses Carriage Return When changing data values press this key before pressing the Store key to cancel the change and leave the data as previously stored clear entry In Parameter Mode use this key to change between parameter sets A1 A2 and B1 Store Press to store save values entered while in Parameter Mode or feed rate feed length and batch program values while in other modes In other modes use to move the cursor to the home position of the particular display Use to toggle between certain displays see next section When on the respective display press this key to freeze the Total Length value for two seconds or to change state of Jog Step Mode press the CL key and the Store key together to reset the Piece Count or to clear the Total Length value to zero Plus and Minus Use to specify the feed length direction micro adjust data fields Numerical Keys Use for entering data values Left and Right Arrow Use to move the cursor to the lef
128. feed length or increase the feed rate DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 11 DLC R Feed To Length Control User s Manual INDRARMA 8 12 Diagnostics and Troubleshooting e Increase speed decrease cycle time of the press external to DLC If Parameter A113 0 then the material was tugged out of position due to press contact Movement While Feed Angle Low Displayed when the axis material slips out of the position window after while the Feed Angle is low The setting in Parameter A113 Low Feed Angle Threshold is used to determine if the material is tugged out of position due to press contact To correct this fault condition raise the Low Feed Angle Threshold check for other parameters that may be causing instability check cables or system mechanics for cause of axis movement Press Timeout Has Expired Occurs when the press has not cycled high to low feed angle transition in Automatic Mode for a period defined in Parameter B109 Set the time in the parameter as required for the application The limits are from 1 to 99 minutes Set time to 00 to disable After this fault is cleared a resume input is required to continue the cycle Invalid Mode Selection This indicates that the Auto and Set up modes are both selected both inputs high Check the following inputs X 17 Pin2 Automatic Mode X 17 Pin 13 Set up Mode NOTE The Parameter Mode can override any other mode when
129. for additional information 8 6 Minor Error Messages This section provides a complete list of Minor Error diagnostic messages and an explanation of the potential cause s DLC System Error Code MNROO An internal system fault has occurred in the DLC NOTE For any DLC system error display call Indramat home office Advise them of the error code number displayed Zero Feedlength Entered This indicates the feed length is set to zero 0 on the DLC or from the IDS etc If in the Automatic Mode enter the desired feed length and press the Resume Cycle button to continue the automatic cycle operation If in Set up Mode select the desired feed length and the diagnostic message will clear DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 15 DLC R Feed To Length Control User s Manual INDRAMA Note This message does not apply when in Set up Mode as the feed rate used is the predetermined jog velocity set in parameter 8 16 Diagnostics and Troubleshooting Zero Feedrate Entered The feed rate entered is set to 096 on the DLC from the IDS etc If in Automatic Mode select the desired feed rate and press the resume button to continue the cycle Drive Is Not Enabled The Digital Servo Drive is not in a Drive Enabled state Check perform the following to correct 1 Apply Power to the amplifier 2 Checkthe amplifier connection 3 Check the amplifier for a fault Ax
130. fore Feed and Figure 3 6 Intermittent Mode Feed Before Press for timing charts which further explain intermittent Press Before Feed and Feed Before Press Modes 3 When the Feed Angle input from the press goes high the next feed movement is initiated At the completion of the feed the Permit Press output is issued if and only if the Minimum Cycle Time has elapsed These actions occur at the appropriate time depending on the selection of Press Before Feed or Feed Before Press During the cycle the DLC issues various outputs as described under continuous operation above When Feed Angle goes low Permit Press output is also pulled low Because of the press clutch retaining circuitry that most press builders employ the press completes one cycle The press clutch engagement retaining circuit releases the clutch and sets the brake such that the ram stops at Top Dead Center TDC The press then waits dwells until the DLC initiates the next press cycle The minimum amount of dwell time at TDC is controlled by the time value entered in Parameter B109 If the minimum cycle time is less than the sum of the press cycle time plus the feed time the Permit Press will be issued immediately output high at the end of the feed The Press Immediate Stop output is also pulled low when Feed Angle is lost during a feed or other various faults occur See Press Immediate Stop Page 3 28 If the user has wired this signal to his press it will attempt
131. ght if the Bipolar Velocity Limit Value and type in the desired velocity in revolutions per minute RPM Note The value entered should not exceed the maximum velocity of the motor If an operating velocity of less than maximum is desired enter that value here Overload Factor The Overload Factor is determined based on the desired intermittent torque and duty cycle of the system Consult the Indramat Digital AC Servo Drive Selection List for the proper Overload Factor Value For the purpose of testing the DLC with the servo drive set the Overload Factor to 10096 Position the cursor to the right of the Overload Factor and type 100 Position Data Scaling At The Analog Output Degrees 10V When the position values are selected for either of the analog outputs the Position Data Scaling defines a zero to ten volt linear scaling based upon the angle of the motor s rotor position For an example if 360 degrees were entered one revolution of the motor would provide on linear voltage ramp from 0 to 10V Position the cursor to the right of the Position Data Scaling and type in the desired degrees Typically 360 degrees is entered Velocity Data Scaling At The Analog Output RPM 10V When the velocity values are selected for either of the analog outputs the Velocity Data Scaling defines a zero to ten volts linear scaling based upon the velocity of the motor in RPM For example if the DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97
132. gth Maximum Change During Cycle 5 21 Parameter B107 Feed Length Micro Adjust Increment a 5 21 Parameter B108 Jog Step Parameter 5 22 Parameter B109 Press Interface Mode 5 22 Parameter B110 Not US d AA 5 24 Parameter B111 Batching Option 5 24 Parameter B112 Measuring Wheel MW Selection sssssenm 5 26 Parameter B113 Not sed coded rose se eh dat fite Do ede hama heo 5 26 Parameter B114 Not Used n 5 26 Parameter B115 Not Used A 5 27 Parameter B116 Measuring Wheel Feed Constant 5 27 Parameter B117 Measuring Wheel Encoder aa 5 27 Parameter B118 Serial Interface 5 27 Parameter B119 Serial Port Operation 5 28 Parameter B120 Not Used eene nnns nnn nnn ntn tr sls s enhn n nnns ness nein 5 29 Parameter B121 Nob Ee WEE 5 29 Parameter B122 Slug Width Compensaiion nennen 5 29 5 7 Parameter Get CO eb op member c erp dede c pet EE eques 5 30 Parameter C000 Analog Output Channel 5 30 Parameter C001 Analog Output Channel 2 5 30 Parameter C002 Overload Factor nennen nnn nnne nnns 5 31 Parameter C003 Position Data Scaling at Analog Outputs AK1 and AK2 5 31 Parameter C004 Velocity Data Scaling at Analog Outputs AK1 and AK2 5 31 Parameter C005 Velocity Loop Monitoring 5 31
133. hanism The MDD AC Servo Motor includes a high resolution feedback which provides velocity and position feedback to the digital servo drive ensuring precise repeatable positioning of the material being fed The final accuracy of the feed system depends on various factors such as type of material gearbox backlash and other machine mechanics DOK DIAXO2 DLC1 1 DR1 02VRS ANW1 AE P 06 97 General Description 1 3 DLC R Feed To Length Control User s Manual INDRARMA System components are modular thus installation and replacement of any component of the system is fast and easy The Indramat Digital AC Servo Drive and the MDD AC Servo Motor have quick connect cabling The drive and MDD Servo Motor are matched for optimum operation using a plug in DSM module Thus should a failure occur replacement of the digital drive is accomplished quickly without the need for electronic fine tuning This results in a minimum of lost production The system is designed to ensure operating integrity and safety using various inputs and outputs for handshaking to assure that the feeder and subsequent processing station or device operate in harmony A complete diagnostic system monitors all inputs outputs and operating conditions and stops the system if a fault is detected Diagnostic messages are displayed to aid the operator in troubleshooting problems and quickly getting the system back into production 1 1 About this Manual This document is written for
134. ibe the installation of the DLC Control Module The installation particulars of the other components such as a TVD TVM or KDV power supply the DDS Digital AC Servo Drive or DKS self contained power supply and digital servo drive module are explained in detail in their respective manuals Tools required A small 1 8 blade standard screwdriver A multi meter VOM meter An appropriate wrench for 1 4 machine type bolts use for mounting module s to cabinet VT 100 terminal or PC with VT 100 terminal emulation software IN 391 Cable PC to Indramat Digital AC Servo Amplifier 6 1 Mounting Cabinet The enclosure should be sufficient to protect the equipment from contaminants such as water oil etc Indramat recommends a NEMA 4 or 12 enclosure or equivalent DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Installation 6 1 DLC R Feed To Length Control User s Manual INDRAMA 6 2 Power 6 3 Cable Routing The DLC receives its power from the controller being used Refer to separate manuals for power requirements of the other modules power supply servo drive etc For higher reliability the high resolution feedback cables must be shielded and routed away from high voltage power sources to reduce electrical noise Do not route the cables near high amperage type machines like welding equipment which produce strong magnetic field interference Suppress inductive loads such as solenoids and motors that are switched ON an
135. ically wired to a normally closed switch or optical sensor for material loop detection If a feed interrupt occurs it typically means you should slow the system so it is not tugging material causing loss of loop tight loop or you should increase the speed of the uncoiler WARNING If the automatic cycle is interrupted by a low 0 Vdc on the Feed Interrupt line all feed motion is suspended Once this signal is restored 24 Vdc the feed cycle will immediately resume Personnel should use extreme caution when entering the work area if the feed has stopped as a result of this signal It is recommend to use the Feed Interrupt Indicator output to advise operating personnel when this condition exists Connector X17 pin8 Function Input Clears the Hard or Soft Fault status of the DLC High momentary Clears the Soft Fault status of the DLC or Clears the Hard Fault status and re initializes the DLC Once a fault occurs the DLC displays a diagnostic message refer to Chapter 8 The operator must then physically correct the problem Next the operator must press the Clear button to clear the diagnostic message For a soft fault or minor error press Resume to restart operation in Automatic Mode message Resume Req d on display With a hard fault the system must now be restarted This signal is typically wired to a normally open push button switch on the user control panel Connector X17 pin9 Function Input Jogs a
136. ies 1 Hard Fault 2 Soft Fault 3 Minor Errors Status Messages A hard fault is the indication of a condition that could result in damage to equipment or harm to personnel It halts all machine operation by dropping the 3 phase power to the motor single phase on some motors The motor is generally stopped as soon as possible by regenerative braking At the occurrence of a Hard Fault the system zeroes out all reference to position Material in the machine is typically scrapped The DLC system must be restarted after the fault is corrected Upon the detection of a hard fault or the loss of the EMERGENCY STOP input causing a hard fault the following occurs e The E Stop chain is broken e The 3 phase power is dropped drive stops e All outputs are switched off except System Fault indicator e A diagnostic fault message is issued displays To clear a hard fault 1 Determine and correct the fault causing condition 2 Initiate the Clear input from the user control panel or the CL key on the CTA keypad to initialize the control the DLC will verify inputs parameter data etc and will clear the fault status and diagnostic message 3 Restart the DLC control system DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA Soft Fault Minor Errors DLC R Feed To Length Control User s Manual A soft fault is an indication of a condition that is inhibiting normal operation of the system At the occurrenc
137. ingle step feature with the start and stop inputs or enter a set up sequence in the Batching program The feed and part counts are not updated in Set up Mode Parameter B102 Interface Option allows you to select the method of entering the feed length and rate into the DLC Refer to Chapter 5 for description of parameter entry The batching parameter options are summarized in this section 4 8 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual Count Mode This option allows the display of the number of parts created or parts remaining count up or down It applies to both the current part count and the feed count Press Before Feed Batch Complete This option specifies whether the last feed in a single part or sequence of parts is performed when Press Before Feed Operation is selected in the Press Interface Parameter end after feed or after press It does not apply to Feed Before Press operation See parameter description in Chapter 5 for an illustration of this function Default Batch Program Values The DLC loads default values if data has been lost due to battery failure or at initial shipment The soft fault Batching Program Was Lost is issued after DLC initialization if default values are loaded in any of the parts The following lists the default values Reprogram or verify data for each part and press the STORE key to save the data to DLC batte
138. ion Axis Jogging In Manual Mode Connections 7 1 Inputs 7 1 7 2 Parameter Entry 7 4 Power up 7 3 Status Diagnostic Display Alphabetical Index System Features 1 6 7 9 7 4 7 8 8 1 8 2 System Status Messages 8 18 Automatic Mode 8 19 E 6 Index DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRARMA C Stop Active Cycle Delay Cycle Stop Feeding No Cycle Start P Stop Active Part Stop Resume Active Resume Req d Start Active Wait Fd Angle Waiting Press General 8 18 8 20 8 20 8 19 8 19 8 19 8 21 8 21 8 20 8 20 8 20 8 19 8 20 DLC R PARAMETER MODE Initializing Sys 8 18 Jog Input Active 8 19 Manual Mode Feed Forward Feed Reverse No Jog Cmd Wait Fd Angle 8 21 8 21 8 21 8 21 Manual Mode Messages Setup Mode Fd Incomplete Feed Forward Feed Reverse Release Jog Start of Feed Wait Fd Angle Waiting Press 8 22 8 22 8 22 8 22 8 22 8 22 8 22 Setup Mode Messages x x zi o Go Ka e o co Ka Si rd o co DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 8 21 8 22 DLC R Feed to Length Control User s Manual 8 18 Index E 7 READER COMMENT CARD AND REGISTRATION FORM We welcome your evaluation of this manual Please complete this form to help us to improve our publications and also to receive notification of revisions to this manual Publication DLC R Feed to Length Control with SOT Supplement Publication No IAE 68003 Revision B June 1997 P
139. ion the feed length and feed rate are entered into the DLC using the IDS thumb wheel switches This display shows IDS in the first line indicating the option is selected It does not contain a cursor or allow editing from the keypad The display is only for information of the settings made through the IDS connected to the RS 232 connector of the DLC The display shows the last data entry processed after a two second delay from when the thumb wheel switch is changed If the serial port transmits an invalid character a will display instead of a digit or digits Enter the settings again check connections etc until the display data is valid IDS Feed Length Rate 001 234 12 Feed Length and Feed Rate Display DLC R with the IDS Interface Option Feed Length and Feed Rate on a DLC with the Batching Option Enabled The batching option allows setting multiple feed lengths and feed rates for each part and up to 99 different parts The Current Part feed length display on Row C shows information for the current feed of the part currently executing or ready to be executed Procedures for entering changing data feed lengths feed rates etc for the batching option are described in this section under Rows G and H Current Feed Length Rate 001 234 12 2 Feed Length and Feed Rate Display DLC R with Batching Option Selected DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s M
140. is 1 Has Not Reached Position This indicates the input to select Automatic Mode or Set up Mode is high but the axis is not stopped within the position threshold To correct ech Check the In Position Threshold setting in Parameter A110 Setting may be too tight N Check for amplifier failure e Verify Encoder and cable is functioning properly Stop Due To Interrupt Input The Feed Interrupt input X17 Pin 7 has gone low causing the axis motion to halt WARNING In Automatic Mode the feed will resume automatically when this signal returns Use the Feed Interrupt output to advise operating personnel of this condition DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual Feed Angle Is Missing This error is issued in three different situations 1 Appears upon entry into Automatic or Set up Mode if the DLC detects the Feed Angle input is low 2 After either soft fault Feed Angle Lost During Feed or Movement While Feed Angle Low is cleared and the Feed Angle input is low 3 Ifa Cycle Start is actuated while the Feed Angle input is low Check the feed angle switch or sensor and its connections This error will clear when the Feed Angle input goes high Change in Fdlgth Exceeds Limit The limit is set in Parameter B106 Feed length Maximum Change It is the maximum amount that the programmed feed length can change during a cycle This limit is checke
141. is used by the programmed feed The percent value displayed provides an estimate of the maximum press stroke rate that can be used with the current feed length feed rate and feed angle For example if the current hit rate is 100 strokes min and the time used is 75 the maximum hit rate would be approximately 100 0 75 133 strokes min SPM When the time used approaches 100 the soft fault Feed Angle Lost During Feed will be issued because the press rate is too fast and the feed angle will go low before the feed is complete In Press Intermittent mode the maximum Strokes Minute is limited by the minimum cycle time specified in the Press Interface Parameter The Time Used display does not go above 99 percent A Time Available output can be used to indicate when the stroke rate can be safely increased without loss of the feed angle A light can indicate when the feed time is within 9096 of the maximum hit rate allowed See Chapter 3 for further description When an Automatic mode cycle is not in progress the last Strokes per Minute Time Used values will be displayed After a cycle stop the data can be read even though the press is not cycling The page is not updated in Manual Set up and Parameter modes Hard faults soft faults and minor errors also will not affect the Strokes per Minute value At power up the values are reset to zero Pressing the Store key freezes the display for two seconds The current press mode selection is d
142. isplay will show numeric codes for diagnostic messages The code list index for the IDS is in section 8 8 of this chapter DLC Display Page A C Stop Active 8 20 A Cycle Delay 8 20 A Gycle Stop uuu 22 asss 8 19 Ac Eeeding hie 8 19 A No Cycle Start 8 19 A P Stop Active 8 21 cart STOD ziehen 8 21 A Resume Active 8 20 A Resume Req d 8 20 A Start Active 8 20 A Wait Fd Angle 8 19 A Waiting Press sess 8 20 Amp Overtemp Warning 8 20 Auto Mode Exit Required 8 18 Aux Feedlength is Zero 8 13 Axis 1 Drive Runaway 8 8 Axis 1 Drive Stalled 8 7 Axis 1 Amplifier Hardware Fault 8 8 Axis 1 Amplifier Is Not Ready 8 16 Axis 1 Has Not Reached Position 8 16 Batching Program was Lost 8 14 Battery is Low Replace it Soon 8 14 Change in Fdlgth Exceeds Limit 8 17 DLC SYSTEM ERROR Code HRDOO 8 6 DLC SYSTEM ERROR Code MNROO 8 15 DLC SYSTEM ERROR Code SFT00 8 10 DPR Not Readable e
143. isplayed in the bottom line of the Strokes Min display These modes of operation are described in Chapter 3 e Press Interface Mode PBF Press Before Feed FBP Feed Before Press e Press Cycle Mode Intermittent or Continuous This is changed whenever the corresponding input is changed It may be changed during a cycle Press the right arrow key once The display changes to the Software Version Display The following display shows the current hardware version and the current internal software version Version Numbers DLC1 1 R DLC1 1 DR1 02V06 DSM 2 1 C11 03V02 Software Version Display Press the right arrow key once The display changes to the Jog Step Mode Display This feature allows defining the distance that the DLC will feed when the Jog button is pressed in Manual Mode Jog velocity is set in parameter DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Controls and Indicators 2 7 DLC R Feed To Length Control User s Manual INDRARMA 2 8 Controls and Indicators Jog Step Mode ON Jog Step Mode Display With normal jog Jog Step Mode set to OFF the DLC will feed as long as the forward or reverse jog button is pressed and stops when the button is released With Jog Step Mode set to ON the DLC will feed a parameter defined distance when a jog button is pressed To change the jog mode from Normal Jog to Step Jog press the STORE key while on the Jog Step Mode page The display will indicate the Step Mode is ON or OFF
144. ithout notice Check with Indramat to be sure you are working with the latest drawings prior to installing wiring and powering equipment NOTE This appendix includes a separate set of interconnect drawings for DLC1 1 R DLC1 1 DR1 02VRS Drawing BE1166 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Schematics C 1 MYT IHOBAdOO 32N38343M 03SV3T38 NO Q3i402 38 Ol LON NO ASN H3NOLSND HO4 INANNOOO SIHL O3lIBIHONd SINId3H Ady M33NIDN3 YSCqIING ANIHOVW 3HL 40 AL lTIBISNOdS3H AB Oe S 3HL ATALVWLEIN IXY SIN3NOdWOO LYNVYGNI NON TIY JO ONIZIS ONY NOILO3T3S IHL SII ETE E ve si y Z3NIBIWO we NOlLvOllddv YSWOLSND OI3ID3dS v YO4 Q3033N NOLLVAHOJNI ONINIM 3HL 8 4o 1 mme SIN Jos N38WON Leva M38ADN 003 3NVN ava NOlLdlios 3d ava 3NVN OANI 20 TIY NIVLNOO LON AVW HO AVN LI ATNO SGIND v Sv QdHid4O SI LAS SNIMVHO SIHL CITT 9911 38 mos I Salvis3 NvWa4oH 39V1 OA INN Yad ONIMIM H3dONd NO Een OLLOANNOOMGLNI AJVNVUGNI SAV3OVIO NOLLO3NNOO H3JWSOJSNVHL Ol X343 Z QW 3 210 S xa H LOt1X Siti N3389 38v SIYM ONnOSO TW L TALON DLN DR SN HOLON OAM3S OQ SOLON eist Ze v NH3HL E DEET EE O i r a 8303808 dol L 0 SAI M3QNO8 1331 318vo 133HS d 139A L L SIXV eve H3MO 8 QAN
145. ition Distance Moved Display on DLC R DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual The Lag Display shows the following error the difference between actual and commanded position used by the DLC to calculate the command voltage to the servo amplifier Axis Position Lag 00001 234 Axis Position Lag Display on DLC R Pressing the CR key toggles between the Lag Display and the Distance Moved Display pages The Lag or Dist indicates the Lag or Distance page of the position display respectively A or indicates direction Both display pages have eight 8 digits and are shown in the unit of measurement selected by parameter for the application inches millimeters degrees etc The Distance Moved Display has the same number of decimal places as the feed length resolution set in Parameter A100 In Manual Mode the total distance jogged displays In Automatic and Set up Modes the distance moved during each feed displays At the start of a feed in Automatic or Set up Modes the display is cleared to zero 0 Pressing the CL key will also clear the display to zero when this page is showing on the display The Lag Display has the same number of decimal places as the feed constant one more decimal place than the Distance When the axis is not moving a small lag value will display In order for the axis to be in position the In Position Threshold set in Parame
146. ity commands to the servo amplifier which controls the current driving the servomotor which drives the mechanical feed mechanism The servomotor includes a tachometer and encoder which provide velocity and position feedback to the control ensuring precise repeatable positioning of the material being fed The final accuracy of the feed system depends on various factors such as type of material gearbox backlash and other machine mechanics System components are modular thus installation and replacement of any component of the control system is fast and easy The DLC card servo amplifier and servomotor have quick connect cabling This results in a minimum of lost production The system is designed to ensure operating integrity and safety using various inputs and outputs for handshaking to assure that the feeder and subsequent processing station or device operate in harmony A complete diagnostic system monitors all inputs outputs and operating conditions and stops the system if a fault is detected Diagnostic messages are displayed to aid the operator in troubleshooting problems and quickly getting the system back into production 1 6 Specifications The following sections provide full specifications for the DLC Control and options NOTE Performance specifications can vary depending on the mechanical limitations of the system 1 12 General Description DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA Physical Contro
147. iu 10 0 S 318V9 IVAVSONI Ka quies xo3Ho dnvi 8 TANNVHO 8 ver V Duer V uwen B3 DEE RES 300 YJ009NF TWLNANSYONI 133HM NIYNSYIW MOTI3A N3389 Nid AVES N3349 NMOMN8 aay Move NMOS uv 8190 S f 318v9 LVWVHONI ALIHM 393V1 O od 10 eO O CIV NOLLdO Quvo M30029N3 TVIN3AGSONI 430 Schematics C 7 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 OID RAMAN DLC R Feed To Length Control User s Manual MW11HORAdOO JONAA Een YO 031202 38 Ol LON ATNO ISN YANOLSNO NO4 IN3AT2O0 SIHL O3LIBIHONd SLICES NAONddV M33NIN3 AB O3xo3H2 ap A8 Y6 Gl h ZJNUNVWO NMYMO A8 G3SA33 M04 NOISA3H S L190 6 WO 46 41 20 003 Mad SAY 8 402 133HS SUN 31voS H38WhN Lued N38ADN 0 03 SAWN Alva NOLdI4OSaQ ava INYN OANI AHlHHULI 9911 38 SEALS Vd 7l S31v183 NVW4JOH SAI NOILO3NNOO3BINI IVIAVHONI OOW 3 210 S a H ILOUWX3iu OVA OLL ONnO3S9 NI WIdas IVNOLLdO SI TANVd SAI 3HL dO ASN JHL ALON NI WIdas AV IdSIO ANYOA 1d OS H19N31 XVW ZC lM3SNI OITIVL3A V dO SNVAN A8 ONISNOH YOLOANNOO OL Q3lO3NNOO SI Q HIHS P 8400 SmI J18Y9 SLO ITAS ZEZSY F Lex YOLOANNOD Nid 6 L
148. justed feed length is automatically stored as the new feed length value The micro adjustment feature is disabled when 0000 00 is entered and stored in this parameter Parameter B108 Jog Step Parameter Jog Step B108 0000 50 Unit Input units Decimal Places See Parameter A100 figure shown A100 02 Limits None Use this parameter to set the incremental distance that will be fed with a jog forward or reverse input when Jog Step Mode is set ON from the DLC control panel or from SOT or other host via the serial interface port If this parameter is set to zero jog step operation is not allowed Parameter B109 Press Interface Mode 5 22 Parameters Press Interface B109 01 1 0s 02 A B C A Press interface mode 00 Press before feed 01 Feed before press 02 Press before feed for Set Up mode B Minimum cycle time in press intermittent mode 0 0 9 9 time in seconds C Permit Press Timeout in Automatic Mode 00 disable timeout fault 01 99 timeout in minutes Select one of the feed press modes Input Value Limit 00 01 or 02 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRARMA DLC R Feed To Length Control User s Manual Press Before Feed At Cycle Start the DLC allows the press to complete a press cycle At the end of that cycle the DLC feeds the material into position Once in position the press cycle repeats At Cycle Stop the cycle will end at the completion of the feed Feed Before P
149. k 20 Linked Part on Information Page The Current Part Information Page will indicate a linked part to distinguish it from a normal part The linking process is also indicated since the DLC does not find the Part Quantity until the last link in the chain is found There is the possibility of an infinite loop if no part quantity is found These displays will aid the programmer in detecting this error condition When two or more parts are linked together the Current Part Info Display will indicate that the part is being linked by displaying Linking Part in place of the part quantity As soon as the count is found INFO in the upper left 4 6 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual corner is replaced by LINK and the count of the total part entered at the end of the chain is always displayed INFO 10 10 Qty Count 000000 Feed 1 Cnt 000 Current Part Information Display before linked part is executed INFO 10 10 Linking Part Count 000000 Feed 1 Cnt 001 When executing linked part but count has not been found LINK 20 20 Qty 000100 Count 000001 Feed 1 Cnt 000 After part quantity has been found for linked part Batching in Automatic Mode This section describes the operation of the DLC in Automatic Mode when using the batching option It begins after the part information has been programm
150. l Specifications DLC R Feed To Length Control User s Manual Operating Environment Cooling Allowable Ambient Temperature Range Storage and Transport Temperature Range Maximum Operating Altitude at Rated Values Position Feedback Feed Length Resolution Feed Rate Normal Jog Convection 41 to 113 deg F 5 to 45 deg C 22 to 185 deg F 30 to 85 deg C 3 280 ft 1000 meters higher altitudes permitted with proper cooling Indramat high resolution single turn encoder 0 0001 inches 0 001 mm 0 1 99 9 of Maximum Feed Rate Operator Selected 0 1 99 9 of Maximum Feed Rate Parameter Selected NOTE Maximum Feed Rate will vary depending on the mechanical design of the system Jogging Status Fault Display Entry Keypad DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Forward Reverse Manual Set up Modes only LCD Four lines Alphanumeric 16 Characters Line optional backlit version available 20 membrane switch keys General Description 1 13 DLC R Feed To Length Control User s Manual Power Requirements Optional IDS Module I O Interface Inputs Outputs Interface Options RS 232 485 IDS Module Remote Display SOT 1 14 General Description INDRARMA 50 mA 24 Vdc additional 15 24 Vdc 10 mA pre defined function 16 24 Vdc up to 100 mA sourcing pre defined function This interface allows remote operation and
151. lay and view enter information for each feed required for the part feed 1 up to feed 6 Enter data for part 01 on the main programming page Press CR and enter data for the first feed required for part 01 Press enter data for the second feed for part 01 etc Return to the main programming page Press enter data for part 02 Press CR and enter data for the first feed required for part 02 Press and enter data for each feed required for part 02 Continue this process for each part DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Controls and Indicators 2 1 7 INIDRADIZAL DLC R Feed To Length Control User s Manual Chapter 3 Functional Description Standard Features Several input output signals of the DLC control provide communication with the other components of the machine This chapter describes the functional operation of the interfacing inputs and outputs of the DLC The first sections of this chapter describe the various interface functions in terms of the inputs outputs involved with each This section is followed by an individual description of each pre defined I O signal including name pin assignments and functional description The machine designer utilizes these signals as necessary to implement the DLC for his application including the design of his system control panel Also refer to the appendix for example system wiring of these and other optional signals 3 1 Signal Definitions The states of the input and ou
152. lease indicate the degree to which each statement applies to you by circling whether you Q strongly agree agree are uncertain disagree or strongly disagree with the statement 1 The manual is well organized Q 2 I can find the information I want o OG 060 3 The index is thorough OO Q 4 The information is easy to understand Q 5 The manual is clearly written Q 6 Concepts and vocabulary are easy to understand 000020 S Examples are clear and helpful Q 8 The manual contains enough illustrations 009000 9 Layout and format enhance the manual s usefulness Q 10 The quality of this manual would influence any repeat purchase decision 009000 11 The scope of the information in the manual meets my needs OG Q Name Company Address Dept City State Zip Telephone Comments From Technical Documentation Department Rexroth Corporation Indramat Division 5150 Prairie Stone Parkway Hoffman Estates Illinois 60192 U S A The Rexroth Corporation Indramat Division Main Office 5150 Prairie Stone Parkway Hoffman Estates IL 60192 Tel 847 645 3600 FAX 847 645 6201 Rexroth Indramat Technical Center 2110 Austin Avenue Rochester Hills MI 48309 Tel 248 853 8290 FAX 248 853 8298 Part No 274578 mannesmann technology e C Indramat
153. lect the dimensional unit These codes are listed below K B1010020 ft Dimensional Unit hh lt cr gt lt lf gt 4 digit Unit Code K B1010020 ft Dimensional Unit hh cr 1lf or K B101_0010Shh lt cr gt lt 1f gt Dimensional Unit Legend Text Code in 0000 ft 0010 mm 0020 cm 0030 m 0040 rad 0050 deg 0060 rev 0070 Most parameters may be downloaded to the DLC only while the DLC is in Parameter Mode See Serial Port below The strings to send the DLC correspond to those sent from the DLC after a K command If a parameter is detected as invalid after it is input the DLC will send back an error message E K nnnn INVALID K nnn xxxxxxxx hh cr 1f variable data length DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 3 1 DLC R Feed To Length Control User s Manual INDRAMA Action Requests Store String sent to DLC Feed Constant _K_A101_00012345 CD lt cr gt lt lf gt Batching Option K B110_01110 69 lt cr gt lt 1f gt Interface Option K B102_02 F9 lt cr gt lt 1f gt Dimensional Unit K B101 0030 99 cr 1f Note that extra digits may be added to the end of the string which may make the sending software easier to write For example all 8 digits may be sent for feed length resolution although it is a 2 digit parameter They may also be echoed back formatted Serial Port Parameter B103 Auxiliary Feed Length can be changed on line from the s
154. light on the user control panel Cycle Time Available Indicator Connector X17 pin 19 Function Output Used to indicate when the stroke rate can be safely increased High Indicates the time used by the feed is less than 90 of cycle time available 3 24 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DS SA DLC R Feed To Length Control User s Manual Low Indicates the time used by the feed exceeds 90 or when not in Automatic Mode cycle or before the first cycle time measurement A light can be used as a visual indication to the operator that the press stroke rate can be increased without causing loss of feed angle which would cause a fault If the light is OFF during a cycle the stroke rate time for each press stroke should be increased or the feed rate decreased to assure the feed completes before the feed angle input goes low Permit Press Connector X17 pin 20 Function Output Used to permit engagement of the press clutch High Permits clutch engagement for press cycle operation Low Disengages the clutch and press operation halts Permit Press is issued when the control is ready to begin cycling In continuous Mode it remains high during the automatic cycling It goes low if the control sees a fault or error or a Cycle Stop is issued In Intermittent Mode Permit Press is issued after the feed cycle is complete or before the feed cycle in Press Before Feed M
155. ly and includes all batching and auxiliary feed lengths The DLC displays from 6 to 10 digits of data with a floating decimal point The display may be frozen for 2 seconds by pressing the STORE key The total length is retained in memory at power down To clear the length press the CL key then the STORE key as described in the steps above for the Total Piececount Row C Refer to the Display Map in Figure 2 2 Map of CTA Control Panel Display Pages Pressing the down arrow key from any display in the B row changes to the Feed Length Display the home display of the C row Other displays on this row show relevant parameter settings The parameter data display pages are for information only Parameter data can be edited changed only in Parameter Mode The feed length display allows entering the feed length and feed rate desired for system operation The display looks and functions differently depending on the interface option set in Parameter B102 This parameter selects the method of entering the feed length and feed rate into the DLC Feed Length and Feed Rate on a DLC with Standard Interface Option The standard option setting allows entering editing the feed length and feed rate directly from the keypad on the DLC control panel Use the left right arrow keys to position the cursor on the data line Type over an existing entry to edit Press the STORE key to save the new value The cursor returns to home position Current Feed Le
156. message A Part Stop is displayed Notes on Automatic Mode Operation The Press Before Feed Batch Complete parameter option causes an overlap of feeds between parts to maintain the proper tool sequence Cycle Stop and Part Stop The DLC provides a second cycle stop input for batching The Cycle Stop input stops the automatic cycling immediately after the current cycle completes The added Part Stop input stops the cycle at the end of the part after all feeds in the part have been completed When Part Stop is used the cycle won t be stopped in the middle of a part The status message A Cycle Stop is displayed when the Cycle Stop input has been activated or a fault has caused a Cycle Stop This message indicates that the part may be incomplete The status message A Part Stop is displayed when the Part Stop input has been activated or a Part Stop has been executed in the Batching program This message indicates that the part is complete Batching in Set up Mode Interface Options This section describes the operation of the DLC in Set up Mode when using the batching option It begins after the part information has been programmed into the batching pages In set up mode the first feed of the current part is performed The current part can be changed through the same procedure that the starting part in Automatic Mode is selected NOTE Set up mode is provided for single feed applications For set up of multiple feeds use the s
157. mmand encoder polarity will result in unexpected motor direction movement This condition could result in machine damage and or personal injury It is recommended to disconnect the load from the motor when altering this parameter Once operation and direction are verified the load can be reconnected 5 14 Parameters DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DIO SA DLC R Feed To Length Control User s Manual Parameter A112 Monitoring Window for Drive Diagnostics Monitor Window A112 10 0 Units Input Units Decimal Places 1 unaffected by A100 Input Value Limits 00 1 20 0 This parameter selects an error detection monitoring window for Drive Stalled and Drive Runaway hard faults The DLC uses a mathematical model of the system to calculate the expected position error lag Drive Runaway occurs when the motor is moving too far ahead of the expected lag Drive Stalled occurs when the motor is moving too far behind the expected lag Parameter A112 defines the amount of input units the drive can deviate from its expected position error e f the position read from the encoder is greater than the expected position plus the amount of the monitoring window the DLC detects a Drive Runaway condition e If the position read from the encoder is less than the expected position plus the amount of the monitoring window the DLC detects a Drive Stalled condition The suggested value for this parameter is 1096 The allowed devi
158. mote display is available only with the IDS option These units are remotely mounted up to fifteen 15 meters from the DLC The operator selects the required feed length and a feed rate on different sets of thumbwheel switches The decimal place resolution for the feed length is set by parameter The feed rate is selected as a percentage of the maximum feedrate set in parameter Status and diagnostic messages appear on the alphanumeric vacuum tube fluorescent display or status and diagnostic message codes appear on the two digit LED numeric display on the IDS 1 8 General Description DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual A Feeding Figure 1 3 Optional Thumbwheel Switch amp Alphanumeric Display Modules Optional Station Operator Terminal SOT The Indramat SOT is a remote mounted operator control device for the DLC See Figure 1 4 SOT Station Operator Terminal t allows for the same input functions and displays the same information as the DLC control panel but provides several additional features The SOT has a viewing area that measures 4 7 8 by 2 3 4 and can display 16 lines of 40 characters per line The SOT screen is a non glare LCD with cold cathode fluorescent lamp backlighting for high black and white contrast The level of contrast is user adjustable for optimum viewing It can display much more information at a time than the standard four line by 16 char
159. n ua eebe Dee 5 1 5 2 Parameter EISE 2 iui hatte tiun pO D POE T DRUSI REPE 5 2 5 3 Entering the Parameters AA 5 3 5 4 Unit of Measurement Input Unit esses n 5 5 E EE 5 5 Parameter A100 Feed Length Hesolution nennen nnne 5 5 Parameter A101 Feed Constant 5 7 Parameter A102 Drive Max HPM 5 7 Parameter A109 NOGUSOd RE 5 8 Parameter A104 Maximum Feed Hate 5 8 Parameter A105 Jog Feed Hate AA 5 9 Parameter A106 Maximum Acceleration Hate 5 9 Parameter A107 Maximum Deceleration Rate nnne 5 10 Parameter A108 Maximum Allowable Jerk nnne 5 10 Parameter A109 Position Gan 5 12 Parameter A110 In Position Thbreshbold nennen nnns 5 13 Parameter A111 Direction of Operation 5 14 Parameter A112 Monitoring Window for Drive Diagnostics 5 15 Parameter A113 Low Feed Angle Threshbold ener 5 16 Parameter A114 Not Used etes iui direc ils m esi pu rrr pA a askhaia 5 16 5 6 Parameter Set Bi 5 17 Entering the B1 Parameter Get 5 17 Parameter B100 Language nennen nnn nnn nnne tr nsns enne trenes nsns nns 5 17 Parameter B101 Dimensional Units rss 5 18 Parameter B102 Interface Option 5 18 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Contents III DLC R Feed to Length Control User s Manual INDRARMA Parameter B103 Auxiliary Feed Length 5 19 Parameter B104 Feed Length Maximum Uimp nnne 5 20 Parameter B105 Feed Length Minimum Ump nnn 5 20 Parameter B106 Feed Len
160. n Standard Features 3 5 DLC R Feed To Length Control User s Manual INDRARMA Output Signal Descriptions See Page 3 23 e Press Immediate Stop e Permit Press The control system is designed such that feeder operation can occur only when a series of permissive conditions are true This is accomplished by a group of handshaking inputs outputs between the DLC and the press interface They are described below in the general order of occurrence e Press Continuous Intermittent Input from the user s control panel which selects the press operating mode Continuous specifies continuous press cycling synchronized with the material feed Intermittent specifies that the press will be cycled one time at the end of or just previous to each feed cycle e Cycle Start Momentary input signal from the user s control panel that starts the automatic feed cycle see Normal Operation Signals e Permit Press Output from DLC used to permit engagement of the press clutch if all other safety logic circuitry on the press is satisfied This output allows press operation differently when Continuous or Intermittent mode is selected as described in the following sections e Feed Angle Input generally from a limit switch or sensor on the press or processing station indicating that material can safely be fed For a punch press this signal would come up shortly after the ram clears the material on its upstroke See Figure 3 2 Generation of Feed Angle Sig
161. n connector X17 Pin 14 Active low The cycle stops after a feed in Press Before Feed Mode or after the feed angle signal input in Feed Before Press Mode the latter was selected for Parameter B109 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Start Up 7 9 INIDRADIZAL DLC R Feed To Length Control User s Manual Chapter 8 Diagnostics and Troubleshooting This chapter describes some typical states of the Indramat Digital AC Servo Drive as well as the diagnostic messages that are issued and displayed by the DLC and suggests troubleshooting procedures or recommended actions for each display These messages provide the user with information on faults hardware status and operational status of the system When needed request assistance from Indramat See Chapter 1 8 1 Digital Servo Drive Normal Operating Diagnostics The two digit diagnostic display on the front of the servo drive shows the current state of the drive The following briefly describes the most typical diagnostic codes encountered during power up and normal operation For more information consult the digital servo drive s users manual CODE Drive State 93 DLC Watch Dog Error There is a communication error between the drive and DLC Press the clear key or input If this does not clear the error power off the drive CODE Drive State bb 100 Operation Ready The drive is ready for 3 phase main power to be applied CODE Drive State Ab 101 Drive Ready
162. nal The signal would drop go low on the ram downstroke allowing some safety margin before the ram reaches the material The material feed must have stopped before this signal drops or the feed will stop immediately and an error will display e Press Immediate Stop Output from the DLC issued when a Feed Angle Lost During Feed or other various faults are detected See Press Immediate Stop page 3 28 for details This signal commands the user s circuitry to stop the press or other machine as soon as mechanically possible rather than stopping after the current cycle is complete as with a Cycle Stop Warning The Press Immediate Stop signal must be incorporated into the safety logic circuitry of the machine Note that safety design of the system is the responsibility of the machine tool builder 3 6 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMAN DLC R Feed To Length Control User s Manual Figure 3 2 Generation of Feed Angle Signal Press Continuous Operation Conditions Automatic Mode input high Press Continuous Intermittent input high 1 Cycle Start input momentary goes high 2 DLC issues the Permit Press output at the appropriate point and maintains it until the automatic cycle ends Permit Press should be used by the press system to engage the press clutch for automatic cycling IF all other press safety logic circuitry is satisfied Parameter B109 allows selecting on
163. nd hard faults that will be issued by the DLC The maximum message length is 40 characters When these same messages appear as the status page on the DLC control panel display they are abbreviated to fit within two lines of 16 characters each Serial Diagnostic Code 00 01 02 03 04 05 06 07 09 0A 0B DC OD OE 12 13 14 15 16 17 18 19 1A 1B 1C 20 22 23 4 36 Function Description Special Features Serial Port Message X 14 xx U xx Status Messages System Is Ready UN QE E UE b E D EE No Jog Command Feeding Forward No Cycle Start Cycle Stop Feeding Waiting for Feed Angle Cycle Delay Feeding Forward Feed Incomplete Waiting for Feed Angle Waiting for Press Start of Feed DLC PARAMETER MODE S Release Jog Both Jogs High M A S M Waiting for Feed Angle Resume Required Feeding Reverse Feeding Reverse Initializing System A A A A Waiting for Press Cycle Stop Input Active Cycle Start Input Active Resume Input Active Jog Input Active A A Part Stop Input Active Part Stop nnn Xo Xo An lt gt ror lt gt or lt gt lt lt lt gt X gt lt gt np lt gt lt lt lt lt An DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMAI Serial Diagnostic Code 40 41 43 44 46 48 49 4c 4D 4E 53 60 61 62 63 64 65 66 67 68 69 6A 6B 6D 6E 70 71 72 73 74 76 TI 78 7D 7E DOK DIAX02 DLC1 1
164. ndicate all feeds are complete for a single part High Momentary Indicates a single part just completed Remains high about two seconds then returns low When using the batching function this output pulses momentarily as each part completes execution whether executing a single part or several different parts in the Batching Program It remains ON when the Batching Program Complete output turns ON and remains ON until the next cycle start Refer to Chapter 4 for further information on the batching feature Batch Program Complete Indicator Connector X17 pin 31 Function Output Used in batching to indicate the batching program is completed High Indicates all parts in the batching program are completed When using the batching function this output turns ON at the end of a batching program when the last part is programmed with a jump to 00 It remains ON until the next cycle start Refer to Chapter 4 for further information on the batching feature 3 30 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual Chapter 4 Function Description Special Features 4 1 Batching Selecting Batch Option This chapter describes special features available and provides the general information required to use these features e Batching e RS 232 485 Interface e Measuring Wheel e Single Step Using Start and Stop Inputs If the ap
165. ng the Store key or by pressing the or keys until a correct feed length is entered A Feed Length Limit minor error can be cleared also by storing a legal value while in the Batch Feed Length Feed Rate Programming page Row F Slug Width Compensation value is entered in parameter B122 This is used in applications that remove a slug from the material being fed This value is added to the feed length to compensate for the material removed Press the left or right arrow key from the feed length feed rate display until the desired Parameter Information page displays These displays are for information only Min Feed 000 500 Max Feed 100 000 Max Chg 010 000 Units in Parameter Information Display Minimum and Maximum Feed Length Limits are set in Parameters B105 and B104 respectively These limit the range of the feed length entry that the DLC will accept Maximum Change setting is made in Parameter B106 This parameter limits the amount that the programmed feed length can change during an Automatic Mode cycle before causing a fault to occur Units Setting selection is set in Parameter B101 as desired for the application It can be set for inches in feet ft millimeters mm degrees deg etc Row D Refer to the Display Map in Figure 2 2 Map of CTA Control Panel Display Pages Pressing the down arrow key from any display in Row C changes to the Measuring Wheel M W Display Row D if enabl
166. ng too far ahead of the expected lag The Monitoring Window Parameter A112 must be set to a value that is greater than the deviation in position error caused by normal mechanical and electrical characteristics see Chapter 5 for parameter description The following items should be checked 1 Axis motion is detected without a velocity command ensure that signal feedback and command cables are properly installed 2 Parameter A111 Direction of Operation is inconsistent with wired polarity verify the settings correspond to the feedback and polarity of the drive motor 3 Deceleration rate is too high when Acceleration is okay correct in Parameter A107 4 Monitoring Window is too small for calculated Max lag correct entry in Parameter A112 Axis 1 Amplifier Hardware Fault Issued when the Drive dropped out of its Drive Enable state in Auto Mode or when motion is commanded Check the wiring from the amplifier to the DLC and verify proper amplifier operation Check the two digit diagnostic display on the front of the drive and consult the drive s manual for additional information DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual Drive Error Press the CR Key Issued when the digital servo drive is not in the Drive Enable State Determine drive error and correct the problem Check the two digit diagnostic display on the front of the drive and consult the drive
167. ngth Rate 001 234 12 2 Feed Length and Feed Rate Display Standard Interface DLC R To scroll up or down to the previous or next row of displays from this display page note that the cursor must be in the home position It automatically returns to home after storing new data Press the CR key or use the left right arrow keys to properly position Micro adjust explained later in this section is allowed only when the cursor is in home or the first digit position DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Controls and Indicators 2 1 1 DLC R Feed To Length Control User s Manual INDRARMA 2 12 Controls and Indicators When changing the feed length or feed rate value while the DLC is in cycle on the fly this new value typically takes effect on the next cycle If you press the CR key or leave the keyboard inactive for 30 seconds before pressing the STORE key the cursor returns to home position and the program and display returns to the last stored information data The decimal placement in the feed length depends on the setting in Parameter A100 The feed rate is a percentage of the Maximum Feed Rate set in Parameter A104 If you press the CR key or leave the keyboard inactive for 30 seconds before pressing the STORE key the cursor returns to home position and the program and display returns to the last stored information data Feed Length and Feed Rate on a DLC with the DS Interface Option When using the IDS opt
168. ns do not require all the lines or character spaces For simplicity this manual typically illustrates the example displays at the size required for the screens data e All displays illustrated in this manual use an underline character to represent the cursor e The cursor must be in home position of the display to scroll up down to different rows DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Controls and Indicators 2 3 DLC R Feed To Length Control User s Manual INDRARMA The following display appears only at power up when clearing a hard fault or when exiting from Parameter Mode It shows the internal software version while the Initializing Sys message is displayed during system initialization Initializing Sys DLC1 1 DR1 02V06 DLC Initializing System Display 2 4 Controls and Indicators DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DLC R Feed To Length Control User s Manual DESDE 2 SN SMNACO LNO0 VL 19 10 A NOISHJA SYVMLIOS YOs GI IVA AV1dSIO ONININV SO9O0Sd NIVN 66 L0 HO1VH 9 1 s0334 HOlV8 SN3BIARN 2018 LYVd AHL LIN3A3H23G ONY LN3A3NONI OL QVdA3x VLO JHL NO A3M ONY SHL ISN E AE NOLLdO ONIH2IVH AV 1dSIQ NOILYWYOJNI L d LN3HBNIJ I Y QVdA3 VLO JHL NO SAX A C e A MOMMY GH LHOIN YO 1431 3HL ONISN IHD NO 1431 JHL OL AVIdSIG SHL
169. nted using the or key DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 3 DLC R Feed To Length Control User s Manual INDRAMA The user can assign a Part ID to be associated with each Part Block number This is any eight digit number that has meaning to the user a part number die number customer number etc It is stored in the DLC as a matched set with the part block number Each part s data may be accessed by entering either the Part Block or the Part ID number A unique Part ID must be selected for each block when using the DLC keypad The numbers 1 to 9 and may be entered through the keypad Alpha characters may be used when entered from an SOT or other host device but are not available from the DLC keypad Jump to Block Batching allows automatically executing several different parts Enter in the Jump To Block the next part block to be executed after completion of the entered part quantity of the starting or previous part block A jump to any of the 99 part blocks can be executed Each part block can jump to another after it is completed This allows executing several different parts automatically Different batches of parts can be programmed to execute together Enter the starting number of the batch to select the desired batch program to execute If a part jumps back to itself if pp nn itis a free run part The part will run continuously until a cycle stop or part stop in
170. numbers 01 to 99 will send the information to the corresponding part If a 00 is in the string the information will be entered into the current part If is sent the working part is accessed See Batching Input Working Part and Wild Card page 4 29 The feed number is only needed when feed data is accessed B F and B Z If a space is sent instead of the feed number the data from feed 1 will be accessed If a zero is sent as the feed number information from the current feed will be sent Unless otherwise noted the strings correspond to the DLC keypad and display Refer to the batching section in this chapter for additional information Batching Requests The requested information corresponds to that displayed on the DLC Data may be echoed back to the DLC in the same format by adding a 8 and a checksum Part ID Early Warning and Jump to Part B WO2 cr 1lf The alphanumeric part ID number early warning count and jump to part will be sent 4 24 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual B WO2 1234ABCD 012 O3 hh cr 1f l l Jump to Part _Early Warning _Part ID number Part Quantity Current Part Count Current Feed Number and Count B COl1 cr 1f The part quantity and current count for this part are sent back by the DLC The current feed number and feed count are also sent in this string The f
171. ock diagram of a typical system configuration DOK DIAXO2 DLC1 1 DR1 02VRS ANW1 AE P 06 97 General Description 1 1 DLC R Feed To Length Control User s Manual INDRARMA INDRANAU Figure 1 1 DKS DLC R Feed To Length Positioning Control System 1 2 General Description DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual The DLC requires a DEA 4 card to be plugged into the U2 slot of the DKS The DEA 4 card provides 15 system inputs and 16 system outputs Other information such as batch programs parameters and system status can be communicated two way between the DLC and a host device such as a computer or Indramat SOT via a multi format serial communications port OPERATOR INTERFACES OPTIONAL DKS DIGITAL COMPACT CONTROLLER Inputs Outputs Figure 1 2 Block Diagram The DLC Digital AC Servo System configuration consist of DLC control card DEA 4 Input Output card Digital Controller DKS DDS MDD Digital AC Servo Motor The machine builder or user enters data into the DLC parameters to specify the mechanical and operating characteristics of the system Based on this data plus the feed length and feed rate entered by the operator the DLC issues positioning commands to the digital controller a DKS Digital Compact Controller or DDS Digital Controller which controls the current driving the MDD AC Servo Motor which drives the mechanical feed mec
172. ode and dropped during the actual feed cycle The timing of this signal stopping the press depends on the four possible mode combinations See Press Permissive Interfacefor a complete discussion of this signal and other I O s in the Press Permissive interface See the timing charts Figure 3 3 Figure 3 4 Figure 3 5 and Figure 3 6 for specific timing of this signal WARNING The machine builder should tie this signal into the other Safety Logic Circuitry for the press system Do Not use this signal to fire the press without regard for other safety conditions interlocks open machine E Stop etc The following is a list of faults which will cause the Permit Press signal to go low causing the press cycle to stop All Hard Faults All Soft Faults Note See Chapter 8 for more Minor Errors specific information on faults Zero Feedrate Entered Zero Feed Length Entered Change in Feedlength Exceeds Limit Feedlength Exceeds Maximum Feedlength Less than Minimum DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 25 DLC R Feed To Length Control User s Manual INDRARMA System Fault Indicator Feed Interrupt Indicator Feed Complete Indicator Connector X17 pin 21 Function Output Indicates a fault has occurred High The DLC has detected a fault Low The system is functioning properly or the DLC is experiencing a power loss or its microprocessor is defective This output is
173. oesn t match the one transmitted which could result from a faulty serial cable or port It also is issued when the checksum is invalid or missing E 04 String Invalid S hh lt Cr gt lt Lf gt This message is sent when the received data is invalid e g if the feed length data is not decimal characters 4 40 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DIESIBOD ZZ DLC R Feed To Length Control User s Manual E 06 K A100 Invalid hh Cr Lf Ai00 Parameter Downloaded To DLC This message is sent when a downloaded parameter exceeds its limits It corresponds to the is invalid message on the DLC display E 07 Para Not Allowed hh Cr Lf This message is sent when a parameter download is attempted when the DLC is not in parameter mode Note f an error is detected when exiting parameter mode the status code X 07 or at end of string if XD from the DLC will be a generic Parameter is Invalid The DLC will send the message Knnn Invalid the next time a parameter is requested E OE Flp Err O0001 hh cr 1f This is an internal DLC system error Call the Indramat service department if this error is received from the DLC E OF Part i4 Not Found hh cr 1f This error is sent when no match is found for the part ID received by the DLC for starting part working part or Jump to Part Message Acknowledgment Y cr lf ifB118 mode is 1 RS 232 Yn
174. of the DLC control including fault diagnostic messages The following example indicates that the DLC is ready for automatic operation awaiting a Cycle Start input to begin automatic cycling A No Cycl Start Example Status Display This Status Display is the home display of the first line Row A on display map Each status display page is described in Chapter 8 along with corrections for fault error diagnostic status display messages Pressing the CR key toggles between the Status Display and the Drive Diagnostic Page Drive Diagnostic 102 Drive Enabled Drive Diagnostic Page The drive diagnostic display shows the current status of the digital servo drive Refer to the drive manual for description of diagnostics Press the right arrow key once The display changes to the Strokes Minute Display which also shows the time used and current press mode selection Each line of the display is described below Strokes Min 200 Time Used 80 PBF Continuous Strokes Minute Display The Strokes Minute display page shows the current stroke rate of the press during an Automatic Mode cycle The DLC measures the time between press strokes and updates the Strokes per Minute display when the feed angle signal goes from high to low DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual The display page also shows Time Used Time Used is the amount of time during a high feed angle that
175. oll backwards through the parameter set Press the CR key to toggle between the A B and C Parameter sets Press the left or right arrow key to move the cursor left or right within the display Each parameter can be accessed directly without scrolling Press the Hot blank key on the keypad to move the cursor to the parameter number Type over the number to directly select the desired parameter to display The parameter displays are visible in the DLC s control panel display and on the optional SOT or other host via the RS 232 485 serial interface when used Note The optional remote florescent tube display available with the IDS option will only display the message Parameter Mode while the DLC is in this mode The two digit display on the IDS shows code number 17 when this mode is selected Perform the following steps to change or edit the value of a parameter from the DLC control panel see Chapter 4 for procedures to download from a PC or SOT via the serial interface 1 Move the cursor arrow keys over the digit you want to change DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual 2 Enter the desired number from the DLC keypad type over existing entry 3 Verify data changes are correct in the display 4 Press the STORE key to save the new parameter values displayed data into memory 5 Maintain a current list of parameter entries Appendix C provides work she
176. or RS232 serial interface Standard drive parameters are set using CTA keypad only In both cases processing must not occur simultaneously over the CTA keypad and RS232 serial drive interface Drive parameters are viewed and edited in the same manner as for A and B parameters C parameters are administered in the drive With each new power up the C parameters are sent from the drive to the DLC DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 1 DLC R Feed To Length Control User s Manual 5 2 Parameter List 5 2 Parameters INDRAMA The following table lists all of the parameters for the DLC with software version DR Only the parameters available for your type of control will show on your DLC display for entry Parameter Set A1 Parameter A100 Parameter A101 Parameter A102 Parameter A103 Parameter A104 Parameter A105 Parameter A106 Parameter A107 Parameter A108 Parameter A109 Parameter A110 Parameter A111 Parameter A112 Parameter A113 Parameter A114 Feed Length Resolution Feed Constant Drive Max RPM Not Used Maximum Feed Rate Jog Feed Rate Maximum Acceleration Rate Maximum Deceleration Rate Maximum Allowable Jerk Position Gain In Position Threshold Direction of Operation Monitoring Window for Drive Diagnostics Low Feed Angle Threshold Not Used Parameter Set B1 Parameter B100 Parameter B101 Parameter B102 Parameter B103 Parameter B104 Parameter B105 Parameter B106 Parame
177. p can be performed by activating the Cycle Stop Cycle Start simultaneously The DLC will step one feed and one press stroke With batching enabled activating Part Stop Cycle Start simultaneously causes the DLC to perform the feeds and press strokes for one part Several outputs are issued by the DLC during normal system operation They include e Feed in Progress Indicator Indicates that a feed is in progress and the feed axis is not within the position threshold specified in parameter A110 e Feed Complete Indicator Indicates that the commanded feed is complete and the axis is within the position threshold e Axis In Position Indicator s Indicates that the feed axis has stopped within the position threshold specified in Parameter A110 A feed interrupt can occur as a normal part of an automatic cycle A high on the Feed Interrupt input indicates normal operation If this signal goes low the feed cycle is interrupted the Feed Interrupt Indicator output goes high and an appropriate status message appears in the display When the signal is restored high the feed cycle immediately resumes DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRARMA DLC R Feed To Length Control User s Manual RIAL LOOP Q Tt SOURCE DETECTOR Figure 3 1 Use of Feed Interrupt Input This signal is often used in conjunction with a material loop as illustrated in Figure 3
178. part ID or micro adjust as shown above A change of the starting part is done only at cycle start If there is no block number found when selecting by Part ID the message E Part Not Found is sent from the DLC Change Working Part Number B PO1 Change by part block number 4 28 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DIESIBOD ZZ DLC R Feed To Length Control User s Manual 4 B PN111 1111 Change by part ID number send N and Part ID 4 B PM B PM Micro adjust working part block number The working part can be selected by block number part ID or micro adjust as shown above When wild card characters are used the information from this part is sent or received Current Feed Length Feed Rate Input X 00 4001 234 56 7 hh cr 1f If sign isn t included positive value is stored The feed length can be input using the X 00 and X 01 commands when batching is enabled These commands can be used to download the current feed length and feed rate for Axis 1 X 00 Batching Input Working Part and Wild Card A batching string may be sent with a wild card part number designated by two stars When two stars are sent the data is stored or received from the working part To change the working part the string 8 B P is used The working part may be changed by part block number part ID or micro adjust see string descriptions in this document
179. plication requires making different parts use batching to reduce the set up time and eliminate possible entry errors by entering the required data for each part into a separate batch memory The batching option allows multiple feed lengths for each part It allows program branching to automatically execute different parts The DLC can store up to 99 different parts each with unique set of feed lengths feed rate number of pieces to execute and a user s part number Up to 594 Feeds can be stored in the DLC S battery protected memory You can select to sequentially execute several or all different parts or to execute any single part from the DLC control panel You can externally select a part to execute from an SOT a PLC or similar host device through the communications port to the DLC The DLC display can show a running piece count display user part number assignment plus outputs to indicate when the part is nearing completion when each part is complete and when all parts in the batch run are complete All information assigned in batching can be viewed and edited in any mode even while the press is in operation Automatic Mode however is the only mode in which parts are counted as they are made Parameter B102 interface option allows you to select the method of entering the feed length and feed rate into the DLC With the batching interface option selected you typically enter the data for each part ahead of time Then simply selec
180. ption Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DIESIBOD ZZ Batching Input DLC R Feed To Length Control User s Manual DLC Response B P N0O1234567 hh cr 1lf l Working part number The DLC will respond with the working part number See Batching Input Working Part and Wild Card Page 4 29 The input requests correspond wherever possible to the output from the DLC Extraneous information is discarded so that the strings received from the DLC may be sent back to the DLC without causing any errors Data may be also be accessed by part block in some cases Selective storage of any of the information in the string may also be done by sending stars in place of the data Part ID Early Warning Jump to Part B WO2 1234ABCD 012 90 hh cr 1f l Jump to Part Block l Early Warning Part ID number The Jump to Part may also be entered as a Part ID number The DLC looks up the number and if a matching part block isn t found it sends back the error E Part Not Found _B WO2 1234ABCD 012 N0090 000S hh lt cr gt lt 1lf gt I Jump to Part ID N Part ID number A free run part may be selected either by jumping to the same part or by sending an F in place of the Jump to Part B WO2 1234ABCD 012 FShh lt cr gt lt lf gt alternate way of selecting Free Part Quantity Current Part Count micro adjust B CO1 012345 M Shh lt cr gt lt l1f gt _Current Part count micro adj flag I P
181. put is activated The part quantity display is replaced with the word FREERUN and the Early Warning count with all stars If 00 is entered here no jump is performed and the cycle will be stopped after the part quantity is completed Enter 00 for the jump to block in the last part block to be executed in the batch Part Quantity qqqqaqq The part quantity is the number of times each part is repeated before jumping to the next part or stopping If a zero is entered in every digit the current count for the part will be cleared without affecting the part quantity Parts may be linked together to create a part with more than six feed lengths by entering a in the part quantity See Part Linking page 4 6 for a detailed description Early Warning Count eee The Early Warning count allows an output to be turned ON near the end of a part run The output is turned ON when the number of parts remaining reaches this number The output is turned OFF at the start of a new part 4 4 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual Batch Feed Programming Display There are six Feed Programming Pages associated with each Batch Main Programming Page Feed lengths rates and gag sets may be edited for each feed which may be executed up to 999 times Part nn iiiiiiii Feed f Qty xxx Length Rate mll lll rr r Batch Feed Programming Pag
182. r Error is automatically cleared when the error condition is corrected WARNING Once the Minor Error condition Feed Interrupt is corrected the DLC immediately returns to operation A Minor Error condition does not require a Clear input signal to continue operation See description in Hard Fault Messages for further information These information messages indicate the current status of the DLC system such as System Is Ready or A Feeding A fault or error message will override a status message on the display Status messages as well as fault and error messages are each described in the following sections 8 4 Hard Fault Messages 8 6 Diagnostics and Troubleshooting This section provides a complete list of hard fault diagnostic messages and an explanation of the potential cause s DLC System Error Code HRD00 An internal system fault has occurred in the DLC The following hard fault system errors can occur code HRD00 PL001 FXPM0001 UPRGO1 FLPMO003 NOTE For any DLC system error display call Indramat home office Advise them of the error code number displayed Parameters Lost Clear to Cont This message indicates the parameters were lost when the DLC was powered up in the Parameter Mode It is also displayed after installing new firmware Press the Clear push button on the user control panel to continue with parameter entry Check the memory backup battery if parameters were previously entered DOK
183. red 8 15 Soft Fault Messages 8 10 Aux Feedlength is Zero 8 13 Batching Program was Lost Battery is Low Replace it Soon Count Exceeds Part Quantity DLC R System Error 8 10 Feed Angle Lost During Feed Invalid Mode Selection 8 12 Movement While Feed Angle Low Para Invalid Select P mode Press Cycle Without Feed 8 12 Press Timeout Has Expired Serial Com Port RS485 Bus Error Serial Com Port Disconnection Serial Com Port Framing Error Serial Com Port IDS Format Error Serial Com Port Overrun Error Serial Com Port Parity Error Set Up Mode Cycle Incompleted Zero Feedrate Programmed Diagnostics and Troubleshooting Display Screens 2 3 Axis Position Lag Display on DLC R Batch Feed Programming 2 17 Batch Main Programming 2 16 Current Part Information 2 15 Example Status 2 6 Initializing System 2 4 Jog Step Mode 2 8 Parameter Information 2 13 Software Version 2 7 Strokes Minute 2 6 System Inputs 2 9 System Outputs 2 10 Total Length 2 10 Total Piececount 2 10 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 8 16 8 16 8 17 8 15 8 17 8 17 8 18 8 16 8 14 8 14 8 14 8 12 8 14 8 12 8 11 8 10 8 11 8 11 8 10 8 11 8 13 8 13 8 1 2 9 Index E 3 DLC R Feed to Length Control User s Manual INDRARMA E EMERGENCY STOP 3 3 F Fault Diagnostic Monitoring 3 14 H Hard Fault Messages 8 6 Hardware and Software Support 1 4 IDS Status Diagnostic Codes Index 8 25 Illustration X17 Input Connec
184. ree methods still provide safety by monitoring the deviation between the motor encoder and MW encoder If the Measuring Wheel Enable is turned ON or OFF during a cycle none of the feed lengths positive negative auxiliary batching will be affected Operation in or out of the Length Compensation mode continues until a Cycle Stop is issued or a fault or error occurs The MW Enable Input is only read at Cycle Start or Resume Cycle 4 42 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual 4 4 Single Step Using Start and Stop Inputs A single step may be performed by activating the Cycle Start input and the Part Stop or Cycle Stop input simultaneously The Part Stop input can be used for single step only when batching is enabled If the Cycle Stop Cycle Start are activated the DLC will step one feed and press stroke at a time The status message A C Stop Active will be displayed by default indicating that the cycle stop input is active A single feed will take place when the cycle start input is activated If the Part Stop and Cycle Start are activated in batch mode the DLC will step one part at a time and the status message A P Stop Active will be displayed DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 43 INIDRADIZAL DLC R Feed To Length Control User s Manual Chapter 5 Parameters This chapter
185. ress At Cycle Start the DLC feeds the material until it is in position Once the material is in position the press begins the press cycle At Cycle Stop the cycle will end at the completion of the press cycle Press Before Feed for Set Up mode Entry into Set Up mode does not require the Feed Angle Input transition before jogging i e Permit Press output is not high upon entry to Set Up Mode Notes 1 Once the DLC detects a Cycle Stop it must detect the high to low transition of the Feed Angle input before the final cycle is complete 2 For more specific information refer to Chapter 3 Standard Features and refer to the Cycle Timing Charts Minimum cycle time Input Unit seconds Decimal Places 1 fixed not affected by A100 Input Value Limit 0 0 to 9 9 Set the minimum delay time from the start of a press cycle to the start of the next press cycle during Intermittent Mode operation This setting is used primarily for press brake clutch protection The user sets the minimum cycle time to minimize the duty cycle of the press brake clutch assembly This reduces brake clutch overheating and premature failure Example Operating Conditions Press cycle time and feed cycle time are equal to eight 8 seconds Parameter B108 is set to nine 9 seconds The press would delay for one second at top of its stroke before starting a new cycle Note Setting Minimum cycle time for 0 0 indicates no delay time is required
186. ress the Drive On pushbutton The H1 status should display AF and torque should be applied to the MDD servomotor If problems exist consult the servo drives manual or Chapter 8 of the DLC manual to correct the problems To verify proper motor hook up and control of the motor jog the axis in Manual Mode Turn the selector switches to the OFF position so that Automatic nor Parameter Mode inputs are high defaults to Manual Mode 1 Press the Forward Jog pushbutton connected to X17 Pin 9 The axis should jog in the forward direction until the button is released 2 Press the Reverse Jog pushbutton connected to X17 Pin 10 The axis should jog in the reverse direction until the button is released 3 Should either the forward or reverse motor movement fail to react check all cable connections and verify the DLC is in Manual Mode 7 9 Automatic Operation To check Automatic operation 1 Turn the selector switch to Automatic Mode wired to connector X17 Pin 2 2 Press the Cycle Start pushbutton connected to X17 Pin 4 NOTE The DLC should follow the feed length and velocity settings entered from CTA keypad with Parameter B102 set to 00 or the decade switches on the IDS if connected and Parameter B102 set to 01 3 Manually activate the Feed Angle switch pushbutton connected to X17 Pin 6 each cycle to simulate the ram movement and allow the next feed cycle 4 Press the Cycle Stop pushbutton to stop operatio
187. rlock DLC R Feed To Length Control User s Manual Parameter Automatic and Set up Modes are selected by bringing the appropriate signal line high 24 Vdc A fault is diagnosed and an Invalid Mode Selection error message is issued if both Automatic and Set up Mode signal lines are high simultaneously However the Parameter Mode input overrides any other mode presently selected The suggested interface design is to wire the Parameter Mode signal to a key switch where a key is required to enter Parameter Mode and or mount the switch inside the electrical cabinet This helps to prevent unauthorized parameter changes Wire the Automatic and Set up Mode input signals to a three position selector switch where Manual Mode is selected when the switch is set to an open contact position This method prevents selecting Automatic and Set up Mode at the same time The DLC has outputs to verify the currently selected mode These are typically wired to indicator lights on the user s control panel or to a PLC for total system control Input Signal Descriptions See Page 3 15 e Emergency Stop Output Signal Descriptions See Page 3 23 e NA As described above the DLC and its servo must perform operational checks and provide the proper signals to enable operation Emergency Stop The Emergency Stop input must remain high for the DLC to operate The system incorporates an Emergency Stop E Stop chain which is a circuit connected in series
188. rmat with any other device The RS 485 interface can be used to network up to 15 DLC R and DLC A units Each unit must have a unique station number from 01 to 15 which is defined in parameter for each unit Each DLC unit will accept and send strings that have its station number in the second set of characters in the string For normal RS 232 operation a space is used instead of the station number 4 10 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual Connector Wiring X31 The serial interface connector X31 is located on the front of the DLC Card Refer to Figure 4 1 DLC X31 Connector for a pin out diagram of the multi function port X31 connector It shows the pin numbers and definitions of signal connections for each type of communication CAUTION Do not connect to any pin numbers other than those shown in Figure 4 1 DLC X31 Connector Some pins are used for Indramat options and factory diagnostics RS 232 CONFIGURATION SHIELD RECEIVE TRANSMIT GROUND RTS CTS RS232 CTS RS232 RTS GROUND Rx Tx RS485 TxD RS232 RxD RS232 RS485 Rx Tx SHIELD RS 485 CONFIGURATION SHIELD Rx Tx GROUND DN DLC X31 x CONNECTOR Figure 4 1 DLC X31 Connector DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 1 1 DLC R Feed To Length Control User s Manual
189. rt will be performed at the end of the cycle The machine is then ready for operation at the next cycle start without the danger of a double hit of the press DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 25 DLC R Feed To Length Control User s Manual INDRARMA Parameter B112 Measuring Wheel MW Selection Note The MW feature requires Measuring Wheel the DEF1 1 hardware option B112 11 00 25 0 A B C A 00 Disable Measuring Wheel 10 Measuring wheel is used to dynamically correct feed length variations during the feed 11 Position loop closed on MW encoder when Feed Angle is high closed on motor encoder when Feed Angle is low 12 Position loop is continuously closed on Meas Wheel encoder B B200 Parameter B103 Auxiliary Feed Length is zeroed and the Auxiliary input is used as MW enable B 01 MW mode is enabled as if the enable input was high 100 of the time C Allowed deviation between measuring wheel and motor encoders defined in percent of one motor revolution before encoder fault occurs The Measuring Wheel function is active only in Auto and Setup modes displays are active in allmodes The Axis Position display is updated with data from whichever encoder closes the position loop The Total Length display is updated only by the motor encoder Refer to Chapter 4 Function Description Special Features for information on the Measuring Wheel option Parameter B113 Not Used Not Used
190. ry Para Invalid Select P mode Fault is displayed when power is applied to the DLC or when you switch out of Parameter Mode In either case this fault indicates that required parameter s data is missing or incorrectly entered Switch to Parameter Mode The display shows the first sequential number of the parameter requiring correction Enter the data correctly and press STORE for each parameter that appears as invalid Refer to section 5 3 for added information on this and related Parameter Is Invalid fault conditions Batching Program was Lost This fault is issued if batching data is invalid upon power up lost due to battery failure or at initial installation Default values are loaded for any part in which data is invalid See Default Batch Program Values in section 4 1 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual Amp Overtemp Warning The Indramat Servo Drive has issued this warning diagnostic The DLC latches this warning and will issue a cycle stop if cycling in Automatic Mode Check the two digit diagnostic display on the front of the drive and consult the drives manual for additional information Moter Overtemp Warning The Indramat Servo Drive has issued this warning diagnostic The DLC latches this warning and will issue a cycle stop if cycling in Automatic Mode Check the two digit diagnostic display on the front of the drive and consult the drives manual
191. ry protected memory Data Default Value Part ID Number 6 stars followed by Part Block Jump to Block 00 for stop at end of part Part Quantity 000001 Early Warning 000 Current part and feed counts Zero Current Feed Number 1 Feed quantity Feed 1 001 Feed quantity Feeds 2 6 for end of part Feed length and rate Both zero Starting part Block 01 4 2 RS 232 485 Serial Interface Operation The DLC Control includes a multi format RS 232 485 port for two way communication between the DLC and a host The interface protocol is designed to easily transmit and receive data to and from the DLC It can communicate with a Personal Computer SOT IDS PLC or other devices at rates of 150 up to 19200 baud using RS 232 or RS 485 format This chapter describes the protocol and other communication requirements The host device must strictly adhere to the communications format as described in this chapter to achieve proper communication or one of several RS Format Errors will be returned through the port or indicated on the control status display indicating that the information was not properly formatted or understood DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 9 DLC R Feed To Length Control User s Manual INDRARMA Any parameter may be uploaded from the DLC at any time Parameters may be downloaded to the DLC only while it is in Parameter Mode If attempted in any other mode the ho
192. s Lost Clear to Cont 8 6 Parameters Lost Select P Mode 8 7 PARAMETER MODE 8 18 Press Cycle Without Feed 8 12 Press Timeout Has Expired 8 12 S Fd Incomplete 8 22 S Feed Forward sss 8 22 S Feed Reverse 2 7 8 22 S Release Jog 8 22 S Start of Feed 8 22 S Wait Fd Angle _ 8 22 S Waiting Press 8 22 Serial Com Port Framing Error 8 11 Serial Com Port Overrun Error 8 10 Serial Com Port Parity Error 8 11 Serial Com Port Disconnection 8 10 Serial Com Port IDS Format Error 8 11 Serial Com Port RS485 Bus Error 8 11 Set Up Mode Cycle Incomplete 8 13 Stop Due To Interrupt Input 8 16 Zero Feedrate Entered 8 16 Zero 96 Feedrate Programmed 8 13 Zero Feedlength Entered 8 15 Diagnostics and Troubleshooting 8 3 DLC R Feed To Length Control User s Manual INDRARMA 8 3 Diagnostic Display Categories Hard Fault 8 4 Diagnostics and Troubleshooting The faults errors and diagnostic status messages are separated into four 4 categor
193. s manual for additional information Invalid Drive Configuration The DLC R software verifies a valid drive hardware configuration at power up Only the DLC DEA4 1 and DEF1 1 are allowed Any other cards in the drive will result in this fault Drive Diagnostic 102 Drive Enabled The drive diagnostic display shows the current status of the digital servo drive Refer to the drive manual for description of diagnostics Drive Watch Dog Error The communication between the DLC card and the Indramat servo drive has faulted Clear the error with the CL key or clear input or power cycle the servo drive If this error reoccurs contact Indramat Service for further assistance Measuring Wheel Encoder Fault With the measuring wheel MW feature enabled the DLC monitors the deviation between the motor encoder and MW encoder in automatic and set up modes The percentage of deviation that is allowed is set in Parameter B112 This fault occurs when the deviation exceeds that setting Check cable connections and tracking on material Invalid Drive Software The combination of software in the Indramat servo drive and DLC card is not compatable DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Diagnostics and Troubleshooting 8 9 DLC R Feed To Length Control User s Manual INDRAMA DPR Not Readable The Dual Port Ram memory between the Indramat Servo Drive and the DLC card has faulted Clear the error with the CL key or clear input
194. s parameters entry has been completed The parameter management section allows the user to save and load the parameters to and from diskette Consult the servo drive s manual for more information The next step is to configure the DLC Control Card to operate with the parameters entered in the digital amplifier DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Start Up 7 7 DLC R Feed To Length Control User s Manual 7 7 Parameter Entry INDRAMA The parameters given here are the minimum required to operate the DLC for this example Turn the key switch to the Parameter Mode and enter the following parameters see Chapter 5 for procedures A100 A101 A102 A104 A105 A106 A107 A108 A109 A110 A111 A112 B102 IDS B104 B109 7 8 Start Up Feed Length Resolution Feed Constant Max Motor RPM Maximum Feed Rate Jog Feed Rate Maximum Acceleration Rate Maximum Deceleration Rate Maximum Allowable Jerk Position Gain KV In Position Threshold Direction of Operation Monitor Window for Drive Diagnostics Interface Option Feed Length Max Limit Press Interface Mode 03 0001 0000 03000 001500 00 000300 00 000100 00 000000 00 000000 00 03 00 00 0100 Enc 0 Cmd 0 10 00 or 01 for 000 000 01 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual 7 8 Axis Jogging In Manual Mode With bb displayed on the servo drive and no errors displayed on the CTA p
195. s required for this parameter are 1920 8 1 0 0 When the interface option Parameter B102 is set for the IDS the port is automatically configured to work with the IDS board This serial interface parameter is then ignored DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 UDP SA DLC R Feed To Length Control User s Manual Parameter B120 Not Used Not Used B120 Disabled Parameter B121 Not Used Not Used B121 Disabled Parameter B122 Slug Width Compensation Slug Width Cmp B122 000 050 A A 000 000 No Slug Width Compensation will be added to feed 000 050 Every feed in Automatic and Set up mode will have 000 050 inches mm etc added For example if the commanded feed length is 10 000 inches the actual length fed will be 10 050 inches This will be shown on the Axis Position Dist display as well as the Total Length and MW display DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 29 DLC R Feed To Length Control User s Manual INDRAMA 5 7 Parameter Set CO This parameter set allows drive tuning through the DLC Drive parameters can be set using CTA keypad or RS232 serial interface Standard drive parameters are set using CTA keypad only In both cases processing must not occur simultaneously over the CTA keypad and RS232 serial drive interface Drive parameters are viewed and edited in the same manner as A and B parameters C parameters are administered in the drive With each new power up
196. selected When de selected the DLC returns to the previously selected mode Auto Set up or Manual defaults to Manual Mode when other modes de selected Press Cycle Without Feed Indicates a double hit of the press Fault occurs if there is more than one press cycle when the Feed Interrupt input is active DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRARMA DLC R Feed To Length Control User s Manual Zero Feedrate Programmed The feed rate programmed for the part selected to execute in batching or value downloaded through the serial port from a host is set to zero Scroll to the feed programming display page and correct the feed rate or correct in host device Set Up Mode Cycle Incomplete This indicates the user has tried to exit the Set up Mode without completing the cycle Verify the Press Interface Mode Press Before Feed or Feed Before Press setting is selected as desired Parameter B109 The user has the following two 2 options ch Reenter Set up Mode and complete the cycle press jog key until the entered feed length is complete and or cycle the press if required to complete the cycle 2 Press the Clear push button on the user s control panel or press the CL key on the DLC keypad This will clear the diagnostic message and recognize any mode change selection Aux Feedlength is Zero Indicates the Auxiliary Feed Length option was selected but Parameter B103 is set at zero To corre
197. st receives a Invalid Mode error message through the port Parameters can be read from the DLC in any mode To ensure that the correct data is being sent and received a checksum is calculated and checked by the DLC If the host software does not calculate a checksum it can be disabled Special cabling is required for use with RS 485 communications as described in the following section The DLC and the optional Indramat SOT Station Operator Terminal can communicate in half duplex to facilitate using the RS 485 interface RS 485 uses a single twisted pair of wires to provide superior noise immunity at distances of up to 1000 meters The DLC can also communicate with the SOT using the RS 232 interface without any parameter changes However the maximum distance allowed for an RS 232 cable is 15 meters The optional Indramat SOT Station Operator Terminal is a remote mounted operator control device for the DLC It is used to communicate commands status and parameter information between the DLC and SOT The software in the SOT includes Help screens to assist the operator in using the SOT and for entering information correctly Refer to the supplement included with this manual for complete information on using the SOT The RS 485 interface is primarily used with the SOT which provides the special hardware and software needed for proper operation Contact Indramat Applications Engineering for assistance if you wish to use this interface fo
198. stic message Change in Fdlgth Exceeds Limit will appear in the display Reenter the new feed length correctly If this parameter is set to all zeros 0000 00 there is no software maximum change limit on a feed length entry Parameter B107 Feed Length Micro Adjust Increment Feed Increment B107 0123 45 Units Input Units Decimal Places See Parameter A100 figure shown A100 02 Upper Limit B104 feed length maximum limit This parameter specifies a length that will be added or subtracted from the feed length each time the or key is pressed while the current feed length is displayed and the cursor is in home position This parameter is designed to allow fine tuning of the feed length in both the standard feed length operation or when the Batching option is selected The micro adjustment can be entered from the DLC keypad or from an SOT or other host option via the RS 232 485 serial interface port DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 21 DLC R Feed To Length Control User s Manual INDRARMA Refer to Chapter 2 Controls and Indicators for procedures to perform the micro adjust from the DLC control panel for axis 1 and for axis 2 on the DLC Z As an example if the current feed length is 4 050 inches and Parameter B107 is set to the value of 0 005 inches the feed length will increase by 0 005 each time the key is pressed Each change in the micro adjustment is reflected in the DLC display The ad
199. sume Cycle Press Continuous Intermittent Select Set up Mode Select Connector X17 pin 12 Function Input Used to select press operating mode High Selects continuous operation Low Selects intermittent operation During Continuous Mode operation the press stroke is continuous When the press ram is on the upstroke away from the material Feed Angle goes high the DLC feeds The feed should finish before the press ram nears the material on its down stroke Feed Angle goes low This operation continues in either Press Before Feed or Feed Before Press Modes until a Cycle Stop is issued or a fault or error occurs During Intermittent Mode operation the DLC issues a Permit Press output signal the press clutch engages and the stroke begins When the press ram nears the material on its down stroke the Feed Angle goes low and the DLC drops the Permit Press output The press clutch retaining circuit normally employed keeps the press operating one cycle When the press ram is on the upstroke away from the material Feed Angle goes high the DLC feeds At the end of the feed and the end of the dwell time need both conditions the DLC again issues the Permit Press to start the next cycle This operation continues in either Press Before Feed or Feed Before Press Modes until a Cycle Stop is issued or a fault or error occurs The press cycle mode may be changed on the fly using this input at any time during an automatic mode
200. t block number or the part ID number to select the starting part to execute can start with any of the up to 99 parts programmed Press the STORE key If the current part is selected as the starting part the batching program will be reset to the start of the current part The starting part entry is allowed only when the DLC is not in an Automatic Mode cycle Note that batching information must be programmed into pages on the following rows before using this page to start the batching program The current part count can be micro adjusted from this page Press the right arrow key to move the cursor out of home position then press the down arrow key to move the cursor to the first digit of the Count data field Press the key to add to the count press the key to subtract from the count Key use for increasing decreasing the total number of parts to execute is dependent on the count mode selected count up or count down Row G Refer to the Display Map in Figure 2 2 Map of CTA Control Panel Display Pages Press the down arrow key to see the Batch Main Programming Display page Main 01 11111111 Jump to Block 02 Quantity 000010 Early Warn 002 Batch Main Programming Display Batching programs are entered on this page using part data entered on the following related pages This section summarizes the programming procedures Refer to Chapter 4 for more specific information on entry procedures and options available From this page
201. t Parity Error 8 11 Serial Com Port IDS Format Error 8 11 Feed Angle Lost During Feed 8 11 Press Timeout Has Expired 8 12 Invalid Mode Selection 8 12 Press Cycle Without Feedl 8 12 Zero 96 Feedrate Programmed 8 13 Set Up Mode Cycle Incomplete 8 13 Motor Overtemp Warning 8 15 Amp Overtemp Warning 8 15 Aux Feedlength is Zero 8 13 Count Exceeds Part Quantity 8 14 Battery is Low Replace it Soon 8 14 Para Invalid Select P mode 8 14 Batching Program was Lost 8 14 Hard Faults 80 81 82 86 88 89 90 8C 92 93 94 95 96 97 DLC SYSTEM ERROR Code SHPUDOO 8 6 Parameters Lost Clear to Cont 8 6 Axis 1 Drive Runaway 8 8 Parameters Lost Select P Mode 8 7 EMERGENCY STOP 1 8 7 Axis 1 Amplifier Hardware Fault 8 8 Measuring Wheel Encoder Fault 8 9 Axis 1 Drive Stalled 8 7 Invalid Drive Configuration 8 9 Drive Watch Dog Error 8 9 DPR Not Readable 8 10 Drive Diagnostic 8 9 Drive Error Press the CR Key 8 9 Invalid Drive Software 8 9 INDRARMA DOK DIAX02 DLC1 1 DR1 02VRS ANW1 A
202. t or right one position at a time when in Parameter Mode when editing the feed length and feed rate or when entering batch data Press the key to change between display pages on the same row of the display map see next section Up and Down Arrows Use to scroll through display pages see next section or parameters see Chapter 5 Blank Key unlabeled Press from any other page displaying to cause the Status Page to display Press before typing over a parameter number to change displays DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual 2 2 Display Screens The operating mode and keyboard selections determine the resulting display When in Parameter Mode data for each parameter can be viewed entered or edited Refer to Chapter 5 for procedures to scroll through parameter displays While in Automatic Set up or Manual Mode display screens show operation status messages status of each input and output etc and allows entry of feed length feed rate etc The following section describes procedures for scrolling through each of these display screens Refer to the Display Map in Figure 2 2 Map of CTA Control Panel Display Pages for a full illustration of the display access procedure The same illustration is included in Appendix A for convenience This section describes the basic procedures for reading this map to scroll through the different display screens and describes
203. t the part or batch of different parts to execute automatically from the DLC keypad or from an SOT or other host via the serial interface Note that you cannot use the IDS option with the batching option DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 1 DLC R Feed To Length Control User s Manual INDRARMA Batch Entry and Status Displays Section 2 2 describes the procedures for scrolling through the display screens movement of the cursor within the display page and how to enter data into fields The following sections further describe the entry procedures and options for batch programming Current Part Information Display The Current Part Information Page has three functions 1 select the starting part number 2 micro adjust the current part count 3 display real time part information Before using this page to start the batching program the part information must be programmed on the other batching pages as described in the following sections INFO nn iiiiiiii Qty qqqqqq Count cccccc Feed f Cnt xxx Current Part Information Page Starting Part Selection Before starting automatic operation enter a starting part of the batch on this page A batching program may start with any of the 99 parts This allows the storage of several batching programs each having a unique starting part and set of parts to execute automatically To avoid an accidental part change starting part entry
204. tandard Drive Tuning Parameters Over CTA 5 3 Entering the Parameters The DLC must be in Parameter Mode to enter or edit parameters The Parameter Mode is normally selected via a switch on the user control panel This selector switch will typically require a key to enter this mode to prevent unauthorized changes to the parameter values Parameters are entered or changed by writing over any previous data stored These changes are made through the DLC keypad or via a serial interfaced host After you correctly enter the desired value of each parameter press the STORE key to save the new value in memory A Lithium backup battery assures this memory is retained when the DLC is powered down or if the system experiences a power loss In Parameter Mode the DLC display shows the parameter name number and data value of the parameter selected as illustrated below Feed Length Res A100 02 When selecting Parameter Mode the display shows the first parameter of the A1 set of parameters A100 unless a fault exists as described below Note Should the displayed message appear in a language other than the language desired by the user enter the B1 Parameter Set as described in the section Entering the B1 Parameter Set Set Parameter B100 to change the display to the desired language as explained in the section Parameter B100 Language Two conditions exist which can result in a parameter Is Invalid fault message 1 The DLC softw
205. te The Measuring Wheel MW enable input replaces Aux Feed Length input when MW is enabled See Parameter B112 Measuring Wheel MW Selection When the B value of Parameter B112 is set to 00 this also forces the Aux Feed Length Parameter value to 00 Note This Paramater can be changed on line from the serial port DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 19 DLC R Feed To Length Control User s Manual INDRAMA Parameter B104 Feed Length Maximum Limit Feed Length Max B104 1234 56 Units Input Units Decimal Places See Parameter A100 figure shown A100 02 Input Value Limit none This parameter sets the maximum limits for feed length that the DLC will accept from the DLC keypad or the IDS SOT or other RS 232 485 host option if so equipped If this parameter is set to all zeros 0000 00 there is no software limit on feed length CAUTION When you set this parameter to 0000 00 exercise caution to insure that you always enter the correct desired feed length An accidental or incorrectly entered feed length could result in damage to the machine or material Should the feed length entered be larger than the maximum limit set in this parameter the diagnostic message Feed Length Limit Exceeded will appear in the display Parameter B105 Feed Length Minimum Limit 5 20 Parameters Feed Length Min B105 1234 56 Units Input Units Decimal Places See Parameter A100 figure shown A100 02 Upper
206. ter A110 must be greater than this lag value When the axis is moving at maximum velocity the display lag should be within 1096 of the calculated maximum lag Press the right arrow key once The display changes to the System Inputs Display Press the right arrow key again to see the System Outputs Display The numbers in the top row of the display indicates which of the lines of connector X17 of the DEA4 card are being monitored These displays are helpful to verify wiring during start up or troubleshooting They also provide a quick summary of system UO status during normal operation The first line of these displays also show the system status A No Cycl Start Sys Inputs 1 15 211 1 11 11 System Inputs Display DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Controls and Indicators 2 9 DLC R Feed To Length Control User s Manual INDRARMA 2 10 Controls and Indicators The status of each of the input or output signal lines are represented by a character in the bottom row of the display A Low signal 0 volts is represented by a decimal A High signal 24 volts is indicated by a one 1 The signal lines count from left to right on the display Press the right arrow key to see the System Outputs Display Interpret the information displayed the same as described for inputs A No Cycl Start Sys Outputs 1 16 21711 12 cls System Outputs Display Press the right arrow key to see the Total Piececount Display
207. ter B107 Parameter B108 Parameter B109 Parameter B110 Parameter B111 Parameter B112 Parameter B113 Parameter B114 Parameter B115 Parameter B116 Parameter B117 Parameter B118 Parameter B119 Parameter B120 Parameter B121 Parameter B122 Language Dimensional Units Interface Option Auxiliary Feed Length Feed Length Maximum Limit Feed Length Minimum Limit Feed Length Maximum Change During Cycle Feed Length Micro Adjust Increment Jog Step Parameter Press Interface Mode Not Used Batching Option Measuring Wheel MW Selection Not Used Not Used Not Used Measuring Wheel Feed Constant Measuring Wheel Encoder Serial Interface Serial Port Operation Not Used Not Used Slug Width Compensation DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 UDP p SA DLC R Feed To Length Control User s Manual Parameter Set C0 Parameter C000 Analog Output Channel 1 Parameter C001 Analog Output Channel 2 Parameter C002 Overload Factor Parameter C003 Position Data Scaling at Analog Outputs AK1 and AK2 Parameter C004 Velocity Data Scaling at Analog Outputs AK1 and AK2 Parameter C005 Velocity Loop Monitoring Parameter C006 Not Used Parameter C007 Not Used Parameter C008 Error Reaction Parameter C009 Current Loop Proportional Gain Parameter C010 Velocity Loop Proportional Gain Parameter C011 Velocity Loop Integral Reaction Time Parameter C012 Smoothing Time Constant Parameter C100 Set S
208. tering data into a set of parameters using the CTA 20 digit keypad and liquid crystal display LCD or from a host via the serial port These parameters define the characteristics of the machine such as maximum and minimum feed lengths jog acceleration and deceleration rates units of feed measurement communications port characteristics etc This allows one single type of DLC control to handle the mechanics of various roll feed units Thus plant personnel need be familiar with only one feed control system Generally parameters are entered once when the system is set up then changed only if the configuration changes or if different types of materials are fed The factory installed DLC executive program interprets the parameters to match the DLC to the machine and translates operator entered commands into motion control signals coordinating the feed motion with the press or other machinery Complicated system programming is not required Parameters are described in Chapter 5 Fully Self Diagnostic System protection is paramount The DLC detects normal operating status operator errors errors in the control itself and machine faults For example in a metalforming application the DLC monitors the press crank angle and halts the system if the selected feed cannot be made without damaging the press tooling or material If a feed is not completed during the allowable press feed angle a diagnostic error message is displayed and the feed
209. th Control User s Manual INDRARMA Set up Mode Messages 8 22 Diagnostics and Troubleshooting The following messages are displayed in Set up Mode S Feed Forward Indicates the axis is feeding in the forward direction Jog Forward input active in Set up Mode causes the DLC to feed the entered feed length then stop S Feed Reverse Indicates that the axis is feeding in the reverse direction S Fd Incomplete Indicates that the jog button has been released before the end of the feed entered feed length for set up Press and hold the jog button until set up feed is complete S Wait Fd Angle Indicates that the Feed Angle input is low X17 Pin 6 The DLC will not allow the axis to jog until the feed angle is available indicating that the press ram is clear of the material S Waiting Press Indicates the DLC is waiting for the press to complete its stroke cycle before allowing the next feed cycle to start after completing the jog feed length manually initiate a press cycle then initiate the next jog feed S Start of Feed Indicates that the axis is at the start of the feed position S Release Jog Indicates the DLC is ready to start the next feed but the jog button has not been released since the previous feed If the Jog button is not pressed check push button switch operation and wiring DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual 8
210. th parameter text and is requested from the DLC with KF The K input string allows either format so that strings sent from the DLC can be echoed back Request to DLC for Condensed format _K_A101 lt cr gt lt 1f gt Response from DLC K A101 00012345 hh cr 1f lt 12 digit gt unformatted string Request to DLC for Extended format _KFA101 lt cr gt lt 1f gt Response from DLC K_A101 0001 2345 Feed Constant hh cr 1f I lt gt lt gt I Formatted Parameter Text Parameter in current language 16 char 16 char Request to DLC for an Extended format for a C Parameter _KFC003 lt cr gt lt 1f gt Response from DLC 000360 0 Position Data Scaling A Output hh cr 1f lt 16 digit gt Parameter Text in current language 32 char 4 30 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DIESIBOD ZZ Parameter Input DLC R Feed To Length Control User s Manual Send to DLC K A101 00012345 hh cr 1lf or K A101 001 2345 FeedConstant hh cr 1f Remaining characters discarded by DLC K B111 101101 hh cr 1f or K B111 1 O G 110 1 Batching Option hh cr 1f Dimensional Units Parameter The DLC will send both the code and the text for Parameter B101 Dimensional Units but uses the code to se
211. the C parameters are sent from the drive to the DLC When entering the C parameters If Row 4 of the CTA displays Not Accepted after the store key is pressed clear the error and try re storing the value Parameter C000 Analog Output Channel 1 Analog Output 1 C000 02 02 Output type 0 Current command 1 RPM command 2 RPM actual value from feedback 3 Position Actual value from feedback 4 Motor encoder Sinusoidal feedback 5 Motor encoder Cosinusoidal feedback Parameter C001 Analog Output Channel 2 Analog Output 2 cool 05 05 Output type 0 Current command 1 RPM command 2 RPM actual value from feedback 3 Position Actual value from feedback 4 Motor encoder Sinusoidal feedback 5 Motor encoder Cosinusoidal feedback 5 30 Parameters DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DES SA DLC R Feed To Length Control User s Manual Parameter C002 Overload Factor Overload Factor C002 0400 00000 Not used must be set to 00000 400 Overload factor in percent 000 400 Parameter C003 Position Data Scaling at Analog Outputs AK1 and AK2 Position Data Scaling A Output C003 0000360 0 0000360 0 Degrees 10V 0000000 1 1474560 0 Parameter C004 Velocity Data Scaling at Analog Outputs AK1 and AK2 Velocity Data Scaling A Output C004 02000 02000 RPM 10V 00001 65000 Parameter C005 Velocity Loop Monitoring Velocity Loop Monitoring C00
212. the mode inputs above also apply to this request Clear Fault Request CLEARShh lt cr gt lt 1f gt This string functions the same as the CL key or the Clear input and clears a soft fault or hard fault Cycle Stop and Part Stop Requests Note that for safety reasons an operator Cycle Stop or Part Stop push button should always be wired to the DEA 4 These strings can provide a secondary method of stopping the cycle from a remote site STOPShh lt cr gt lt 1f gt This string functions the same as the Cycle Stop input STPT hh cr 1lf This string functions the same as the Part Stop input A polling request may be used to see if the DLC is on line The SOT on the RS 485 bus periodically sends this request to ensure the integrity of bus communications This response is compatible with DLC A and DLC R and consists of a colon a station number diagnostic code a carriage return and a linefeed no checksum Polling Request 1 lt cr gt lt lf gt 1 Request to station number 1 Polling Response snn s station nn diag code 101 cr 1f The DLC Responds to the SOT with the station number and the current status diagnostic code In this example the station number is 1 and the diagnostic code is 01 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Function Description Special Features 4 33 DLC R Feed To Length Control User s Manual INDRAMA Checksum To ensure that the correct data is being sent and recei
213. tion or exactness of a parameter value The level of resolution is relative to the input unit or dimensional unit Typically the number of decimal places indicates the category of the unit of measurement Table 5 2 shows the typical relationship of decimal placement resolution to unit of measurement commonly used DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 5 DLC R Feed To Length Control User s Manual INDRARMA Decimal Placement Unit of Measurement Angular Measurement e g Degrees Radians International System Metric e g Millimeters Centimeters XXX US Customary System e g Inches Feet XXXX High Resolution Usually Used With US Customary System Table 5 1 Typical Decimal Placement Note The decimal placement relationship to unit of measurement as shown in Table 5 2 is typically used in the Motion Control industry However this relationship is not restricted to the categories shown Any of the four levels of decimal placement can be used with any unit of measurement desired The final selection is dependent on the level of resolution required Although Parameter A100 affects most of the other parameters not all the parameters are affected in the same way All velocity and acceleration parameter displays have one less decimal place than the feed length parameters The Feed Constant and Position Tolerance parameter displays have one more decimal place than the feed length parameters refer to Table 5
214. to both the DLC and the user s machine Should any sensor in the E stop chain open all press and feed operations immediately stop Note that the time taken to stop depends on the wiring method used inertia of the machine press clutch brake retaining circuit etc Elements connected in the E stop chain commonly include the Emergency Stop switch on the user s control panel E stop switch es on the press or feeder switches on lubrication or coolant pumps and various die guards and safety interlock switches DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 3 DLC R Feed To Length Control User s Manual INDRARMA Normal Operation Signals 3 4 Functional Description Standard Features Input Signal Descriptions See Page 3 15 e Cycle Start e Cycle Stop e Feed Interrupt Output Signal Descriptions See Page 3 23 e Feed In Progress Indicator e Feed Complete Indicator e Axis 1 In Position Indicator e Feed Interrupt Indicator The automatic feed cycle begins when the Cycle Start line goes high momentary with the DLC in Automatic Mode Once the automatic feed cycle begins it is normally stopped by a Cycle Stop input line goes low momentary Feed will stop after completing the current cycle The system will also stop if a fault is detected either immediately as an Emergency Stop or after the cycle as a Cycle Stop depending on the level of the fault In Automatic Mode a Single Ste
215. to stop as soon as mechanically possible 3 10 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INIDRADIZAL DLC R Feed To Length Control User s Manual Figure 3 5 Intermittent Mode Press Before Feed T Minimum cycle time specified by Parameter B109 when the press is in intermittent operation S Stroke T is longer than the cycle time needed by the press and feed sequence therefore it limits the stroke rate Figure 3 6 Intermittent Mode Feed Before Press T Minimum cycle time specified by Parameter B109 when the press is in intermittent operation S Stroke T is shorter than the cycle time needed by the press and feed sequence therefore it has no effect on the stroke rate DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 11 DLC R Feed To Length Control User s Manual INDRARMA Jogging Inputs Set up Mode Input Signal Descriptions See Page 3 15 e Axis 1 Jog Forward e Axis 1 Jog Reverse Output Signal Descriptions See Page 3 23 e NA The DLC s Jog inputs allow jogging the material forward and reverse Parameter A105 specifies the jog feed rate It usually is set to approximately 10 of the maximum feed rate It can never be more than the maximum feed rate In Manual Mode a high on the Jog Forward Reverse input causes the axis to feed forward reverse at the velocity set in Parameter A105 as long as the respective jog input is high
216. top Bits 1 Connect the VT 100 terminal or PC with VT 100 terminal emulation software to the servo drive s connector X2 via an IN 391 cable and press the lt Enter gt key This will bring up the Main Menu screen Changing The Display Language In order to change the language displayed on the screen press the number 3 from the Main Menu German Text Press the number 1 English Text Press the number 2 After the selection the Main Menu screen will be displayed 7 6 Main Menu The Main Menu allows you to view the following information 1 Drive Status 2 Parameters 3 Language Selection 7 4 Start Up DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual ESC Exit Program In order for the DLC to operate properly the servo drive s parameters must coincide with the parameters programmed in the DLC To check or adjust the parameter currently in the amplifier press the number 2 from the Main Menu screen The Drive Parametrization screen will be displayed Consult the amplifier s manual for a description and the proper parameter values for the amplifier motor combination being used press the letter c to continue The Parameter Menu screen will display the following selection list application parameters drive parameters and parameter management When setting up a servo drive with the DLC the application and drive parameters must be set correctly Setting The Drive s Par
217. tor and Pin Designations 3 15 Illustrations of DLC R Control 1 10 Input Signal Descriptions 3 15 Automatic Mode Select 3 16 Auxiliary Feed Length Select 3 20 Clear 3 19 Cycle Start 3 17 Cycle Stop 3 22 Emergency Stop 3 16 Feed Angle 3 17 Feed Interrupt 3 18 Jog Forward 3 19 Jog Reverse 3 20 Measuring Wheel 3 20 Parameter Mode Select 3 16 PART STOP 3 22 Resume Cycle 3 17 Setup Mode Select 3 21 Installation 6 1 Cable Routing 6 2 DLC R Connectors 6 3 Electrical 6 3 Hardware Installation 6 2 Mounting Cabinet 6 1 Power 6 2 Transformer Heat Dissipation 6 2 Interface Descriptions 3 1 J Jogging Inputs 3 12 E 4 Index DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DS SA DLC R Feed to Length Control User s Manual M Measuring Wheel 3 20 N Normal Operation Signals 3 4 O Operating Mode Selection 3 2 Inputs 3 2 3 3 3 4 3 5 3 12 3 14 Outputs 3 2 3 3 3 4 3 6 3 12 3 14 Options 1 14 Output Signal Descriptions 3 23 Automatic Mode Indicator 3 24 Axis 1 In Position Indicator 3 28 Batch Program Complete Indicator 3 30 Cycle Time Available Indicator 3 24 Feed Complete Indicator 3 26 Feed In Progress Indicator 3 27 Feed Interrupt Indicator 3 26 Feeder In Cycle 3 27 Manual Mode Indicator 3 24 Parameter Mode Indicator 3 24 Part Complete Indicator 3 30 Part Early Warning Indicator 3 29 Permit Press 3 25 Press Immediate Stop 3 28 Setup Mode Indicator 3 29 System Fault Indicator 3 26
218. tput signals described in this manual are High 24 Vdc Low OVdc A signal line is described as active high when its associated action is initiated by a high 24 Vdc signal level It is described as active low when its function is initiated by a low signal 0 volts This chapter describes the function with the active state of each I O connection 3 2 Interface Descriptions The DLC interfaces with a feed device of some type The DLC system is designed for control of a continuous indexing process such as a press feeder The DLC input and output signals provide communication to from the machine builder s equipment and should be considered as functional groups of signals working in concert These functions include e Operating Mode Selection e Servo System Operation Enables e Safety Interlocks e Normal Operation Signals e Handshaking or Press or Processing Station Permissive Interface e Jogging Inputs e Set up Mode e Fault Diagnostic Circuitry DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 1 DLC R Feed To Length Control User s Manual INDRARMA The following functions are further described in Chapter 4 Batching RS 232 485 Multi format Communications Interface Measuring Wheel Single Step Using Start and Stop Inputs The following sections describe the basic operation theory of the DLC They group signals by interface function listing the I O signals involved
219. ts per minute The feed rate in Automatic Mode is expressed as a percentage of the Maximum Feed Rate entered in this parameter This percentage is entered through the DLC keypad or through the thumb wheel switches of the optional IDS assembly optional SOT keyboard or other host via the serial port Use the following formula to calculate the maximum feed rate Maximum Feed Rate Maximum Motor RPM x Feed Constant from A102 from A101 The entry in A104 should reflect the maximum feed rate desired for the application This is not necessarily the same as the maximum the system is capable of performing Note Maximum Feed Hate is specified in units of measurement per minute Convert seconds to minutes when required CAUTION If the motor employed with this system is overrated for the application feeding at the maximum feed rate may damage the feed rollers or its associated hardware Adjust the entry in A104 to reflect the maximum feed rate desired for the application 5 8 Parameters DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DIO SA DLC R Feed To Length Control User s Manual Parameter A105 Jog Feed Rate Jog Feedrate A105 0123456 7 Input Unit Input Units per minute Input Value Minimum 00000100 regardless of decimal point Input Value Maximum less than or equal to maximum feed rate entered in parameter A104 Decimal Places A100 1 figure shown A100 02 This parameter specifies the maximum jog feed rate in Manual an
220. tt 4 1 BatehEntry and Status Displays s itte ette eae ee falute fetu coelo dest 4 2 Current Part Information Display nennen nennen isse nnn nnn ns 4 2 Batch Main Programming Display Page nennen nnns 4 3 Batch Feed Programming Display 4 5 Part bInkipgia a asa eh oe E PD DPDIOSCDDIZPoU DPI irirtxirivids 4 6 Batching in Automatic Mode enne ss 4 7 Batching in Set ups M06067 u u 4 8 nterface Options see 4 8 Default Batch Program Values A 4 9 4 2 RS 232 485 Serial Interface Operation 4 9 Connector in ue HRC 4 11 BY Maler nici EDD pu puc pu 4 14 Message FOMA EE 4 14 Status Ee EE 4 17 Elle 4 23 Contents DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DIO SA DLC R Feed to Length Control User s Manual Batching INformation EE 4 24 Batching Requests eee 4 24 Batching Inputs cachet E 4 27 Batching Input Working Part and Wild Card 4 29 ENEE UE 4 30 Parameter npLit ee suceden eene ene 4 32 Action BIequesltse itr ti c RR GEHT RENE ERREUR TETIM ROI OYMAMIDEI A iT 4 33 Polling e e osito dedos 4 34 eec aa aksa ss 4 35 RS 232 Flow Control 4 35 Block Jploads seo n oc detecte te d oe s tote d ts Den 4 36 Serial Diagnostic e EE 4 37 Serial Interface ETTOIS eege eege TW DN Pes PP PS 4 39 SOT ScreenManager EE E 4 42 4 3 Measuring Wee 4 43 4 4 Single Step Using Start and Stop Input Chapter 5 Parameters 5 1 5 1 Parameter Set Descriptio
221. tting causes the system to be too sensitive This results in motor oscillation A by product of motor oscillation is an audible buzz or ringing noise Load inertia friction motor dynamics and velocity are just some of the elements which affect gain Because of the many variables that influence the proper gain there is no established setting for this parameter However it is recommended that the user begin with a small number such as 00 50 and increase the numeric entry until optimum performance is achieved Note The Position Gain A109 the Acceleration Rate A106 the Deceleration Rate A107 and Maximum Jerk A108 directly interact with one another Before operating after setting the position gain insure the acceleration rate is set correctly for the application WARNING If the gain is set too high the motor could begin oscillating the moment power is applied This condition could result in damage to the machine and or personal injury Disconnect the motor from the machine for initial testing Parameter A110 In Position Threshold In Pos Threshold A110 000 123 Units Input Units Decimal Places A100 1 figure shown A100 02 Input Value Limits from 000 000 to 999 999 This parameter sets the in position threshold window for Axis 1 This is the defined window or area in which the DLC will consider the axis in position A close or tight threshold requires more time for the axis to reach position within threshold windo
222. typically wired to an indicator light on the user control panel NOTE Any Hard Fault Soft Fault or Minor Error will turn on this output See Chapter 8 for a description of faults Connector X17 pin 22 Function Output Used to indicate an interrupted feed cycle High Indicates the DLC has lost the Feed Interrupt input signal and drive motion is decelerating or stopped See Feed Interrupt page 3 18 Low Indicates the DLC has not lost the Feed Interrupt signal Typically this output is wired to an indicator light on the user control panel WARNING If the automatic cycle is interrupted by a low on the Feed Interrupt input all feed motion is suspended However when the input returns high the feed cycle will immediately resume Use this output to alert personnel of the condition so they can use proper caution Connector X17 pin 23 Function Output Used to indicate commanded feed is complete 3 20 Functional Description Standard Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRARMA High Low DLC R Feed To Length Control User s Manual Indicates the axis is in position within the In Position Threshold set in Parameter A110 and the commanded feed is complete Indicates that a feed is commanded but is not presently complete Typically this output is wired to an indicator light on the user control panel Feeder In Cycle Connector Function High Low X17 pin 24 Output
223. ual INDRARMA Jogi FOWA A ranna R E E E aan daeetetenaeiaele 3 19 leie ME 3 20 Auxiliary Feed Length Select Measuring Wheel Enable a a a 3 20 Press Continuous Intermittent Geet 3 21 SeLu p le 3 21 E e Ee EE 3 22 acm L O OUEMTT 3 22 3 4 Output Signal Descriptions nennen nnn nn nennen ss set nnn nnne nnns 3 23 Manual Mode Indicator esses nennen nnns isst sns 3 24 Automatic Mode Indicator enne enne nennen nnns nnns nhnnnnnr nnns nnn 3 24 Parameter Mode Indieator ete duet Glue a luas EL a GO eadera Rs 3 24 Gycle Time Available Indigalor J l UU UU aa buindleais neem ate asa FE aa a Aeee 3 24 Permit Kreesser deeg dde kuka datu ege ee e 3 25 Systermi FaultIhndiGaltoriu uui tete eterna dde e 3 26 Feed Interrupt Indicator EE 3 26 Feed Complete Indicator AAA 3 26 Ree 3 27 Feed In Progress Indicator nennen nnne nnnntrn nnne nnn nre nen nnns 3 27 AXIS FA In de E tel Lee e 3 28 Press Immediate Grop A 3 28 Setup Mode nelle e 3 29 Part Early Warning Indicator nennen enne nennen qaa aa nsns enn 3 29 Part Comiplete IfidiCatOl iiti ete ete tet ie tetie tetti iactis 3 30 Batch Program Complete Indicator sssssssssssssseseeeeeeeneeen enne 3 30 Chapter 4 Function Description Special Features 4 1 4 1 BalChing EE 4 1 Selecting Batch Option ctore te eee tee oteatgnasvaeans conn edesasanseseacdagvenereccteagasavaeieanenen
224. ud rate of the host or if the start stop bit parameters are not the same for both Check and verify settings are same Also issued if DLC has missed data due to a faulty cable or port Chapter 4 describes the serial port communication settings and error diagnostics Serial Com Port Parity Error This indicates the parity type of the DLC does not match that of the host It is also issued during RS 232 485 communication if the parity check fails indicating a faulty serial cable Chapter 4 describes the serial port communication settings and error diagnostics Serial Com Port IDS FormatError This indicates the serial communication is not functioning properly for the IDS Check the cable and connections between the IDS and the RS 232 port of the DLC Serial Com Port RS485 Bus Error This error is issued when data is being sent and received at the same time when SOT operation is selected in Parameter B118 If the device communicating with the DLC is not a DLC R compatible SOT or is communicating in full duplex the Interface mode in B118 should be setto 1 If the DLC is talking to an SOT this error indicates a faulty cable or port Verify that you are using an RS485 cable Feed Angle Lost During Feed This indicates the feed angle input went low before the DLC had completed the current feed Check the input connection from the feed angle switch Ensure the mechanical functions and timing are sequenced properly Decrease the
225. uest for the text message corresponding to the selected diagnostic code The DLC will respond with a 40 character string in the parameter selected language For minor errors soft faults and hard faults the text is the same as the DLC LCD message but without the spaces used for centering unlike X 01 For status messages a more specific response than the DLC LCD will be sent For example instead of M Wait Fd Angle the response is M Waiting for Feed Angle These messages are compatible with the SOT Response format X 14 cc 40 character message hh cr 1lf Examples X 14 8BAxis 1 Motor Has Overheated hh cr 1f X 14 O1M No Jog Command hh cr 1f 4 20 Function Description Special Features DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 DIESIBOD ZZ DLC R Feed To Length Control User s Manual The DLC is also able to send all the messages in each fault table at once after an upload request See Block Uploads page 4 35 and Serial Diagnostic Codes page 4 36 for a current listing of status error and fault messages DLC Inputs in Binary Request X 15n The DLC will send the value of fifteen inputs as a 1 or a 0 24V or OV from left to right n 0 Inputs 1 15 Example Responses X 15 O 1010011000000110 hh cr 1f Inputs 1 15 n increasing input 8 DLC Outputs in Binary Request X 16n The DLC will send the value of sixteen outputs as a 1 or a 0 24V or
226. ust be set to 000 00800 mAsec rad 00000 65000 Parameter C011 Velocity Loop Integral Reaction Time Velocity Loop I Reaction Time C011 2500 0 000 Not used must be set to 000 2500 0 msec 0000 1 6500 0 Parameter C012 Smoothing Time Constant Smoothing Time Constant C012 00600 000 Not used must be set to 000 00600 us 00250 65000 DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 33 DLC R Feed To Length Control User s Manual INDRARMA Parameter C100 Set Standard Drive Tuning Parameters Over CTA 5 34 Parameters Set to Standard Param C100 0000 This menu consists of only the parameter C100 The standard parameters are set after entering the number 5301 and pressing the block store key After pressing the block store key this menu item exits to the A parameter set If the entry is made incorrectly the menu exits to Drive Parameters without setting the standard parameters i e there is no control monitoring of the entry DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 INDRAMA DLC R Feed To Length Control User s Manual Chapter 6 Installation This Chapter covers the installation of the DLC control system The typical DLC Control system consists of the following components DLC Control Module DEA 4 System l O Card CTA Keypad amp Display Power Supply Digital AC Servo Drive MDD Digital AC Servo Motor The instructions in this chapter primarily descr
227. ved a checksum is calculated and checked by the DLC Itis recommended that the checksum be enabled However if the host software doesn t calculate a checksum checksum can be disabled in the Interface parameter To compute the checksum add together the hexadecimal ASCII values of all of the characters before the Then add the most significant digit of the checksum to the two least significant digits Then negate on a calculator this value to form the two s complement Take the last 2 digits of this number The result is a 2 digit checksum to be transmitted to the DLC Example B_A03 B6 lt cr gt lt lf gt Checksum on B A03 23 hex 20 42 20 41 30 149 49 1 4A Checksum 4A B6 RS 232 Flow Control The DLC supports both hardware and software flow control handshake The device communicating with the DLC must have either or both types of handshake or characters may be missed during high speed transmission The method of flow control is selected in the Serial Port Operation parameter B119 The options are described below Software handshake uses the XON ASCII 11 and XOFF ASCII 13 characters to provide flow control When an XOFF is sent to the DLC transmission is interrupted until an XON is sent The DLC will send an XOFF when an interruption in transmission is necessary because of buffer overflow due to a high transmission rate Software handshake is always enabled Hardware handshake uses the RTS
228. w DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Parameters 5 13 DLC R Feed To Length Control User s Manual INDRAMA Enter the value in the unit of measurement common to the rest of the parameters inches to inches or millimeter to millimeter The DLC should always make the exact feed within feed length resolution as shown in Figure 5 3 In Position Threshold This parameter is used to determine when the axis is not feeding and if set small enough will not affect the accuracy of the feed This parameter should not be misinterpreted as feed accuracy 4 POSITION THRESHOLD AXIS DIRECTION gt f FINAL COMMAND POSITION POINT Figure 5 3 In Position Threshold Parameter A111 Direction of Operation Direction A111 Enc 0 Cmd 0 Input Value Limit 0 or 1 This parameter allows changing the axis direction by software in the DLC Direction and polarity changes are provided by this parameter without the need for wiring changes Enc 0 Direction of operation remains unchanged as wired 1 Reverse direction of operation inverts operating polarity of the motor encoder Cmd 0 Direction of operation remains unchanged as wired 1 Reverse direction of operation inverts the polarity of the DLC velocity command output WARNING Runaway conditions can occur if this parameter is changed so that the phase relationship between feedback and command is incorrect Incorrectly defined velocity co
229. wings supplied with this manual see Appendix D show an example of the DLC connections to a typical machine 6 7 DLC DEA 4 Connectors This section describes the connectors on the DLC DEA 4 plug in cards Refer to Figure 1 5 in Chapter 1 for an illustration of the DLC DEA 4 card and its connector locations in the Digital servo drive X17 DEA 4 System Input Output Cable X30 CTA Keypad amp Display Female 34 pin shielded ribbon cable connected to the front panel of the DLC The standard length for the cable is 2 meters It connects from the DLC to the back of the CTA Refer to the DKS DLC interconnects in Appendix D for the proper orientation of the cable X31 RS 232 485 Communications Port Interface Female DB 9 connector is located on the lower front panel of the DLC It is used for serial communication between the DLC and a host terminal SOT or the IDS option Refer to Chapter 4 for description of this multi functional two way communications port DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Installation 6 3 INDRAMA DLC R Feed To Length Control User s Manual Chapter 7 Start Up 7 1 Connections The following sections are intended to provide the user with an example of a DLC Digital AC Servo System start up They provide an example of a single axis application that will verify proper function of the system WARNING The information given in the following sections may not be suitable for a specific application
230. xis 1 forward High In Manual Mode the axis feeds forward at the velocity set in Parameter A105 The axis will feed forward as long as the high signal is present switch held closed With Jog Step set ON from DLC control panel the axis will feed forward until reaching the feed length set in parameter B108 This input is typically wired to a normally open push button switch on the user control panel DOK DIAX02 DLC1 1 DR1 02VRS ANW1 AE P 06 97 Functional Description Standard Features 3 19 DLC R Feed To Length Control User s Manual INDRARMA Jog Reverse High In Set up Mode the axis feeds forward at the velocity set in Parameter A105 The axis will only feed forward the current commanded feed length then stop Connector X17 pin 10 Function Input Jogs axis 1 in the reverse direction High In Manual Mode the axis feeds in the reverse direction at the velocity set in Parameter The axis will feed in reverse as long as the high signal is present switch held closed With Jog Step set ON from DLC control panel the axis will feed in reverse until reaching the feed length set in Parameter B108 High n Set up Mode the axis feeds in the reverse direction if it was jogged forward previously at the velocity set in Parameter A105 In Set up Mode Jog Reverse only functions if the feeder has been jogged forward previously The axis can be jogged back only as far as the starting point of the feed If the feeder is
231. ycle This prevents a feed from being interrupted by an erroneous feed length entry during the current cycle An erroneous entry will cause the error to display and turn off the Permit Press output Change length to within limits and press Resume Cycle to continue Auto Mode Exit Required This diagnostic is issued when a fault occurs while in automatic mode To continue you must exit automatic mode perform any necessary alignment feed manually and then re enter automatic mode 8 7 System Status Messages General Messages Note The SOT displays PARAMETER MODE as acknowledgment of the DLC mode of operation This section provides a complete list of status messages provided by the DLC Certain messages are dependent on the selected mode of operation These are described separately in this section The following messages are not exclusive to a particular operating mode Initializing Sys This message indicates the DLC is performing the system self test following a power up It performs computations based on the parameter values If all conditions are correct a mode specific status report message will display Should any condition not be met the DLC will display the appropriate diagnostic message PARAMETER MODE This indicates the DLC is in Parameter Mode and appears only in the optional vacuum florescent tube remote display The DLC control panel display shows the actual parameter and its data A100 etc DOK DIAX02 DL

DLC-R Feed-to-Length Control With SOT Supplement

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